Leading Indian defense manufacturer enhances safety and visibility across a critical production facility

Fire safety requirements in ammunition manufacturing environments differ significantly from those in traditional industrial facilities. Process buildings handle energetic materials where rapid detection and response are essential, while supporting utility buildings must remain protected to maintain operational continuity.

The customer needed an integrated fire protection and detection solution covering eight process and utility buildings, with centralized monitoring and automated response capabilities. The system also needed to comply with NFPA standards and India's Defense Testing Infrastructure Scheme (DTIS) requirements while being delivered on an accelerated project timeline. Given the nature of the facility, the solution needed to support automated detection and response capabilities without relying primarily on operator intervention.

The defense and aerospace manufacturer partnered with Johnson Controls to design and implement a fully integrated Fire Protection System (FPS) and Fire Detection and Alarm System (FDAS) for the ammunition manufacturing complex.

The solution combined automated fire suppression, fire detection and centralized command capabilities within a single architecture. Key components included:

• Automated medium-velocity water spray (MVWS) fire protection systems with deluge valves
• PLC-based pumping stations with automated operation and diesel-engine backup
• Hybrid fire detection technologies including gas, heat and smoke detection
• Manual call points, hooters and exit signage
• A centralized Fire Control Room with graphics-based monitoring and command capabilities
• Real-time visibility across all eight buildings from a single operator station

The integrated solution was designed to comply with both NFPA standards and DTIS requirements, supporting the facility's operational and regulatory objectives.

Working with Johnson Controls, the manufacturer established a fire safety infrastructure designed to support continuous operations in a complex, high-risk production environment. Automated response capabilities reduce reliance on manual intervention, while centralized monitoring helps teams respond quickly to events across the facility.

The deployment supports the customer's operational objectives by improving visibility, simplifying system management and helping ensure compliance with industry and defense-sector requirements. It also supports the deployment of automated and centralized fire safety management capabilities across the facility.

Key outcomes include:

• Delivered integrated fire protection and fire detection coverage across eight process and utility buildings
• Enabled site-wide visibility and coordinated monitoring from a single Fire Control Room
• Increased readiness through automated fire detection and suppression capabilities
• Reduced manual touchpoints in the fire response process through automation and centralized monitoring
• Achieved compliance with NFPA and DTIS requirements from commissioning