Mundra, Kutch · Port logistics operator
Mundra Port-Adjacent Facility — Hydrant & Corrosion Protection
A port-adjacent logistics facility in Mundra required a hydrant network capable of meeting insurer-mandated flow rates for a 6,500 sq.m cargo handling yard and single-storey storage shed — with equipment specified to survive coastal salt-air corrosion that destroys standard carbon steel components within three to five years. The client's previous fire equipment vendor had installed standard hydrant pillars at a neighbouring facility; within three years, 60% of outdoor valve assemblies were seized or leaking due to corrosion. The insurer's pre-coverage survey identified corrosion risk as a condition for policy issuance, requiring documented marine-grade specifications and a maintenance programme with corrosion inspection protocols. Rachna Fire & Safety was engaged to design and install a complete hydrant system with corrosion-resistant specifications and a two-year AMC programme with quarterly corrosion inspection built into the maintenance scope.
Systems Installed
- •External hydrant ring main
- •Diesel/electric pump house
- •Hose reels
- •Corrosion-resistant valves and pillars
Challenge
The insurer survey demanded documented flow test results at three hydrant points operating simultaneously while maintaining minimum residual pressure — a test configuration exceeding standard single-hydrant NOC testing. The facility's fire water supply needed a dedicated 280,000 litre underground tank and pump house sized for dual-hydrant plus hose reel demand at the hydraulically most remote outlet across the 6,500 sq.m site.
Coastal salt-air corrosion at the Mundra site degrades standard cast iron valve bodies, carbon steel pipe fittings, and unprotected pillar box hardware within three to five years. The client's explicit requirement — based on their neighbouring facility's failure experience — was a system with documented corrosion-resistant specifications and an expected outdoor component service life exceeding 10 years with proper maintenance.
Site logistics added complexity. The cargo handling yard operates 16 hours daily with heavy vehicle traffic along the proposed ring main route. Hydrant pillar locations had to provide coverage without obstructing container movement lanes or creating collision hazards for yard equipment. Installation had to proceed in phases around active cargo operations.
Solution
Rachna Fire & Safety designed a 150 mm ring main with six external hydrant pillars positioned for full yard coverage and fire brigade vehicle access. Pump house specification: electric main pump 1500 LPM at 7 bar, diesel standby 1500 LPM at 7 bar, jockey pump 150 LPM, with 280,000 litre dedicated underground tank. All outdoor components specified with corrosion-resistant materials: stainless steel valve bodies on external pillars, hot-dip galvanised pipe and fittings for above-ground yard mains, epoxy-coated underground pipe, and nylon/stainless fasteners on pillar box assemblies.
Installation proceeded in two phases: underground ring main and pump house during a scheduled yard maintenance shutdown, then above-ground yard mains and pillar installation during a second shutdown window two weeks later. Each pillar box included drainage provision and protective bollards at vehicle-adjacent locations. Hose reels installed at the storage shed interior with 30 m semi-rigid hose reaching all interior areas.
Commissioning flow test demonstrated simultaneous operation of three hydrants with 4.8 bar residual pressure at the remotest outlet — exceeding the insurer's 3.5 bar minimum and NBC requirements. The insurer surveyor witnessed testing and issued coverage confirmation within one week. PSIP panel installed at the security desk provides continuous pump status visibility for 24/7 yard operations staff.
Outcome
Insurer survey passed on first visit with documented flow test results and corrosion specification datasheet accepted as meeting marine environment requirements. Fire NOC obtained from the Mundra fire authority with witnessed test results matching insurer test configuration.
Two-year AMC track record shows zero corrosion-related failures on outdoor components — compared to the client's previous vendor experience at the neighbouring facility where 60% of standard pillars required replacement within three years. Quarterly AMC inspections include valve exercise, pillar box drainage check, coating condition assessment, and diesel pump load test.
The client has extended AMC into a third year and referenced the installation specification for a second facility currently under construction at the same Mundra site — validating the corrosion-resistant approach as their standard for all coastal logistics installations.
Technical Details
Site area: 6,500 sq.m cargo handling yard with 2,800 sq.m single-storey storage shed. Ring main: 150 mm MS epoxy-coated underground with 100 mm hot-dip galvanised above-ground yard mains. Hydrant pillars: 6 external with SS316 valve bodies, HDG pillar boxes, and protective bollards at 2 locations. Hose reels: 4 internal units with 30 m semi-rigid hose.
Pump house: electric main 1500 LPM at 7 bar (55 kW), diesel standby 1500 LPM at 7 bar (water-cooled engine), jockey 180 LPM. Fire water tank: 280,000 litres dedicated underground RC tank. Flow test result: 3 hydrants simultaneous — 4.8 bar residual at remotest, 2100 LPM total measured flow.
Corrosion specification: SS316 valve bodies, HDG pipe (100 μm minimum coating thickness), epoxy internal pipe lining for underground sections, nylon/stainless pillar box fasteners, drainage holes in all pillar box bases. AMC: quarterly valve exercise and coating inspection, monthly diesel run under load, annual full flow test with documented results.