M4 East Motorway Tunnel Fire System , NSW, Case Study

5.5 kilometre six- motorway tunnel

Pertronic analogue addressable fire detection and alarm system

Pertronic FireMap graphical user interface

Integrated linear heat detection (LHD) system

Bi-directional Modbus integration with plant management system Contents

Introduction ...... 2 Fire System Overview ...... 3 The Pertronic F220/Net2 Network ...... 6 Roadway Fire Detection and Suppression ...... 6 Tunnel Drainage Sump ...... 6 Pump Controls ...... 6 Hydrant Valve Controls ...... 7 Pertronic FireMap® Graphical User Interface ...... 8 Communication Between Fire System Network and PMCS . . . . 8 Pre-Configured Messaged Between Fire System and PMCS . . . . 9 Tunnel Fire Suppression Control System ...... 10 Ancillary Facilities FACP Control and Monitoring ...... 11 Configuring the M4 East Fire System ...... 11 Conclusion ...... 11

Cover Page: Opened on July 13, 2019, the 5.5-kilometre six-lane M4 East motorway tunnel between Homebush (shown) and Haberfield is the main feature of a 6.5 km extension to the eastern end of Sydney’s . The tunnel and its occupants are protected by a network of 93 Pertronic F220 fire indicator panels. Opposite: A roadheader working on the M4 East tunnel project. At the peak of tunnelling, 21 roadheaders were employed on the project. (Image: WestConnex) Introduction

Pertronic Industries has supplied networked fire provide emergency exit routes. Some cross passages system equipment for the M4 East motorway tunnel have electrical equipment rooms. on Sydney’s $A 16.8 billion WestConnex motorway project. The tunnel opened on July 13, 2019, marking The M4 East has a surface at Homebush the completion of Stage One of WestConnex. Bay Drive and an underground interchange at Concord Road. At the eastern end, the motorway connects with The three-stage WestConnex project will deliver more Wattle Street and Road. In addition to the than 30 kilometres of new or upgraded motorways, main roadways, the interchanges have an additional including 22 kilometres of tunnels. Due for completion three kilometres of tunnelling. in 2023, the project will improve the roads between Sydney’s airport and seaport, and communities to the The Motorway Control Centre (MCC) building is located west and southwest of the city. near Homebush. A Disaster Recovery Site (DRS) with backup controls shares a building at Cintra Park with WestConnex stage one was completed in two phases. one of the motorway’s electrical substations. There are Phase one involved widening the M4 between additional motorway substations at Underwood Road, Parramatta and Homebush to eight . This was Ismay, Concord Road, and Haberfield (Parramatta completed in 2017. Phase two was the M4 East Road). Motorway ventilation facilities are located at project. This is a new 6.5 kilometre motorway between Underwood Road, Cintra Park, and . Homebush and Haberfield, about 8 kilometres west of the Sydney CBD. With these improvements, the M4 Construction began in 2016. Tunnelling advanced from stretches 51.5 kilometres from Haberfield to Glenbrook more than 20 locations. A fleet of road-headers bored in the Blue Mountains west of Sydney. the tunnels, which were finished and fitted out by a large workforce. According to M4 East project director The $.8 billion M4 East project includes a 5.5 Terry Chapman, “We had over 2300 people on the kilometre tunnel with two parallel bores. Each bore project working directly, and probably another 2000 carries a three-lane road with 5.3 metres of vertical plus companies supplying components and product.” clearance. Cross-passages link the tunnel bores at regular intervals along their length. The cross-passages

Sydney’s motorway network, showing how the WestConnex projects connect with existing roads, and the NorthConnex project. The WestConnex and NorthConnex projects are due for completion in 2024 and 2020 respectively. (Graphic: )

Page 2 Fire System Overview

The M4 East fire system is based on a Pertronic to over-ride the automatic suppression system when F220/Net2 network with ninety-three F220 fire manual intervention is considered appropriate. panels. Duplicated Pertronic NET2CARD Modbus interfaces connect the fire system with the tunnel’s If excessive heat is detected in the roadway tunnels, plant monitoring and control system (PMCS). Two the F220/Net2 network automatically signals an Pertronic NET2CARD Ethernet interfaces connect alarm monitoring service, which calls the fire brigade. the network with two Pertronic FireMap® graphic The network also sends an alarm signal to the plant user interfaces (GUI). monitoring and control system (PMCS), initiates a water deluge system in the affected zone, and activates Fire detection in the tunnel is based on six LIOS four- alarm strobes at the tunnel portals. channel fibre-optic linear heat detection systems connected to F220 fire panels via Pertronic SPIB-LIOS On receiving an alarm signal, the PMCS initiates an (Modbus) interfaces. The networked F220 fire panels evacuation according to pre-programmed plans, also monitor heat and smoke detectors in cross which may include taking control of ventilation fans passages, equipment areas, and buildings throughout and signage, and broadcasting pre-recorded voice the tunnel complex, together with hydrocarbon messages over loudspeakers throughout the tunnel. detectors in the drainage sumps, and aspirating smoke The Pertronic FireMap® graphical user interface allows detectors in server rooms. tunnel operations staff to over-ride the automatic fire The Pertronic FireMap® graphic user interface provides system response if manual intervention is justified. touch-screen control and monitoring of the fire detection and suppression systems. This allows tunnel operators

Fire suppression system valve assemblies awaiting installation. One of the cross-passages is visible, alongside the white ute. (Photo: WestConnex)

Page 3 Scope

The M4 East fire detection, alarm and suppression system has the following main parts:

> A Pertronic FireMap® graphical user interface (GUI) in the Motorway Control Centre (MCC) (near the Homebush DFO shopping complex), together with a second Pertronic FireMap® GUI in the Disaster Recovery Site (Cintra Park) > A Pertronic F220/Net2 network with 93 F220 analogue addressable fire alarm control panels (FACP) and four Pertronic NET2CARD network interface units > Two bi-directional high-level (Modbus) interfaces between the fire system network and the tunnel plant monitoring and control system (PMCS), providing comprehensive control and monitoring of the fire system from the tunnel PMCS > Alarm signalling equipment for transmitting the fire alarm signal to an alarm monitoring service > Six four-channel LIOS linear heat detector controllers, interfaced via Modbus with the Pertronic fire system. The controllers are configured with 517 linear heat detection zones covering the east-bound and west-bound roadways, together with the entry and exit tunnels > 517 solenoid valve control relays for deluge system activation > Duplicate hydrocarbon gas detectors in the drainage sump > 26 Pertronic hydrant valve control boards, in addition to Pertronic FireMap® GUI hydrant controls > More than 500 analogue addressable point type smoke and heat detectors in tunnel cross passages, egress passages, ventilation facilities, substations, and buildings > Three aspirating smoke detectors in the equipment rooms at the MCC > Sprinkler system monitoring sensors in the Ismay and Parramatta pump rooms > Emergency warning devices such as strobes and sounders in ancillary buildings > An additional stand-alone Pertronic F220 FACP in the Cintra Park water treatment station, with alarm signalling equipment to transmit the alarm signal to an alarm monitoring service. This fire panel monitors six analogue addressable point type smoke detectors and a manual call point

Seventy-nine Pertronic 28U weatherproof F220 fire indicator panels (above) are installed in underground locations throughout the M4 East motorway tunnel complex. Another fifteen F220 fire indicator panels are installed in ancillary buildings.

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MCIE PMCS MOTORWAY CONTROL M4 East Fire System: Simplified Block Diagram This diagram presents the key components of M4 East fire system. Please note that multiple elements and details have been omitted for clarity. The Motorway Control Centre is shown at the beginning of tunnel, connecting to multiple F220 fire panels in a Net2 Ring Circuit. Also displayed further along the tunnel is the Disaster Recovery Site, Drainage Sump Plant, and Linear Heat Detection Controllers (Linear cable not shown). Not to scale. The Pertronic F220/Net2 Network

The fire detection, alarm, and suppression system and ventilation facilities, together with the Motorway is based on a Pertronic F220/Net2 network with Control Centre and the Disaster Recovery Site. 93 F220 fire alarm control panels (FACP), two Net2 BMS interface units, and two Net2 FireMap The Pertronic F220/Net2 network controls fire interface units. detection and suppression functions, and transmits alarm signals to an alarm monitoring service. Pertronic The panels are networked over a fibre-optic backbone fire panels also control alarm devices such as strobes consisting of two dedicated cores within a multi-core and sounders in ancillary buildings. Alarm devices cable. The cable traverses the entire complex including and evacuation systems in the roadway tunnels are the motorway tunnels, pump stations, sub stations, controlled by the PMCS.

Roadway Fire Detection and Suppression

The roadway tunnels are divided into 517 fire control the water deluge system via Pertronic analogue detection and suppression zones. Most of these zones addressable loop responder and Pertronic analogue are 30 metres long. Selected areas have shorter zones. addressable loop relay modules. The F220/Net2 network monitors a system of fibre- optic linear heat detection (LHD) cables. Each zone Four of these panels monitor the six LHD controllers is traversed by two separate cables (Each LHD cable via Pertronic LHD (Modbus) Interface units. If excessive covers multiple zones). LHD controllers at each end of heat is detected in the roadway tunnels, the network each cable are able to pin-point a heat alarm signal to initiates an automatic deluge release sequence. a precise location, corresponding to a detection and Unless the deluge sequence is over-ridden during the suppression zone within the tunnel complex. three-minute deluge delay period, the network will activate the water deluge suppression system in the The linear heat detection and suppression system is zone containing the heat alarm. The network will also monitored by Pertronic F220 weatherproof fire panels activate the deluge system in an adjacent zone, and located in the cross-passages. They are well-protected up to two additional zones, depending on the alarm during normal tunnel operations. They are built in location. Pertronic IP65 weatherproof cabinets to cope with possible flooding during an emergency. These panels

Tunnel Drainage Sump Pump Controls

A networked Pertronic F220 fire panel monitors two The F220/Net2 network monitors and controls hydrocarbon gas detectors in the tunnel drainage pumps at Ismay Ave and Parramatta Road. Upon sump. If hydrocarbon gas is detected, the F220 opens deluge activation, the F220/Net2 network starts a a foam deluge valve, blanketing the sump with fire deluge pump in the pump room appropriate to the suppressing foam. alarm location. If the main pump shows a fault, the network will start the backup pump at the same location.

The network also signals the other pump room, to inhibit the pumps at that location for thirty seconds after deluge activation.

Page 6 Hydrant Valve Controls

The Pertronic F220/Net2 network controls and monitors 32 motorised hydrant valves designed and built by Pertronic Industries throughout the tunnel complex. The network provides remote and local control options. These weatherproof control boards were retrofitted several months after the M4 East Tunnel opened for traffic.

Remote Control and Indication Local Control and Indication

The Pertronic FireMap GUI provides remote control Local control and monitoring of the hydrant valves of the motorised hydrant valves from the Motorway is provided by 26 Pertronic Special Purpose Control Control Centre (MCC). Staff at the MCC are able to and Indicating Boards. These boards are located in select one of the following hydrant configurations: underground areas such as cross-passages or pump rooms. Some of these boards have controls for several > Eastbound hydrant valves. The display boards in the Motorway > Westbound Control Centre, and the FireMap GUI, show the status of each motorised hydrant valve: Open, or Closed. > East Eastbound > West Eastbound > East Westbound > West Westbound > Eastern half (East Eastbound & East Westbound) > Western half (West Eastbound & West Westbound) In addition to the FireMap display, a Pertronic Special- Purpose Indicating Board in the Motorway Control Centre shows the status of each motorised hydrant valve.

ABOVE: One of 26 Hydrant Valve Control and Indicating Boards. The F220/Net2 network was reprogrammed to activate the new functions using Pertronic FireUtils®, which uploads a complete system configuration in less than six minutes.

LEFT: This Pertronic Special-Purpose Indicator Board was built for installation in the Pertronic F220 fire alarm control panel at M4 East Motorway Control Centre. The board shows the status of each hydrant valve at M4 East.

Page 7 Pertronic FireMap® Graphical User Interface

The M4 East tunnel fire system can be controlled and monitored from either of two independent Pertronic FireMap® Graphical User Interfaces (GUIs).

Each GUI provides remote monitoring and graphic-based touch-screen control of the fire detection, alarm, and suppression system. If excessive heat is detected in a roadway tunnel zone, FireMap automatically displays a map of the affected area, with the zone containing the alarm signal highlighted in red. The FireMap water deluge zone display shows the time remaining until automatic deluge activation, together with touch-screen controls allowing tunnel operators to manually release or inhibit the deluge system. Used in concert with the tunnel’s closed-circuit video system, FireMap allows tunnel operators to respond appropriately to any alarm incident.

A Pertronic FireMap® touch-screen graphical user interface helps tunnel operators to respond appropriately to any alarm incident.

Communication Between Fire System Network and PMCS The M4 East fire system features a duplicated communication link with the PMCS. A Pertronic NET2CARD Modbus Interface at the Motorway Control Centre provides bi-directional communication with the PMCS. A second NET2CARD Modbus Interface at the Disaster Recovery Site provides the backup communication link.

Each Pertronic NET2CARD Modbus Interface is configured to communicate 2,598 unique Boolean messages. The communication system allows the PMCS to display the source of an alarm or fault signal. For example, there are 517 linear heat detection zones. If excessive heat is detected in multiple linear heat detection zones, the fire system will send a separate alarm message for each affected zone.

Ninety-seven Pertronic Net2 network cards are installed in F220 fire panels at M4 East. This example is fitted to a weatherproof Pertronic F220 fire panel, and interfaces the weatherproof fire panel to the F220/Net2 network. Two of the M4 East Net2 network cards interface the F220/net2 network with the tunnel PMCS. Another two Net2 network cards interface the network with Pertronic FireMap® graphical user interfaces.

Page 8 Pre-Configured Message Between Fire System and PMCS

The Pertronic NET2CARD Modbus interface allows the following messages to be transferred between the fire system and the PMCS.

Number of Message Content Individually Identified by Messages 517 Water Deluge Pressure Switch Zone identifier 517 Linear Heat Detection Alarm Zone identifier 92 Cross Passage/ Long Egress Passage Smoke Detector Alarm Passage identifier 3 Underground Substation Smoke Detector Alarm Substation identifier 1 Sump Plant Heat Detector Alarm 92 Cross Passage/ Long Egress Passage Smoke Detector Fault Passage identifier 3 Underground Substation Smoke Detector Fault Substation identifier 1 Sump Plant Heat Detector Fault 1 Ismay Avenue Sprinkler Alarm 1 Parramatta Pump Sprinkler Alarm 1 Foam Deluge Zone Discharged 2 Sump Hydrocarbon Detector Alert Detector identifier 2 Sump Hydrocarbon Detector Alarm Detector identifier 2 Sump Hydrocarbon Detector Fault Detector identifier 2 Sump Hydrocarbon Detector Isolated Detector identifier 1 Foam Tank Low Level Alarm 15 Pump Run Pump identifier 15 Pump Fault Pump identifier 4 Tank Low Tank Identifier 4 Tank High Tank Identifier 2 Main Fire Panel Fault Panel identifier 12 Sub Fire Panel Fault Panel identifier 1 DGU Main Fire Panel Fault 79 panels grouped together 6 LHD Controller Fault LHD controller identifier 79 Cross Passage/ Long Egress Passage Deluge Valve Fault Passage identifier 1 Sump Pump Deluge Valve Fault 79 Deluge Manifold Fault Passage identifier 54 Deluge Main Fault Passage identifier 27 Hydrant Valve Fault Passage identifier 19 Smoke Detection Alarm Point detection zone 1 Manual Local Fire Mode 1 Parramatta FPR Boost Inlet In Use 1 MCE1200 MCC Heartbeat 1 Ismay Avenue FPR Boost Inlet In Use 517 PMCS Disable Deluge Zone Zone identifier 517 PMCS Initiate Deluge Zone Zone identifier 1 Manual Foam Deluge Sump Pump 1 Automatic Deluge Global Accept 1 Automatic Deluge Global Cancel 1 MCE1200 MCC Heartbeat

Page 9 Tunnel Fire Suppression Control System

The Pertronic F220/Net2 system features duplicate connections with the tunnel’s plant monitoring and control system. Dual Pertronic FireMap® Graphic User Interfaces (GUIs) provide touch-screen control and monitoring of the fire detection and suppression systems.

Fire suppression in the tunnels includes hydrant and water deluge systems for the roadways, as well as a foam deluge system within the drainage sump. Deluge zones in the roadway tunnels correspond with LHD alarm initiation zones.

Automatic Mode

If the LHD communicates a fire alarm condition to the F220/Net2 network, the network relays the alarm signal (with zone information) to the GUI, the PMCS, the FACP controlling the zone containing the alarm Upper: Multi-Function Loop Responder: This module signal, and all other networked FACPs. interfaces the Pertronic F220 fire panel with external sensors such as flow switches on the deluge system. If there is no manual intervention within 60 seconds Lower: Loop Relay: This module interfaces the after the alarm signal, the FACP automatically activates Pertronic F220 fire panel with solenoids controlling the water deluge suppression system within a set of the deluge system, allowing the fire panel to activate pre-configured zones. This includes zone containing the water deluge fire supression system. Each Loop relay module controls up to four suppression zones. the alarm system. Usually the adjacent (upstream) zone is also activated. At selected locations, one or two additional zones are also activated.

Manual Mode

Tunnel operations staff monitor the tunnels via CCTV.

If the tunnel operator notices a fire incident before automatic deluge activation, they may initiate a manual fire response using the Pertronic FireMap® graphic user interface. The GUI allows manual deluge activation.

Manual deluge activation is also possible using the PMCS.

Foam Deluge Control

An automatic foam deluge system protects the tunnel drainage sumps. An F220 fire panel monitors two hydrocarbon sensors. If either hydrocarbon sensor detects an alarm condition, the FACP activates the solenoid control valve. This opens the deluge valve, allowing water to mix with foam concentrate which is sprayed onto the surface of the sump.

Page 10 Ancillary Facilities FACP Control and Monitoring

The M4 East fire system includes Fire Alarm Control the location. The pump station fire panels also monitor Panels (FACPs) at the following ancillary facilities: automatic fire sprinkler systems. > The Motorway Control Centre (MCC) near the A fire panel at the MCC monitors three aspirating Homebush DFO shopping centre smoke detectors, which protect mission critical > The Disaster Recovery Site (DRS), in the Cintra equipment. Park Substation Ancillary building fire panels control emergency > Ventilation facilities at Underwood Road, Cintra warning devices such as strobes and sounders. Park, and Parramatta Road The fire panels in all ancillary buildings (except the > Pump stations at Ismay and Parramatta Road Cintra Park water treatment facility) are integrated into > Above-ground electrical substations at the Pertronic F220/Net2 network. Underwood Road, Ismay, Concord Road, Cintra The stand-alone Pertronic F220 FACP in the Cintra Park, and Parramatta Road Park water treatment station monitors six analogue > A water treatment plant at Cintra Park addressable point type smoke detectors and a manual The fire alarm control panels in these facilities monitor call point. The fire panel is fitted with alarm signalling fire detection systems based on analogue addressable equipment to transmit the alarm signal to an alarm point type smoke and heat detectors as appropriate to monitoring service.

Configuring the M4 East Fire System

Configuration programming for the entire M4E network can be updated from a single Ethernet connection. This simplifies system alterations or modifications. For example, the 26 hydrant valve control boards were installed several months after the tunnel was opened. In order to integrate the new control boards into the F220/Net2 network, it was necessary to reprogramme twenty-six fire panels in underground locations, in addition to the fire alarm control panel in the Motorway Control Centre.

Pertronic FireUtils® makes it easier to implement programming changes. The complete configuration programme for the entire F220/Net2 system at M4 East uploads through a single connection in less than six minutes.

Conclusion

The M4 East fire system exemplifies the advanced information-processing capabilities of the Pertronic F220. With 97 nodes, 93 fire alarm control panels, Pertronic FireUtils® is a computer application that makes and more than 11,600 inter-panel mappings, the it easy to configure a Pertronic F220 system. FireUtils® system generates and processes very large amounts displays configuration data in matrix-based editing grids. of data. With a powerful 32-bit processor in every With a few mouse-clicks, users can insert, modify, and move fire alarm control panel and network node, the F220/ large numbers of loop devices and other objects, within Net2 system has the power to process this deluge or between loops. FireUtils® provides disgnostic, debugging, of data. To ensure rapid transmission even under and event log management tools, and runs on Microsoft Windows 7, 8 and 10. extreme network load situations, adaptive messaging in the Pertronic Net2 Network prioritises alarms and important control signals.

The Pertronic F220/Net2 network system puts M4 East tunnel operations staff in control. Page 11 A Pertronic F220 Fire Alarm System provides vital safety systems for the thousands of motorists travelling between Central Sydney and the Western Suburbs every day

PERTRONIC INDUSTRIES LIMITED HEAD OFFICE

17 Eastern Hutt Road, Wingate, Lower Hutt 5019, New Zealand Phone: +64 4 567 3229 Fax: +64 4 567 3644 Email: [email protected] FIRE ALARM www.pertronic.net SYSTEMS December 2020