FMDS-07-01 (04.2020) - Fire Protection For Textile Mills

FM Global
Property Loss Prevention Data Sheets 7-1

January 2012
Interim Revision April 2020
Page 1 of 42
FIRE PROTECTION FOR TEXTILE MILLS
Table of Contents
Page
1.0 SCOPE ................................................................................................................................................... 4

1.1 Changes .......................................................................................................................................... 4
2.0 LOSS PREVENTION RECOMMENDATIONS ....................................................................................... 4
2.1 Greige Goods .................................................................................................................................. 4
2.1.1 Introduction ............................................................................................................................ 4
2.1.2 Construction and Location .................................................................................................... 4
2.1.3 Protection .............................................................................................................................. 4
2.1.3.1 General ...................................................................................................................... 4
2.1.3.2 Baled Fiber Warehouse ............................................................................................. 6
2.1.3.3 Baled Fiber Staging Area .......................................................................................... 6
2.1.3.4 Bale Breaking Area .................................................................................................... 6
2.1.3.5 Opener Room ............................................................................................................ 6
2.1.3.6 Feeder Blending ........................................................................................................ 7
2.1.3.7 Automatic Bale Openers ........................................................................................... 7
2.1.3.8 Blender/Reserve Hopper ........................................................................................... 9
2.1.3.9 Waste Fiber Recovery System ................................................................................ 10
2.1.3.10 Magnetic Separators ............................................................................................. 10
2.1.3.11 Metal, Spark and Fire Diverters ............................................................................. 10
2.1.3.12 Carding .................................................................................................................. 10
2.1.3.13 Spinning ................................................................................................................. 11
2.1.3.14 Warping, Beam Storage ........................................................................................ 11
2.1.3.15 Slashing ................................................................................................................. 11
2.1.3.16 Weaving ................................................................................................................. 12
2.1.3.17 Creels .................................................................................................................... 12
2.1.3.18 Pin Trucks .............................................................................................................. 14
2.1.3.19 Air Conditioning Systems ...................................................................................... 14
2.1.3.20 Wool ....................................................................................................................... 15
2.1.3.21 Synthetics .............................................................................................................. 15
2.1.3.22 Nonwovens ............................................................................................................ 17
2.1.3.23 Carpet .................................................................................................................... 17
2.1.3.24 Synthetic Yarns ........................................................................................................ 17
2.1.4 Operation and Maintenance ................................................................................................ 17
2.1.5 Electrical .............................................................................................................................. 18
2.1.5.1 General .................................................................................................................... 18
2.1.5.2 Load Centers ........................................................................................................... 18
2.1.5.3 Enclosures ............................................................................................................... 18
2.1.5.4 Lighting Equipment .................................................................................................. 18
2.1.6 Human Factor ...................................................................................................................... 18
2.2 Finishing Operations ...................................................................................................................... 19
2.2.1 Introduction .......................................................................................................................... 19
2.2.2 Protection ............................................................................................................................ 19
2.2.2.1 General .................................................................................................................... 19
2.2.2.2 Bleaching ................................................................................................................. 19
2.2.2.3 Dyeing ...................................................................................................................... 19
2.2.2.4 Ovens, Dryers, Tenter Frames ................................................................................ 19
2.2.2.5 Heat Transfer Oil Systems ...................................................................................... 19
©2009-2020 Factory Mutual Insurance Company. All rights reserved. No part of this document may be reproduced,
stored in a retrieval system, or transmitted, in whole or in part, in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without written permission of Factory Mutual Insurance Company.
7-1 Fire Protection For Textile Mills
Page 2 FM Global Property Loss Prevention Data Sheets
2.2.2.6 Heat Set Range ....................................................................................................... 19

2.2.2.7 Printing Dyes and Screen Manufacturing ............................................................... 20
2.2.2.8 Nappers ................................................................................................................... 20
2.2.2.9 Cutting and Sewing ................................................................................................. 20
2.2.3 Human Factor ...................................................................................................................... 20
3.0 SUPPORT FOR RECOMMENDATIONS ............................................................................................. 20
4.0 REFERENCES ..................................................................................................................................... 20
4.1 FM Global ...................................................................................................................................... 20
4.2 NFPA Standards ............................................................................................................................ 20
4.3 Others ............................................................................................................................................ 20
APPENDIX A GLOSSARY OF TERMS ..................................................................................................... 21
APPENDIX B DOCUMENT REVISION HISTORY ..................................................................................... 21
APPENDIX C SUPPLEMENTARY INFORMATION ................................................................................... 21
C.1 Greige Goods ................................................................................................................................ 21
C.1.1 Construction and Location .................................................................................................. 21
C.1.2 Protection ............................................................................................................................ 22
C.1.2.1 Automatic Sprinkler Protection ................................................................................ 22
C.1.2.2 Special Protection Systems .................................................................................... 22
C.1.2.3 Detection ................................................................................................................. 22
C.1.2.4 Extinguishing Agent ................................................................................................ 23
C.1.2.5 Testing and Maintenance of Special Protection Systems. ..................................... 23
C.1.2.6 Portable Extinguishing Equipment .......................................................................... 23
C.1.3 Operation and Maintenance ............................................................................................... 24
C.1.4 Occupancy .......................................................................................................................... 24
C.1.4.1 Opening Equipment ................................................................................................ 24
C.1.4.2 Waste Recovery ...................................................................................................... 28
C.1.4.3 Magnetic Separators ............................................................................................... 28
C.1.4.4 Carding .................................................................................................................... 30
C.1.4.5 Drawing Through Weaving Processes ................................................................... 30
C.1.4.6 Pin Trucks ............................................................................................................... 34
C.1.4.7 Creels ...................................................................................................................... 34
C.1.4.8 Air Conditioning and Pneumatic Waste Recovery Systems ................................... 35
C.1.5 Utilities ................................................................................................................................. 40
C.2 Wool .............................................................................................................................................. 40
C.3 Synthetic Fibers ............................................................................................................................ 40
C.4 Finishing Operations ..................................................................................................................... 40
C.4.1 General ............................................................................................................................... 40
C.4.2 Singeing .............................................................................................................................. 41
C.4.3 Bleaching ............................................................................................................................ 41
C.4.4 Dyeing ................................................................................................................................. 41
C.4.5 Printing ................................................................................................................................ 42
C.4.6 Ovens, Dryers and Tenter Frames ..................................................................................... 42
List of Figures
Fig. 1. Opener (1), cleaner (2), inclined opener (3), blending machine (4), condensor (5), card feeding unit
(6), cards (7), and spark diverter or metal/spark diverter (8). ........................................................... 5
Fig. 2. Automatic bale feeder. ....................................................................................................................... 7
Fig. 3. Bale opener. ...................................................................................................................................... 8
Fig. 4. Automatic bale opener. ...................................................................................................................... 9
Fig. 5. Spark diverter. .................................................................................................................................. 10
Fig. 6. Card line protected by FM-200 system or by spark diverter. .......................................................... 11
Fig. 8. Old style creel with an open mezzanine. ......................................................................................... 13
Fig. 7. Modern creel with a solid mezzaine. ............................................................................................... 13
Fig. 9. Pin truck containing acrylic yarn located within enclosure constructed of metal panel on steel
frame. ............................................................................................................................................... 14
Fig. 10. Waste House. ................................................................................................................................ 16
Fig. 11. Blender-opener combination. ......................................................................................................... 25
Fig. 12. Opening feeder. ............................................................................................................................. 26
©2009-2020 Factory Mutual Insurance Company. All rights reserved.

Fire Protection For Textile Mills 7-1
FM Global Property Loss Prevention Data Sheets Page 3
Fig. 13. No. 16-1 opener with No. 11 condenser feed. by the air stream. .................................................. 27
Fig. 14. Lattice opener with No. 11 condenser feed. ................................................................................. 29
Fig. 15. Axial flow cleaner. .......................................................................................................................... 30
Fig. 16. Aeromix. ......................................................................................................................................... 31
Fig. 17. Permanent-plate magnets and housing. ....................................................................................... 31
Fig. 18. Permanent-plate magnet above spiked lift apron. ........................................................................ 32
Fig. 19. Open-end spinning frame. ............................................................................................................. 33
Fig. 20. Modern creel with one mezzanine, shows both loading and tie aisles. ....................................... 35
Fig. 21. Air conditioning system of a modern mill. ..................................................................................... 36
Fig. 22. Lint accumulation above supply air duct. ...................................................................................... 37
Fig. 23. Supply air duct with openings (registers) in the side of the duct. ................................................. 38
Fig. 24. Lint accumulation in supply air duct. ............................................................................................. 38
Fig. 25. Supply air ducts with vertical drops to registers. .......................................................................... 39
List of Tables
Table 1. Recommended Types and Placement of Portable Extinguishers .................................................. 6
Table 2. Protection of Synthetic Yarn Storage .............................................................................................. 17
Table 2. Spacing of Detectors in Round Ducts .......................................................................................... 22
Table 3. Field Survey of 96 Locations to Determine Type of Yarn Stored on Pin Trucks ......................... 34

1.0 SCOPE
This data sheet covers the fire hazards and necessary protection recommendations for various textile
processes that use both natural and synthetic fibers. Recommendations are based on a study of fires over
a recent five-year period and a field engineering survey aimed at identifying specific hazards conducted by
Loss Prevention Specialists after visits to fifty large textile mills. The cotton or cotton blend process is the most
common. Processes handling other fibers, natural and synthetic, use similar equipment and have similar
hazards.
Storage of baled fibers is covered in Data Sheet 8-7, Baled Fiber Storage. Storage of plastics and rubber,
storage of greige and finished goods on pallets, and storage in racks is covered in Data Sheet 8-9, Storage
of Class 1, 2, 3, 4 and Plastic Commodities.
1.1 Changes
April 2020. Interim revision. Updated protection guidance for the storage of synthetic yarns.
2.0 LOSS PREVENTION RECOMMENDATIONS
2.1 Greige Goods
2.1.1 Introduction
Maintenance and housekeeping are critical to reducing the frequency and lowering the severity of fires in
the textile industry. Loose fiber and oil mist can be airborne and will collect above the ceiling, on the ceiling,
on machinery, at the floor, below the floor and inside ducts. Increased production demands can result in
reduced or skipped housekeeping and increase the probability of a fire. Written corporate and plant policies
on housekeeping are needed to ensure cleaning cycles are adequate, cleanings are not skipped, and spot
cleaning is completed as needed. Skipped cleanings must be rescheduled promptly. There must be a
documented line of authority for authorizing a cleaning delay and rescheduling. As a general rule the maximum
deposit thickness for loose fluffy lint is 1⁄2 in. (13 mm) over a maximum of 500 ft2 (46.5 m2). Dense deposits,
should be limited to 1⁄4 in. (6 mm) and oil saturated deposits should be limited to 1⁄8 in. (3.2 mm).
Changes in production scheduling can result in overloaded and inadequately protected storage areas.
Protection is needed for the worst case storage arrangement (storage height and depth, aisle width, flue width
and spacing, and aisle storage). In process storage in production areas should be protected by the applicable
storage standard. Excessive storage should be relocated to a properly protected storage room or warehouse.
Plastic tubs and trays have become common and need appropriate protection.
Enclosed production equipment has resulted in the need for internal protection systems in many situations.
Plant interdependencies are common in the textile industry. One or more operations in the manufacturing
process may take place in a different plant(s), for example yarn mills, weaving, tufting, knitting, and finishing
plants.
Automatic sprinkler protection is needed throughout the mill and in equipment containing large quantities of
fiber. Protection for equipment such as compressors and cooling towers also is necessary. Compressors
are essential to continued operation of air jet looms; cooling towers are needed to maintain temperature and
humidity within operating limits.
2.1.2 Construction and Location

2.1.2.1 Make floors water resistant above valuable storage or sensitive high value equipment.
2.1.2.2 Provide one-hour rated fire partitions with FM Approved (See Appendix A for definition) automatic
closing doors to separate raw material and finished goods storage from processing areas.
2.1.3 Protection
2.1.3.1 General
2.1.3.1.1 Install automatic sprinklers at ceiling level in all areas including concealed spaces, in accordance
with Data Sheet 2-0, Installation Guidelines for Automatic Sprinklers.

2.1.3.1.2 Design ceiling sprinkler protection for textile plant production areas for 0.15 gpm/ft2 (6 mm/min)
using automatic sprinklers of any temperature rating. If a wet-pipe system is used, design for an operating
area of 2,500 ft2 (230 m2). If a dry-pipe system is used, design for an operating area of 3,500 ft2 (330 m2). This
applies to all process areas unless other greater hazards are also located in these areas.
2.1.3.1.3 Provide a water supply adequate for two hours capable of meeting the sprinkler discharge flow
rate plus 250 gpm (950 L/min) for hose streams.
2.1.3.1.4 Test or replace old style sprinkler heads in accordance with Data Sheet 2-81, Fire Safety Inspections
and Sprinkler System Maintenance. Hydraulically analyze 3⁄4 in. (1.9 cm) pipe for adequacy and replace as
necessary.
2.1.3.1.5 Provide special protection for cotton processing in enclosed systems from opening to chute fed
cards. Install infrared (IR) detection in the duct downstream of equipment (see Fig. 1). Arrange extinguishing
agent (dry chemical or a gaseous agent) to discharge into equipment downstream of the detectors, where
there is fiber hold-up.
a) Shut down process equipment to prevent fire spread.
b) Interlock exhaust fans to shutdown if they would be likely to reduce agent concentration in the protected
space.
c) If a keyed abort switch is used for maintenance have the key under the control of either the department
head or maintenance personnel.
d) Have replacement agent available on site to enable protection to be restored immediately.
Fig. 1. Opener (1), cleaner (2), inclined opener (3), blending machine (4), condensor (5), card feeding unit (6), cards (7),
and spark diverter or metal/spark diverter (8). IR detection is in inlet and outlet ducts of all equipment where there
is fiber build-up. FM-200 is automatically discharged into equipment in areas of fiber build-up. Automatic sprinkler
protection is shown in equipment containing in excess of 500 lbs (227.3 kg) of fiber (blending machine). A spark
diverter or metal/spark diverter is provided between opener and cleaner.

2.1.3.1.6 Provide the following protection within equipment containing fiber shielded from overhead sprinkler
systems:
a) Automatic sprinkler protection or special protection in equipment containing 100 lb (45.5 kg) or more
of cotton or rayon.
b) Automatic sprinkler protection and special protection in equipment containing 500 lb (227 kg) or more
of cotton or synthetic fiber. Install automatic sprinklers in accordance with section 2.1.3.1.9. Special
protection systems are not a substitute for automatic sprinkler protection in equipment having this amount
of fiber.
c) Install automatic sprinkler protection in accordance with section 2.1.3.1.9 in waste recovery system
bins, filter houses, etc.
2.1.3.1.7 Install automatic sprinkler protection in accordance with section 2.1.3.1.9 within spinning frames
where combustible insulation is used behind the spinning positions. Protection is not needed if combustible
insulation is used only in the headstock and tailstock.
2.1.3.1.8 Provide portable extinguishing equipment as recommended in Table 1.
2.1.3.1.9 Install automatic sprinkler protection in equipment using ordinary hazard pipe schedule on 100 ft2
(9.3 m2) spacing. If areas are shielded by vertical partitions additional heads are needed. Automatic
sprinklers should be 1⁄2 in. (1.3 cm) orifice with a temperature rating of 165°F (74°C). If location within the
equipment is such that there would be fiber accumulation the heads may be installed within a recessed
enclosure provided the enclosure does not interfere with the spray pattern of the automatic sprinkler.
Table 1. Recommended Types and Placement of Portable Extinguishers

Portable Extinguishing Equipment Areas Where Use Recommended Recommended Spacing
Dry Chemical Extinguishers All Areas An operator should not have to go
Or more than 50 ft (15 m) to reach
Gaseous Extinguishers
3⁄4 in. (1.9 cm) Fiber laydown, Opening, Cleaning, As necessary to cover all areas
Water Spray
minimum Blender bin areas, and Filter Rooms,
From
11⁄2 in. (3.8 cm) Baled Cotton & Finish Goods Storage
Small Hose
minimum
Water Pump Tank All Areas An operator should not have to go
Or more than 100 ft (30.5 m) to reach
Pressurized Water Extinguisher
2.1.3.2 Baled Fiber Warehouse

2.1.3.2.1 Provide automatic sprinkler protection at ceiling level as outlined in Data Sheet 8-7, Baled Fiber
Storage and Data Sheet 8-9, Storage of Class 1, 2, 3, 4 and Plastic Commodities.
2.1.3.2.2 Provide a one hour rated firewall with automatic closing Class B fire doors at openings between
the warehouse and production areas.
2.1.3.3 Baled Fiber Staging Area

2.1.3.3.1 Separate laydown area from storage by a distance of 25 ft (7.6 m) or a one hour rated wall with
automatic closing Class B fire doors.
2.1.3.4 Bale Breaking Area

2.1.3.4.1 Remove as many metal bands as practical before bales enter the lay down area and account for
all bands.
2.1.3.4.2 Protect lighting fixtures from flying metal bands.
2.1.3.5 Opener Room
2.1.3.5.1 Location

2.1.3.5.1.1 Locate the opener room(s) on the first floor, cut off from the remainder of the mill by a
noncombustible fire partition. A 5 ft (1.5 m) deep draft curtain is acceptable in place of the fire partition.
2.1.3.5.1.2 Provide access doors to permit firefighting and cotton removal.
2.1.3.5.2 Laydown
2.1.3.5.2.1 General
2.1.3.5.2.1.1 Provide painted lines on the floor showing the limits of the fiber laydown area and clear space.
2.1.3.5.2.1.2 If plant operations require some unopened bales in the opener room, separate bales from
opened fiber by a 10 ft (3 m) space or by a partition extending the height of the storage.
2.1.3.5.2.1.3 Separate laydown for each opener line by a 10 ft (3 m) space, or by a 6 ft (1.8 m) high sheet
metal or plywood partition extending 2 ft (0.6 m) beyond sides of bales.
2.1.3.6 Feeder Blending

2.1.3.6.1 Install automatic sprinkler protection over the feed conveyor in accordance with section 2.1.3.1.7.
2.1.3.6.2 Provide magnetic separators at the top of the conveyor or apron.
2.1.3.7 Automatic Bale Openers

Ceiling automatic sprinkler protection can be expected to protect bales on the opener. A special protection
system will be needed to prevent fire propagation to equipment downstream.
2.1.3.7.1 Prevent fire that occurs in the opener from spreading to the laydown and to down stream equipment
as follows:
a) Train operators to manually shutoff the crane in event of fire for automatic bale feeder designed similar
to that shown in Figure 2.
Fig. 2. Automatic bale feeder. When a photocell senses that the apron needs fiber, the crane is moved
into position over a bale in front of the apron. The pickup head is lowered, peels off fiber, and
the crane transports it back to the feed apron where it is dropped onto apron. Each opened
fiber bale is mounted on its own pallet with rollers.
b) Provide a special protection system to detect a fire and discharge agent onto opened cotton in front
of and behind the distributor for an automatic bale opener designed similar to that shown in Figure 3. Also
interlock the opener to automatically shutdown.

Fig. 3. Bale opener. Fiber is removed from top of bales by opening rolls within the distributor. Fiber enters the telescoping
tube in the turret to a duct laying between the tracks. Protection consists of four FM-200 nozzles mounted on the
distributor directed at the laydown (two nozzles are in front and two behind the distributor). One nozzle located
in the distributor is in direction of fiber flow. IR detectors at top of telescoping tube actuate the system.
c) Provide a special protection system to detect a fire and discharge agent into downstream equipment
for an automatic bale opener designed similar to that shown in Figure 4.

Fig. 4. Automatic bale opener. Fiber bales are placed in one of several chambers on a rotating circular platform. The
platform rotates slowly over a fixed subplatform containing beaters. As a bale goes over a beater, small tufts of
fiber are removed from the underside of the bale, drawn into a duct and conveyed to cleaning equipment.
2.1.3.7.2 Provide a magnetic separator and diverter between the automatic bale opener and other
downstream equipment. Magnetic humps and plates require frequent inspection and cleaning.
2.1.3.7.3 Separate laydown for each automatic bale opener line by a 10 ft (3 m) space or by a 6 ft (1.8 m)
high sheet metal or plywood partition extending 2 ft (0.6 m) beyond sides of bales.
2.1.3.8 Blender/Reserve Hopper

2.1.3.8.1 Provide special protection for blender reserve hoppers, as a fire in this equipment should shut
down production.

2.1.3.9 Waste Fiber Recovery System

2.1.3.9.1 Locate waste or garnetting machines in a separate, well cut- off room. If not possible, maintain a
10 ft (3 m) clear aisle between the waste machine area and opened fiber or opener machinery.
2.1.3.10 Magnetic Separators

2.1.3.10.1 Provide a magnetic separator immediately at or downstream of fiber entering any pneumatic
transfer system. Typical positions are at the discharge end of an automatic bale opener, at the end of the
opener line take away conveyor, and upstream or in cleaners.
2.1.3.11 Metal, Spark and Fire Diverters

2.1.3.11.1 For cotton or other fiber that may contain tramp metal provide a metal, spark and fire diverter
system downstream of all fiber input points (see Fig. 5).
Fig. 5. Spark diverter. IR detectors detect sparks and divert stock feed to the collection can. A FM-200 system or a water
spray system can be used to extinguish fire in the collection can. (Courtesy of ARGUS Fire Control, Charlotte, NC.)
2.1.3.12 Carding
2.1.3.12.1 Provide a special protection system for the card line feeder (flock feeder).
2.1.3.12.2 Provide one of the following means of protection for the card line (see Fig. 6):
a) A special protection system in the supply duct to each card line. Locate one nozzle upstream of the
first four card chutes. If cards can be fed from two directions, arrange nozzles to protect card chutes in
either direction activated by IR detectors or
b) A spark diverter in the supply duct to the cards activated by IR detectors.

Fig. 6. Card line protected by FM-200 system or by spark diverter. For FM-200 system one nozzle is located upstream
of the first four card chutes. IR detectors in the duct-supplying fiber to these cards activate the system. The spark
diverter is an alternate method of protection.
2.1.3.12.3 For cotton or other fiber that may contain tramp metal if fire frequency warrants, provide a magnetic
separator at the bottom of each card chute.
2.1.3.13 Spinning
2.1.3.13.1 Remove oil and lint deposits inside the frame and head filter on a scheduled basis.
2.1.3.13.2 Use noncombustible insulation inside the frame.
2.1.3.14 Warping, Beam Storage

2.1.3.14.1 Provide automatic sprinkler protection below the mezzanine floor in multilevel creel racks as
described in section 2.1.3.17.
2.1.3.14.2 Provide protection for beam storage as recommended in Data Sheet 8-9, Storage of Class 1, 2,
3, 4 and Plastic Commodities.
2.1.3.15 Slashing
2.1.3.15.1 Provide automatic sprinkler protection in combustible ducts and hoods, see Data Sheet 7-78,
Industrial Exhaust Systems.
2.1.3.15.2 Limit combustible build-up to no more than 1⁄4 in. (6 mm) between cleanings or provide automatic
sprinkler protection.

2.1.3.15.3 Safely arrange handling of dry starch. See Data Sheet 7-76, Prevention and Mitigation of
Combustible Dust Explosions and Fires, for information on controlling dust hazards.
2.1.3.16 Weaving
2.1.3.16.1 Run service for compressed air and electric power above the floor rather than in trenches.
2.1.3.16.2 Locate compressors needed for air jet looms in noncombustible buildings or rooms, and protect
in accordance with Data Sheet 7-95, Compressors. Provide emergency quick connects for replacement
compressors that may be needed to replace fire-damaged compressors.
2.1.3.16.3 Blow down machinery at time of warp out.
2.1.3.16.4 Provide small, hose with spray nozzles for weave rooms.
2.1.3.17 Creels
2.1.3.17.1. Old Style Creels With Solid Mezzanines

2.1.3.17.1.1 Provide sprinkler protection in the aisles between creels or within the creels beneath the
mezzanines and beneath mezzanine overhangs. Design to deliver 22 gpm (84 l/min) from each of the 6 most
remote mezzanine sprinklers (for single level mezzanine arrangements) or the 12 most remote heads (six
heads on two levels) if more than one mezzanine level is being protected. Include a 500 gpm (1900 l/min)
allowance for hose streams.
2.1.3.17.1.2 Do not include ceiling sprinkler system demand with the mezzanine sprinkler water demand if
there no combustibles between sprinklers and the edge of the mezzanine. Design ceiling sprinklers to deliver
a 0.15 gpm/ft2 (6 mm/min) density over 2500 ft2 (232 m2). Include a 500 gpm (1900 l/min) allowance for hose
streams.
2.1.3.17.1.3 Provide 165°F (74°C) rated, 17⁄32 in. (13.5 mm) orifice, quick response sprinklers under the
mezzanine. Space sprinklers no more than 10 ft (3 m) apart in the aisles and beneath the mezzanine
overhangs. Install sprinklers within 18 in. (45.7 cm) of the mezzanine overhang faces. Coverage should not
exceed 110 ft2 (10.2 m2) per head (see Fig. 7).
In Figure 7 there are six creel trees are shown. Automatic sprinkler protection is provided in tie aisles on
10 ft (3 m) spacing. Automatic sprinklers are also provided below the overhang on 10 ft (3 m) spacing.
Automatic sprinklers would be needed for loading aisles if aisles were used for storage. In this example yarn
carts and aisle conveyors are used to replenish cones on creel trees. All automatic sprinklers are 165°F
(74°C) rated, 17⁄32 in. (13.5 mm) orifice quick response rack sprinklers.
2.1.3.17.1.4 Provide sprinkler coverage at the ceiling of no more than 130 ft2 (12.1 m2) per head and either
the 165°F, 212°F, or 286°F (74, 100, 141°C) rated sprinklers are acceptable.
2.1.3.17.2 Modern Creels With Solid Mezzanines

2.1.3.17.2.1 Provide coverage of 110 ft2 (10.2 m2) per sprinkler beneath solid mezzanines. Install sprinklers
in tie aisles beneath the mezzanines and beneath the mezzanine overhangs. Sprinklers should be designed
using the criteria outlined in section 2.1.3.17.3. Provide sprinkler protection for loading aisles when aisles
are used for storage of yarn. Coverage should not exceed 110 ft2 (10.2 m2) per head.
2.1.3.17.3 Creels with open grated mezzanines and solid mezzanines with openings 4 in. (10.2 cm) or wider.
2.1.3.17.3.1 Install automatic sprinklers within creel trees at or just below the mezzanine floor level(s) and
beneath mezzanine overhangs. Do not space sprinklers more than 8 ft (2.4 m) apart within the creels and 10 ft
(3 m) apart beneath mezzanine overhangs. Install sprinklers within 18 in. (45.8 cm) of the mezzanine
overhang faces. Stagger sprinklers horizontally and also vertically if more than one mezzanine level is
involved.
2.1.3.17.3.2 Base the design of the system on the operation of the 6 most remote mezzanine sprinklers
flowing 22 gpm (84 l/min) each or 12 heads (six on two levels) if more than one mezzanine is involved
vertically. Design 500 gpm (1900 l/min) for hose plus the ceiling sprinkler density of 0.20 gpm/ft2 (8 mm/min)

over 2000 ft2 (186 m2) or 0.15 gpm/ft2 (6 mm/min) density over 2500 ft2 (232.3 m2). Use Approved 165°F
(74°C) rated, 17⁄32 in. (13.5 mm) orifice, quick response rack sprinklers in the creels beneath the mezzanines.
See Figure 8 for old style creel with open grating.
Fig. 8. Old style creel with an open mezzanine.

Fig. 7. Modern creel with a solid mezzaine.

In Figure 8 three creel trees are shown. There typically would be several creel trees. Automatic sprinkler
protection is provided in the creel tree on 8 ft (2.4 m) spacing. Sprinklers are staggered. Automatic sprinklers
are also provided below the overhang on 10 ft (3 m) spacing. All automatic sprinklers are 165°F (74°C) rated,
17⁄32 in. (13.5 mm) orifice quick response rack sprinklers.
2.1.3.17.3.3 Automatic sprinklers at the ceiling may be 165°, 212°, or 286°F (74, 100, 141°C) rated with
coverage up to 130 ft2 (12.1 m2) per head.
2.1.3.17.3.4 Provide additional sprinkler protection if aisles parallel to creels are used for yarn storage.
2.1.3.17.4 Creels with No Mezzanines

2.1.3.17.3.1 Provide ceiling sprinkler protection for creels up to 8 ft (2.4 m) high designed to deliver a
0.15 gpm/ft2 (6 mm/min) over the most remote 2,500 ft2 (232 m2) plus 500 gpm (1900 l/min) for hose streams.
2.1.3.18 Pin Trucks

2.1.13.18.1 Use the following precautions with acrylic and blends of acrylic yarn stored on pin trucks:
a) Provide noncombustible enclosures for each row of pin trucks. Design enclosures such that a vertical
barrier is provided between each row of pin trucks. Design the barrier over the storage to be approximately
24 in. (61 cm) above the top of the pin truck. Design the barrier to extend 18 in. (46 cm) beyond the face
of the pin truck (see Fig. 9).
Fig. 9. Pin truck containing acrylic yarn located within enclosure constructed of metal panel on steel frame. Automatic
sprinkler protection designed for in-rack storage shown within the enclosure. Automatic sprinkler protection not
shown at ceiling level.
b) Provide automatic sprinklers, on a separately valved connection, on 8 ft (2.4 m) centers above each
row of pin trucks. Use large orifice (17⁄32 in. [13.5 mm]) pendent automatic sprinklers with a temperature
rating of 165°F (74°C) should be used. Design the system to flow a minimum of 30 gpm (114 l/min) from
each of the 8 most remote sprinklers with allowance for 500 gpm (1900 l/min) hose stream demand.
2.1.3.19 Air Conditioning Systems
2.1.3.19.1 General
2.1.3.19.1.1 Protect cooling towers in accordance with Data Sheet 1-6, Cooling Towers.
2.1.3.19.1.2 Develop a recovery plan to allow for immediate replacement or provision of an alternate system
for cooling in the event of loss of a cooling tower.

2.1.3.19.2 Construction and Maintenance of Ducts and Tunnels

2.1.3.19.2.1 Construct tunnels large enough for personnel entry or regular housekeeping. Provide a smooth
epoxy coating to reduce lint buildup. Inspect these tunnels regularly and clean as necessary.
2.1.3.19.2.2 Provide sheet metal sleeves for through the floor openings to air return. Arrange metal sleeves
to extend above and below the floor to reduce the chance of fire spread through openings. Provide tight
fitting covers for the openings for use by the Emergency Response Team (ERT) to prevent fire spread.
2.1.3.19.2.3 Round, small diameter, branch feeder tunnels and ducts will require more frequent cleaning
with mechanical devices to facilitate regular housekeeping operations.
2.1.3.19.2.4 Keep underfloor return air ducts and tunnels clean. No matter how well they are designed,
periodic scheduled cleanings are necessary. Provide clean out openings in ducts that are not otherwise
accessible for cleaning.
2.1.3.19.2.5 Design HVAC systems in opening through weaving or knitting so that in case of fire in the main
plant areas or in the ventilation system, smoke from the fire will be exhausted directly to the outside. Interlock
electrical controls to: a) stop the supply fan, b) close the recirculating air dampers, and c) open the exhaust
damper. The exhaust fan should be kept running so that smoke-laden air will be drawn through the exhaust
system to the outside. Arrange controls to be on a single circuit with the switch(es), and either automatically
activated by fire protection equipment or manually activated by personnel in the area serviced by the
ventilation system. Train personnel to activate only the switch controlling the ventilation system for the area
in which the fire occurs. If an exhaust system is in operation or is started to vent smoke from the area, do
not shut it off until the fire is extinguished. If a fire occurs when the exhaust system is not in operation do not
start fans until fire is extinguished.
2.1.3.19.2.7 Filter all return air through a filter media capable of removing fine particles of lint before the
air enters the supply air duct system.
2.1.3.19.2.8 Stock enough filter media to recover the largest filter.
2.1.3.19.3 Fire Protection

2.1.3.19.3.1 Provide automatic sprinklers on 8 ft (2.4 m) spacing designed to maintain a flow of 22 gpm
(84 l/min) from each sprinkler over V-Type or flatbed filters in the wall if ceiling protection is obstructed.
2.1.3.19.3.2 Provide automatic sprinkler protection in accordance with section 2.1.3.1.7 over the filter unit
in the air conditioning system where there is combustible construction or lint accumulation (see Fig. 21).
2.1.3.19.4 Pneumatic Waste Recovery and Cleaning Systems (see Fig. 10)
2.1.3.19.4.1 Provide automatic sprinkler protection in accordance with section 2.1.3.1.7 for waste bins and
houses.
2.1.3.19.4.2 Provide automatic sprinklers in accordance with section 2.1.3.1.7 in waste houses, including
filter units where appreciable quantities of fiber lint accumulate and over V-type or rotating drum-type filters.
2.1.3.19.4.3 Provide automatically operated special protection systems (dry chemical) if cotton or other fiber
may contain tramp metal. Arrange for automatic fan shutdown.
2.1.3.19.4.4 Provide watertight joints where ducts pass through floors to reduce water damage.
2.1.3.19.4.5 Stock enough filter media to recover the largest filter.
2.1.3.20 Wool
Follow protection recommended for cotton processing for comparable operations in wool processing. Due
to low loss frequency, special protection systems generally are not cost effective.
2.1.3.21 Synthetics
2.1.3.21.1 Provide protection as recommended for cotton and cotton/synthetic blends. Provide automatic
sprinkler protection if amounts of fiber are equal to or greater than 500 lbs (227 kg).
2.1.3.21.2 Protect acrylic yarn on pin trucks as described in Section 2.1.3.18.

7-1
Page 16

Fig. 10. Waste House. Lint-laden air is filtered by a rotary drum filter and returned to the room. Waste removed from the surface of the filter is ducted to
the baler through a stripper duct. IR detection is provided in inlet duct, waste house and stripper duct. The rotary drum filter is protected by an
automatic dry chemical system activated by IR system. In addition, the waste house has automatic sprinkler protection.
Fire Protection For Textile Mills
FM Global Property Loss Prevention Data Sheets
2.1.3.22 Nonwovens
2.1.3.22.1 Protect areas without in-process or finished product storage as outlined in synthetics.
2.1.3.22.2 Protect rolled nonwoven fabric and batting storage in accordance with Data Sheet 8-23, Rolled
Nonwoven Fabric Storage. Protect sheets of nonwoven fabric on pallets up to 6 ft (1.8 m) high in accordance
with Data Sheet 8-9 as Group A unexpanded plastic. Treat sheets of highloft nonwoven batting the same
as rolled highloft nonwoven batting as defined in Data Sheet 8-23.
2.1.3.22.3 Design and maintain chemical bond spray guns to keep overspray to a minimum. Keep the area
around spray guns clear of over spray and fiber buildup.
2.1.3.22.4 Emphasize housekeeping around garnett machines.
2.1.3.22.5 Keep fiber, in-process and finished product storage away from machinery and other potential
ignition sources.
2.1.3.23 Carpet
2.1.3.23.1 Provide protection for production areas as described in Synthetics.
2.1.3.23.2 Provide automatic sprinkler in creel racks as described in Section 2.1.3.17.
2.1.3.23.3 Protect carpet racks as described in Data Sheet 8-30, Storage of Carpets.
2.1.3.23.4 Provide automatic sprinkler protection in carpet ovens.
2.1.3.24 Synthetic Yarns

2.1.3.24.1 Synthetic yarns are yarns having a synthetic content of more than 50%. Protect Synthetic yarns
per the guidance in Table 2.
Table 2. Protection of Synthetic Yarn Storage

Storage Arrangement Storage Height Data Sheet Reference
Solid-piled <16 ft (<5 m) 8-9 Treat as rack storage and
use Table 10.
Solid-piled >16 ft (>5 m) 8-9 Treat as rack storage and
Rack Any use Table 11 or Section 2.
In-Process 6 ft (1.8 m) 3-26 Use Table 2 or Table 3.
2.1.4 Operation and Maintenance

Prevention and control of fires depends largely on good maintenance, cleaning and lubrication programs.
2.1.4.1 Establish written corporate and plant policies on housekeeping to ensure scheduled cleaning for floor,
wall, ceiling, supply and return air ventilation systems. Promptly reschedule skipped cleanings. Provide a
documented line of authority for authorizing a cleaning delay and rescheduling. As a general rule the maximum
tolerable deposit thickness for loose fluffy lint is 1⁄2 in. (13 mm) over a maximum of 500 ft2 (46.5 m2). Limit
dense deposits to 1⁄4 in. (6 mm) and oil saturated deposits to 1⁄8 in. (3.2 mm).
2.1.4.2 Replace corroded sprinkler heads, pipes and hangers. See Data Sheet 2-81, Fire Safety Inspections
and Sprinkler System Maintenance.
2.1.4.3 Flush and hydrostatically test underground fire mains over 50 years old at 50 psi (3.4 bars) above
maximum operating pressure as described in Data Sheet 3-10, Installation/Maintenance of Private Fire
Service Mains and their Appurtenances.
2.1.4.4 Conduct flushing investigations, as described in Data Sheet 2-81, Fire Safety Inspections and
Sprinkler System Maintenance, for dry pipe sprinkler systems at 15 yrs and 25 yrs and at 5 year intervals
after system installation.
2.1.4.5 Establish a maintenance, cleaning and lubrication schedule for all equipment. The maintenance and
cleaning schedule will vary with type of fiber processed and the equipment used. Lubricate equipment in

accordance with manufacturer’s recommendations. Review plant fire loss records to determine whether
cleaning or equipment maintenance was a factor, and increase frequency as needed.
2.1.5 Electrical
2.1.5.1 General
2.1.5.1.1 Maintain electrical systems in good working order and keep free of lint buildup to reduce the
potential for ignition. This includes cleaning inside junction boxes, buses, trays, tunnels, etc. Housekeeping
is critical.
2.1.5.1.2 Provide FM Approved electrical equipment for use in areas containing airborne lint or dusts.
Equipment should be approved to national standards. Where national standards are not available use
equipment approved for Class III Hazardous locations as defined by the National Electrical Code.
2.1.5.1.3 Establish a program of preventive maintenance so that all electrical equipment is periodically
inspected. (See Data Sheet 5-20, Electrical Testing.) Include annual IR inspections of electrical equipment
in the program.
2.1.5.2 Load Centers

2.1.5.2.1 Locate load centers in noncombustible rooms maintained at a positive pressure. Prevent use of
the room for other purposes.
2.1.5.2.2 Where computer programming is used for load centers keep a copy of the program in a separate
fire area. One method of doing this may be by having the vendor (installer) maintain and update software.
2.1.5.2.3 Dry-type transformers are preferred. See Data Sheet 5-4, Transformers.
2.1.5.2.4 If ventilated dry transformers are used, locate them where they will not be exposed to lint
accumulations, dust or corrosive atmospheres.
2.1.5.3 Enclosures
2.1.5.1.3 Provide FM Approved electrical equipment for use in areas containing airborne lint or dusts.
Equipment should be approved to national standards. Where national standards are not available use
equipment approved for Class III Hazardous locations by the National Electrical Code. If FM Approved
equipment is not available, equipment listed, labeled or approved by another recognized testing laboratory
is preferable to unapproved equipment. If such equipment is not available use NEMA Type 12 equipment.
2.1.5.4 Lighting Equipment

2.1.5.4.1 Do not use temporary lighting units (e.g., drop cords, etc.) since there is a greater chance that
temporary units will be improperly hung and as a result, broken.
2.1.5.4.2 Provide FM Approved electrical equipment for use in areas containing airborne lint or dusts
(ventilation tunnels, air wash rooms, dirty side dust houses, etc.). Equipment should be approved to national
standards. Where national standards are not available use equipment approved for Class III Hazardous
locations by the National Electrical Code.
2.1.5.4.3 Do not install high voltage series cold-cathode fluorescent lights.
2.1.6 Human Factor

2.1.6.1 Develop an emergency procedure to alert the Public Fire Department promptly in an emergency.
2.1.6.2 Develop an emergency plan that includes emergency supervision of sprinkler control valves, fire
pumps, and special protection systems.

2.2 Finishing Operations
2.2.1 Introduction
Maintenance and housekeeping are critical to reducing the frequency and severity of fire losses. Fire
frequency in finishing operations is expected to be highest in ovens, dyers and ducts associated with this
equipment. Written corporate and plant policies are needed to ensure cleaning schedules are adequate.
Changes in production scheduling can result in overloaded and inadequately protected storage areas.
Protection is needed for the worse case storage arrangement. Relocate excessive storage to a properly
protected storage room or warehouse.
Plant interdependencies are common. Several greige goods mills may supply yarn or fabric to a finishing
plant.
2.2.2 Protection
2.2.2.1 General
2.2.2.1.1 Install automatic sprinklers at ceiling level in all areas. Provide a density of 0.15 gpm/ft2 (6 mm/min)
for 2500 ft2 (232 m2) for wet pipe systems and 0.15 gpm/ft2 (6 mm/min) over 3500 ft2 (325 m2) for dry systems
for a duration of 60 minutes. Use 250 gpm (950 l/min) for hose streams.
2.2.2.1.2 Protect heat transfer systems in accordance with Data Sheet 7- 99, Heat Transfer by Organic and
Synthetic Fluids.
2.2.2.2 Bleaching
Follow recommendations pertaining to protection of hydrogen peroxide as described in Data Sheet 7-84,
Hydrogen Peroxide. In particular, mixing with any alkaline material (e.g., sodium hydroxide) can cause
increased decomposition rates.
2.2.2.3 Dyeing
Where pin trucks or yarn carriers are used to force air-dry yarn, provide a sprinkler water flow interlock to
shut off air flow to the dryer in event of automatic sprinkler actuation.
2.2.2.4 Ovens, Dryers, Tenter Frames

2.2.2.4.1 Provide automatic sprinkler protection in multi-pass and festooned ovens, dryers, and exhaust
stacks as recommended in Data Sheet 6-9, Industrial Ovens and Dryers. Provide automatic sprinkler
protection for carpet dryers even though they may be single pass.
2.2.2.4.2 Protect exhaust ducts as recommended in Data Sheet 7-78, Industrial Exhaust Systems.
2.2.2.4.3 Establish a scheduled cleaning program for the above areas, and maintain records to ensure that
cleaning is being done.
2.2.2.4.4 Follow additional protection recommendations as described in Data Sheet 6-9, Industrial Ovens
and Dryers, and Data Sheet 7-78, Industrial Exhaust Systems.
2.2.2.5 Heat Transfer Oil Systems

2.2.2.5.1 Design and protect and heat transfer fluid (HTF) systems in accordance with Data Sheet 7-99,
Heat Transfer by Organic and Synthetic Fluids. Systems may include rotating couplings and elevated holding
tanks.
2.2.2.5.2 Provide interlocks to automatically shutdown the HTF system in event of fire.
2.2.2.5.3 Provide automatic sprinkler protection for ovens and dryers heated by HTF systems.
2.2.2.6 Heat Set Range

Provide adequate housekeeping and cleaning cycles inside and around these ovens based on usage and
chemicals used.

2.2.2.7 Printing Dyes and Screen Manufacturing

2.2.2.7.1 Protect flammable liquids in accordance with Data Sheet 7-29, Ignitable Liquid Storage In Portable
Containers.
2.2.2.7.2 Provide high temperature and low liquid level interlocks to shutoff and alarm for plastic tanks.
2.2.2.8 Nappers
2.2.2.8.1 Provide an exhaust ventilation system for lint removal if the operation produces lint.
2.2.2.9 Cutting and Sewing

2.2.2.9.1 Provide automatic sprinkler protection below tables or keep these areas clear of combustibles at
all times.
2.2.3 Human Factor

2.1.6.1 Develop an emergency procedure to alert the Public Fire Department promptly in an emergency.
2.1.6.2 Develop an emergency plan that includes emergency supervision of sprinkler control valves, fire
pumps, and special protection systems.
3.0 SUPPORT FOR RECOMMENDATIONS

Textile mills are often located in rural areas serviced by fire departments that may have limited equipment,
training, and personnel. Fire departments may have had little or no training in fighting fires in industrial facilities
or buildings equipped with automatic sprinklers. Congested conditions, deep-seated fires and concealed
spaces make firefighting difficult. The lack of adequate fire department preplanning and training can result
in inefficient firefighting.
4.0 REFERENCES
4.1 FM Global
Data Sheet 1-6, Cooling Towers.
Data Sheet 2-0, Installation Guidelines for Automatic Sprinklers
Data Sheet 2-81, Fire Safety Inspections and Sprinkler System Maintenance.
Data Sheet 3-10, Installation/Maintenance of Private Fire Service Mains and Their Appurtenances.
Data Sheet 5-4, Transformers.
Data Sheet 5-20, Electrical Testing.
Data Sheet 6-9, Industrial Ovens and Dryers.
Data Sheet 7-29, Ignitable Liquid Storage in Portable Containers.
Data Sheet 7-76, Prevention and Mitigation of Combustible Dust Explosions and Fires.
Data Sheet 7-78, Industrial Exhaust Systems.
Data Sheet 7-84, Hydrogen Peroxide.
Data Sheet 7-95, Compressors.
Data Sheet 7-99, Heat Transfer By Organic and Synthetic Fluids.
Data Sheet 8-7, Baled Fiber Storage.
Data Sheet 8-9, Storage of Class 1, 2, 3, 4 and Plastic Commodities.
Data Sheet 8-23, Rolled Nonwoven Fabric Storage.
4.2 NFPA Standards

NFPA 70, National Electrical Code, 1999.
4.3 Others
Canadian Electrical Code.

APPENDIX A GLOSSARY OF TERMS

FM Approved: References to ″FM Approved″ in this data sheet mean a product or service has satisfied
the criteria for FM Approval. Refer to the Approval Guide, an online resource of FM Approvals, for a complete
listing of products and services that are FM Approved.
Ignitable Liquid: Any liquid or liquid mixture that is capable of fueling a fire, including flammable liquids,
combustible liquids, inflammable liquids, or any other reference to a liquid that will burn. An ignitable liquid
must have a fire point.
New England Mill Construction: textile mill buildings with multistory plank on timber floors and roof with
brick wall construction.
APPENDIX B DOCUMENT REVISION HISTORY

The purpose of this appendix is to capture the changes that were made to this document each time it was
published. Please note that section numbers refer specifically to those in the version published on the date
shown (i.e., the section numbers are not always the same from version to version).
April 2020. Interim revision. Updated protection guidance for the storage of synthetic yarns.
January 2012. Terminology related to ignitable liquids has been revised to provide increased clarity and
consistency with regard to FM Global’s loss prevention recommendations for ignitable liquid hazards.
January 2009. Sprinkler density and water supply recommendations for textile plant production areas were
added.
September 2002. The following changes were made for this revision:
1. The need for a written corporate and plant policy on housekeeping to ensure that cleaning is conducted
when scheduled. A documented line of authority is necessary to authorize a delay and rescheduling. Also
guidelines on depth of deposits are included.
2. Recommendations have been made for protection of in-process storage.
3. Recommendation removed for automatic sprinkler protection for sliver cans under spinning frames due
to the lack of adequate clearance. Stressed improvement in housekeeping to prevent fire exposure to sliver
cans.
4. Recognition that plant interdependencies are common in the textile industry and that manufacturing
operations leading to a finished product may occur in several different plants.
September 2000. This revision of the document has been reorganized to provide a consistent format.
APPENDIX C SUPPLEMENTARY INFORMATION
C.1 Greige Goods

Greige goods are unfinished yarn or fabric. The raw material is received as natural or synthetic staple in
bales. The processing involves aligning the fiber, cleaning (for materials such as cotton and wool), forming
a rope-like material and then combining and twisting to produce yarn. Yarn may be the finished product of a
greige goods mill, or it may be woven into a fabric that is generally shipped elsewhere for further processing.
C.1.1 Construction and Location

Older mills can be of multistory plank on timber floors and roof with brick wall construction. Concealed spaces
are common below floors, within floors, above ceilings and inside walls. Floor penetrations are also common
and in event of fire can result in increased water and smoke damage. Older mills are often located along
rivers and flood plains.
Heavy wood timbers and planks can withstand fire exposure longer than exposed steel but will add
considerable combustible loading and can result in a deep-seated fire.
Exposed steel construction, piping and electrical in bleaching and dying areas will deteriorate from exposure
to moisture and caustics.

Mills are often located in small towns and rural areas with fire departments having limited resources,
equipment, and training for preplanning for firefighting in large industrial sprinklered buildings.
C.1.2 Protection
The protection systems typically encountered in a mill should include: 1) automatic sprinkler systems
throughout the mill at ceiling level and in equipment such as waste houses, mixers and blenders containing
large quantities of fiber, 2) special protection systems for enclosed processing of fiber. These systems will
normally consist of high speed detection systems with discharge of agent into equipment to quickly control a
fire in areas from opening to carding, 3) portable extinguishing equipment.
C.1.2.1 Automatic Sprinkler Protection

Automatic sprinkler protection should be at ceiling level in all areas of the mill. Protection also should be
provided within equipment containing 100 lb (45.5 kg) or more of cotton fiber not protected with a special
protection system. Protection should be provided for equipment containing more than 500 lb (227 kg) of any
fiber regardless of whether a special protection system is used.
C.1.2.2 Special Protection Systems

Special protection systems are needed in areas of the mill where cotton is handled within enclosed systems.
Examples are the early stages of processing from opening to chute fed cards. Unless special protection is
provided in these areas, a fire starting in an opener could spread through cleaning and blending equipment
to chute fed cards. Special protection systems consist of optical detection and an extinguishing agent. A
special protection system installation is shown in Figure 1 in an opening through carding installation.
FM-200 or dry chemical is typically used. These agents will not extinguish a deep seated cotton fire. The
fire must be detected by flame detection systems in the equipment or in the duct upstream of the equipment.
Agent is discharged within 50 milliseconds and arrives at about the same time as the spark or burning ember.
This temporarily provides an inert atmosphere that will prevent re-ignition. Provisions should be made on
all equipment to remove fiber and extinguish residual fire with portable extinguishers.
C.1.2.3 Detection
Infrared detection systems are used to detect fires in ducts between process equipment. The reliability of
detection depends on proper installation, maintenance and testing. The response time from detection to
discharge of agent is typically 50 to 60 milliseconds.
Ultraviolet detectors may be used for detection of fire on filter media in rooms lighted by incandescent lamps.
Infrared detectors may also be used and are more sensitive to detection of burning embers. Lighting must
be off in the room under normal operation. When entry to the room is required the detector circuit is arranged
to be shut off by a keyed switch. The key is then used to operate another switch turning on the lights in the
room. When the detectors are bypassed the fire protection control panel indicates a trouble condition.
The number of infrared detectors used depends on duct diameter and quantity of material transferred. Stock
transfer ducts are typically 12 in. (300 mm) and 14 in. (350 mm) and have large quantities of material passing
through the duct. For these ducts there would normally be three detectors positioned at 120° angles. Waste
air ducts have lower quantities of material, detectors are able to ‘‘see’’ greater distances. The number of
detectors used by one leading installer of textile fire protection equipment is shown in Table 2.
Table 2. Spacing of Detectors in Round Ducts

Type of Duct Duct Diameter No./Location of Detectors 1
Stock Transfer Up to 12 in. (300 mm) 2 opposite each other
12 to 14 in. (300 to 350 mm) 3 detectors at 120° spacing
Waste Transfer Up to 16 in. (400 mm) 2 detectors opposite each other
16 to 36 in. (400 to 900 mm) 3 detectors at 120° spacing
36 to 48 in. (900 mm to 1200 mm) 4 detectors at 90° spacing
48 to 60 in. (1200 to 1500 mm) 5 detectors
1. Detectors should not be located in the bottom of the duct.

C.1.2.4 Extinguishing Agent

Tests have been conducted on several extinguishing agents for protection of textile equipment. These agents
include CO2, dry chemical, Halon 1211, and FM-200. It was found that the CO2 concentration required for
effective operation is 75% with a 20 min soak time. CO2 is not practical for most equipment since there is a
substantial amount of condensation which requires extensive cleanup. Experiments have been conducted
with both BC and ABC dry chemical agents. ABC leaves a corrosive residue. BC type dry chemical was one
of the first agents used for special protection systems. It continues to be used for protection of waste air
filtration systems since the airflow in many of these units will draw gaseous agent out. Dry chemical is also
drawn out but enough remains on the filter media to control and stop the progress of the fire. Halon 1211
was the most effective agent and may still be used in some mills. Halon 1211 systems may not be permitted
by regulatory authorities. FM-200 is used for new systems.
The FM-200 design concentration for internal equipment protection is 15% for 20 minutes. The agent quantity
and number of nozzles used depends on the volume protected. A concentration of 0.08 lbs/ft3 (1.3 kg/m3)
is used to determine adequacy of agent supply. The number of nozzles used ranges from two to twelve
nozzles. The sodium bicarbonate dry chemical design concentration for protection of the filter media is
typically: a) rotary drum filters less than 16 ft (4.9 m) long are protected with one 30 lb (13.6 kg) cylinder,
b) rotary drum filters 16 ft (4.9 m) or longer are protected with two 30 lb (13.6 kg) dry chemical cylinders,
and c) ‘‘V’’ filters are protected with one 30 lb (13.6 kg) cylinder.
C.1.2.5 Testing and Maintenance of Special Protection Systems.

Few failures of special protection systems have been reported.
The system should be tested quarterly. During this time the system should be visually inspected and the
detectors tested. Agent discharge is not required. The cylinder should be replaced with a test light and the
detectors activated by an infrared LED.
Some installations have been reported that are 20 to 25 years old. As systems age electrical components
tend to fail. It has been reported that control panels tend to fail at a higher rate than detectors over the life
of the installation.
Cartridge operated dry chemical systems are sometimes found with empty CO2 cartridges because they
were not properly charged after the last actuation. Also, cartridges have a greater chance of leaking when
improperly filled. A PDG valve was developed for the FM-200 and Argus dry chemical systems. This valve is
designed with a low-pressure switch that will produce a trouble signal on loss of pressure.
C.1.2.6 Portable Extinguishing Equipment

Recommended Equipment: dry chemical will control a surface fire, but a smoldering fire will continue to burn
beneath the surface regardless of whether the cotton is in an unopened bale or loose fiber in a condenser.
Dry chemical extinguishers are available in a wide range of capacities. However, the 10, 15, and 20 lb (4.5,
6.8, 9.1 kg) units are most widely used for textile applications.
Small hose with combination straight stream and spray nozzles is recommended for areas of the mill where
large concentrations of cotton or lint are located. The hose water supply should be independent of the
sprinkler system so that it can be used for firefighting during an impairment or for mop-up operations after
the sprinkler system has been shut off. In some cases, this may not be practical. As a minimum, hose can be
connected to a sprinkler system in an adjacent area. If a dry-pipe system is used, hose should be connected
to the wet side of the dry valve. For most process areas, a garden hose nozzle on 3⁄4 in. (1.9 cm) rubber
hose is effective. For jacquard and plush weave rooms, a spray nozzle on a 6 ft (1.8 m) long applicator on
a 3⁄4 in. (1.9 cm) rubber hose is effective.
Water pump tanks and stored pressure water extinguishers are effective in extinguishing fires involving small
quantities of cotton. Water pump tanks are available in 2-1⁄2 and 5 gal (9.5 and 19 l) capacity. Stored pressure
extinguishers are available in 2-1⁄2 gal (9.5 l) capacity. These units have short lengths of hose. Spray nozzles
should be provided to prevent scattering of loose cotton by the discharge.
Equipment Not Recommended: The following equipment is effective on many types of fires, but is not
recommended for use in textile mills. Multipurpose Dry Chemical (Mono-Ammonium Phosphate Base) is as
effective as other dry chemical agents in controlling surface fires. However, the powder tends to soften and
become sticky under fire conditions, making cleanup difficult, particularly on cards.

Carbon dioxide and halon extinguishers have difficulty maintaining an extinguishing concentration. In addition,
the discharge tends to scatter burning cotton.
Foam extinguishers are impractical to apply agent over a wide area, and the chemical content of the agent
may cause more damage than plain water. (One type of foam extinguisher using AFFF foam is suitable for
use on Class A fires as a stored pressure water extinguisher.)
C.1.3 Operation and Maintenance

The area of greatest improvement has been in maintenance and lubrication of textile equipment. Mill
maintenance specialists handle preventive maintenance on a scheduled basis, where the work order
describing the specific activity is either automatically generated by computer or manually by a card file system.
In some mills, operators are responsible for lubrication of machinery. In other mills, maintenance personnel
handle both lubrication and maintenance.
Some mills evaluate fire losses by department to determine whether equipment cleaning and maintenance
frequencies need to be increased.
Once cleaning schedules are established for walls, ceiling, floor, exhaust and supply air ventilation systems,
they should be adjusted based on observations made when cleaning is done, i.e., some areas may need
more frequent cleaning.
C.1.4 Occupancy
C.1.4.1 Opening Equipment

The purpose of the preparatory equipment is to open up the tightly compressed cotton and remove foreign
material such as motes, leaves or dirt. These are the first machines into which the fiber is introduced.
Arrangement of Opener Room
Use of automated opener equipment has resulted in more efficient use of floor area in the opener room.
This equipment also results in essentially unmanned opener rooms with a corresponding increase in time
to detect and manually fight a fire. Usually, on the first shift, a large enough supply of cotton and synthetic
bales are brought in to last the 24-hour period. Unopened bales in storage in the opener room are wrapped
with polypropylene, jute, or polyethylene and secured with metal wire or bands. They are generally well
removed (by distance) from opening equipment.
Most fires caused by opening equipment result in fires in equipment downstream rather than in cotton
laydown. Opening rooms are generally cleaner now than in the past due most likely to the use of automated
opening equipment. The 20 ft (6 m) separation between bale laydown for feeder blending was reduced to
10 ft (3 m) for bale laydown for automatic bale openers for this reason. Wrapping of bales with polypropylene,
jute or polyethylene generally results in less likelihood of fire spread across unopened bales. The loss
experience has been favorable with regard to fires in opener rooms.
Blending Feeders
Blender-openers (Fig. 11) were the first step in the opening process and were hand-loaded. They may still
be hand-loaded when synthetics are used. Where cotton is used, and in most cases where synthetics are in
use, they are the second step in the process. They often are equipped with individual auxiliary cleaning
sections. Their speed is low and they create little fire hazard. In many cases, these units replace vertical
openers.
Choking or excessive wrapping of fiber around bearings can be reduced by not overloading blending feeders.
Keeping the hopper not over two-thirds full is the practice at most mills.
For new installations and where loss experience indicates that bale breakers or older blending feeders are
a factor in recurring fires, fully enclosed opening feeders (Fig. 12) offer several desirable safety features.
Included are sealed bearings that are not likely to become choked by stock, enclosed hopper design that
results in rapid sprinkler actuation, and an exhaust system for removing dust and fine lint.
Automatic Bale Openers
There are several types: In one type, fiber laydown is on the floor adjacent to the machine. In the type shown
in Figure 2, an overhead crane is used to transfer fiber to the blender. The crane is activated by sensors

Fig. 11. Blender-opener combination. Layers of cotton from several bales are placed on the feed apron. Cotton is drawn
up the lift apron, under doffer rolls, between feed rolls, and over cleaning grids to break the matted cotton up
into tufts and remove leaves, motes, etc.
on the feed table of the blenders. The crane automatically positions itself over a bale in the row in front of
the blender, pulls off a layer of cotton and drops it on the blender feed table.
It often is difficult to maintain a space between cotton laydown and the feed table due to cotton dropping
off the crane or operators pushing bales too close to equipment. Fires start in bale laydown will probably
involve blending feeders. If not quickly controlled, fires starting in blending feeders will spread to cotton
laydown. Fires typically start when foreign material such as metal or stones in the bales are struck by the
blades of the opening roller.
In the most frequently used bales of opened cotton are located parallel to a track (Fig. 3). The opener travels
along the track. A turret extends out over the tops of bales on one side. Opening rolls within the turret pluck
cotton from the bales and it is drawn through a telescoping tube to a duct to downstream cleaning equipment.
Depending on type of opener there may be as many as 90 bales on either side of the opener.
In the opener shown in Figure 13, bales are mounted on a turntable. Small beaters pull tufts of cotton from
the bottom of each bale. The fiber is carried by an air stream to downstream equipment. In another type,
several opened bales of fiber are mounted on a conveyor that moves forward and backward while steel fingers
penetrate the bale, pull out cotton tufts and drop it onto a conveyor belt below. Both machines essentially
eliminate the need for cotton laydown. Unopened bale storage will probably be found in opener rooms using
this equipment.
Vertical Openers
In some cotton mills, the vertical opener is the first equipment having rapidly rotating parts. The cotton is
pneumatically conveyed upward through the machine. The arms of a vertically mounted steel beater,
surrounded by adjustable steel grid bars, throw the cotton outward against the grid bars. Motes, leaves and
dirt pass through the grid and are removed.
Horizontal Openers and Cleaners
The several styles of horizontal cleaners are usually fed by a lattice apron and a fluted feed roller (Figs. 13,
14, 15). The beater is mounted horizontally, giving either an upward or downward stroke to the cotton held
between the feed rollers. Surrounding the beater are a number of grid bars that remove fly, dirt or motes.

Fig. 12. Opening feeder. Layers of cotton from several bales are placed on the feed apron. Cotton from the layers is drawn
up the lift apron and broken up into tufts by two combs before being deposited into a weigh hopper or directly
onto a feed table.

Fig. 13. No. 16-1 opener with No. 11 condenser feed. Used to further open and clean cotton that has passed through
preliminary cleaning and opening equipment such as shown in Figure 20. Cotton enters the No. 11 condenser
and impinges on the face of a perforated cylinder (condenser cage). Cotton impinging on the cage is retained;
impurities such as dust and trash pass through the perforations, through the exhaust fan and duct, and are filtered.
The doffer strips the cotton from the surface of the cage and drops it into the reserve box. Delivery rolls ensure
an even flow of stock to a short lattice apron that transports the cotton to feed rolls, revolving grids, and a beater
that further cleans the fiber. Cotton is then passed into a vertical trunk where it strikes an adjustable plate or trap.
Heavy particles are deflected downward and the cotton is carried upward by the air stream.

Some lattice openers are equipped with supplementary beater assemblies for improved cleaning. The number
of fires appears to increase rapidly with operating speed.
Centrif-Air Machines
The Centrif-Air machine is somewhat similar in action to the vertical opener. The cotton enters one end of
the machine and is pneumatically carried through it. The beater shaft is mounted horizontally; this is one of
the few opener-cleaning machines having non-ferrous beaters or beaters protected by brass sheathing. Dirt,
motes or fly are removed from the stock through slotted openings in a screen surrounding the beater. There
is a tendency for cotton to wind around the beater shaft at the discharge end of the machine.
Blending Equipment
Blending needed for uniform yarn quality can be achieved in a mixer of the type shown in Figure 16. The
height of the machine and number of chambers and, therefore, the quantity of fiber varies with model of the
machine. Fiber enters the machine from upstream cleaners and is conveyed into the feed duct above the
chambers. The entry of fiber into the chambers is controlled by dampers that open on low level sensors. Fiber
that has arrived from the upstream machine at different times is combined in the chambers. Fiber passes
through opener rolls and is ducted to downstream equipment.
C.1.4.2 Waste Recovery

Most cotton mills recover all reworkable waste from cards, combers, drawing frames, slubbers and spinning
frames.
Card lap ends, if kept off the floor, can be kept relatively free of foreign material and are less hazardous
than baled cotton.
Clean sliver waste is obtained from cards, combers, drawing frames and slubbers; if collected in sliver cans
or boxes, it usually is free of foreign material. As sliver waste contains parallel fibers with a slight twist, it
has some tensile strength. Unless broken up into small pieces, it has a tendency to wrap around moving
machine parts, causing friction fires.
The most positive method of breaking up sliver waste is to pass it through a separate waste machine having
a beater section or through a garnetting machine. A less positive method is to feed the waste directly into
a separate blending feeder equipped with an oscillating comb. With a setting of the comb close to the lift apron,
the sliver is fairly well broken up.
Roving and scavenger waste from slubbers, intermediates or spinning frames contains considerable twist
and is accumulated in boxes or cans. This waste often contains ring travelers (usually metal).
C.1.4.3 Magnetic Separators

Most opener fires in cotton mills can be traced to the presence of tramp metal in raw or waste stocks. Magnetic
separators (Figs. 17, 18) provide automatic means of extracting such foreign material during the preparatory
process, thus protecting against mechanical damage to machinery as well as removing a possible fire cause.
Two types of magnets are available: 1) electromagnets consisting of wire-wound pole pieces and requiring a
reliable source of direct current for excitation and 2) permanent magnet units made up of several high-
intensity magnets. Both styles are manufactured as either plate or pulley magnets. The permanent magnet
type is used in most modern installations.
The plate type consists of two magnetic separator plates installed in angular settings for direct impingement
of fibers against the magnet (Fig. 15). The magnetic plates extend the full width of the housing and are hinged
for accessibility and removal of collected debris.
The pulley type is available for installation above spiked lift aprons (Fig. 18) that feed directly to garnets, or
cards where preparatory equipment does not include intervening feed tables, openers or cleaners. This
installation is adaptable particularly to bedding and batt-making plants.
The use of the permanent-magnet pulley in the textile field is recommended only where a plate magnet is
not applicable. Pulley magnets are designed to operate in conjunction with a belt conveyor and are
continuously self-cleaning. Magnetic pulleys cannot be used with lattice or slat aprons because of the danger
of wedging solid materials between the conveyor and the pulley.

Fig. 14. Lattice opener with No. 11 condenser feed. Used to further open and clean cotton that has passed through
preliminary opening and cleaning equipment. The condenser is normally used to deliver cotton to the reserve
chamber of the lattice opener. Feed rolls deliver the stock to the beater. Foreign material drops into the waste
compartment as the cotton is drawn over the grid bars by the action of the beater blades.

Fig. 15. Axial flow cleaner. Entering stock from preliminary cleaning and opening equipment is further opened and cleaned.
Stock is drawn over the grid bars by the projecting pins on the cylinders. Waste accumulates in the compartment
below the grid bars.
C.1.4.4 Carding
Carding orients the fibers into a more parallel arrangement and removes short fibers. A rope-like strand (sliver)
or a flat web is produced depending on whether the end product is to be a woven or a nonwoven fabric.
Sliver may be wound into a can or several cards may be set up, in line, to deliver sliver to an endless belt.
The belt may be located below or beside the card. High speed cards are widely used. Ventilation systems
are necessary for high speed cards. Lint and fly are removed from between the cylinder and flats and from
the area around the feed and doffer rolls. The lint-laden air is then drawn through a duct to a filter assembly.
Essentially all cards are chute fed. Ducts and conveyors are used to transfer cotton from blenders or cleaners
to flock feeders. Flock feeders then distribute stock to card condensers that serve as holding chambers to
maintain a reservoir of cotton to ensure continued operation. This method of operation has generally resulted
in cleaner, more lint-free work areas.
A fire starting on a card usually will be drawn through a duct to the filter bank. Unless there is quick detection
and subsequent application of extinguishing agent, such a fire is likely to cause equipment damage and
prolonged shutdown. High speed infrared detection is presently the most effective method of detection of
flaming or smoldering cotton in a duct. The detectors usually are arranged to shut down equipment and to
activate an extinguishing system in the nearest downstream equipment with fiber holdup. Equipment access
is necessary to allow operators to pull smoldering fiber from equipment involved and completely extinguish
a fire.
C.1.4.5 Drawing Through Weaving Processes

Drawing Through Slashing
Drawing mixes multiple slivers and draws the mix out to the size of the original single sliver.
Combing removes short fibers from the lap. Roving drafts the sliver to a reduced size and gives it a slight
twist to increase strength.

Fig. 16. Aeromix. Cotton is blended in the plenum above the vertical filling trunks. Conveying air is exhausted and cotton
drops into filling trunks, leaves trunks in six layers, and is carried by conveyor belt to opening rollers. Opened
cotton is then ducted to downstream equipment. IR detectors are located in inlet and outlet ducts. Detection
automatically shuts equipment down, closes exhaust damper and operates special protection system. Special
protection is FM-200 (usually) or dry chemical arranged to discharge into trunks. Flush-type standard concealed
sprinklers are shown above the second and fifth filling trunks, controlled by an accessible OS&Y valve.
Fig. 17. Permanent-plate magnets and housing.

Fig. 18. Permanent-plate magnet above spiked lift apron.
Spinning is a texturizing process that gives the yarn strength by combining, drawing out and twisting yarns.
Spinning makes warp and fill yarn for weaving, as well as yarn for knitting.
Spooling results in yarn from a warp bobbin being rewound in a cheese pattern on another warp bobbin.
Warp yarn runs the length of the woven cloth.
Warping is the transfer of warp yarn from bobbins to a beam in preparation for weaving. Hundreds of bobbins
are placed on metal frame racks (creel rack) and wound in parallel onto the beam.
Slashing is an operation in which warp yarn from beams is run through a tank containing a sizing solution,
dried on steam or hot-air heated cylinders, and rewound on beams. The sizing strengthens, lubricates, and
protects the yarn during the weaving operation.
Spinning

There are two types of spinning: ring spinning and open end spinning. The inside surfaces of the head stock
have been insulated on most frames to reduce noise from gears and electric motor drives. At least one
manufacturer markets a spinning frame with insulation behind the spinning positions (Fig. 19). Polyurethane
is sometimes used. Lint tends to accumulate on its surface, making it difficult to clean. Most spinning frames
are constructed to allow location of sliver cans under the spinning frame. Sliver cans range in size from 16
to 24 in. (40.6 to 61 cm) in diameter and are approximately 3 ft (0.91 m) high. Cans are constructed of plastic
or a resin impregnated fiber. The plastic used may be polyethylene or polypropylene. Most of the sliver cans
used are resin impregnated fiberboard. Areas below the spinning frame are partially shielded from automatic
sprinklers at ceiling level.
Fig. 19. Open-end spinning frame. This spinning frame has combustible insulation in the headstock, tail stock, and behind
the spinning positions. Automatic sprinkler protection is shown for the area behind the spinning positions.
Weaving
Weaving interlaces one set of yarn (warp) with another set (fill) to produce the fabric. Several types of looms
are available: 1) air jet, 2) water jet, 3) projectile and 4) rapier. Older looms (projectile) were equipped with
large shuttles with interior packages of fill yarn. The shuttles were mechanically moved back and forth
between layers of warp yarn. Modern looms, such as air jet or water jet, do not require as many manual
operations as mechanical type projectile looms. This results in fewer workers increasing the time to detect
a fire and reducing capability to fight a fire in an area of the mill with the highest fire frequency.
For air jet looms, a reliable air supply is as important as a reliable power supply. A spare compressor should
be provided or plans made to bring in and connect a mobile air unit. Compressed air should be piped into
the weave rooms as close as possible to the looms. A shutoff valve should be provided on the pipe for each
loom. A length of plastic hose is then run to the loom. Burn-through of the hose may result in spread of burning
lint over several looms.
It is advisable to run services such as power cable and compressed air above the floor rather than in trenches.
Trenches are more difficult to keep clean. Loss experience has indicated that a fire in a trench area will spread
rapidly through the trench across cotton lint; the trench will be quickly filled with water, interrupting power
to a number of looms.

Due to the high fire frequency, it is necessary to keep the building and equipment clean. Continuous cleaning
is needed for floor and wall areas. The ceiling should be cleaned periodically, during plant shutdown. Looms
should be cleaned on warp change.
C.1.4.6 Pin Trucks

Pin trucks can be found in any textile operation. Pin trucks are used to move packages or spools of yarn
or thread from one process to another. A pin truck is a metal frame on wheels. Cross members are mounted
on the metal frame. Rods or pins are welded to cross members. The spools or packages of thread or yarn
are placed on the pins. Pin spacing depends on the size of the package or spool. There could be from 30
to 450 spools or packages of yarn per truck depending on the size of the yarn package. Pin trucks are
approximately 5 × 21⁄2 × 5 ft high (1.5 × 0.75 × 1.5 m).
A large loss involving acrylic yarn resulted in a survey to determine types of yarn stored on pin trucks in
insured plants. The results of the survey are included in Table 3. At the time of the survey few plants stored
acrylic yarn on pin trucks.
Table 3. Field Survey of 96 Locations to Determine Type of Yarn Stored on Pin Trucks
Polyester 27%
Polyester-cotton blends 25%
Cotton 19%
Nylon 19%
Miscellaneous (includes acrylic, rayon, and various blends, none of which exceeds 6%) 12%
C.1.4.7 Creels
General
There are two types of creels (sometimes referred to as creel trees) used to supply yarn to carpet tufting
machines, Both types are available without mezzanines, with open mezzanine and with solid mezzanines.
Old Style Creels
These creels have posts (trees) with prongs used to hold yarn packages. The prongs are arranged in groups
of four approximately 12 in. (30.5 cm) apart vertically. There may be 5 to 8 levels below and above
mezzanines. If one mezzanine level is used, the total height of the yarn on the trees is about 13 to 15 ft (4
to 4.6 m) with the mezzanine being at the midpoint. There may be up to three mezzanines vertically, although
most have only one. Aisles between creel tree rows are generally 36 to 52 in. (0.9 to 1.3 m) wide. The yarn
is loaded and tied from these aisles. The creels, with their frame support structure, take up approximately
60 in. (1.5 m) between adjacent aisles. There may be 460 to 2880 cones of yarn per creel mezzanine unit per
tufting machine. The mezzanines are most often placed side-by-side and can be several hundred feet long
and approximately 40 ft(12.2 m) wide. Mezzanines have overhangs that are often used to stage yarn used
for re-supply. This yarn is stored below and on mezzanine overhangs at the rear of the mezzanine. Often, yarn
is also staged between mezzanines where wide aisles are sometimes maintained for this purpose.
Modern Creels
Modern Creels are similar in design. They have two prongs per position. They also have a loading aisle and
a separate tie aisle. The loading aisle is generally about 48 to 53 in. (122 to 135 cm) wide while the tie aisle
is generally about 25 in. (64 cm) wide. Yarn is loaded onto the creels from the loading aisle and yarn ends
tied together from the tie aisles (see Fig. 20). This allows continuous operation of the tufting machine. The yarn
is fed to the tufting machines through plastic tubing.
Yarn is often put into yarn carts, which are then pushed down the loading aisles for replenishing the spent
yarn cones. Roller type conveyers are also used for moving yarn in corrugated cartons down the loading aisles
for replenishing yarn cones. Loading aisles can vary considerably in width depending upon the individual
needs of the operation. Carts and roller conveyers may be used on each mezzanine level. When roller
conveyors are used, generally there will be more cartons of yarn in aisles.

Fig. 20. Modern creel with one mezzanine, shows both loading and tie aisles. Automatic sprinkler protection is needed
for the tie aisles. Automatic sprinkler protection is needed for loading aisles if used for storage of more than a
few boxes or carts of yarn.
Solid mezzanines have no openings except where vertical creel tree posts and framing penetrate the
mezzanine decking. These openings are no more than 3 in. (7.6 cm) wide and the width of the mezzanine
(front to back).
Open mezzanines have either open steel grating or planking, plywood or steel plate with openings 4 to 60 in.
(10.2 to 152 cm) wide the width of the mezzanine.
C.1.4.8 Air Conditioning and Pneumatic Waste Recovery Systems

Air Conditioning
General
An air-conditioned mill has several independent conditioning systems. One system or a combination of
systems is used to maintain an area at a temperature and humidity best suited to the process. Because
air-conditioning systems are responsible for most of the air movement in areas they serve, they can be
effectively used to limit smoke damage from fires occurring within these areas.
Cooling Towers
A cooling tower is critical to maintaining temperature and humidity in the mill and for cooling equipment such
as air compressors. While cooling towers may not be needed for plant air conditioning at all times of the
year, they are critical to continued operation during warm weather. The possibility of loss of a cooling tower
should be considered. A recovery plan should be established to expedite replacement; or an alternate plan,
such as use of public water supplies or connection of a mobile unit to maintain operation of the mill, should
be developed.
Duct & Tunnel Systems
Mills constructed before air-conditioning systems have had these systems added. They may be through-the-
wall, through-the-floor or through-the-roof systems. In the through-the-wall system, air is drawn from main
plant areas into an adjoining air-conditioning room. Filters are mounted in the wall between the main plant and
the air-conditioning room to remove lint. Some air is exhausted, make-up air is added, the mixture is heated

or cooled, humidified or dehumidified as necessary, and returned to the room at ceiling level. In the
through-the-floor system, air is withdrawn from the main plant areas through grated duct openings in the floor
and filtered; then make-up air is added and the same process as above is followed. Through-the-roof systems
are similar to through-the-wall except the air wash/air conditioning system is located in a penthouse on the
roof.
Rectangular shaped ducts of light-gauge sheet metal are used to convey the air into and in some cases
out of main plant areas. Rough edges, turning vanes, and dead air spots within ducts tend to accumulate
concentrations of lint. These ducts should be cleaned regularly even if access is difficult.
In newer mills, lint-laden air is drawn into ducts through grated openings located below machinery. The air
flow is such that it helps remove lint from machine surfaces. The ducts then run into side tunnels, and the side
tunnels feed into main tunnels running the width of the mill. The air is then filtered and processed in the same
manner as above (Fig. 21). The FM Global survey conducted at 50 mills indicated that through the floor
systems have a better transfer efficiency since the air is taken from around the machine (technical air).
Fig. 21. Air conditioning system of a modern mill. Lint-laden return air from the main tunnels, which run the width of the
mill, is filtered through the main filter, some air is exhausted, make-up air is added, the mixture is heated or cooled
and humidified as necessary, and then blown back into the room through supply ducts.

Side and main tunnels of the return air system are of concrete construction, and are part of the foundation
of the mill.
The system’s return air tunnels in newer mills are largely for air movement, not for lint transfer to the filter
media. As a result, lint is deposited on the tunnel surfaces. Air velocity in side tunnels is low. Side tunnels are
often of rectangular shape with cross sections too small to allow access for easy cleaning. In main tunnels,
lint collects on lighting, conduit and rough wall surfaces. Hand cleaning, usually done on weekends, is slow
and expensive.
Supply air ducts may be part of the ceiling construction, but rectangular shaped light-gauge sheet metal ducts
are most common. In some cases, suspended ceilings are located above plant areas such that supply air
passes through these ceilings. FM Global loss prevention specialists have found heavy loadings of lint above
supply air ducts (Fig. 20) and in areas above suspended ceilings. When the space above the ceiling is used
for supply air they are fairly clean.
The design of some supply air ducts with ventilation openings (registers) in the side of the duct (Fig. 23)
may result in lint accumulation in the supply air duct (see Fig. 24). This caused by negative pressure near
edges of the register which draws airborne lint into the duct. This as opposed to a design that is less likely to
accumulate lint (see Fig. 25).
Regular inspection and cleaning of the supply and return ducting, including areas above suspended ceilings,
is needed. Lint buildup is related to equipment enclosure, air velocity, discharge location, and pickup location
rather than room air volume changes.
Fig. 22. Lint accumulation above supply air duct.
Filter Rooms
Mills using air-conditioning systems recirculate most of the air in the main plant. The air must be filtered before
it is returned. A V-type wall filter (Fig. 19) or a rotary filter assembly (Fig. 5) is used for this purpose. The
filter assembly is usually located within an enclosed room of noncombustible construction.

Fig. 23. Supply air duct with openings (registers) in the side of the duct.
Fig. 24. Lint accumulation in supply air duct.

Fig. 25. Supply air ducts with vertical drops to registers.
The filter media is usually polyester or polyvinyl chloride. While this filter media is not readily ignited, lint
accumulations on the upstream face will burn readily, ignite the filter and the filter will melt and burn. In some
cases, polyurethane is used as filter media. Its use will contribute substantially to the heat released in a fire
on the filter media, and may lead to damage of filter frames, causing lengthy shutdown for repair.
Air flow through a filter makes fire detection by heat or smoke sensing devices difficult. Infrared (IR) detection
and special extinguishing systems should be considered. Automatic sprinklers are recommended. If the
exhaust fan is stopped while fire is in progress, sprinklers will prevent the fire from spreading back through
the ventilating tunnel(s) and into main plant areas.
Pneumatic Waste Recovery and Cleaning Systems
Waste handling systems are provided for opening, high speed carding, drawing, and spinning frames. Air
suction points designed to remove fly, trash and dust are provided on the equipment.
The systems used at spinning and drawing frames consist of suction tubes, called ‘‘flutes,’’ which are located
near the roll deliveries on the frame. The flutes, which replace scavenger rolls, are connected to a collecting
header and a filter collector unit with a built-in motor and fan assembly. Air is continually drawn into the
suction flute. Free lint and foreign materials are removed from the yarn as it emerges from the front rolls.
When a thread (end) is broken, it is picked up by the suction orifice and conveyed pneumatically to the
collector unit. Here it accumulates in the form of untwisted fibers ready for reprocessing.
Pneumatic waste recovery and air cleaning systems make possible better cleaning of stock in preparatory
areas. A waste house is typically used for opening and cleaning equipment. In some cases this also includes
carding equipment. The waste house is an approximately 10 × 15 × 8 ft (3 × 4.6 × 2.4 m) high sheet
metal-on-metal frame enclosure located in or adjacent to the opener room. It contains a condenser and a
rotary drum filter. Waste laden air goes through the condenser then through the rotary filter. Waste collected

on the surface of the condenser and rotary filter is doffed and ducted to a baler. The waste house is usually
protected by an automatic dry chemical system actuated by IR detectors and an automatic sprinkler system.
C.1.5 Utilities
A textile mill requires uninterrupted electric power. Electric power for mills is usually supplied directly from
a local utility-owned substation to one or more load centers at the mill. From the load center, feeders extend
to various control panels located throughout the plant to supply power and lighting equipment.
Modern equipment such as open-end spinning frames, air jet looms, and controls require large amounts of
compressed air.
Equipment cooling and control of building atmosphere requires large amounts of compressed air.
Slashers and finishing operations require large volumes of steam capacity.
C.2 Wool
Wool may be processed from raw (greasy) wool or wool reclaimed from used fabric. Raw wool contains fats
and oils in addition to vegetable substances like twigs, straw, leaves, etc. Scoured wool is raw wool or
reclaimed wool that has been cleaned and dried. Scoured wool is used for the two major systems of yarn
manufacture: woolen and worsted. The woolen system produces a yarn with fibers randomly arranged. Two
operations are required: carding and spinning. The yarn is used for soft bulky fabrics such as dress material,
blankets, etc. The worsted system uses a longer length staple. It produces a yarn with fibers arranged
parallel to each other. Several operations are involved: carding, gilling, combing, drawing and spinning. The
yarn is used to produce hard textured fabrics.
Fire tests have been run on both types of wool in bulk. Both are difficult to ignite. Once ignited, scoured wool
burns steadily until consumed. Flames do not flash over the surface as they do in a cotton fire. Raw (greasy)
wool is more difficult to ignite. When ignited, it tends to smolder. Fires in both types give off large quantities
of dense, acrid smoke.
C.3 Synthetic Fibers

General
Synthetic fiber production is an extrusion process often using heat transfer fluid where plastic chips melted
under pressure are forced through spinnerets to form filaments. Continuous filaments (partially orientated
yarn) is used in the spinning process to give it proper feel. This section includes burning characteristics and
loss experience for synthetic staple commonly used to weave synthetic or blends of synthetic and cotton
fabric.
Blending
Cloth can be 100% synthetic or a cotton synthetic blend. Synthetics can be blended with cotton in the opener
equipment, drawing frames, winding or weaving.
C.4 Finishing Operations
C.4.1 General
Finishing of textile fabric includes mechanical, heat-related and chemical treatments to improve specific
properties of these fabrics. Mechanical treatments, such as calendering, involve application of heat and
pressure to a fabric to develop a permanent effect, such as a change in the surface appearance.
Chemical treatments involve the application of a chemical as a surface coating or one that chemically
combines with the fabric. Properties that can be obtained are change in how a fabric feels (hand), pretreatment
for dyeing and printing, wash and wear, water repellant, fire retardancy, etc.
Chemicals are usually applied by immersion of the fabric in an aqueous finishing formulation, squeezing
the fabric to remove excess formulation, drying and curing the finish. Most of the finishes used are water
base.

C.4.2 Singeing
Singeing is a preparatory step in dyeing cotton. Fabric is exposed to flame from a ribbon burner to remove
lint and fuzz from the surface. The gas burner usually is interlocked so the burner will swivel away and the
main gas valve will close in the event fabric stops moving.
C.4.3 Bleaching
The bleaching process whitens the fabric, removes impurities and blemishes. The cloth is treated in large
tanks or vats with caustics and detergents. Diluted concentrations of hydrogen peroxide also may be used.
C.4.4 Dyeing
Dyeing can be done on either raw stock, sliver, yarn or cloth. It is most commonly done on yarn or cloth.
Generally it is done by one of the following methods:
Kier
A kier is a stainless steel vessel containing perforated spindles. The textile is packed around the spindles
in baskets. The dye liquor is pumped through the spindles and textile, then collected in the bottom of the kier
and recirculated. Some machines are arranged so liquor flow is in one direction only. Some are arranged
so that flow can be reversed. The plate containing the spindles can be removed for loading and unloading.
In some cases the dyed textile is air dryed by passing heated air through the spindles.
Continuous Dyeing
Most dyeing is done on a continuous dye range. Dye is applied by passing the fabric through a vat containing
dye liquor and between squeeze rollers (dye pad). The fabric passes through the vat, then is drawn through
a gas or IR heated dryer to reduce moisture content, and over drying cans to an oven used to fix the dye
(the oven may be a hot air unit or an oil-heated contact machine). In the next step, fabric passes through a
chemical pad for immersion into an alkaline or reducing solution (depending on the dye). Finally, the goods
pass through 8 to 10 wash boxes and are dried and cooled by passing over can dryers and cooling cans.

Dyes
Most dyes used are water based. Attempts have been made to develop solvent based dyes to reduce energy
consumption and increase dyeing speed. The organic solvents tried have been trichloroethane and
perchloroethylene. Other organic solvent based dyes may be used.
C.4.5 Printing
Printing is essentially a dye applied by mechanical and chemical means that results in a design or pattern
on the fabric. Attempts are being made to develop dyes that can be applied as solids to reduce energy
consumption and increase processing speeds. The two most commonly used methods of applying water
and solvent base dyes are:
Roller Printing
The print is transferred by passing the fabric between a cast iron cylinder and a copper print roller with a
pattern or design engraved on the surface of the copper roller. The fabric absorbs print paste from the
engraved areas of the print roller. A separate roller and cylinder is used for each color. Flammable solvents
may be used to clean the print rollers and other surfaces.
Tubular Screen Printing
Most printed textiles are produced by this method. The tubes are lightweight metal cylinders on support
frames. The pattern or design is a series of small openings made in the wall of the tube by a laser or a photo
sensitive chemical etching process. A dye or ink is injected into the tube and passes through these openings
to transfer a pattern onto the fabric. A separate tube is used for each color and flammable solvents may
be used to clean the tubes and other surfaces.
Screen Printing
Print paste is transferred through a stencil to the fabric. The stencil is made of polyamide or polyester cloth
stretched tightly over a metal frame. The design, originally on film, is transferred by coating the cloth with
a light sensitive material, exposing the film and rinsing off the unexposed areas. The printing operation can
be carried out manually (silk screening) or automatically by mechanically lifting the screen, advancing the
fabric, lowering the screen and applying print paste (mechanized screen printing).
Paper Transfer and Digital Printing
In paper transfer printing the pattern is printed on paper and transferred to cloth using a heated roll. Digital
printing is similar to ink jet printing.
C.4.6 Ovens, Dryers and Tenter Frames

Ovens and dryers are used to dry dyed fabric or cure coatings that have been applied to fabric. Tenter frames
are used to control shrinkage by holding the web in two dimensions during a heating cycle.
These units may be heated directly by gas- or oil-fired burners or IR heaters, or indirectly by heat transfer
oil or steam heating systems. Where heat transfer fluids are used, the fluid is usually an oil with flash point
of 250-400°F (120-204°C). Oil is heated usually in an adjacent building and circulated through heat
exchangers within the unit.
There may be multiple exhausts from each oven, dryer or tenter frame. The exhausts from one unit are
manifolded. If several ovens, dryers or tenter frames are present, they may all be manifolded before entering
pollution control equipment. The pollution control equipment may be a scrubber, a dry filter unit or an
electrostatic precipitator. Automatic sprinkler protection will be needed where any of the following conditions
exist: a) oil heating systems are used b) cloth is festooned or c) multiple pass dryers are used. Usually
single pass dryers do not need protection unless there is lint or oil buildup. Where exhaust ducts from more
than one dryer or tenter frame are manifolded, automatic sprinkler protection is needed in the exhaust duct
to prevent fire spread from one unit to the other.
Steam suppression systems have been installed. These systems are manually operated and are designed
to a wide variety of criteria. They should not be considered primary protection for the above conditions but may
be effective when used in addition to automatic sprinkler protection.

FMDS-07-01 (04.2020) - Fire Protection For Textile Mills

Uploaded by

Copyright:

Available Formats

FMDS-07-01 (04.2020) - Fire Protection For Textile Mills

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

FMDS-07-01 (04.2020) - Fire Protection For Textile Mills

Uploaded by

Copyright:

Available Formats

FM Global

Property Loss Prevention Data Sheets 7-1

FIRE PROTECTION FOR TEXTILE MILLS

1.0 SCOPE ................................................................................................................................................... 4

2.2.2.6 Heat Set Range ....................................................................................................... 19

©2009-2020 Factory Mutual Insurance Company. All rights reserved.

©2009-2020 Factory Mutual Insurance Company. All rights reserved.

2.0 LOSS PREVENTION RECOMMENDATIONS

2.1 Greige Goods

2.1.2 Construction and Location

©2009-2020 Factory Mutual Insurance Company. All rights reserved.

©2009-2020 Factory Mutual Insurance Company. All rights reserved.

Table 1. Recommended Types and Placement of Portable Extinguishers

2.1.3.2 Baled Fiber Warehouse

2.1.3.3 Baled Fiber Staging Area

2.1.3.4 Bale Breaking Area

2.1.3.5 Opener Room

©2009-2020 Factory Mutual Insurance Company. All rights reserved.

2.1.3.6 Feeder Blending

2.1.3.7 Automatic Bale Openers

©2009-2020 Factory Mutual Insurance Company. All rights reserved.

©2009-2020 Factory Mutual Insurance Company. All rights reserved.

2.1.3.8 Blender/Reserve Hopper

©2009-2020 Factory Mutual Insurance Company. All rights reserved.

2.1.3.9 Waste Fiber Recovery System

2.1.3.10 Magnetic Separators

2.1.3.11 Metal, Spark and Fire Diverters

©2009-2020 Factory Mutual Insurance Company. All rights reserved.

2.1.3.14 Warping, Beam Storage

©2009-2020 Factory Mutual Insurance Company. All rights reserved.

2.1.3.17.1. Old Style Creels With Solid Mezzanines

2.1.3.17.2 Modern Creels With Solid Mezzanines

©2009-2020 Factory Mutual Insurance Company. All rights reserved.

Fig. 8. Old style creel with an open mezzanine.

©2009-2020 Factory Mutual Insurance Company. All rights reserved.

2.1.3.17.4 Creels with No Mezzanines

2.1.3.18 Pin Trucks

2.1.3.19 Air Conditioning Systems

©2009-2020 Factory Mutual Insurance Company. All rights reserved.

2.1.3.19.2 Construction and Maintenance of Ducts and Tunnels

2.1.3.19.3 Fire Protection

©2009-2020 Factory Mutual Insurance Company. All rights reserved.

©2009-2020 Factory Mutual Insurance Company. All rights reserved.

2.1.3.24 Synthetic Yarns

Table 2. Protection of Synthetic Yarn Storage

2.1.4 Operation and Maintenance

©2009-2020 Factory Mutual Insurance Company. All rights reserved.

2.1.5.2 Load Centers

2.1.5.4 Lighting Equipment

2.1.6 Human Factor

©2009-2020 Factory Mutual Insurance Company. All rights reserved.

2.2 Finishing Operations

2.2.2.4 Ovens, Dryers, Tenter Frames

2.2.2.5 Heat Transfer Oil Systems

2.2.2.6 Heat Set Range

©2009-2020 Factory Mutual Insurance Company. All rights reserved.

2.2.2.7 Printing Dyes and Screen Manufacturing

2.2.2.9 Cutting and Sewing

2.2.3 Human Factor