19BR9322Q0001_Fire Pump_Specifications.doc

PAGE

UNCLASSIFIED

U.S CONSULATE GENERAL SAO PAULO, BRAZIL

DIESEL FIRE PUMP ASSEMBLIES/APPUTURES SPECIFICATION

CONTENT:

This section references contractor’s participation in: (1) material submittal process, and (2) installation. Whereas this section clarifies OBO/OPS/FIR/FPS requirements, and narrows the scope, the most expansive collection of technical data is contained in those referenced documents noted in Part 4.

STANDARDS AND DEFINITIONS

FIRE PUMP, MODULAR SKID‑MOUNTED AND NON SKID MOUNTED & APPUTURES

PART 1 ‑ GENERAL

1.1 ‑ RELATED DOCUMENTS

A.

Contract Drawings and general provisions of the Constitution Contract, including Contract Clauses and Conditions apply to work of this Section.

1.

Other Specifications Sections: Comply with applicable requirements of other fire protection codes hereof, for work of this Section, and interfaces of related work. In particular, comply with basic mechanical/material/method requirements, basic electrical requirements for mechanical equipment, and basic system piping.

Materials/methods/controls/supports/anchorages; to the extent more stringent requirements are not specified herein for work in this Section.

2.

Related Work: Other Sections of these Specifications indicate requirements for related work; which is not work of this Section, except to the extent, certain portions of such work are required for inclusion in the fire pump assemblies/assembly; refer to related Sections specifying: mechanical insulations, fuel handling, electrical provisions, alarm/control systems, labeling, identification/ signage, painting/special coatings, and similar requirements.

1.2 ‑ STANDARDS AND DEFINITIONS

General: Comply with applicable standards as indicated herein, and as required by governing authorities; refer to:

"Definitions and Standards", hereof for general requirements to comply with applicable standards for work in this Section. The editions of the following industry standards contain provisions which are explicitly applicable to work of this Section.

"Approval Guide" by Factory Mutual (FM)

"Fire Protection Equipment Directory" by Underwriters Laboratories, Inc. (UL)

3.

Standards by the National Fire Protection Association (NFPA), including the following:

a. Std. 13, - Installation of Sprinkler Systems & Annex “A” – 2007 Edition

b. Std. 20, - Installation of Centrifugal Fire Pumps & Annex “A” – 2007 Edition

c. Std. 24, - Installation of Private Fire Service Mains/Apparatuses &Annex “A” – 2007 Edition

d. Std. 25, - Water Based Fire Protection Systems – 2007 Edition & Annex “A”

e. Std. 70, - National Electric Code – 2008 Edition & Annex “A”

f. Std. 14, - Installation of Standpipes& Annex – 2007 Edition & Annex “A”

e. Std. 110 - Emergency and Standby Power Systems – 2005 Edition & Annex “A”

g. Std. 30 - Flammable and Combustibles Liquid Code – 2008 Edition & Annex “A”

h. Std. 37 – Installation and Use of Combustion Engines – 2007 Edition & Annex “A”

I. Std. 72 – National Fire Alarm Code – 2007 Edition & Annex “A”

4.

IBC & IFC

B. Definitions: Except as otherwise indicated herein, refer to NFPA 20 & Annex “A” for definitions of general fire pump terminology used in this Section.

1.3 ‑ PERFORMANCE REQUIREMENTS

A. General: Provide installed fire pump assemblies/assembly which performs operationally in accordance with provisions of this Section, including each "Fire Pump Assembly Data Sheet" as attached hereto.

1.4 - EXTRA MATERIALS, PUMP ASSEMBLY/CONTROLLER:

Initial Spare Parts Stock: For each required fire pump assembly and controller, furnish an initial stock of expendable items, specific maintenance materials, and spare parts. Comply with OBO/FIR requirements, and manufacturers' recommendations on items. Include not less than the following categories/quantities of materials: One (2) complete fire pump water cooled gland packing seals and O‑rings. Two (4) engine filters, engine air filters and engine fuel filters. One set (1) set of drive belts. One (1) complete set of all fuses for fire pump and jockey pump controller (if applies). One (1) 0‑300 psi, liquid filled discharge gauge. One (1) suction gauge liquid filled (-30-300) and one (1) heat exchange gauge (0-60). All spare parts inventory to be housed in a separate, designated, storage cabinet, attached to, or located adjacent to the fire pump assembly, and in all cases located in the fire pump room. There shall also be a parts list, with corresponding, manufacturers' part numbers, and manufacturers' telephone and fax numbers permanently attached inside of the same cabinet.

1.5 - MAINTENANCE AND OPERATION

A.

General: Following completion of installation and start‑up/field testing of the fire pump assemblies on the project site, and through the remainder of the project construction time, provide continued maintenance, and scheduled weekly automatic testing, and/or emergency operational readiness of units; until final inspections are completed and is turned over to Post personnel. Contractor to comply with instructions and recommendations of the manufacturer. Operate units weekly for a continuous running period of not less than 30 minutes (If Applies).

PART 2 ‑ PRODUCTS

2.1A - COMPONENTS

Include the following, in addition to the primary components, encompassing the fire pump, drive unit, pump controllers, fuel tank, and batteries with charger, flow meter, skid assembly internal‑to‑package skid piping systems (if applies) and electrical/electronic control wiring as applicable for each unit as required.

The jockey pump shall be equipped with a pressure relief valve on the discharge side. The pressure relief valves shall be installed after the discharge side of the pump flange and before the system OS&Y valve. It shall be UL listed and/or FM rated and no smaller than 3/4" and rated at 175 psi.

The jockey pump relief valve drain shall be visibly piped to an open floor drain or out the building structure so the flow can be regulated and adjusted.

The jockey pump relief valve line drain line shall be piped of a non-corrosive copper piping material. Solder joints shall meet the requirements of NFPA 13.

The jockey pump shall be equipped with a full size dimension piping strainer and a plug to facilitate maintenance and shall be installed on the supply side located between the OS&Y and inlet flange of jockey pump.

5.

All piping for the jockey pump shall be black steel on both suction and discharge on the jockey pump.

6.

Jockey pump check valve are to be rated at no less then 175 psi and have a rubber faced clapper with a removable clapper assembly. All control valves are to be the indicating type UL & FM approved. Valves are not to be monitored by means of tamper switches. Upon completion they are to be chained in locked in the open position and keys turned over to Post personnel.

7.

All fire pump casing assemblies shall be equipped with an automatic air casing relief valve. No screw swing check valves will be allowed installed on vertical type pumps if applies. Ball operated float type valves are only allowed and shall be sized per NFPA 20 or manufacture.

8.

Suction and discharge gauges, Ashcroft mfg., or equal, (‑30 to 300 psi suction, 0‑300 psi discharge) 3.5 inch dials on the fire pump. Suction and discharge pressure gauges shall be liquid Glycerin filled and piped so they can be readily viewed by the operator from the fire pump controller. Gauges shall have a brass ballcock or ¼” globe valve to facilitate gauge maintenance.

9.

The fire pump and jockey pump controller sensing lines shall have one (1) each, 0‑300 psi liquid filled gauge, Ashcroft mfg., or equal, piped with a ½” brass globe valve 1'‑0" above the piping entrance to their respective enclosures and installed between the ½” test valves for both controllers.

10.

The fire pump discharge piping shall have a 0‑300 psi liquid filled gauge, Ashcroft mfg., or equal, with a brass ballcock, located on the discharge flange of the fire pump and, after the discharge check valve and flow meter by‑pass, and at the furthest point of the pump manufacturers discharge piping.

11.

The fire pump on the suction flange shall have a-30‑300 psi liquid filled gauge, Ashcroft mfg., or equal, with a brass ballcock.

12.

Flow meters are too be sized per NFPA 20 and piped back to the water storage tank to the farthest point in the tank away from the suction inlet of the fire pump. Flow meter valves do not require tamper switches, but are to be chained and locked closed upon completion and keys turned over to Post once accepted. The piping into the tank shall be stainless steel.

13.

All drains located on the fire pump package shall be undependably run and supported with non corrosive copper piping/hangers. All solder drain lines/joints can be soldered with 50/50. All drains shall be installed so that visual monitoring and final adjustments can be made pertaining to making proper adjustments upon completion. Steel piping will be allowed as noted below only:

a) Fire pump and jockey pump controller sensing line drains. (Copper)

b) Heat exchanger discharge piping drain. (Steel).

d) Drip gland drain piping. (Copper).

e) Main system drain sized per NFPA 13. (Steel).

f) Ball drip drains. (Steel).

e) Jockey pump relief valve. (Copper).

g) Electric fire pump Klunkle valve. (Copper).

h) Air casing valves. (Copper).

14.

Tapered flanged concentric increaser at discharge outlet. Tapered flanged eccentric reducer at suction/discharge inlet. Both must be flanged X flanged cast iron and with straight tapers. Welded reducers/increasers, tees, elbows and welded flanges are not acceptable, nor allowed.

15.

Main relief valve, when a diesel driven unit, shall be piped back to the furthest point of the reservoir away from suction inlet of pump. The piping must have a sight glass of the type with removable window. The relief valve discharge piping must have a check valve installed if the piping is returned below the expected reservoir water level, or the piping is installed in such a manner as to trap five gallons or more water. If trapped water is present, a drain valve must be installed after the relief valve, and before the check valve, sized per NFPA 13 and to facilitate maintenance on the sight glass, relief valve or check valve. If a drain is required it must be piped to a floor drain or out the building structure. This drain is to be installed in black steel piping and secured. At no time will the relief valve line be recirculated into suction piping. The piping into the tank and in the tank shall be stainless steel.

16.

A water level detecting device capable of signaling auto‑fill solenoids for the fire pump reservoir, piped in liquid tight fittings, junction boxes, conduit, and other connections and devices in line. The water level monitor must also be capable of signaling a remote fire pump alarm panel of high/low water levels. If the water level detecting device is mechanical, it must be constructed of brass, stainless steel or equal rust inhibitive materials.

17.

The fire pump assembly shall be monitored by a fire alarm panel, and shall supervise the following: Engine Run, System Failure, Controller Selector Switch Position, or meet the requirements of NFPA. All new diesel/electric controllers are to be digital/micro based processors and NEMA 4 X rated. Jockey pump controller to be NENA 4 X. Electric controllers are to have a factory matching dedicated transfer switch.

18.

Name plates on fire pump package and components must be permanent, and legible throughout the life of the equipment. If component name plates are not easily accessible, or subcontracted component labels of the fire pump manufacturer are not of the permanent stamped steel type, a permanent label shall be constructed and placed in a conspicuous location near the referenced equipment by the fire pump package manufacturer. If the fire pump manufacturer utilizes an "in‑house" reference number, the number shall appear on a permanent metal placard, attached to the skid in a conspicuous location.

19.

Flow meter shall be grooved and manufactured by GVI or equal.

20.

An OS&Y valve with a DPDT tamper switch shall be provided on the suction side of the pump. A butterfly valve equipped with a DPDT tamper switch shall be provided on the discharge side of the pump.

21.

A UL & FM listed wafer type check valve or swing check valves shall be provided on the discharge side of the fire pump. All system control valves and system check valves shall be UL listed and/or FM approved. They shall be rated not less than 175 PSI. All check valves shall have Rubber Faced/”O” rings Clapper assemblies with removable clapper assemblies.

22.

The fuel tank shall be 180 gallon capacity, and be provided with a mechanism to drain sediment from the tank bottom. A ball valve, with a locking feature and designed to maintain integrity against diesel fuel should be provided. All tanks are to be double lined/walled. It shall incorporate two emergency approved type vents with proper leak detection for double walled tanks and an approved leak detection switch.

23.

The fuel tank/ diesel driver shall be provided with semis support.

24.

The jockey pump shall be a Grundfos mfg. or equivalent.

25.

The diesel day tank shall be monitored by the diesel fire pump controller by means of a low fuel switch, and a fuel tank leak sensor. Tanks shall also have a manual float indicator.

26.

All vent piping/manual fill piping to be piped outside building structure and vented with spark arrestors and installed in black steel with malleable fittings.

27.

All diesel day tank fuel piping to be installed in ½” black steel with malleable fittings. Flexible and Non Flammable connectors shall also be furnished on supply and return lines and are to be of braided steel flexible hoses.

28.

The batteries shall be dual acid starting type. Plywood is to be installed under the batteries.

29.

All control valves shall be tamper equipped, except ball valves on the heat exchanger lines, fuel tank, jockey pump isolating valves, controller test/drain valve, and other miscellaneous drain valves installed for service use. All valves are to be listed or approved and can not close within 15 seconds.

30.

Both controller sensing lines shall be equipped with brass check valves, with 3/32" orifices or 3/32" restricting unions, installed per NFPA 20 guidelines for pressure switch protection against surges. All related piping for sensing lines shall be Schedule 40 screw brass piping and no smaller than 1/2" in size with threaded screw brass fittings.

31.

Red factory finish for (virtually) entire assembly. The fire pump suction and discharge piping, flow meter return piping, heat exchanger discharge piping, (at contractor's connection point), and pressure relief piping (for diesels), shall be provided with flanged, braided, stainless steel type vibration isolation devices. Diesel exhaust piping shall be connected to the engine with a flanged strain relief, rated for diesel exhaust use. Mufflers shall be supplied with a condensation drain with valve and plug. Mufflers shall be sized by the factory for exhaust back pressure requirements. All piping, pressure sensing lines, by‑pass with check valves (when applicable), shut‑off valve drains, meters, controllers, and pumps shall be firmly anchored to the steel skid by means of structural steel supports. All electrical wiring between controllers, motors, and engine shall be completed and tested at the factory in water proof connections and boxes. The entire package will require one power connection by the electrical contractor.

32.

No type of back flow preventer will be allowed to be installed in the discharge or suction piping of the fire pump. If the fire pump is installed with a reliable incoming pressurized city water supply, it then will require a back flow preventer only on the incoming service of the fire pump if the water service has a connection/outlet for domestic water (when/where required).

33.

All apertures shall be UL/FM or Approved for fire suppression/pump use.

34.

No type of strainers is to be installed on the suction side of the fire pump piping.

35.

Where the pump and its suction supply are on separate foundations with rigid interconnecting pipe, the pipe shall be provided with strain relief.

36.

All fire pump “I” beam frames are to be mounted rigid to floor or housekeeping pad with the minimum of 5/8” concrete inserts, washers and nuts which shall be galvanized and per manufacture instructions

37.

I beam base shall be grouted light weight concrete when completed and accepted.

38.

Heat exchanger drain line shall be sized per NFPA 20 discharge at floor drain or outside building structure.

39.

Heat exchanger shall be equipped with a Liquid filled gauge that reads 0-60 psi and have a shut off valve.

40.

The existing diesel driver shall have a dedicated control panel.

42.

Installation of Companion Flanges to Pump Shafts and Stub Shaft bolts are required to be installed with “Loctite”603” thread lock.

2.1B – CONTROLLERS

A.

Diesel Fire Pump Controller:

Description – It shall be a combined automatic and manual based diesel engine fire pump controller intended for starting and monitoring fire pump diesel engines. It shall be suitable for use with both mechanical and electronic type engines. The controller shall be available for 12 or 24 volt negative ground systems, using lead acid or Nickel-Cadmium batteries. The controller monitors, displays, and records fire pump information which can be downloaded via USB port.

Approvals – Shall be listed by Underwriters Laboratories, Inc. in accordance with UL 218 and approved by Factory Mutual. It is to meet or exceed the requirements of the approving authorities as well as NEMA and the latest addition of NFPA 20.

Standards Features:

1. AC Line & Battery circuit features

2. Manual-Off-Auto selector switch

3. Manual Test push –button

4. Two manual crank push-buttons

5. Two 10 Amp battery chargers with 4 stage charging cycle, selectable AC voltage (110/220), selectable battery type (lead acid, Ni-Cad 9-18 Cell Ni-Cad 10/20 Cell

6. Door mounted display/interface panel featuring a 128 x 64 pixel backlight LCD graphical display. Membrane type user control push-buttons and easy read Indicators for:

1. AC Power

2. Alarm

3. Main Switch in Auto

4. Main Switch in Manual

5. System Pressure Low

6. Engine Running

7. Engine Failed to Start

8. Engine Temperature High

9. Engine Oil Pressure Low

10. Engine Overspeed

11. Engine Alternate ECM

12. Engine Fuel Injector Malfunction

13. Fuel level low

14. Automatic Shut Down Disabled

15. Charger Malfunction

16. Battery #1 Trouble

17. Battery #2 Trouble

18. Minimum Run Timer / Off Delay Timer

19. Programmable Daylight Saving Time Option

20. Weekly Test Timer

21. Engine Run Timer

22. Digital Pressure Display

23. USB Host Controller and Port

24. Solid State Pressure Transducer

25. Data Long

26. Event Log (3000 events)

27. Disk Error message

28. Disk Near Full Message

29. Pressure Error Massage

30. Failed to Start

31. Low Suction Pressure

32. Crank Cycle Status Indication

33. 300 psi wet parts.

Standard user set options:

1. AC Power Loss Start

2. Low pressure Aud.

3. Main Sw. Mis-Set

4. Pump Run Alarm

5. User Defined Input

6. Low Pump Room Temp.

7. Relief Valve Open

8. High Reservoir

9. Interlock Alarm

10. Low Suction

11. Manual Test

12. Remote Start

13. Low Reservoir Low

14. High Fuel Level

Required Options:

· Nema 4X

· Voltage Surge Arrestor

· Dual high/Low fuel switch

· Leak Senor Tank switch

· Space heater With Thermostat/where required

· Spare Parts Kit

· Removable Gland Plate

· 12” Mounting legs Stainless

· Seismic Certification

· Tropicalization

2.1 C.

Jockey Pump Controller Description - The jockey pump controller shall be factory assembled, wired, and tested specifically designed for this type of service. This controller shall be UL listed, and shall be of the same manufacturer as the main fire pump controller. Controller to be Nema 4 X rated.

Approvals - Are listed by Underwriters Laboratories, Inc., in accordance with UL508A, Standard for Industrial Controls, and CSA, Standard for Industrial Control Equipment (CUL). They are built to meet or exceed the requirements of the approving authorities as well as NEMA and the latest edition of NFPA 70, National Electrical Code.

Standard Features - The following are included as standard with each controller:

· Circuit Breaker

· Horsepower rated motor starter

· Suitable for use as service equipment

· HAND-OFF-AUTO selector switch

· Minimum run timer

· On-Delay timer

· Pump Restart Timer

· Control circuit transformer with 24VACsecondary

· 0-300 psi (0-20.7 bar) stainless steel solid state pressure transducer

· Overpressure indication

· Low Pressure indication

· Failed to start indication

· Main switch not in “Auto” alarm

· Pressure recording

· Event log (3000 events stored in controller memory)

· Data log (including cycle counter)

· Door mounted display/user interface featuring a 128 x 64 pixel backlit LCD Graphical

Display, Membrane Type User Controller Push-buttons and LED indication for:

· Power ON Light

· Pump Running Light

· Alarm

· 2 lines of user selectable display information

Operator Interface - The fire pump controller shall feature an operator interface with user keypad. The interface shall monitor and display motor operating conditions, including all alarms, events, and pressure conditions. The display shall be a 128x64 Backlit LCD capable of customized graphics. A minimum of 3 password levels shall be provided. The operator shall have the ability to choose up to 2 lines of data to be displayed on the main (home) information screen.

Digital Status/Alarm Messages - The digital display shall indicate text messages for the status and alarm conditions of:

• Pump Running • Sequential Start Time

• Minimum Run Time • Low System Pressure

• Pump Restart Timer • Fail to Start

• Automatic Start • System Overpressure

• User Selectable #11 • Main Switch Position

• User Selectable #21

The Sequential Start Timer, Minimum Run Timer/Off Delay Timer and Pump Restart Timer shall be displayed as numeric values reflecting the value of the remaining time.

LED Visual Indicators - LED indicators, visible with the door closed, shall indicate:

• Power ON

• Alarm

• Pump Running Data Logging - The digital display shall monitor the system and log the following data:

• Motor Calls/Starts • Pump Total Run Time

• Pump Last Run Time • Total Controller Power On Time

• Last Pump Start • Min/Max System Pressure

• Last Phase Fail/Reverse • Cycle Counts

Event Recording - Memory - The controller shall record all operational and alarm events to system memory. All events shall be time and date stamped and includes an index number.

The system memory shall have the capability of storing 3000 events and allow the user access to the event log via the user interface. The user shall have the ability to scroll through the stored messages in groups of 1 or 10.

Serial Communications - The controller shall feature a RS485 serial communications port for use with 2 or 4 wire Modbus communications.

Solid State Pressure Transducer - The controller shall be supplied with a stainless steel solid state pressure transducer with a range of 0-300 psi (0-20.7 bar) ±1 psi. The solid state pressure transducer shall be used for both display of the system pressure and control of the jockey pump controller. Systems using analog pressure devices or mercury switches for operational control will not be accepted. The START and STOP PRESSURE shall be adjustable through the user interface. The pressure transducer shall be mounted inside the controller to prevent accidental damage. The pressure transducer shall be directly pipe mounted to a bulkhead pipe coupling without any other supporting members. Field connections shall be made externally at the controller coupling to prevent distortion of the pressure switch element and mechanism.

Seismic Certification - The controller shall be certified to meet or exceed the requirements of the 2006 International Building Code and the 2010 California Building Code with Importance

Factor 1.5 and Sds equal to 1.88 or less. Qualifications shall be based upon successful tri-axial shake-table testing in accordance with ICC-ES AC-156. Certification without testing shall be unacceptable. Controller shall be clearly labeled as rated for installation in seismic areas and a Certificate of Conformance shall be provided with the controller.

Operation - A digitally set On Delay (Sequential Start) timer shall be provided as standard. Upon a call to start, the user interface shall display a message indicating the remaining time value of the On Delay timer. The controller shall include a Minimum Run Timer. It shall be turn off for Jockey Pump only. The timer shall be programmable type through the user interface. A pump restart delay timer shall be provided to allow the residual voltage of the motor to decay prior to restarting the motor and to prevent severe short cycling of the motor. The timer shall be programmable through the user interface. A Lamp Test feature shall be included. The user interface shall also have the ability to display the status of the system inputs and outputs. An Audible Test feature shall be included to test the operation of the audible alarm device (if supplied). The disconnect switch shall be mechanically interlocked so that the enclosure door cannot be opened with the handle in the ON position except by hidden tool operated defeater mechanism. The disconnect switch shall be capable of being padlocked in the OFF position for installation and maintenance safety. The controller shall also incorporate a Voltage Surge Arrestor.

2.2 - INSTALLATION MATERIALS

General: Except as otherwise indicated, provide materials for completing connections for mechanical and electrical service lines to installed fire pump assemblies so as to match materials of those service lines, either as specified in other Sections hereof, or as existing on previously installed lines; applicable to piping, conduit, wiring and other lines for materials, finishes, operational equipment and devices, including valves and switches. Fire pumps are to sit rigid to the floor of house keeping pads. At no time will rubber pads or spring isolator will be allowed under skid frame or driver and pump assemblies.

Skid Anchor Bolts: (if required) Provide steel‑pipe sleeved anchor bolts of the size/shape and quantity indicated for casting poured‑in‑place concrete foundations as work in this Section. Fabricate and deliver anchor bolts in coordination with time scheduled for construction of foundations, so as to avoid construction delays. Anchor bolts for mounting the skid shall be not less than 5/8” inch.

Pump Foundation Materials: Comply with applicable provisions of this Section, hereof for concrete and reinforcing materials as required to form/pour/reinforce, pump foundations as indicated; using 4000 PSI (27,580 kPa), Portland cement mix. Comply with fire pump manufacturers' printed directions/recommendations for selection of materials.

Skid Grout: Non‑shrinking and non‑metallic grout mix, complying with ASTM 1107, Grade B; with a design‑mix strength of 5000 PSI (34,470 kPa), for 28 day compression. Assembly shall be filled level to top of skid and not cover any type drain, power, control, or sensing line of any type.

Engine Exhaust Piping: ASTM A 53 Type E/S, schedule 40 galvanized or black steel pipe; ANSI B16.9, weld type pipe fittings, ANSI B16.21, non‑metallic gaskets 0.0625" (1.6mm), thick, and ASTM A 193/194 steel bolts/nuts of grade B8/8. Exhaust gasses shall not be discharged outside the structure where they will affect persons, disrupt occupants, or endanger buildings occupants. Follow NFPA 20 guide lines pertaining to runs of piping which might require sizing pipe to larger dimensions.

Exhaust Piping Insulation: Provide inorganic, high temperature, fabric jacketed type pipe insulation, rated by the manufacturer for pipe temperature up to 1000 degrees F. (538 C); with a thermal conductivity (K‑value) of 0.5 Btu/inch, (102 mm).

6. Exhaust Sound Suppression: Engines exhausting from normally occupied buildings shall maintain a maximum db of 60 or less and utilize hospital/residential grade mufflers. Provide low point ¼” drains on all mufflers.

Engine Exhaust Installation: The exhaust piping shall be connected to the engine with a flanged, strain relief, rated for diesel exhaust use. All exhaust piping must be suspended by approved devices that allow limited movement of the pipe, to prevent stress cracks from developing. Piping that must pass through walls shall utilize steel sleeves, with a minimum of one inch (1") clearance. The exhaust piping-to-sleeve clearance shall be filled with a non-hardening, fire proofing.

8.

Heat Exchanger Discharge: The manufacturer of the fire pump assembly shall provide a stainless steel, flexible hose connection at the discharge of the heat exchanger for the installing contractor to begin piping back to the reservoir. A sight glass for the heat exchanger discharge line must have a spring loaded "ball" to indicate water flow. The heat exchanger discharge gauge must be liquid filled, isolated from destructive engine vibration, and be equipped with a brass ballcock to facilitate maintenance. If piped to an floor drain independently with-in the pump room none of the above is required. At no time will this be allowed to be tied into Main Relief Valve or Flow Meter discharge piping.

9.

Suction Piping: Shall be a minimum diameter of 8" or as dictated by NFPA 20. Larger pipe sizes may be required for hydraulic losses, or pumps greater than 1000 GPM. The fire pump must be capable of flowing 100% of rating, never delivering a suction pressure less than zero. 150 percent flow is not required per NFPA`20 when supplied off an water storage tank.

PART 3 ‑ EXECUTION

3.1 - ASSEMBLY INSTALLATION

General: Comply with manufacturers' and OPS/FIR instructions/recommendations for installation, alignment of equipment, and connected piping. Comply with industry standards, see Part 1 hereof. Support connected pipelines independently from support of the fire pump components. Include flow meter and heat exchanger discharge return lines to water source, unless otherwise approved by FBO/FIR. Locate lines so as not to interfere with access to components for service and maintenance, including removal of driver units, couplings, pump impellers, seals, and accessories. Proceed as follows:

Disconnect driver‑to‑pump couplings during the setting, leveling, anchoring, and grouting of structural skid on foundation. It shall be the contractor's responsibility to assure qualified personnel perform this function correctly.

2. Support structural skid at required elevation on steel plate wedge shims at each anchor bolt location, nominally at one inch (1"/ 25.4mm) above concrete foundation. Adjust level of skid so that pump shaft and driver are level. Check to insure coupling face and suction/discharge flanges are plumb when anchor bolts are nominally tightened. At not time will rubber dampers or shims will be allowed under the diesel driver mounts to frame, or under skid package “I Beam”. All pumps are to sit solid to floor and or house keeping pad.

Install forms at edges of foundation to retain grout, and to form edges of grout into a one inch (1", 25.4mm), chamfer.

Pour skid grout to a depth of approximately 1.5 inches (38.lmm), inside skid and strike to level of skid bottom for exposure outside skid. Ensure grout is substantially under skid frame members so as not to have any voids under the skid. Allow initial pour to harden and cure.

Nominally retighten anchor bolt nuts, and recheck level/plumb of main components.

6.

Align pump and driver shafts and reconnect driver to pump couplings. Ensure with dial indicator, precision straight edge and taper gauge (if applicable), alignment is correct.

Fill skid/pump- driver frame: (if required) to top flange with skid grout, allow hardening and curing. Tighten the anchor bolts and nuts. Recheck pump/driver alignment, and correct as necessary, complying with the manufacturer's recommendations. Repeat coupling alignment checks after making pipe connections.

B.

Connections, General: Reinstall any components, connections, or accessories that might have been temporarily removed, or disassembled for the fire pump assembly installation. Exercise care to remove temporary fluids, coating and closures. Replace with operational fluids, coatings, and lubricants as specified by the manufacturer. Proceed with final pipe sizes and connections with suction piping elevations and configurations fully complying with standards, manufacturers' recommendations, and OBO/OPS/FIR/FPS. Keep pipe and equipment clean internally by the use of plugs and temporary closure plates for the extension of pipelines to fire pump assemblies, and for the connections thereto, including the installation of flanges, unions, valves, and other pipe line devices indicated. Refer to NFPA 70 hereof for the extension of electrical/electronic services to fire pump assemblies and for connections thereto; for supplying power, controlling equipment, operating connecting alarms, devices, and other systems; not work of this Section, except as otherwise indicated.

1. Exhaust System: Fabricate engine exhaust piping as required to remove exhaust gas from the pump room, and/or building. Connect flexible piping units to engine, and mount muffler units as indicated near shield/cage units to protect personnel from accidental contact and resulting burns. Install exhaust piping system with vibration dampeners, and supported independently from the fire pump assembly. Insulate extended piping system, except where shown to be non‑insulated; apply indicated thickness of exhaust piping insulation in compliance with insulation manufacturer's instructions and recommendations.

Welding: Comply with "Welding and Brazing Qualifications" for qualification of welding processes and operators used in the fabrication of exhaust piping systems.

C.

System Finishes, General: "Painting" hereof for cleaning/priming/painting exposed surfaces of any work of this section; to include touch-up of abraded factory finishes on fire pump assemblies, and extensions of red enamel finishes, and other finishes as indicated on connected service piping, conduits, and similar work not in this section.

FIELD: QUALITY CONTROL:

General: Perform each fire pump assembly installation and field testing procedure under direct supervision, at the project site, by the manufacturer's authorized, technical representative; who is acceptable to, and provides supervision, acceptable to OBO/OPS/FIR/FPS. Advise and provide OBO/OPS/FIR/FPS a minimum of 45 days advance notice.

Piping Tests: Prior to proceeding with fire pump operating tests, complete hydrostatic tests to confirm water tight installation of pressurized piping systems at 200 psi or 50 psi above rated fire pump boost pressure, for two hours. A two hour, 200 psi, hydrostatic test is also acceptable. The test shall be witnessed by the COR, or representative appointed by the COR, before any suction piping is covered in any manner. Failure to comply may result in excavation of the piping. Comply with applicable standards (NFPA) for hydrostatic testing.

Preparations for Equipment Start‑up: Prior to field start‑up of installed fire pump assemblies, check installations and make the following preparations comply with manufacturer's instructions and recommendations:

(a) Test and adjust controls and safeties. Pressure switches MUST be set with certified, liquid filled gauges. Pressure differentials shall be recorded in the fire pump log book.

(b) Check motor/engine for proper direction of rotation, and check pump impeller for unimpeded rotation.

(c) Check engine coolant fluid level, and adjust to manufacturer's recommended anti-freeze mixture percentages, a minimum of 50% anti-freeze/water.

(d) Insure engine oil level is correct.

(e) Verify all valves are in their normal position for testing the fire pump.

(f) Check to insure pump casing is primed.

(g) Adjust stuffing boxes/mechanical seals, and open supply lines.

(h) Verify hot‑start operation.

(i) Grease drive shaft and Faulk couplings with proper recommended manufacture required grease.

(j) Charge batteries.

3. Assembly Field Tests: Promptly, upon nominal completion of installation work, proceed with operating tests on the fire pump assembly(s); comply with NFPA 20. Perform direct on‑site, operation and testing in coordination with the manufacturer's representative. Comply with manufacturer's operating instruction, and demonstrate to OBO/OPS/FIR/FPS, and the government's operating personnel, every operational feature and capability of the installed equipment, including accessory elements which make up the systems. All testing, final acceptance, and commissioning of the water reservoir, suction piping, and fire pump assembly are to be performed by the installing contractor, the fire pump manufacturer's representative in the presence of OBO/OPS/FIR/FPS personnel and Post COR. The contractor shall provide 4 week notice prior to that system will be set 100% completed, so arrangements can be made for travel.

4. Once accepted the contractor is to provide one full day of training to Post personnel on the operation and maintenance of the complete fire pump skid package.

5. Contractor is to perform all operations pertaining to the main FACP and new controllers. Contractor shall pretest per NFPA 20 and 72 connections prior to final acceptance test and shall forward documents to OBO/FPS for review.