GIS 24-233 - Fire Water Pumps and System Design - 0900a8668010d09f

Guidance on Industry Standard Firewater Pumps and System Design

GIS 24-233

BP GROUPENGINEERING TECHNICAL PRACTICES

30 December 2005 GIS 24-233Guidance on Practice for Firewater Pump and System Design

Foreword

This is the first issue of Engineering Technical Practice (ETP) BP GIS 24-233. This Guidance on Industry Standard (GIS) is based on parts of heritage documents from the merged BP companies as follows:

British Petroleum

GS 124-4 Hydraulic motor driven Firewater Pumps for Offshore use.

Amoco

A PE-SMU-00-P Packaged Equipment Skid Mounted Units.

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Copyright 2005, BP Group. All rights reserved. The information contained in this document is subject to the terms and conditions of the agreement or contract under which the document was supplied to the recipient’s organization. None of the information contained in this document shall be disclosed outside the recipient’s own organization without the prior written permission of Manager, Standards, BP Group, unless the terms of such agreement or contract expressly allow.


Table of Contents

Page

Foreword............................................................................................................................................2

1. Scope........................................................................................................................................4

2. Normative references................................................................................................................4

3. Symbols and abbreviations.......................................................................................................5

4. Mechanical................................................................................................................................6

4.1. General..........................................................................................................................6

4.2. Pumps............................................................................................................................7

4.3. Piping.............................................................................................................................9

4.4. Diesel Engine drivers.....................................................................................................9

5. Instrumentation.......................................................................................................................15

6. Electrical..................................................................................................................................15

7. Materials..................................................................................................................................16

8. Coatings..................................................................................................................................16

9. Noise control...........................................................................................................................16

10. Drawings.................................................................................................................................17

11. Testing....................................................................................................................................17

11.1. General........................................................................................................................17

11.2. Diesel engine tests.......................................................................................................17

11.3. Pump tests...................................................................................................................18

11.4. Performance tests........................................................................................................18

12. Offshore..................................................................................................................................18

12.1. General........................................................................................................................18

12.2. Skid..............................................................................................................................19

12.3. Pumps..........................................................................................................................20

12.4. Shipping preparation....................................................................................................21

List of Figures

Figure 1- Sample Functional Test Sheet..........................................................................................22

Figure 2- Horizontal Pump Materials................................................................................................23

Figure 3- Vertical Pump Materials....................................................................................................23

Figure 4- Sample Firewater System Data Sheet..............................................................................24

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1. Scope

This GIS provides guidance on industry standards for firewater pump and system design.

2. Normative references

The following normative documents contain requirements that, through reference in this text, constitute requirements of this technical practice. For dated references, subsequent amendments to, or revisions of, any of these publications do not apply. However, parties to agreements based on this technical practice are encouraged to investigate the possibility of applying the most recent editions of the normative documents indicated below. For undated references, the latest edition of the normative document referred to applies.

American Institute of Steel Construction (AISC)

ASD Standards for Steel Construction

American Petroleum Institute (API)

RP 2-A Design and Construction of Offshore Platforms

RP 14C Testing Safety Systems

RP 14E Offshore Piping Systems

RP 2 FPS Practice for Design of Floating Production Facilities

STD 541 Form Wound Squirrel Cage Induction Motors

STD 610 Centrifugal Pumps

American Society of Mechanical Engineers (ASME)

ASME B 16.204 Gaskets

ASME B 31.3 Process Piping

ASME B 31.1 Power Piping

ASME B 16.5 Pipe Flanges

ASME B 16.3 Valves

American Society for Testing and Materials (ASTM)

A 106B Carbon Steel Pipe

A 234 Fittings

A 105 Carbon Steel Forgings

A 193 Bolting

A 194 Bolting

American Welding Society (AWS)

Structural Welding Code

BP Engineering Technical Practices (ETPs)

GP 6-60 Onshore and Offshore Paints and Coatings

GP 6-63 Internal Coating of Equipment and Piping

GP 12-20 Electric Motors

GP 12-25 Grounding

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GIS 12-201 IEC Low Voltage Induction Motors

GIS 12-202 NEMA Low Voltage Induction Motors

GIS 12-203 IEC High Voltage Induction Motors

GIS 12-204 NEMA High Voltage Induction Motors

GIS 12-205 IEC Synchronous Motors

GIS 12-206 ANSI / NEMA Synchronous Motors

GP 30-25 Field Instrumentation-General

GP 30-70 Instruments and Controls in Vendor Packaged Equipment

GP 32-20 Testing, Pre-commissioning

GP 32-50 Inspection and Testing of Electrical Equipment (ANSI)

GP 32-51 Inspection and Testing of Electrical Equipment (IEC)

GP 34-00 Rotating Equipment and Machinery

GIS 34-201 Centrifugal Pumps

GIS 34-202 Horizontal Centrifugal Pumps

GIS 34-203 Vertical Centrifugal Pumps

GIS 34-204 ISO Centrifugal Pumps

GIS 34-205 ISO Centrifugal Pumps

GP 36-10 Materials Selection

GP 40-10 Structural Skids

GP 42-10 Metallic Piping Systems

GP 60-50 General Issues – Utility Packages

GP 62-01 Valves Selection

British Standards Institute (BSI)

BS 5514 Reciprocating Internal Combustion Engines

Engineering Equipment and Materials Users Association (EEMUA)

Publication 140 Noise Procedure Specification

International Standards for Organization

STD 2548 Acceptance Testing for Centrifugal Pumps

National Electrical Manufacturers Association (NEMA)

Standards for Electrical Cabinets

National Fire Protection Association (NFPA)

NFPA 20 Centrifugal Fire Pumps

NFPA 70 National Electrical Code

Occupational Safety and Health Administration (OSHA)

29 CFR 1910 Subpart D Working Walking Surfaces

3. Symbols and abbreviations

For the purpose of this GIS, the following symbols and abbreviations apply:

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BTU British Thermal Units

BHP Brake Horsepower

FM Factory Mutual

FOI Floating Offshore Installation

LB-FT Foot Pounds

NPS National Piping Size

NPT National Pipe Thread

NPSH Net Positive Suction Head

PPM Parts Per Million

PSI Pounds per Square Inch

RMS Root Mean Square

RPM Revolutions per Minute

SS Stainless Steel

TIR Total Indicator Readout.

UL Underwriters Laboratory

VDC Volts Direct Current

4. Mechanical

4.1. General

a. Construction of this equipment shall be as per:

1. ASME B31.3, "Process Piping" and GP 42-10.

2. AISC "Manual of Steel Construction-ASD MO 16, 17 & 21,"

3. AWS D1.1 / D1.1M:2002, "Structural Welding Code – Steel."

b. No statement contained in this GIS shall be construed as limiting the design to minimum requirements.

c. Design and construction of this equipment shall ensure that all equipment and materials are suitable for operation in the conditions and environment of the facility location.

d. The design information included in this GIS is not intended to cover complete details.

e. The overall design should recognize that the fire pump package will be required to operate on an intermittent basis and be able to start and operate independently of external supplies.

f. If not specifically stated in this GIS, the fire water pump package shall conform to the requirements in GP 60-50.

g. Due to varying operating scenarios the design should be based on the most severe option. The options should include the discharge valve being open, partially open or closed and the fire main being pressurised anywhere within the range of atmospheric pressure to the

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discharge pressure of an already operating fire pump. In all cases there will be a check valve between the pump discharge and pump isolating valve.

h. The run up time of the combined unit shall be kept to a minimum (approx. 15 secs.).

i. Measures should be taken to prevent freezing of water mains that provide the necessary fire service requirements.

j. Interconnecting or looping of lines in vital services is desirable, but process and fire water systems should be separate whenever possible. If the systems are connected, piping and valves should be installed to prevent the loss of fire water.

k. The design shall provide for easy equipment access by operations and maintenance personnel.

l. The design shall provide for removal of components for routine maintenance purposes.

m. All associated working and walking surfaces shall comply with OSHA 29 CFR 1910 subpart D.

n. The design shall provide for operation to be normally un-attended by operations or maintenance personnel.

o. Contamination of fire water by process water that may contain hydrocarbons, or additives that might cause foam breakdown, should also be prevented.

4.2. Pumps

a. Steam, electric motor, or diesel engine pump drives may be used, depending upon the reliability of the power source. Gas or petrol (gasoline) pumps drivers are not normally used and shall be installed only after approval from the company.

Multiple pumps, each using a different type of drive, often provide optimum reliability. Total capacity should be sized based on normal needs and emergency scenario analysis.

b. The firewater system, if offshore, shall include a minimum of two 100% vertical turbine firewater pumps. One maybe electrically driven and the other shall be driven by diesel engines. Two diesel engine driven pumps should give the greatest fire risk mitigation.

c. For offshore installations, the engineer shall follow the guidance in GP 24-23.

d. For onshore installations, the engineer shall follow the guidance in GP 24-10.

e. Spare engine-driven water pumps shall be installed where the possibility of electric power outages exists.

f. If offshore, the firewater pumps shall be located in a safe area on a lower deck, with adequate separation between the pumps.

g. If jockey pumps are installed, they shall be used for pressure maintenance and for small demands on the system.

h. Selection and design of pumps shall be as per:

1. GP 34-00,

2. GIS 34-201,

3. API 610,

4. NFPA 20

i. Suction strainers shall be of the basket type bolt-on construction and shall have a free area of at least four times the area of the pump suction.

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j. Clutches or any other devices with power transmission interrupting capabilities shall not be used.

k. It shall be possible to remove couplings without the need to move the engine or driven equipment. All flexible couplings incorporating a spacer piece shall be of a design in which the spacer piece is positively constrained from flying out in the event of failure of the flexible elements. The maximum coupling torque shall be limited to a maximum of 80% of the coupling rating.

l. An alternative means of remotely stopping pump drivers should be considered.

m. Water pumps for fire service should be located as close as possible to the water supply source. This will permit the use of short suction mains for effective and reliable pump operation.

n. Column pipe flanges shall have registered fits and bearing retainers shall have parallel and concentric surfaces machined within 50 micrometers (0.002 inch) Total Indicator Readout (TIR) from the center of the pipe or shaft. Outside diameters of flanges shall be machined within 50 micrometers (0.002 inch) TIR for column sections exceeding 12 meters (40 feet).

o. Line shafts shall comply with the following minimum standards:

1. Surface roughness not to exceed 1 micrometer (40 µ inches) Root Mean Square (RMS).

2. Straightness: TIR shall not exceed 127 micrometers (0.005 inch) for every 3 meters (10 feet) of shaft.

3. Diameter tolerances shall follow the schedule listed below:

a) 0.0 in (mm) to 1.5 in (38 mm) Dia.: (–) 0.001 in (0.025 mm)

b) 1.5 in (38 mm) to 2.5 in (63 mm) Dia.: (–) 0.0015 in (0.038 mm)

c) 2.5 in (63 mm) to 3.0 in (76 mm) Dia.: (–) 0.002 in (0.050 mm)

p. The capacity specified on the data sheet will be that required from the pump package into the firewater system. Design should include allowance for any cooling water or other requirements of the pumping package when determining the capacity of the pump itself. The fire water systems demands shall also take into account any other water requirements such as foam making.

q. Suction and discharge pressures specified on the data sheet will be those required at the termination points of the pump package. Design should consider allowance for internal losses from pipe-work, strainers, changes in elevation, etc., when determining pump pressures and head.

r. Low flow relief or leak-off valves will be provided by the purchaser downstream of each pump to maintain the minimum continuous stable flow (as defined in API 610) with no flow into the firewater system.

s. The capacity of the relief or leak-off system shall take into account any permanent internal flows such as for cooling.

t. Provision for measuring pump capacity and differential head will be provided in the firewater pump system.

u. A lateral critical speed analysis shall be carried out on all multi-stage pumps. It shall include both wet and dry criticals and shall be calculated both at design clearances and twice design clearances.

v. Wet critical speeds, both at design clearances and at twice design clearances, shall be at least 20% above maximum continuous speed.

w. A torsional analysis shall be carried out as specified in API 610 clauses 2.8.3.2 and 2.8.3.3.

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x. Strainers in the lift pump's suction shall have a minimum free area of four times the pump's first stage suction cross sectional area and a maximum slot dimension of 12 mm.

y. Horizontal pumps shall have non-lubricated, flexible disc, spacer type couplings.

z. Thrust bearings shall be rated for at least twice the maximum thrust (up and down).

aa. The design safety factor for fire pumps shall be at least 1 bar (15 psig) additional pressure for the lowest flow, highest pressure demand, and 10% additional flow for the largest controllable scenarios. The pumps shall also have a 25% run-out capacity in excess of this maximum demand at 80% of the pressure.

bb. A reduced run-out, NFPA 20 requires a 150% run-out at 65% pressure, shall be permissible only where a thorough analysis of the water demands for a range of events has given an accurate prediction of the realistic water use.

cc. The hydraulic modelling of the fire water system shall be carried out assuming a friction factor relevant to the type of piping material and taking into the account of deterioration in the surface during the working life of the facility.

4.3. Piping

a. Piping shall be designed, fabricated, and tested in accordance with ASME B31.1 and ASME B31.3.

b. Piping 50 mm (2 in.) and smaller shall be carbon steel threaded schedule 80 minimum with 205 bar (3000 psi) fittings. Piping larger than 50 mm (2 in.) shall be carbon steel butt welded and flanged.

c. Anti-seize compound shall be used on all stainless steel threaded mating surfaces to prevent seizing regardless of the force applied. The compound shall be impervious to washout and will not drip or run or lose lubricity under severe weather conditions.

4.4. Diesel Engine drivers

4.4.1. General

a. Fire pump engines shall be in accordance with NFPA 20.

b. Engines utilized as fire pump drivers shall be rated at SAE conditions with the altitude and temperature deductions as stated in NFPA 20. These deductions apply to naturally aspirated, supercharged and turbocharged engines.

c. High priority shall be given to the design, package, construction, and installation to ensure simple and reliable starting of the diesel engine driver unit and ease of access and maintenance.

d. The listed engine rating for fire pump drivers shall be for the quoted engine model, speed and accessories.

e. The Rated Engine BHP after NFPA 20 deductions shall be a minimum of 110% the required pump BHP at 150 % of rated pump capacity, including gear and / or other transmission losses. The rated engine BHP shall be at the rated engine speed. Unlisted engine ratings shall be the shaft BHP after power reductions due to required accessories, such as water pump and cooler fan.

f. The engines shall have a continuous site rating which exceeds the total absorber power of the pump package, transmission system and any auxiliaries under all operating conditions by a minimum of 5%. This continuous rating shall have a minimum of 10% overload capacity.

g. Each engine shall be provided with two starting systems. The preferred primary system shall be electric, based on the use of batteries; the secondary system may be either

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hydraulic or compressed air. Any project preference for the type of secondary will be identified in the data sheets. Initiation of the secondary start system shall be by the manual operation of a single control button or equivalent.

4.4.2. Engine internals

a. All cylinders shall have removable liners. Wet liners must have suitable sealing methods that allow for thermal growth and a positive means of preventing water from entering the crankcase.

b. Piston ring type, and construction shall be clearly defined. The first compression ring, as a minimum, on aluminum pistons shall have a wear resistant insert.

c. All bearings shall have a positive means of anti-rotation, such as locking lugs and bearing crush shall be achieved without the use of shims.

d. All engines shall have valve-guide inserts and, if available, valve-seat inserts.

e. There shall be a means of ventilating the crankcase, such as a connection to the air intake manifold, through an oil trap.

f. Lube oil filters shall be of the replaceable element type and shall be equipped with relief valves and, if no other lube oil pressure indication is provided, a differential pressure gauge. Filters shall be of duplex type with manual changeover facility.

g. Engines shall be suitable for starting under all conditions without the need for engine pre-lube.

h. Electric sump heaters, if provided, shall have a power density not exceeding 2,3 W/cm².

4.4.3. Governors

a. Requirements for type, manufacturer, and model of governor, where applicable, shall be indicated on the data sheet. A electronic governor shall be supplied if not otherwise specified.

The current prevalent engine governor type is mechanical-hydraulic or electronic design.

b. The minimum and maximum range set-points and the speed set-point of the governor shall be manually adjustable. The governor class shall meet the following restrictions that are given as a percent of rated speed:

1. NEMA Governor Class A B C D,

2. Speed Regulation 10.00% 6.00% 4.00% 0.50%,

3. Speed Variation +0.75% +0.50% +0.25% +0.25%,

4. Max Speed Rise 13.00% 7.00% 7.00% 7.00%.

Speed Regulation is the allowable speed change from the rated speed set-point when the engine load is gradually reduced from rated power to zero. Speed Variation is the allowable speed fluctuation from the rated speed set-point at constant load with all other engine operating conditions remaining constant. Max Speed Rise is the allowable momentary increase in speed when the engine is producing rated power at rated speed and the load is rapidly dropped to zero.

c. There shall be a separate and independent method of detecting crankshaft over-speed which closes the fuel shutoff valve at 110 % of the rated continuous speed.

4.4.4. Cooling system

a. Either direct air cooling or water cooling of the engine is acceptable providing they are of the manufacturer's standard design.

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b. The cooling system shall be sized for the engine continuous net brake power at the maximum ambient and cooling water temperatures. If specified on the data sheets the system shall also include capacity for cooling the air within the engine enclosure or room and for cooling the engine exhaust.

c. If provided the radiator fan shall be driven from the engine either directly or by the use of hydraulic transmission. It shall not be independently powered.

d. The engine shall be provided with thermostatically controlled jacket water heaters and, if necessary, circulating pump to ensure optimum engine starting temperature at the minimum specified ambient temperature.

e. If necessary, provision shall be made for the prevention of over heating of the coolant due to local high temperature after shut down.

f. The engine jacket and lube oil cooling system shall be of the closed circuit type, including a circulating pump driven by the engine, a 90-10 cuprous nickel heat exchanger and engine jacket temperature regulating device. The cooling water supply for the heat exchanger shall be from the discharge of the fire pump.

g. The cooling water supply loop shall include shut-off valves, strainer, constant pressure pilot operated valve in accordance with NFPA-20, and a bypass. The cooling loop shall also be tied into the cooling coil in the right-angle gear for vertical units.

4.4.5. Fuel

a. The fuel tank working capacity, not including expansion and sump volume, shall be sized for twenty-four hours operation (minimum) based on the engine manufacturer's maximum fuel rate between 50% and 100% of rated power.

b. The fuel tank construction shall be per NFPA 20 with exception to the fuel supply valve being at an elevation equal to or greater than the engine fuel pump.

c. Where possible, the fuel tank for skid mounted packages shall be mounted under the engine support structure.

d. The skid shall not be used as a fuel tank.

e. The total lift for the engine mounted fuel pump shall not exceed 152 cm (5 ft) at the lowest fuel level and be supplied through a stilling tube. The fuel supply stilling tube inlet shall be approximately 50 mm (2 in) above the bottom of the fuel tank, at the opposite end from the drain valve. In addition, the fuel return shall utilize a stilling tube located at drain end of the tank.

f. The diesel fuel system shall be UL listed type per NFPA-20.

The only exception to the requirements detailed in NFPA-20 concerning the fuel system is the requirement that 95 % of the fuel tank volume is above the fuel pump center-line.

g. Each diesel engine shall have a dedicated fuel storage tank designed and sized to provide a net capacity of fuel in accordance with statutory regulations

h. When specified, diesel engines shall have a day tank. The total volume shall equal 115 % (minimum) of the capacity specified on the data sheets, 5 % excess in the bottom and 10 % excess in the top. The day tank shall be sloped toward the drain at a rate of 21 mm per meter (¼" per foot). As a minimum the day tank accessories shall include - inlet supply valve, manual fill with screen, vent and fuel return with degassing feature, overflow connection, inspection port, armored level gauge, drain valve and low level alarm.

i. The fuel tank location will be specified in the scope of supply data sheets. Under no circumstances shall the tank be located above the hot exhaust ducting or the engine itself.

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The diesel engine data sheets shall state the maximum allowable height of the tank bottom above the underside of the diesel engine skid / package frame.

j. In all cases a locally operated manual valve shall be installed in the fuel line to the engine at the tank outlet. If the tank is located within the diesel engine room / enclosure this valve shall also be operable from outside the room / enclosure.

k. A thermostatically controlled tank heating system shall be provided if ambient conditions could result in the viscosity of the fuel exceeding the maximum recommended by the engine vendor.

l. The fuel suction filters shall be of the duplex type with replaceable elements and a changeover facility to permit removal and replacement of either element without need for engine shut-down. Filter mesh size shall be specified by the engine supplier.

m. Provision shall be made for priming and bleeding the fuel injection system.

n. For unmanned installations high pressure fuel lines between the fuel pumps and injectors shall be double-skinned, seamless tubing with fuel leak monitoring and alarm. On manned installations the fuel lines may be as above or heavy seamless tubing.

o. Flame resistant flexible hoses shall be provided within the fuel supply and return piping systems between the engine and off skid pipe-work at the edge of the engine. There shall be no shut-off valve in the return line to the tank.

4.4.6. Intake, exhaust

a. Dry replaceable filters shall be provided for the combustion air intake. Filter condition gauges shall be provided.

b. An automatic shut-off valve actuated by engine over-speed shall be fitted in the air intake manifold. Operation of the valve shall be independent of external power sources and shall be capable of manual operation.

c. The exhaust system shall include silencers, bellows and spark arrestors. If two or more fire pump packages are provided each engine shall have its own exhaust system.

d. Hot exhaust system piping within the confines of the package shall be insulated or protected to limit surface temperature to 65ºC (149ºF).

e. Where exhaust systems can be exposed to hazardous area conditions, they shall be water cooled to limit surface temperature. The temperature and the length of the system requiring cooling will be specified within the data sheets. The discharge location from the exhaust system shall be specified.

4.4.7. Air starting

a. The engine shall be equipped with an air starter, strainers, starting air valves, gauges and regulators as required.

b. The air start facility shall normally be by use of an air driver starting motor using compressed air from a storage reservoir. Direct air injection systems may only be considered for larger engines when available as a standard engine feature. The starting air receiver shall be supplied and mounted off-skid and shall not be a part of the fire pump package scope. Design shall include the start air requirements (rate vs. pressure). Design specifications shall indicate the maximum allowable backpressure at the edge of skid flange for the starter at the full rated starting airflow. The air storage reservoir shall be sized for 180 seconds continuous cranking without recharging.

c. A constant pressure regulator capable of supplying the required amount of air to the starter shall be provided on skid between the starting air receiver and the air starter. A flow control valve shall be provided between the regulator and the air starter. A 316 SS flexible braided hose with threaded ends shall be between the skid air piping and the starter.

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d. The air starting system, including the reservoir, shall either be recharged from high pressure storage bottles or via an intensifier from a separate air supply, independent of the fire pump package. In both cases a hand started diesel engine driven compressor shall be provided as back-up. A by-pass with manual valve or switch shall be provided for supplying compressed air to the engine starter in the event of control circuit failure.

4.4.8. Electric starting

a. The electric starting system shall include a 24 VDC starter, DC contactor, sealed maintenance free batteries per NFPA 20, skid mounted in a fiberglass battery box.

b. Power for successive cranking cycles shall alternate between two battery systems. In the event of a battery failing during the cranking period, the healthy battery shall be brought in automatically to provide power for all the remaining cranking cycles.

c. Each battery unit shall have sufficient capacity at the site minimum temperature to maintain the cranking speed recommended by the engine manufacturer through a 6 minute cycle (15 seconds cranking and 15 seconds rest in 12 consecutive cycles).

d. The starting batteries shall be capable of being isolated by a remotely controlled contactor contained within a NEMA 4X enclosure. The contactor shall be used for isolation purposes only. Control of this contactor will be from the installation's Fire and Gas Detection system.

e. A means of recharging the storage batteries shall be provided. It shall be based on automatically controlled chargers taking power from a separate alternating current power source. The controller shall have dual UL / FM approved current limiting type chargers with float charging design so as not to overcharge and damage the batteries. When current demand is high on starting, charger shall disengage to limit current input to batteries

f. Each battery system shall have its own independent dedicated charger. Each charger shall comply with the following:

1. Have a rate of charge consistent with recharging the respective battery in the minimum time, not causing damage to the battery, not reducing battery design life, restoring full charge of the battery within 24 hours following any style of discharge.

2. The charger shall be marked with the ampere-hour rating of the largest capacity battery that it can recharge in compliance with (a) above.

3. An ammeter with an accuracy of ±5% of the normal charging rate shall be furnished to indicate the operation of the charger.

4.4.9. Hydraulic starting

a. When hydraulic starting is used the accumulators and other accessories shall be located on the same skid base as the diesel engine.

b. The hydraulic starting facility shall comply with the following conditions.

1. The hydraulic cranking device shall operate independently of external power supplies.

2. The overall hydraulic system shall contain at least two accumulators each capable of being isolated from the system and removed from maintenance without depressurising the system. The removal arrangements shall also facilitate in-situ checking of the accumulator pre-charger pressure.

3. For recharging the accumulators the hydraulic systems should contain one engine driven pump and one manually operated pump.

4. The capacity of the hydraulic cranking system shall provide not less than six cranking cycles at the site minimum ambient temperature.

c. Piping for hydraulic systems shall be stainless steel.

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4.4.10. Controls and instrumentation

a. The engine control system shall be designed and furnished with a skid mounted electronic control panel and engine-mounted sensing and control devices.

b. All engine instruments such as gauges and indicators shall be placed on a suitable panel securely mounted on the same side of the skid as the fire pump control panel.

c. The fire pump package operator shall be able to see engine and pump control panels at the same time.

d. The engine shall be equipped with controls to perform following functions:

1. To initiate and terminate cranking on engine start;

2. Crank cycles shall be 15 seconds crank followed by 15 seconds rest;

3. Any failure to crank shall be alarmed;

4. To initiate automatically cranking on primary or back up start systems;

5. To shut down the engine by shutting off fuel supply, by initiating a signal to the governor;

6. To sense engine trouble malfunctions - "Low Engine Oil Pressure", "High Jacket Water Temperature" and "Over-speed";

7. To select "automatic", "manual start" and "off" modes on control panel;

8. To operate in "manual" mode so that the engine will shut down on "Trouble" malfunctions;

9. To operate in "automatic" mode so that engine will start on a signal from a remote device and will not shut down except by the stop control. The control valves shall be arranged so that once the engine is started it will not shut down for loss of instrument air.

e. The control panel shall provide the following:

1. Start / Stop push buttons,

2. Selection of starting method,

3. Jacket water heater and, if fitted, other heater switches,

4. Local / Remote control switch,

5. Start selector with manual / auto-standby / off,

6. Emergency stop,

7. Normal / Test changeover switch,

8. Hydraulic circulating pump start / stop push buttons,

9. Individual indicators for:

a) High jacket water temperature,

b) Engine oil pressure,

c) Engine speed,

d) Failure to start (over-crank),

e) Starting air pressure.

10. Pressure switches to provide signals for the following indications on main control panel:

a) Pump running,

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b) Pump not in “auto” mode,

c) Pump malfunction.

11. Remote "auto" start at the pump when panel receives a signal from main alarm system.

f. Design shall provide for mounting controls on the engine, mounting the control panel and installing all tubing and wiring.

g. All faults which will ultimately lead to a shutdown shall have a pre-alarm which shall be set to give reasonable warning of an imminent shutdown.

h. When the operating mode or select switch is in the normal position, all trips other than the over-speed trip shall be inhibited. When in the test mode all trips shall be operational. Resetting of trips shall only be possible locally.

5. Instrumentation

a. All instrumentation shall comply with GP 30-25 and GP 30-70.

b. Instrumentation shall be provided as indicated on the drawings.

c. All instruments and controls shall be removed or sufficiently protected prior to sandblasting, testing, and painting of equipment and piping.

d. The control system shall be UL listed for fire pump control.

e. Control boxes on the skid shall be mounted with vibration dampers.

f. Control panel enclosures shall be NEMA 4X and fabricated from 316 SS. All bolts, screws or fastening hardware for the panel, including nameplate screws shall be 316 SS with aircraft locking nuts.

6. Electrical

a. NFPA 70 and GP 12-45 shall govern the work.

b. All electrical materials and equipment shall be fabricated in accordance with NEMA Standards and shall be labeled or listed as approved by the Underwriters Laboratory (UL) or Factory Mutual (FM). Panels shall be NEMA 4X and fabricated from 316 SS. All bolts, screws or fastening hardware for the panel, including nameplate screws shall be 316 SS with aircraft locking nuts.

c. Electric motor shall be sized to meet the loading conditions of the pump specified on the data sheets, including the supply of maximum horsepower to the pump with the rated impeller at run out on the performance curve without using any portion of the motor safety factor. Electric motors selection shall be based on the following:

1. GP 12-20,

2. GIS 12-201,

3. GIS 12-202,

4. GIS 12-203,

5. GIS 12-204,

6. GIS 12-205,

7. GIS 12-206,

8. API 541.

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d. Available power shall be as specified in the data sheets.

e. Design shall include grounding provisions and shall comply with GP 12-25 and shall include grounding provisions for all equipment. Bolted equipment shall have separate ground lugs with ground bonding cable connected to the skid structure.

f. Electrical components shall be suitable for service in the environment and hazardous area classification defined in the data sheets.

7. Materials

a. The material of construction shall be appropriate for the type of water in the system: Any project preferences for the materials to be used are given in the data sheets.

b. Materials should be selected as per GP 36-10.

c. Generally materials should be as follows:

1. Pipe: as per GP 42-10,

2. Fittings: as per ASTM A-105, A-234, or ASME B 16,

3. Gaskets: Flexitallic or as per ASME B 16.204,

4. Bolting: as per ASTM A-193, 194,

5. Valves: as per GP 62-01, ASME B 16.3,

6. Structural steel: galvanized,

7. Pumps: see Figures 3 and 4.

8. Coatings

a. Coatings for materials and equipment should be as per GP 6-60 and GP 6-63.

b. Coatings should be applicable for the environment at the location of the facility.

c. Structural steel shall be galvanized to protect against the environment.

9. Noise control

a. Noise control shall conform to the requirements in GP 14-01 and GIS 14-011.

b. In the absence of any stated noise limits the maximum noise level, irrespective of pump output, at or beyond 1m from the machine surface shall not exceed 110 dB(A). Any requirements for a lower maximum noise level shall be described.

c. The manufacturer shall provide details of the noise emission from his equipment in octave bands. He shall also provide details of any narrow band noise emitted by his equipment that is noticeable to the ear, together with the octave band or bands in which it occurs.

d. Where the noise-limiting requirements of GP 14-01 and GIS 14-011cannot be met without the provision of noise-reducing features, the levels with and without these features shall be stated. Such features shall not compromise, in any way, the correct operation of the machine, or any other requirements and will only be accepted when there is no alternative for noise control. Noise-reducing features shall be cost quoted separately in the supplier’s quotation and shall be subject to company approval.

e. Noise levels shall be measured and calculated in accordance with the procedures stated in EEMUA Publication No 140. Alternatively, by prior agreement such measurements and calculations may be carried out by other standard noise test procedures.

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10. Drawings

a. The package shall be designed and constructed as specified on drawings and data sheets.

b. Documentation shall conform to the requirements in GP 60-50.

11. Testing

11.1. General

a. Close coordination during the test run phase to ensure the satisfactory functioning of the complete package , i.e., pump, driver, transmission, controls and other ancillaries is recommended.

The satisfactory functioning of the complete package is normally part of the vendor's guarantee.

b. All fire control and safety equipment shall be tested prior to shipment to insure proper operation and satisfaction.

c. A five days notice prior to testing is recommended.

d. All instrumentation and electrical devices shall be calibrated before attempting mechanical run or performance testing.

e. Rotating equipment shall be aligned with driver before testing.

f. Acceptance of performance, mechanical run or operational tests shall not constitute a waiver of requirements to meet the specified operating conditions.

g. During the tests, the equipment shall operate to satisfaction without vibration in excess of 5 mils or 0.20 IPS, noise, or other unacceptable characteristics.

h. All pressure containing parts shall be hydrostatically tested in accordance with API 610.

i. Electrical equipment testing should follow GP 32-50 and GP 32-51.

j. Testing requirements may also be found in GP 60-50.

11.2. Diesel engine tests

a. The panel and engine shall be shop run tested per requirements of NFPA-20. The control panel shall be assembled and connected to the engine for a complete functional test and shop run test the engine in accordance with Factory Mutual.

b. Diesel engines shall be tested in accordance with BS 5514. Standard data sheets compiled for BS 5514 purposes are the preferred format for the data.

c. A diesel engine performance map shall be provided and shall indicate minimum turndown conditions recommended for continuous service and shall include:

1. Engine speed (RPM),

2. Specific fuel consumption (BTU / BHP-HR),

3. Output power (BHP),

4. Torque (LB-FT), BMEP (PSI),

5. Exhaust temperature (ºC/ ºF).

d. All testing shall be carried out in accordance with written procedures. Test procedures shall detail, as a minimum, the scope, duration, and acceptance criteria of all tests, measurements to be taken, and shall include the following data:

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1. Declaration of power, fuel consumption, lubricating oil consumption and information detailed in BS 5514,

2. Outline technical documentation concerning the engine and type.

e. Diesel engines shall be tested against a water brake, to demonstrate full load power and 10% overload capability.

f. A “torsional vibration analysis” of each complete equipment string shall be completed. Each engine, coupling, driven unit system shall be so designed to ensure that the complete installation starts, operates and stops free from torsional vibration and oscillation. The first lateral and torsional critical speeds for the complete train shall be at least 10% above the maximum operating speed. No lateral or torsional critical speed shall lie within the operating speed range of the system.

g. Diesel engine RMS velocity of vibration shall not exceed 11 mm/s (0.433 in/s) at any operating condition.

h. All testing shall be carried out using the contract heat exchangers, filters, governor and over-speed device. The operation of the over-speed protection system shall be demonstrated mechanically or hydraulically without the use of electrical power.

i. Engine oil having identical characteristics to the contract oil shall be used.

11.3. Pump tests

a. A witnessed shop run test shall be conducted on pumps.

b. NPSH tests on horizontal pumps shall be carried out on the first pump of each type when the NPSH required at 150% rated capacity exceeds 80% of the NPSH available as specified on the data sheet for the same capacity.

c. Submergence tests should be performed on vertical well-type pumps.

d. As a consequence of the length of the columns employed for vertically mounted pumps and the limitations of test facilities, vertically mounted pumps may have to be tested with shortened columns. Prior to such tests, agreement with the purchaser shall be reached on the head losses in the test and final configurations, and the corrections to be applied to the test measurements.

11.4. Performance tests

a. Performance and NPSH tests shall be carried out in accordance with ISO 2548, and shall be within the limits specified. The tests shall be extended as required to demonstrate the characteristics defined in NFPA 20.

b. Test results and performance characteristics shall be recorded and kept on file for availability on request.

c. All diesel engine performance tests shall be based on site conditions and shall certify fuel usage (BTU / BHP-HR) for 50%, 75% and 100% of engine rated shaft BHP at site conditions.

d. Pump performance tests shall be performed within 10% of pump rated speed. A characteristic curve showing the pump performance based upon the results of the shop tests shall be provided.

12. Offshore

12.1. General

a. Fuel storage capacity for diesel engine drivers must meet local requirements, e.g., offshore use in UK is 12 hours based on fuel consumption at engine continuous net rated power.

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b. Applicable offshore codes shall be applied to include:

1. API RP 2A,

2. API RP 14C,

3. API RP 14E,

4. API RP 2FPS.

c. The fire pump package shall be self-supporting and designed to withstand a wind load as specified on the data sheets. Wind loadings shall be determined in accordance with API RP 2A. The wind load shall be applied to the vertical projection of the fire pump package, including all appurtenances.

d. As all offshore installations will have at least two fire pumps, the package will be required to operate in parallel with other fire pumps.

e. The driver will be located in a non-hazardous area, within a fully walled and roofed room or enclosure: the enclosure, if included as part of this package may be located in an exposed location as indicated in the data sheets.

f. The design of these systems should be based on starting the engine and pump from rest. Consideration should also be given to preventing reverse rotation.

g. For floating installations, equipment shall be capable of operating at a sustained maximum inclination as stated in the data sheets.

h. An analysis of axial loads, static and hydraulic, during starting and stopping and while operating with flow between minimum continuous stable flow and 150% rated flow shall be provided. The analysis shall include minimum and maximum speeds and internal pump clearance at both design values and twice design values.

i. When selecting the materials of construction the design should include the water intake may be dosed for antifouling purposes.

j. Circulating water for diesel engines shall be cooled in either an air cooled radiator or in a water / water heat exchanger using sea water from the pump discharge. Any project preference shall include cooling method and / or location of the air cooled radiator (if needed) and such details shall be given in the data sheets.

12.2. Skid

a. The fire pump package be completely confined within the boundaries of and mounted upon a structural steel skid designed for single point lifting by a crane.

b. Skids shall be designed, fabricated and inspected in accordance with GP 40-10.

c. Skid components shall not interfere with the installation or removal of lifting gear such as slings, shackles, etc. Slings shall not contact skid components during lifting.

d. A drip pan shall be installed under the engine and shall be constructed of not less than ⅜" plate properly supported and sloped to a 6” channel drain trough installed across the center of the skid and drained on each side. Accessible skid surface shall be covered with grating.

e. The skid shall be constructed to provide easy removal of the engine oil pan without removing the engine from the skid. Oil drain shall be accessible for draining without draining into the skid drain pan.

f. Electrical end devices shall be terminated at a skid mounted equipment control panel. All field switches, e.g., hand / off / auto, reset, etc., and status indication lights shall be mounted on this panel.

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12.3. Pumps

12.3.1. General

a. Pumps shall have a continuously rising head capacity curve from design point to shut-off. The pumps shall be capable of delivering 150 % of rated capacity at not less than 65 % of rated discharge pressure. The shut-off or deadhead pressure shall not exceed 140 % of the rated pressure at design capacity. Deviations from these percentages shall not be permitted unless specifically reviewed as these requirements are from NFPA 20.

b. The pump / caisson diametrical clearance shall be 100 mm minimum. This shall be maintained over any bumper. The minimum caisson size acceptable while maintaining the required diametrical clearance shall be specified.

c. By means of a small bore pipe, “piggy backed” to the main column pipe, facilities shall be provided for the injection of chemical dosing into the water adjacent to the pump suction strainer. This small bore pipe shall terminate in a flange at the column pipe head piece.

d. Friction loss for vertical column pipe shall not exceed 152 cm (5 feet) of head per 30 meters (100 feet) of pipe.

e. The column pipe shall be in flanged interchangeable sections. The section length shall be consistent with ease of handling and the necessary connections for the hydraulic piping.

f. Each sections length shall be specified in data sheets including the not to exceed length. The top and bottom sections may be unique.

g. The column pipe shall be provided with centralizers to center the pump and column in the pipe casing. Unless specified in the data sheets, design shall include evaluation and recommendation of the number and location of centralizers.

h. The column assembly shall be open line shaft, seawater-lubricated type with cutlass rubber bearings held in place by 316 SS spiders located, as a minimum, at each column flange.

i. The machine bolts and nuts for the column pipe flanges shall be 316 SS, a minimum of 16 mm (⅝ in.) in diameter and a minimum of twelve bolts shall be used at each flange connection. When installed, the end of each bolt shall be flush with the outer end of the nut to avoid marine growth collecting on the threaded surfaces of the bolt.

12.3.2. Lift and booster pumps

a. Dependent upon the platform type, the lift pump will be either of the vertical suspended type located within a caisson (stilling tube) or of the split casing type located within a floatation chamber below sea level. The platform type and required pump type are given in the data sheets.

b. The combined lift and booster pumps performance characteristics shall fully comply with the requirements of NFPA 20.

c. The lift pump shall satisfy the NPSH requirements of the booster pump throughout its entire flow range up to 150% rated capacity.

d. The booster pump and its seal system shall be capable of running dry during start-up.

12.3.3. Vertical pumps

a. Vertical fire pumps are to be vertical shaft, multi-stage, closed impeller, turbine type meeting all of the performance criteria and material requirements in accordance with the specifications listed on data sheets.

b. Vertical pumps shall have universal joint, spacer type couplings.

c. Vertical pumps with fabricated discharge heads shall be provided with a stainless steel NPT coupling for engine and gear cooling water.

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d. Vertical pumps shall not require an enclosure or a pre-lubrication system.

e. Unless other designs in the higher power range are approved, vertical turbine pump shafts shall have:

1. Screwed coupling ends machined at right angles with the center line and threads square with ends of the shaft.

2. Shaft ends finished with a minimum 1/16 inch (1.5 millimeters) chamfer and a minimum 1/16 inch (1.5 millimeters) by a maximum of 1/3 the shaft diameter deep recess at the center of shaft ends.

f. Vertical pump line shaft section lengths shall not exceed 10 feet (3.05 m). Pump shaft shall be "stiff" design with critical speeds at least 10% above normal running speed.

g. Vertical pumps shall have a two-piece top shaft with rigid coupling.

h. Vertically mounted lift pumps shall be designed to be freely suspended from the discharge head with no guide system. A bumper may be provided to protect vulnerable areas.

i. Vertical pumps shall be designed to deliver firewater at a discharge pressure as measured at the discharge head flange with a pumping water level as specified. The total discharge head and performance curves shall include all internal losses in the pumps (including column pipes for vertical units).

j. The line shaft shall be capable of transmitting at least 125 % of the maximum horsepower the engine is capable of producing. Design shall provide “critical” speed dynamic calculations considering the shaft size, speed, and support spacing.

k. The line shaft lengths shall interface consistently with the column pipe lengths in order to ease the installation of the discharge assembly.

l. The discharge head shall be located above the top of the structural skid base and shall be made of carbon steel and internally coated with baked-on phenolic epoxy.

m. The discharge head shall provide the entire support for the right-angle gear, column pipe assembly, line shaft, pump bowl assembly and strainer.

n. A base plate with a minimum thickness of one inch shall be installed on the skid below the discharge head.

o. The discharge head shall be equipped with two lifting lugs designed with a safety factor of 4:1 based on lifting the entire assembly consisting of the column pipe, shaft, and pump bowls and impellers.

12.4. Shipping preparation

a. If not specifically stated below, shipping preparation shall conform to GP 60-50. If requirements below conflict with those in the GP, the most stringent requirement shall prevail.

b. All items designated as shipped loose shall be trial fit in the shop prior to shipment. For vertical pumps this shall include the complete column pipe, spiders, pump bowl assembly, strainer, shaft, and discharge head to ensure the assembly will fit together.

c. At the completion of the equipment testing, the equipment shall be packaged for shipment and storage according to manufacturer’s recommended procedures.

d. Engine oil, coolant and gear housing oil for initial field fill shall be provided.

e. After the run tests are complete, the diesel engine fuel tank shall be drained and leak tested by filling the vessel full of fresh water and approved corrosion inhibitor. After the test, the tank shall be drained and blown dry with air.

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f. Immediately upon completion of all tests, all machined surfaces will be prepared with a corrosion inhibitor.

g. All untapped openings shall be provided with 4 mm (3/16 in.) thick metal or 13 mm (½ in.) wood closures bolted in place with no less than four bolts with full rubber gaskets.

h. All tapped openings including open-ended valves shall be plugged. All tapped openings disconnected for shipping purposes shall be plugged with solid, long-shank steel plugs wrapped with Teflon tape.

i. All connections, including those for instruments, instrument leads, and the like, shall be identified with a securely-attached 316 SS metal tag indicating the type of connection, the instrument, or the line description of the connecting piping.

j. Each major component shall be properly identified with item and serial numbers. All material shipped separately shall be properly tagged or marked with the item and serial number of unit for which it is intended.

k. Small, easily damaged parts shall be removed, tagged, and adequately protected from damage during shipment by storing in wooden crates. The wooden crates shall contain a packing list on the outside.

l. All items that can be damaged by water shall be securely wrapped in waterproof plastic before being placed in crates.

m. The unit shall not be shipped until it is inspected and reviewed.

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Figure 1- Sample Functional Test Sheet

Function Ind Alarm Trip RemoteCONTROLLER

1. Auto start switch off R X - X2. Battery No. 1 Healthy G - - -3. Battery No. 2 Healthy G - - -4. Charger No. 1 Healthy G - - -5. Charger No. 2 Healthy G - - -6. Duty Pump(s) selected A - - X7. Engine Running G - - X8. Panel on automatic G - - X9. Weekly test start due A X - X10 Emergency Manual start selected R - - -11 Battery fault / charger fault R X - C**12 Pump at pressure G - - X

DIESEL1. Failed to start R X - X2. Engine over-speed R X X C3. Oil pressure - Low R X * C4. Cooling water temperature - High R X * C5. Air intake valve - Closed R X * C6. Fuel tank level - Low R X * C7 Secondary start pressure - Low R X - C8 Jacket water level - Low R X * C

INTERFACE1. Remote start R - - X2. Remote start inhibited (local) Flag - - X

AC SUPPLIES1. AC mains on N2. Engine jacket water heater N3. Panel heater on N4 Hydraulic Supply on N

HYDRAULIC PUMP1. Hydraulic oil pump running G - - -2. Hydraulic oil flow failure R X - C3 Hydraulic oil temperature - High R X - C4 Hydraulic oil tank level - Low R X - C

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Figure 2- Horizontal Pump Materials

ITEM FRESH WATER SALTWATERCase Cast Iron A48–Cl30/40 Brz. SAE 63

Case Bolting Steel SAE J429, Gr. 8 Sil–Brz. B98–C651Case Coating Enamel N/A

Impeller Brz. B584 Brz. SAE 63Wear Rings, Case Brz. B584 Brz. SAE 63Pump / Bowl Shaft Steel A108 S.S. A276–316

Shaft Sleeve Brz. or S.S. Brz. or S.S.Packing Graphite Graphite

Radial Bearing Sgl. Row Ball, Steel Sgl. Row Ball, SteelThrust Bearing Dbl. Row Ball, Steel Dbl. Row Ball, Steel

Figure 3- Vertical Pump Materials

ITEM FRESH WATER SALTWATERPump / Bowl Bearings Brz. B584 Brz. SAE 63

Lock Collet S.S. A276–316 S.S. A276–316Line Shaft A582-416 or A276-410 A582-416 or A276-410

Line Shaft Couplings S.S. A276–316 S.S. A276–316Line Shaft Bearings Carbon Fill Teflon Fluted Rubber

Bearing Retainer Brz. B584 Brz. SAE 63Column Pipe / Coating Steel Sch 40 / Epoxy Steel Sch–40 / EpoxyColumn Flgs / Bolting Steel / S.S. 316 S.S. 316 / S S. 316

Disch. Assembly / Coating Cast Iron / Epoxy Fab. Steel / EpoxyPacking Box / Bolting Cast Iron / S.S. Brz. / S.S.

Inlet Strainer Brz. or S.S. Brz. or S.S.Impeller Brz. B584 Brz. SAE 63

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Figure 4- Sample Firewater System Data Sheet

1 Note: Indicates information to be completed by Purchaser By Manufacturer

2 Applicable to: Proposal Purchase As Built

3 Client: Project:

4 Item No.: Job No.:

5 Site:

6 Service: No. Required:

7 Type/Size: Serial No.:

8 Pump Mfr.: Driver Mfr.:

9 Design: Fixed Installation Mobile Installation NFPA 20

10 Pump: Horizontal Split Case Horizontal End Suction Vertical Submerged

11 Service: Primary Fire Pump Booster Pump Jockey Turbine Pump12 Driver Selection: Electric Motor Engine

13 Capacity (US gpm): Rated Design Max.

14 Discharge Pressure (psig): Rated Design Max.

15 Suction Pressure (psig): Rated Design Max.

16 Diff. Head (ft): NPSHA (ft): Hydraulic Horsepower:

17 Firewater Characteristics Saltwater Freshwater

18 Specific Gravity @ °F: Suspended Solids (% by Volume):

19 Pumping (°F): Normal Min. Max.

20 Ambient Temperature (°F): Normal Min. Max.

21 Location Characteristics Outdoors Enclosed Building

22 Area Classification: Class Group Div.

23 Non-Hazardous Area Noise Classification: dBA

24 Connections:

25 Suction:

26 Discharge:

27 Drain:

28 Vent:

29 Pressure Gauge:

30 Casing Mount: Vertical Column Horizontal Centerline Foot Bracket

31 Maximum Allowable Casing Pressure (psig): At 60 °F At Normal Pump Temperature

32 Hydro Test Pressure (psig):

33 Bearing Lube: Oil Pressure Flood Ring Oiled

34 Oil Viscosity @ 100°F (SUS):

35 Bearing Type: Sleeve Antifriction

36 Remarks:

37

38

39

40

41

42

43

44

PUMP CONSTRUCTIONSize (in) Rating (psi) Facing Location

GENERAL DESIGN REQUIREMENTS

OPERATING CONDITIONS

GENERAL INFORMATION

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1 Impeller Diameter (in): Rated Min. Max.

2 Impeller Mount: Between Bearing Overhung

3 Rotation (Viewed from Coupling): Clockwise counterclockwise

4 Test Header Required: Yes No

5 Performance: Performance Curve No.:

6 Speed (rpm) Rated Max.: Efficiency (%):

7 Rated Head, Max. Impeller (ft): Rated Head, Rated Impeller (ft):

8 Rated Power (bhp): Max. Power, Rated Impeller (bhp):

9 Total Head @ Shutoff (psi): Total Head @ 150% Rated Capacity (psi):

10 Suction Lift Pressure (ft): NPSHR (ft Water) @ 3% Drop in Head:

11 Down Thrust (lbs): Up Thrust (lbs):

12 Min. Continuous Flow (gpm):13 Note: All flows and pressures are at pump discharge flange.

14 Air Release Valve: Size: Type: Mfr./Model:

15 Minimum Flow Valve: Size: Type: Mfr./Model:

16 Pressure Switch: Qty: Type: Mfr./Model:

17 Pressure Gauge: Qty: Range (psi): Mfr./Model:

18 Test Meter Assembly: Size: Type: Mfr./Model:

19 Seals/Packing Mfr/Model: Size: Type: Mfr./Model:

20 Suction Reducer: Size: Type: Materials:

21 Discharge Increaser: Size: Type: Materials:

22 Test Header (Outlet): Size: Type: Materials:

23 Seal Flush: No Yes API Plan:

24 Casing: Shaft: Impeller:

25 Wear Rings: Shaft Sleeve: Shaft Bearings:

26 Gland Plate: Base Plate: Coupling Guard:

27 No. of Stages: Bowl (Max. O.D. in): Shaft Diameter (in):

28 Line Shaft Diameter (in): Bowl and Column Assembly Length (ft):

29 Shaft Section Length: Quantity:

30 Column Diameter (in): Column Length: Column Wall Thickness (in):

31 Column Joints: Flanged Threaded

32 Suction Strainer: Basket Cone

33 Materials:

34 Discharge Head Bearing Housing Column

35 Column Flanges Bowls Bowl Wear Rings

36 Impellers Impeller Wear Rings Shafts

37 Shaft Sleeves Keys Collets

38 Lineshaft Bearings Lineshaft Couplings Gland

39 Bearing Retainers Column Bushing Bowl Bushing

40 Suction Bell Suction Strainer Coupling Guard

41 Column Supports Discharge Column Bowl Bolting

42 Column Bolting Soleplate

43 Remarks:

44

45

46

VERTICAL PUMPS ONLY

PUMP CONSTRUCTION (CONT.)

PUMP ACCESSORIES

MATERIALS OF CONSTRUCTION

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1 High Speed Coupling: Rating hp/100RPM Type

2 Manufacturer Model No.

3 Low Speed coupling: Rating hp/100RPM Type


5 Gear: Ratio Max. Allow. RPM: Type


7 Thrust Capacity: Min. Max.

8 Lubrication Type: Pressure Flood

9 Rated HP Efficiency: Service Factor: 10 Cooling Coil Required: Yes No

11 Driver Type: Diesel Engine Gasoline Engine Electric Motor

12 Driver Item No.: Driver Data Sheet No.:

13

14

15 Power (bhp):

16 Speed (rpm):

17 Fuel Consumption (gal/hr):

18

19 Net Power (bhp):

20 Rated Speed of Driven Eqpt.(rpm): Synchronization Non-Parallel Parallel

21 Fuel Type: Fuel Gas Diesel Cetane Rating:

22 Engine Type: Two Cycle Four Cycle

23 Turbo Charged Aftercooled Naturally Aspirated

24 In-Line Cylinders V-Type Cylinders

25 Exhaust Manifold: Single Dual Multiple

26 Air Cooled Water-cooled Insulated

27 Engine Speed Cont.: Manual Automatic Pneumatic Electric

28 Number of Cylinders: Bore (in): Stroke (in)

29 Brake Mean Effective Pressure (psi): Displacement (in3)30 Engine Heat Rejection (Btu/Min): BMEP @ Rated HP

31 Rotation Facing Flywheel: CW CCW Compression Ratio

32 NEMA Governor Class: A B C D

33 Governor Type: Mfr:

34 Speed Range (rpm): Maximum Minimum Rated

35 Ignition: Single Dual Low Tension

36 Crankcase Oil Capacity (gal): Oil Filter: Full Flow Bypass Type

37

38 HP RPM Frame Service Factor

39 Volts Phase Hertz Type

40 Enclosure Temp. Rise (°F) Insulation Full Load AMPS

41 Bearings (R/T) Min. Starting Voltage Lube Locked Rotor AMPS

42 Vert. Thrust Capacity Up (lbs) Down (lbs) (Based on L10=25000 hrs.)

43 Efficiency @ Full Load

44 Remarks:

45

46

47

48

COUPLING/GEAR

DRIVERS

Load Rated Normal

Electric Motor Drivers

Maximum

Continuous

Engine Drivers

Engine Rating

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1 Type: Radiator Tubular Exchanger

2 Engine Mounted Remote Mounted

3 Manufacturer: Model No.:

4 Anti-Freeze Coolant Cooling Sys Furn'd By:

5 Including: Jacket Water Pump Expansion Tank

6 Radiator Duct Flange Thermostatic Temperature Control

7 Heat Rejected to System (Btu/hr): Cooling Water to Exch.(gpm):

8 Engine Skid With Heat Exchanger Mounted

9 Baseplate Common With Driven Equipment

10 Engine Enclosure With Access Doors

11 Manufacturer: Enclosure Material

12 Intake Air Filter Intake Air Filter Type:

13 Mounting: Engine Skid Remote

14 Rain Cover Yes No By Vendor By Other

15 Diff. Pressure Clean Maximum

16 Manufacturer: Element

17 Exhaust Silencer: Commercial Residential dBA Rating

18 Mounting: Skid Remote

19 Rain Cover Yes No BY Vendor By Other

20 Piping BY Vendor By Other Insulated

21 Manufacturer: Material

22 Flexible Exhaust Connector Flexible Connector Material

23 Fuel Transfer Pump Hand Motor Water Pump

24 Fuel Filter Single Duplex Material

25 Vibration Isolators Yes No Type

26 Day Tank Capacity (gal): Tank Size:

27 Jacket Water Heater With Thermostat: kW Volt/Ph/Hz

28 Crankcase Oil Heater With Thermostat: kW Volt/Ph/Hz

29 Oil Filter: Single Duplex Material

30 Pre Lube Oil Pump Air Electric

31 Coupling, Type: Manufacturer:

32 Safety Shutdown System Including: Other

33 Low Oil Pressure High Water Temperature Electric System

34 Overspeed Pneumatic System Vibration

35 Intake Filter Diff. Pressure Lube Oil Filter Diff. Pressure Low Fuel Pressure

36 Engine Mounted Gauge Panel With: Other

37 Fuel Gas Pressure Tachometer Lube Oil Temperature

38 Jacket Water Temperature Hour Meter Lube Oil Pressure

39 Intake Filter Diff. Pressure Lube Oil Filter Diff. Pressure Low Lube Oil Press.

40 Low Fuel Pressure High Fuel Pressure Engine Speed41 Alarms: Indicator Light Annunciator

42 Remarks:

43

44

45

46

47

COOLING SYSTEM

ACCESSORY EQUIPMENT

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2 Governor Range (rpm): Min: Max.:

3 Primary AC Power: Volt Phase Hertz

4 Secondary AC Power: Volt Phase Hertz

5 Enclosure Type: NEMA-3R NEMA-4X NEMA

6 Auto-Start Pres. Set. (psig):

7 Sequential Start Adjustment: Individual Alarm Contacts Energize to Stop Circuit

8 Lube/Fuel Heater: Volt Phase Watts

9 Voltmeter Required: No Yes

10 Speed Indication Required: No Yes

11 Overspeed Required: No Yes Set Point

12 Remote Electric Start: No Yes Voltage

13 Alarm Alarm

14 Required Set Points: Engine Cooling Water Temperature:

15 Low Fuel Supply Level: Engine Overspeed:

16 Low Oil Pressure: Starting System Pressure Low:

17 Low Suction Pressure: Battery Charger Low Voltage:

18 Primary Starting: Battery Electric Air Fuel Gas

19 Secondary Starting: Battery Electric Air Fuel Gas

20 Batteries: Nickel Cadmium Lead Acid In Rack In Box

21 Battery Charger Single Dual By Vendor By Others

22 Rating (amps): Shielded Unshielded

23 Electric Starter (voltage): Starting Air Pressure (psig):

24 Single Starter Motor Dual Starter Motor Air Motor (scf/start):

25 Manual Start Automatic Start Startup Time (sec): No. of Starts:


27 Air/Fuel Gas Piping: By Vendor By Other Material

28

29 Filter Yes No Mfr. Day Tank Yes No

30 Regulator Yes No Mfr. Hand Priming Pump Yes No

31 Exp. Tank Yes No Mfr. Fuel Strainer Yes No

32 SD Valves Yes No Mfr. Fuel Filter Yes No

33 Gauges Yes No Mfr. Gauges Yes No

34 Piping Yes No Mat'l Piping/Tubing Yes No

35 Testing Non-Wit Wit Testing Req'd Non-Wit

36 Hydrostatic Test Shop Performance Test of Package

37 No Load Mechanical Test Offshore Performance Test of Package

38 Full Load Running Test: Pump Bowl Assembly Hydrostatic Test

39 Vibration Test Pump Bowl Assembly Performance Test

40 Engine Shop Test Column Piping Hydrostatic Test

41 Motor Shot Test Shop Test of Engine Starters

42 Shop Test of Controls Others

43 Component Weights (lb): Pump Driver Heaviest Maintenance

44 Assembly Weight (lb): Dry Operating Shipping

45 Assembly Size (in): Length: Width: Height:

ELECTRONIC GOVERNOR

ELECTRONIC CONTROLLER OPTIONS

ENGINE STARTING SYSTEM

WEIGHTS AND SIZE

Fuel Gas System

Req'd

ENGINE FUEL SYSTEMDiesel Fuel System

INSPECTION AND TESTINGWit

CONTROLLER ALARM OPTIONSShutdownShutdown

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1 Skid Mounted Area Lighting By Vendor By Purchaser Qty:

2 Convenience Receptacles By Vendor By Purchaser Qty:

3 Electrical Wiring By Vendor By Purchaser Spec. No.:

4 Skid Grounding By Vendor By Purchaser Spec. No.:

5 Electrical Checkout By Vendor By Purchaser Spec. No.:

6 Skid Edge Electrical J.B. By Vendor By Purchaser Spec. No.:

7 Instrument Tubing By Vendor By Purchaser Spec. No.:

8 Tubing Bulkhead Plate By Vendor By Purchaser Spec. No.:

9 Instrument Checkout By Vendor By Purchaser Spec. No.:

10 Control Panel By Vendor By Purchaser Spec. No.:

11 Skid Edge Instrument J.B. By Vendor By Purchaser Spec. No.:

12 Fusible Plug Loop System By Vendor By Purchaser Spec. No.:

13 Equipment Painting By Vendor By Purchaser Spec. No.:

14 Equipment Piping By Vendor By Purchaser Spec. No.:

15 Equipment/Piping Insulation By Vendor By Purchaser Spec. No.:

16 Piping Supports By Vendor By Purchaser Spec. No.:

17 Piping Hydrotest By Vendor By Purchaser Spec. No.:

18 Other: By Vendor By Purchaser Spec. No.:

19 Conduit: Rigid Aluminum Rigid Galvanized Remarks:

20 Flexible Metal Other: Remarks:

21 Fittings: Aluminum Ferrous Alloy Malleable Iron

22 Wiring: Interlock Armor MC Cable Continuous Corrugated Individual Conductor

23 Raceway: Cable Tray Type: MC Cable Wireway Permitted

24 Remarks:

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WIRING METHOD

PACKAGE REQUIREMENTS

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GIS 24-233 - Fire Water Pumps and System Design - 0900a8668010d09f

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