TE-11-2_DIESEL FIRE PUMP ASSEMBLIES.pdf

63rd Readiness Division Fire Protection Systems

Diesel Fire Pump Assemblies

Report of Annual Inspection, Testing & Maintenance of Fire Sprinkler Systems

ONE REPORT SHALL BE COMPLETED FOR EACH PUMP

(Weekly, Monthly, Quarterly, and Bi-Annual Inspection Tasks are included in this report)

FACID

Building Number

Date of Inspection

Fire Pump ID or Location

Fire Pump Information Fire Pump Manufacturer Model Rated Capacity (gpm) Rated Pressure (psi) Engine Manufacturer Horsepower Rated Speed

Controller Information Controller Manufacturer Model

Complete the remainder of this page once inspection is complete.

VI. Annual Fire Pump Test & NFPA 25 Inspection Summary:

Y N

Fire pump assembly considered acceptable based on inspection and performance tests

Pump results charted on N1.85 graph paper and attached

Deficiencies and corrections needed are noted in comments section or attached

Comments:

Annual NFPA 25 Diesel Fire Pump Inspection & Test

I. Inspection Tasks:

Y N/A N

Fire Pump appears to be in service at time of inspection

Suction reservoir or water storage tank is full

Enter the date of last 5year inspection (type unknown if no information is available) Enter the date of last Obstruction Inspection (type unknown if no information is available) Environment:

Pump room or pump house sufficiently heated (min 40°F) Pump room or pump house adequately illuminated Intake louvers & duct clean Valves:

Control valves completely open (Intake, Discharge, and Bypass) Test header control valve closed Control valves accessible Control valves properly locked or supervised Control valve identification signs in place Control valves are leak-free Gauges:

Gauges appear to be in good condition Suction gauge pressure psi

Discharge gauge pressure psi Gauge readings (suction and discharge) appear to be in expected range when pump is not operating

Diesel Fuel Tank:

Diesel fuel tank 2/3 full Diesel fuel tank vents and overflow piping free from obstructions Diesel fuel piping in good condition Fire Pump Controller:

Controller pilot light or LED screen indicates that the controller is “ON” Controller set to “AUTO” All alarm pilot lights are “OFF” Pilot lights for batteries are “ON” or battery failure pilot lights are “OFF” Pressure recorder graph paper changed (if applicable) Electrical connections appear tight (or corrected if possible) Batteries:

Electrolyte level in batteries is normal Battery terminals are free of corrosion Voltage readings for batteries (2) are normal Charging current readings are normal for batteries

I. Inspection Tasks (cont):

Fire Pump: Y N/A N

Record engine running time from meter hrs

Fire Pump appears free from physical damage Flexible hoses, connectors in good condition Fuel solenoid valve appears operational Crankcase oil level is normal Engine coolant level normal Antifreeze concentration adequate Cooling water jacket heater operational Cooling water jacket piping leak tight Lube oil heater is operational Engine block heater operational Fire Pump shaft end play within specified tolerances Fire Pump coupling alignment within specified tolerances Parallel and angular alignment of fire pump and driver checked Pump shaft end play within specified tolerances Pump coupling alignment within specified tolerances Parallel and angular alignment of pump and driver checked Flexible exhaust section inspected and in good condition Exhaust system hangers and supports in place and in good condition Jockey Pump:

Power is provided to jockey pump Hangers: (Fire Pump or Pump Room Only) Hangers and seismic bracing appear to be in good condition (paint or coatings in place/undamaged, no rust or corrosion)

Hangers and seismic bracing appear securely attached to structural members and piping Hangers and seismic bracing appear undamaged and not missing Piping & Fittings: (Fire Pump and Pump Room Only) Piping appears free of mechanical damage Piping appears free of leakage Piping appears free of corrosion Piping appears properly aligned Piping free of external loading (not supporting other equipment)

II. Maintenance & Testing:

General: Y N/A N

All portions of this system appear to be in service prior to maintenance and testing Alarm monitoring service and all pertinent parties notified before performing maintenance or testing

Valves:

Control valves operated through full range and returned to normal position Operating stems of OS&Y valves lubricated PIVs opened until spring or torsion felt in rod PIVs and OS&Ys backed 1/4 turn from full open Gauges:

System gauges test/replacement date:

System gauges tested by comparison with calibrated gauge System gauges accurate within 3% of full scale System gauges recalibrated or replaced as necessary

Yes - Replaced

Yes - Recalibrated

Diesel Fuel Tank:

Diesel fuel tank float switch operational Drained approx. 5 gal of fuel from the tank sump to remove water and foreign material

Diesel fuel tested for degradation Fire Pump Controller:

Pressure switches for fire pump and jockey pump set correctly

Electrical system boxes, panels, and cabinets clean

Batteries:

Battery terminals clean and free of corrosion

Battery voltage normal (>9 volts on a 12 volt system or >18 volts on a 24 volt system)

Battery electrolyte level normal (NA for maintenance free batteries)

Battery exteriors clean and dry

Either Battery pilot light “ON” or Battery failure light “OFF”

Fire Pump:

Engine has been serviced within the last 12 months or 50hrs Cooling system condensate trap drained Exhaust condensate trap drained Pump bearing lubricated Electrical system safeties and alarms operated Electrical system boxes, panels, and cabinets cleaned Fire pump assembly maintenance performed in accordance with mfg.

recommendations (NA if this information is not provided by the owner)

Parallel and angular misalignment corrected (N/A if no correction needed) Circulation relief valve verified to close in accordance with mfg. spec.

Diesel Run Test:

Jockey Pump Turned Off Engine Starts on battery #1 from the engine control box Engine Starts on battery #2 from the engine control box Engine starts on battery #1 from the fire pump controller box Engine starts on battery #2 from the fire pump controller box No abnormal noises/vibrations observed Fire Pump operated with both primary and backup ECM Operated speed governor Exhaust system examined for leaks Intake air louvers in pump room are operational

II. Maintenance & Testing (cont.):

Y N/A N

Fire Pump:

Engine has been serviced within the last 12 months or 50hrs Cooling system condensate trap drained Exhaust condensate trap drained Pump bearing lubricated Electrical system safeties and alarms operated Electrical system boxes, panels, and cabinets cleaned Fire pump assembly maintenance performed in accordance with mfg.

recommendations (NA if this information is not provided by the owner)

Parallel and angular misalignment corrected (N/A if no correction needed) Circulation relief valve verified to close in accordance with mfg. spec.

Diesel Run Test:

Jockey Pump Turned Off Engine Starts on battery #1 from the engine control box Engine Starts on battery #2 from the engine control box Engine starts on battery #1 from the fire pump controller box Engine starts on battery #2 from the fire pump controller box No abnormal noises/vibrations observed Fire Pump operated with both primary and backup ECM Operated speed governor Exhaust system examined for leaks Intake air louvers in pump room are operational

II. Annual Fire Pump Performance Tests:

Y N/A N

Diesel Fire Pump and all equipment appear to be in service prior to the annual test Jockey Pump turned off for test Care taken to prevent water damage by verifying adequate drainage When testing with a Flowmeter and not flowing water outside, indicate the date of last test where water was flowed through the test header. (Test with flow through test header required every 3 years)

Fire Pump Churn Test:

Electric Pump starts when performing pressure drop test Pump starting pressure psi psi Record time for diesel engine to crank sec Record time for diesel engine to reach running speed sec Suction pressure gauge reading (while pump is running) psi Discharge pressure gauge reading (while pump is running) psi Packing gland discharging water (approx. 1 drip per second) if No, were packing glands adjusted (N/A if no adjustment was required) Oil pressure gauge, speed indicator, water and oil temperatures appear normal No overheating of packing box, bearings or pump casing observed No abnormal noises/vibrations observed Check heat exchanger for cooling water flow Checked packing boxes, bearings, or pump casing for overheating Circulation relief valve operational Pressure relief valve operational (if applicable) At churn, circulation relief valve checked for operation and water discharge At churn, pressure relief valve checked for proper operation At churn, pressure control valve checked for proper operation Alarms activated correctly For Fire Pump Flow Test using Flowmeter Flow meter adjusted immediately prior to testing in accordance with mfg. inst.

Test results using flow meter are consistent with previous annual test results (if “no” – complete flow test using hose streams OR calibrate flow meter)

Diesel Fire Pump Annual Flow Test Annual Fire Pump Flow Test conducted per NFPA 25 Type of device(s) used to determine flows Flow test conducted under minimum, rated, and peak fire pump flows At each flow condition, simultaneous readings of pump suction and discharge pressures and pump discharge flow recorded (see appropriate section in Section III)

At each flow condition, electric motor voltage and current in all lines recorded (see appropriate section on in Section III)

III. Test Data:

Pressure & Flow

Flow Suction

Pressure

(PSI)

Discharge Pressure

(PSI)

Net Pump Pressure

(PSI)

Pump Speed

(RPM)

Pitot Pressure

Dia. of Nozzle

Openings No. of

Nozzles Flowed

Flow Based on Pitot Pres.

Actual Flow

(GPM)

Churn 100% 150%

Voltage & Current

Flow Volts Amps Lead #1 Lead #2 Lead #3 Lead #1 Lead #2 Lead #3

Churn 100% 150%

Remarks on Test

Date of the Test Time of Test

Person Conducting the Test Company

Witness Title

IV. Annual Fire Pump Test Completion:

Y N/A N

Fire Pump Controller returned to the "Auto" setting

Jockey pump returned to service and operates satisfactory

FIRE PUMP LEFT IN SERVICE - DATE TIME

Inspector Name

Inspector Signature

Witness Name

Witness Signature

V. Annual Test Results and Evaluation:

(This section to be completed by after evaluating results) Y N/A N

Pump results charted on N1.85 graph paper Pump results compared to data from previous year Fire pump operated at maximum allowable discharge (where available suction supplies do not allow flowing of 150 percent of rated pump capacity)

Fire pump suction supply provided required flow at 0 psi or higher gauge pressure at pump suction flange (except installations where NFPA 20 permitted negative suction gauge pressures)

Electric fire pump driver did not overload beyond rating (including service factor allowance) while delivering necessary brake horsepower

Theoretical rated speed correction factors not applied to determine pump compliance per testing

Engine speed not required to be increased beyond pump speed rating to achieve rated pump performance

Investigation initiated where degradation in excess of 5 percent of initial acceptance test pressure or nameplate pressure

Voltage readings at motor within 5 percent below or 10 percent above rated voltage Abnormalities observed during inspection, testing, and maintenance promptly reported to responsible party

Annual Fire Pump Flow test matches initial unadjusted field acceptance test curve Annual Fire Pump Flow matches performance characteristics on nameplate Fire pump assembly considered acceptable