Attachment 39 - Section J.39 Tank and Pump System

Attachment 39 Section J.39

Tank and Pump System (TPS) Acceptance Test Procedures, Rev. 1, July 6, 2017

Tank and Pump System (TPS)

Acceptance Test Procedure

Revision 1

July 6, 2017

Tank and Pump System (TPS) Acceptance Test Procedure

Rev. 1.0 June xx, 2017 ii

The team at Logistics will very much appreciate receiving your suggestions about how we can improve and simplify this document and the procedure it descusses.

Please forward your comments to the Logistics team at FEMA Headquarters.

Rev. 1.0 June xx, 2017 iii

Contents

1. OVERVIEW

2. REQUIREMENTS:

3. EQUIPMENT REQUIRED:

4. TEST PAD SETUP:

5. TEST PREPARATION:

6. TEST PROCEDURE:

7. TPS BREAKDOWN / TEST COMPLETION

8. RECORD KEEPING

Figures

Figure 1. Water filter for filling TPS

Figure 2. TPS Water Recycling Connections

Photographs

Photo 1. TPS Sprinkler Hose Assembly (Typical) Photo 2. TPS Power Cord and Plug (Typical) Photo 3. General Air TPS Control Panel, Valves and Connections Photo 4. Darley TPS Control Panel Photo 5. Talco TPS Control Panel Photo 6. Talco TPS Alarm Panel Photo 7. General Air TPS Alarm Bar Photo 8. Darley TPS Alarm Bar Photo 9. Talco Pump Bleeder Valve Photo 10. General Air Pump Petcock Valve Photo 11. Mechanical Interlock with TPS Plug Receptacle (Typical) Photo 12. TPS Power Cord Plug (Typical)

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1. OVERVIEW

FEMA’s Tank and Pump System (TPS) is a custom‐designed solution to provide a reliable and code‐ compliant water supply for the residential fire sprinkler system in the Manufactured Housing Unit

(MHU) that the TPS is connected to. The system is designed to function in all weather conditions typically encountered in the contiguous 48 states. The systems have been tested at ̶ 50°F and + 130°F and have been found to function properly at these extreme temperatures when installed in accordance with the Operation and Maintenance (O&M) manual and FEMA’s standard installation guide.

The TPS is part of a life safety system, and as such, particular attention must be paid to the details of the test procedure described in this document and in the O&M manual. As a life safety system, the TPS is subjected to more oversight and scrutiny during maintenance and installation than any other portion of the MHU.

At FEMA’s sole discretion, FEMA may require that the testing be overseen by an independent third‐party fire protection consultant (FPC). The FPC will be responsible for witnessing and reporting on the setup, testing, and repackaging of the TPS unit. The FPC will not conduct the test or any other work, their role is limited to quality assurance inspection and reporting.

While the TPS units are robust, experience has shown that the units can be damaged during shipping and handling. In order to verify that the TPS is in working order, the Acceptance Test must be performed whenever:

A new TPS is delivered from the factory, A TPS is received at a Staging yard from Selma or Cumberland, A TPS is refurbished, or

A TPS unit is repaired.

Acceptance testing may be performed at Selma, Cumberland, at any Staging Yard, and at any other location as directed by FEMA.

This document provides detailed instructions for testing the TPS unit.

2. REQUIREMENTS:

1. All water added to a TPS unit from any source is to be filtered through a 5‐micron filter. TPS units ordered or refurbished after mid‐2017 will be equipped with the required water filter. On older TPS units, a temporary water filter must be provided by the contractor at the TPS water filling port.

Figure 1 shows the water filter required for filling a TPS that is not equipped with a permanent water filter.

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2. If a TPS fails the testing, it must be repaired, re‐tested and pass the test before being tagged as ready for dispatch.

3. Defective parts should be appropriately tagged and sent back to the manufacturer.

Female Garden Hose

Swivel.

Connect water source here.

¾” close nipple

Adapter as needed

¾” close nipple

Male Garden Hose

Connection to TPS tank.

Adapter as needed

Culligan HF‐150A 3/4‐ Inch Whole House

Sediment Water Filter or equivalent.

Filter cartridge must be 5 micron filter.

Figure 1. Water filter for filling TPS.

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3. EQUIPMENT REQUIRED:

Fork lift or skid steer with pallet fork attachment (standard 42” forks), 5,000

lb. capacity. Power supply.

TPS Operation and Maintenance (O&M) Manuals.

30‐amp, 240‐volt (V), 1‐phase, 60‐Hz power source. A 30‐amp portable generator is acceptable. 1½” Test ball valve.

IEC 60 309‐2 International Pin and Sleeve connector: 3 pole, 4 wire, 30 Amp, 120/240 volt rated 12H, rated IP67 or IP66 (Water tight) to connect to TPS power cord plug. Connector may be either: 1) a mechanical interlock, or 2) a cable mounted plug.

Hand Tools:

Open end wrenches (10 mm and 9/16") 8" adjustable wrench.

Box cutter.

Teflon tape.

Misc. screw drivers (flat and cross‐tip).

A short step ladder. Water supply.

Flashlight. 5‐micron water filter with fittings.

Crimping tool for butt connectors or wire eyelet ends.

Water buffalo, domestic water supply or equivalent.

Multi meter to test voltage amperage and continuity.

Garden hose and fittings.

Two 11" channel lock pliers. Ice.

Two 18" pipe wrenches.

Wire strippers.

4. TEST PAD SETUP:

Select an appropriate location for the test pad that is free from traffic or disruption. The staging area should be a level, solid surface located in close proximity to the water supply, power supply, and water disposal.

1. Power supply. Securely mount the IEC 60 309‐2 mechanical interlock on a post or wall, and connect the interlock to the source of electrical power. If a cable mounted plug is used, mounting is not required.

2. Water supply. If a water buffalo is used, position the buffalo in a location where the TPS can be moved on and off the test pad safely. Connect the garden hose to the water buffalo or water supply. Assemble the water filter and connect it to the end of the garden hose at the TPS. Buffalo water must pass through a 5 micron water filter as it enters the TPS. Hose should be pressure rated to 100 psi.

3. Water disposal. It is preferred that the water be recycled after each test. Where two TPS units are set on the pad, the water may be pumped directly into another TPS using the TPS hose and adaptors

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(see Figure 2). This water must pass through a 5 micron water filter as it enters the second TPS. If recycling of the water is not planned, ensure that the water disposal location and method will not interfere with continuing operations on or near the test pad.

4. Dry Storage. Set up an area to store the parts boxes and to inventory the box contents while the testing is underway. Ensure that the boxes and parts do not get wet.

5. Tool and Equipment Storage. Provide an area where tools and equipment can be stored safely, without creating tripping or other hazards.

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TPS #1 Hose

Test Ball Valve

TPS #2

Water Inlet

5 micron water filter

Coupling Pipe Nipple

Pipe Nipple

Adaptors as needed to connect to hose

Hose

Adaptors as needed to connect to hose

Figure 2. TPS Water Recycling Connections.

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5. TEST PREPARATION:

1. Place the TPS unit in position on the test pad. The TPS can be moved by either a fork lift or by hoisting. Refer to the O&M manual for that TPS for safe hoisting instructions.

2. Remove all boxes from the TPS enclosure and place them in Dry Storage. All boxes should be opened and properly inventoried to ensure all parts are provided. Each TPS is provided with a checklist of provided parts. If parts are missing, the TPS manufacturer should be contacted to request the missing parts.

3. Remove and uncoil the TPS hose assembly (see Photo 1). There is a plastic cap on the end of the sprinkler hose assembly; this is installed by the TPS manufacturer to prohibit debris from entering the sprinkler hose assembly before it is attached the MHU sprinkler riser. The protective cap should remain on the sprinkler hose assembly until the 1½” test ball valve is installed (see below). Do not twist or kink the hose. When pulling the hose do not pull by the heat trace wire that is attached to the hose assembly, pull using the threaded hose end.

4. Remove and uncoil the electrical power cord assembly (see Photo 2). Do not plug in the power cord

(electrical connection) or turn the power ON position until instructed to do so (see below).

Photo 1. TPS Sprinkler Hose Assembly (Typical). Photo 2. TPS Power Cord and Plug (Typical).

5. Open the TPS control panel (located inside the TPS enclosure) and connect the battery leads and verify that all circuit breakers are in the ON position (see Photos 3, 4 and 5). Install and properly connect other required electrical connections as described in the TPS O&M manual.

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Photo 3. General Air TPS Control Panel, Valves and Connections.

Photo 4. Darley TPS Control Panel.

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6. Remove the alarm panel/bar from the TPS enclosure and/or from the cardboard box (see Photos 6, 7 and 8). Install and properly connect alarm panel/bar on the exterior of the TPS as described in the

TPS O&M manual.

Photo 6. Talco TPS Alarm Panel.

Photo 5. Talco TPS Control Panel.

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Photo 7. General Air TPS Alarm Bar. Photo 8. Darley TPS Alarm Bar.

7. If not already connected, connect the sprinkler hose assembly to the TPS discharge valve. Remove the plastic protective cap from the sprinkler hose assembly and install the 1½” test ball valve at the threaded hose end. Save the protective cap so that it can be re‐installed after the test is complete.

8. Set the TPS valves to the following positions:

Discharge Valve – Closed

Suction Valve – Open

Test / Bypass Valve – Closed.

9. Using the proper water filtering apparatus and water supply, connect the garden hose to the TPS fill valve (i.e. tank fill connection). Once connected, open the fill valve and provide water flow. Fill tank to 1/3 to 1/2 full. Note: TPS water level must be above the top of the TPS pump.

10. Open the TPS discharge valve to allow water to flow into the sprinkler hose assembly. Open the 1½” test ball valve until water flows and then shut the ball valve.

11. Depending on the TPS manufacturer, air must be bled out of the pump in order to prime the pump casing up to the check valve.

Talco – open the bleeder valve until a small amount of water discharges from the valve

(see Photo 9).

General Air – open the petcock valve on top of pump manifold until a small amount of water discharges from the valve (see Photo 10).

Darley – no action required.

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Photo 9. Talco Pump Bleeder Valve. Photo 10. General Air Pump Petcock Valve.

12. Insert the plug from the TPS cable into the receptacle on the bottom of the mechanical interlock at the generator (see Photos 11 and 12). The plug can only be inserted one way; look at the tabs on the plug and the receptacle and align them. Once properly aligned, the plug can be properly inserted.

Photo 11. Mechanical Interlock with TPS Plug

Receptacle (Typical).

Photo 12. TPS Power Cord Plug (Typical).

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13. Tighten the locking ring on the plug assembly, securing the plug and cord to the interlock. The mechanical interlock can now be put into the ON position.

14. With the TPS control panel door closed, turn power switch a quarter turn to the ON position. Note that the control panel power switch is also referred to as “Power Disconnect Switch” and “Master

‘ON’ Switch”.

15. The pump will start automatically once power is ON. Open the bypass valve to cycle additional water after the pump actuates.

16. Check for leaks internal to the TPS as well as on the sprinkler hose assembly.

17. When the TPS bypass has steady flow through it, after the air has been bled out of the pump, follow the testing procedures outlined below for the specific TPS manufacturer.

6. TEST PROCEDURE:

The test procedure varies for each manufacturers’ TPS design. Procedures for each model TPS are described in the tables below. FEMA stocks more than one generation of TPS unit from several manufacturers. Instructions for both the 1st generation (Gen 1) and 2nd generation (Gen 2) units are listed below where appropriate.

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DARLEY TPS (Both Gen 1 and Gen 2 units are in inventory.)

Fire Alarm &

Pump Test

Open the by‐pass valve and allow the pump to run until Fire Alarm activates. Check that the alarm strobe flashes and is audible.

Close the valve slowly upon activation of the Fire Alarm. Minimum run time of the pump should be 120 seconds.

Maintenance

Alarm Test

Crack open bypass‐valve to slowly drop pressure. Close valve when pressure is between 50 and 60 psi.

Press TEST button to initiate maintenance alarm strobe and horn.

Heater Test

GEN 1 TPS: The arrow or mark on the heater control dial is pointed to the green mark.

GEN 2 TPS:

(1) Press the TEST button to begin the three‐phase test cycle; Phase 2 will turn on the heater

(2) Place hand in front of the heater and check for heat and that fan is running.

Heat Trace

Cable Test

GEN 1 TPS: The heat trace controller is illuminated and displays the current temperature of the hose. Press “SP” or “SET” button on the controller to display the set point temperature, which should be at 40°F.

GEN 2 TPS: Phase 3 of the self‐test sequence should activate the heat trace. Allow heat trace to warm, then touch cable to check for change in temperature.

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TALCO TPS (Both Gen 1 and Gen 2 units are in inventory.)

Pump Test

Open the by‐pass valve and allow the pump to run until Fire Alarm activates. Check if the alarm strobe flashes and is audible.

Close the valve slowly upon activation of the Fire Alarm. Minimum run time of the pump should be 120 seconds

Maintenance

Alarm Test

Locate room temperature sensor cable. Apply ice to metallic sensor until room temperature reaches 35°F to initiate maintenance alarm strobe and horn.

Heater Test

GEN 1 TPS:

(1) Turn heater control dial all the way right (clockwise). The heater should come on.

(2) Turn the dial all the way left (counter‐clockwise) to reset the heater to 40° F

GEN 2 TPS:

(1) Locate room temperature sensor cable.

(2) Apply ice to metallic sensor until room temperature reaches 40°F.

(3) Place hand in front of the heater and check for heat and that fan is running.

Heat Trace

Cable Test

The heat trace controller is illuminated and displays the current temperature of the hose.

Press “SP” or “SET” button on the controller to display the set point temperature, which should be at 40°F.

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GENERAL AIR TPS (Only Gen 2 units are in inventory.)

Pump Test

Open the by‐pass valve and allow the pump to run until Fire Alarm activates. Check if the alarm strobe flashes and is audible (horn takes up to 15 seconds to sound).

Close the valve slowly upon activation of the Fire Alarm; the minimum run time is

120 seconds.

Maintenance

Alarm Test

Remove black two‐prong temperature sensor plug from control panel to initiate maintenance alarm strobe and horn.

NOTE: The procedure above only applies to TPS with serial number greater than 0100

(e.g. 16‐0204GEN‐16‐0260BB‐0113‐TPS); for serial numbers less than 0100:

Locate room temperature sensor cable. Apply ice to metallic sensor until room temperature reaches 35°F to initiate maintenance alarm strobe and horn.

Heater Test

Turn the heater dial to 4.

Place hand in front of the heater and check for heat and that fan is running.

Return heater dial to setting between 1 and 2.

Heat Trace

Cable Test

The heat trace controller is illuminated and displays the current temperature of the hose. Press “SP” or “SET” button on the controller to display the set point temperature, which should be at 40°F.

Unplug the white two‐prong temperature sensor plug from the control panel. After 5 minutes, a small snowflake icon will illuminate and the heat trace will activate.

Allow heat trace to warm, then touch cable to check for change in temperature.

Re‐connect the white cable after the heat trace cable is warm to the touch.

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7. TPS BREAKDOWN / TEST COMPLETION

1. After the TPS has successfully passed the above testing protocol and has not shown signs of leaks and/or pressure drop (the TPS should hold pressure for approximately one hour), the TPS can be drained and disassembled.

2. If another TPS is to be tested, recycle the water in the tank. Connect a hose to the end of the TPS hose/ball valve assembly to pump the water into the next TPS. Connect the water filter and hose to the next TPS and follow the fill procedure for that TPS. Use the pump in the first TPS to pump the water into the second TPS. A 5‐micron water filter must be used. See Figure 2.

3. When the water transfer is complete, shut off the TPS. With the TPS control panel door closed, turn power switch to the OFF position (if applicable, zip tie the switch in the OFF position).

4. Turn the mechanical interlock at the generator to the OFF position. Loosen the locking ring on the plug assembly and remove the TPS plug from the mechanical interlock.

5. Drain the TPS tank, pipe, hose, and pump. Ensure that all water has been removed to avoid damage during storage. Pay special attention to the small diameter pipe, pressure switches, gauges, and tubing. A shop vac or similar tool may be helpful in removing water from the hard‐to‐drain areas.

Trace amounts of water that will not cause damage if it frozen may remain in the system.

Detailed instructions for draining the TPS unit are included in the TPS O&M manual. Follow the manufacturer’s instructions to remove the water from the unit.

6. Once all the water has drained from the TPS, close the discharge and drain valves and remove the

1½” test ball valve from the end of the hose assembly. Ensure that all water is drained from the assembly hose, and then place the plastic protective cover back on the end of the sprinkler hose assembly.

CAUTION

DO NOT RUN THE PUMP DRY. RUNNING THE PUMP DRY WILL DAMAGE THE PUMP.

CAREFULLY OBSERVE THE TANK LEVEL AND SHUT THE TPS MAIN POWER SWITCH OFF WHEN THE WATER LEVEL

DROPS TO THE PUMP SUCTION PIPE CONNECTION TO THE WATER TANK.

CAUTION

BE SURE TO DRAIN THE PUMP COMPLETELY. TPS PUMPS HAVE BEEN DESTROYED BY FREEZING WATER.

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7. Disassemble the alarm panel/bar and place back into the TPS enclosure. Be sure to pack the alarm panel/bar properly.

8. Disconnect other electrical TPS connections that were made to facilitate testing. Disconnect the battery inside the control panel.

9. Neatly repackage all TPS parts and place all parts back into the TPS enclosure.

10. Carefully and neatly roll up the sprinkler hose assembly and electrical cord and place back within the

TPS enclosure so that they will not damage any parts of the TPS during transport.

11. Ensure everything is put back into the TPS enclosure, close and latch the door shut and lock door.

8. RECORD KEEPING

The Tank & Pump System (TPS) Acceptance Test & Inventory form is to be completed for every TPS.

Place one copy of the completed form in the TPS for permanent record, and distribute additional copies as directed. The form is available as a separate PDF file.