Inspection, testing, and maintenance (ITM) · 2021. 1. 11. · Inspection, testing, and maintenance...

Inspection, testing, and maintenance (ITM) Fixed fire protection and detection July 2016

Inspection, testing, and maintenance (ITM) Fixed fire protection and detection

Author: Global Risk Engineering Technical Center – Property

Cover photo source: Rich Gallagher, Zurich

Table of contents 1. Executive Summary ............................................................... 1

1.1 Are systems in service? ................................................. 1 1.2 Are systems designed right? ......................................... 2 1.3 Do systems work? ........................................................ 2

2. Introduction .......................................................................... 3 2.1 Document overview ..................................................... 3 2.2 ITM checklists ............................................................... 3 2.3 Definitions .................................................................... 3 2.4 Safe work practices ...................................................... 4

3. Water supply ......................................................................... 5 3.1 General ........................................................................ 7 3.2 Water storage ............................................................ 22 3.3 Fire pump weekly ....................................................... 26 3.4 Fire pump semi-annual and annual ............................. 49 3.5 Private fire mains including hydrants .......................... 63

4. Fire sprinkler system ............................................................ 69 4.1 ITM Checklist ............................................................. 69 4.2 ITM Discussion ........................................................... 78

5. Fire extinguishing systems .................................................. 103 5.1 Foam ........................................................................ 103 5.2 Water mist ............................................................... 114 5.3 Carbon dioxide ......................................................... 117 5.4 Halon 1301 (where permitted) ................................. 120 5.5 Clean agents ............................................................ 123 5.6 Fixed aerosol ............................................................ 125 5.7 Dry chemical ............................................................ 126 5.8 Wet chemical ........................................................... 129

6. Fire alarm system............................................................... 132 6.1 General features ....................................................... 132 6.2 Alarm initiating devices ............................................ 144 6.3 Supervisory initiating devices .................................... 155 6.4 Alarm notification devices ........................................ 166 6.5 Emergency control functions .................................... 167 6.6 Fire extinguishing control and release ....................... 169

7. Safe work practices ........................................................... 176

8. Conclusions ...................................................................... 177

9. References ........................................................................ 178


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1. Executive Summary The information in this publication was compiled from sources believed to be reliable for informational purposes only. All sample policies and procedures herein should serve as a guideline, which you can use to create your own policies and procedures. We trust that you will customize these samples to reflect your own operations and believe that these samples may serve as a helpful platform for this endeavor.

When resources are invested in fixed fire protection and fire detection systems to protect property assets, there are three fundamental questions management should ask:

1. Are systems in service?

2. Do systems work?

3. Are systems designed right?

1.1 Are systems in service? For this question, the reader is directed to the Zurich Risktopic titled “Management Practices: Fire Protection Impairments”. This document discusses three forms of fire protection impairments:

• Planned

• Hidden

• Emergency

Planned impairments Planned impairments typically occur in conjunction with scheduled activities. For example, fire protection systems may be taken out of service for changes, additions, or upgrades. These activities require careful planning to avoid unnecessary impairments and to limit the extent and duration of necessary impairments.

Planned impairments may also occur as part of inspection, testing, and maintenance (ITM) activities. It is essential to avoid unnecessary impairments during ITM and to document any necessary impairment so their restoration may be verified once ITM activities are complete.

As a general rule, avoid multiple impairments. For example, do not impair multiple dry-pipe sprinkler systems during ITM. When doing functional tests or full-flow tests of dry pipe valves, test one at a time. Should a fire occur, only one system needs to be restored to service quickly.

Hidden impairments Hidden impairments typically occur outside the impairment management process. Hidden impairments can be discovered suddenly. The worst case is discovering hidden impairments during a fire. The best case is discovering hidden impairments during ITM.

To support the timely discovery and correction of hidden impairments, implement a comprehensive ITM program as discussed in this document.

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Emergency impairments Emergency impairments typically occur suddenly outside the impairment management process. An example of an emergency impairment is the closing of a sprinkler control valve in response to water being released from a sprinkler system. If the release is due to a fire, the objective is to extinguish the fire and then turn the sprinkler control valve off. If the release is not due to a fire, the objective is to stop the flow of water as quickly as possible.

Once an emergency is controlled, consider taking the following actions:

• Post “Watch Personnel” in the impaired area as well as at the impaired fire protection controls.

• Document all impairments following the impairment management program

• Conduct an inspection of all fire protection systems to verify there are no hidden impairments as a result of the emergency

Post a “Fire Watch” in the affected area once fixed fire protection is shut off. Maintain the “Fire Watch” until all fixed fire protection is back in service.

In addition, post a “Fire Protection Watch” at any shut sprinkler control valve or impaired water supply.

Maintain communication between all posted “Watch Personnel” so fire protection can be promptly turned back on if the “Fire Watch” discovers a fire.

Also, maintain communication between the “Watch Personnel”, site emergency team, and the public fire service so any fire may be promptly reported.

1.2 Are systems designed right? For this question, the reader is directed to their Zurich account team for the assessment of installed fire systems.

1.3 Do systems work? This question is the focus of this document.

This document presents Zurich recommendations for periodic inspection, testing, and maintenance activities for the Property insurance line of business.

Those responsible for fire systems should understand the content of this document is only intended to represent guidance for the Property insurance line of business. Therefore, there are three important points to understand:

• First, for any particular location, there are likely other authorities having jurisdiction, especially legal authorities, who may have additional guidelines. Where such additional guidelines exist they will likely vary by region, country, province, state, city, and town. Zurich does not attempt to maintain knowledge or awareness of requirements applied by these other authorities as there are thousands of such authorities globally with many applying different guidelines.

• Second, safe work practices are beyond the scope of this document. Consult with safety experts to develop and implement needed safe work practices. If there is any concern an action or task is not safe … stop! See “Chapter 7 Safe work practices” for further discussion.

• Third, recommendations related to insurance lines of business other than Property are also beyond the scope of this document.

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2. Introduction 2.1 Document overview This document reviews inspection, testing, and maintenance – or ITM – for fixed fire protection systems. The document is arranged in chapters addressing different elements of fixed fire protection and detection. The following is a list of these chapters.

• Chapter 3 - Water supply

• Chapter 4 – Fire sprinkler system

• Chapter 5 – Fire extinguishing system

• Chapter 6 – Fire alarm system

2.2 ITM checklists Each chapter includes one or more ITM checklist. The checklists use a common table format with columns as described in the following table.

Table column headings Table column heading meaning

# Component number

Component Component name

Act. Abbreviation for “Action”

Freq. Abbreviation for “Frequency”

Evaluation The applicable task(s) for that combination of component, action, and frequency.

2.3 Definitions

Inspection A visual activity involving the observation of a system component to confirm its apparent physical condition and serviceability.

Test A functional activity involving the operation of a system component to confirm its ability to perform as intended.

Maintenance A service activity such as cleaning, adjustment, lubrication, renewal, repair, overhaul, or replacement of a system component to maintain its performance and serviceability.

Impairment An abnormal condition affecting the ability of a fire protection system to effectively perform its intended function should a fire occur.

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2.4 Safe work practices Safe work practices are not addressed within the scope of this document.

See “Chapter 7 Safe work practices” for a discussion on the need to consult with qualified safety experts for safety guidance.

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3. Water supply For the purpose of this document, water supplies include the following:

• Public sources

− Town or public water supply

• Private sources

− Elevated water supply

− Static water supply

− Fire pump

− Pressurized water supply

− Fire department connection

− Private fire water mains

Town water supply A town water supply consists of a connection to a town water main along with the pipe, valves, and fittings between the town water main connection and either a private fire water main or a fire system (specifically, at the fire system control valve).

One or more town water supplies may serve a location. While town water supplies may share a common source of water, each is considered separately for the purpose of inspection, testing, and maintenance.

A town water supply may depend upon elevated water storage (e.g. gravity tanks or elevated reservoirs), pumps, or a combination of both to create the pressure needed to cause water flow. Where a town water system has multiple water sources and a varying demand from domestic and commercial water users, a complex interaction develops among sources and users that may make it difficult to compare water flow tests from year to year.

Elevated water supply An elevated water supply consists of an elevated volume of water along with the pipe, valves, and fittings between the water and either a private fire water main or a fire system (specifically at the fire system control valve).

Elevation is used to create the pressure needed to cause water flow.

Fire pump A fire pump is not actually a water supply. Rather the fire pump adds pressure to a water supply.

Fire pumps will be used with the following types of water supplies:

• Private static water supply (ground tank, cistern, lake, or pond)

• Private elevated water supply (gravity tank or reservoir)

• Town water supply

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Pressurized water supply The private pressurized water supply, or pressure tank, is not common. This supply consists of a pressure vessel of limited volume. Two thirds of the volume is intended to contain water, and one third is intended to contain air under pressure.

The pressure tank will have an initial air pressure so the tank pressure does not drop below 1 bar (15 psi) at the point where all water has been expelled from the tank. Boyle’s Law (P1V1 = P2V2) applies.

Pressure tank (Image source: Rich Gallagher, Zurich)

Fire department connection A fire department connection is a water supply inlet to a fire system along with the pipe, valves, and fittings between the connection and either a private fire water main or a fire system. The fire department connection allows the public fire service to supply additional water to a fire system using their vehicle pumps.

Typical fire department connection in North America (Photo source: Rich Gallagher, Zurich)

Private fire water main For the purpose of this document, the private fire water main is addressed under water supplies. These are actually pipe, valves, and fittings connecting water supplies to fire systems. Private fire water mains may also supply private fire hydrants. Private fire water mains may be located above ground, below ground, or a combination of both.

Many private fire systems will have private fire water mains with no valves or private fire hydrants. In these cases, the private fire water main will just consist of

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pipe and fittings. An example would be the pipe and fittings extending from a fire pump installation to sprinkler systems.

Cathodic protection Cathodic protection was originally developed in the UK for the British Navy. Cathodic protection is intended to control corrosion, and may be applied to protect fire system water storage tanks and diesel fire pump engine heat exchangers against corrosion.

Two types of cathodic protection are available; sacrificial and impressed current. Sacrificial systems use zinc metal (the anode) to be preferentially consumed thereby protecting the steel tank or heat exchanger (the cathode). Impressed current systems use an external power supply along with the anode to achieve the same results but with a longer lasting anode. Either approach introduces an active system requiring periodic inspection and maintenance.

3.1 General

3.1.1 ITM Checklist

A. Water supply ITM – General

# Component Act. Freq. Evaluation

A.1 Water pressure and flow

I W

Water source pressure normal ☐ Yes ☐ No

Water source pressure reading _________

Normal water source pressure __________

T V (1)

Flow test of water source normal ☐ Yes ☐ No

Static water source pressure (before test) __________

Water flow rate __________

Flowing water source pressure __________

Static water source pressure (after test) __________

A.2 Control valve

I W (2)

Valve open ☐Yes ☐ No

Valve secure ☐Yes ☐ No

Valve accessible ☐ Yes ☐ No

Valve equipped with operating hardware ☐ Yes ☐ No

Valve not leaking ☐ Yes ☐ No

Valve identified with appropriate sign ☐Yes ☐No

T A

Valve operation okay ☐ Yes ☐ No

Number of turns to shut valve _________

Number of turns to open valve _________

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Valve test okay (3) ☐ Yes ☐ No

A.3 Pipe, fittings, and supports components

I A

Components free of physical damage ☐ Yes ☐ No

Components free of corrosion ☐ Yes ☐ No

Components free of leaks ☐Yes ☐No

A.4

Check valve and Backflow prevention assembly

I W

Reduced pressure backflow prevention assembly:

Pressure relief port not discharging water constantly ☐ Yes ☐ No

I 5 Internal inspection no deficiencies ☐Yes ☐ No

T A Backflow prevention assembly:

Flow test at maximum system demand ☐ Yes ☐ No

A.5

Pressure reducing or regulating valves

I Q

Valve free of physical damage ☐ Yes ☐ No

Valve not leaking ☐ Yes ☐ No

Downstream pressure normal ☐ Yes ☐ No

Valve adapter and cap in place (4) ☐Yes ☐No

T A Full flow test okay ☐ Yes ☐ No

A.6 Fire department connection

I Q

Connection is visible ☐ Yes ☐ No

Sign in place ☐ Yes ☐ No

Connection is accessible ☐ Yes ☐ No

Caps are in place ☐ Yes ☐ No

Hose connections are not damaged ☐ Yes ☐ No

Hose connections swivel freely ☐ Yes ☐ No

No water leaks ☐ Yes ☐ No

T 5 Check valves are functional ☐ Yes ☐ No

Pressure test to 10 bar (150 psi) ☐Yes ☐No

Activity: I = Inspect T = Test M = Maintain

Frequency: W = Weekly M = Monthly Q = Quarterly S = Semi-annual A = Annual

V = Varies 5 = 5 year

Table notes:

(1) Conduct flow tests of water sources on a frequency compliant with local standards which may be as often as quarterly. As a minimum, conduct flow tests on an annual basis for

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water sources supplying fixed fire protection systems. Flow tests involve measuring the supply

(2) Data demonstrates the primary cause of sprinkler system failure is a shut valve. A weekly inspection to verify valves are in the appropriate position is recommended. Secure each valve in a suitable manner which may include plastic seals, plastic or leather straps, locks (including a dedicated and locked fire protection room), and electronic monitoring via a fire alarm system supervised at a constantly attended location.

(3) A valve test may be acceptable if the number of turns to close equals the number of turns to open.

(4) Where a pressure reducing valve is a hose connection, verify hose adapter and cap are in place.

3.1.2 ITM Discussion The following is a discussion of the items in the previous ITM checklist.

A.1 Water pressure and flow Each source of water will impose a static (no flow) water pressure upon the fire systems served. On a weekly basis, it is desirable to verify this static pressure is normal.

Experience with each water supply will lead to an understanding as to what is normal. The normal pressure or pressure range should be incorporated into inspection forms to facilitate the inspection process.

Gauge displaying water pressure (Photo source: Rich Gallagher, Zurich)

For a town main system, water is constantly flowing at varying rates to satisfy domestic, commercial, and industrial users. These varying rates lead to fluctuations in the system pressure. This varying town main system pressure is what appears to the standby fire protection system as the available “water static pressure”.

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As an example, the graph below shows a town water system pressure fluctuating across a 24 hour period. The following list describes the meaning of the letters A, B, C, and D displayed on the graph.

A. Water pressure may be high at night due to low commercial and residential water use.

B. Water pressure may be normal through the day with minor fluctuation as demand is not constant.

C. Water pressure can experience sudden work day fluctuations if there is a business that does draw sudden, large, short-duration flows.

D. Water pressure may increase in the evening as the commercial demand subsides.

Example of town daily water pressure fluctuation (Image source: Rich Gallagher, Zurich)

There are cases where a town main system may be maintained at a low pressure at all times or perhaps during periods of low demand. Should a fire occur, the fire service will have to call the water authority and request an increase in the water pressure for firefighting purposes. If the town main also supplies fixed fire protection, the low pressure condition could adversely affect system performance.

A private elevated water supply such as a gravity tanks or elevated reservoir will generate a static water pressure based upon the following formulas.

P = 0.0981 x h (metric measure)

P = 0.433 x h (US measure)

Where:

P = Pressure developed by the elevated water in bar (psi)

h = Height of water in meters (feet)

A private static water supply such as a ground tank, cistern, lake, or pond will generate a static (no flow) pressure based upon the head of water it forms. Where a ground level tank supplies a fire pump, the pressure generated by the head of water will be visible on the fire pump suction gauge. For vertical turbine fire pumps, the pump will be submerged in the water, and no suction gauge will be provided. Rather, the water elevation (or distance below fire pump room floor level) will provide evidence of normal fire pump suction pressure.

A private pressurized water supply such as a pressure tank will generate static pressure based upon the air pressure maintain in the tank air space.

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Inspection On a weekly basis, verify the static pressure of each water supply is normal.

Test Conduct water supply flow tests at the locally required frequencies which may be as often as quarterly. As a minimum, conduct water supply flow tests annually.

A.2 Control valves

Description The control valve or stop valve controls the water source supplying fixed fire protection discharge outlets (such as automatic sprinklers, spray nozzles, water mist nozzles, and fire hydrant outlets).

Control valves allow a water source to be interrupted so downstream piping can be isolated and drained. This typically occurs to allow system maintenance or extension.

Shutting a control valve causes an impairment. Control valves should be kept normally open. A suitable means of supervision is needed to identify control valves that have been closed without appropriate authorization. An impairment program is needed to manage control valves during impairments. See the Zurich Risktopic “Management Practices: Fire Protection Impairments” for further information regarding impairments.

The following are examples of control valves for water-based systems:

Non-rising stem gate valve with position indicator (Photo source: Stuart Lloyd, Zurich)

Non-rising stem gate valve position indicator (Photo source: Stuart Lloyd, Zurich)

Outside stem and yoke valve (OS&Y) (Photo source: Rich Gallagher, Zurich)

Butterfly valve (BFV) (Photo source: Stuart Lloyd, Zurich)

Post indicator valve (PIV) (Photo source: Stuart Lloyd, Zurich)

Wall post indicator valve (WPIV) (Photo source: Stuart Lloyd, Zurich)

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Underground gate valve accessed by a roadway box and operated using a key wrench. This valve may also be located in a covered pit with the key wrench used to operate the valve from ground level. (Photo source: Stuart Lloyd, Zurich)

Example of a roadway box or curb-box that allows key wrench access to an underground gate valve (Photo source: Rich Gallagher, Zurich)

Key wrench used to operate underground gate valves (Photo source: Rich Gallagher, Zurich)

Key wrench in used to operate an underground gate valve through a roadway box (Photo source: Rich Gallagher, Zurich)

Water-based system can include some normally shut valves. These valves can be used to stop water flow to pipes serving drains and test devices. Test devices include alarm test lines, flowmeters, and fire pump test headers. The normally shut valve is not actually a control valve; however, the normally shut valves may be of the same valve types used for control valves. Normally shut valve need to be kept shut to avoid adverse conditions which may include wasting water to drains or test pipe freeze-up during cold weather.

Inspection On a weekly basis verify each control valve is:

• Open

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− Supervised

− Sealed

− Locked

− Electrically monitored

• Accessible for use

• Equipped operating hardware (e.g. the PIV wrench is present)

• Not leaking

• Identified with an appropriate sign

Each type of control valve includes a means to visually identify valve position (open, partially shut, or shut). There are two exceptions; the gate valve located underground and the gate valve located in a pit. These gate valves do not include visual indication of position and are excluded from this visual inspection process.

Each type of control valve can be sealed, locked, or electrically supervised. This is intended to provide a means to verify there has been no unauthorized operation of the valve since the last inspection. Once again, there are two exceptions; the gate valve located underground and the gate valve located in a pit. These valves do not include features to allow the use of seals, locks, or electrical supervision and are excluded from this supervision practice.

Open PIV supervised by seal, by lock, and electrically. (Photo source: Rich Gallagher, Zurich)

The PIV shown above is supervised with a seal, lock, and electric valve tamper switch.

Seals are usually plastic tie wraps made in a distinctive color such as red, orange, or yellow. Seals are applied in a manner that requires them to be broken if a valve is operated. When applied appropriately, the seal provides a quick, visual means to confirm a valve has not experience operation since the last inspection.

Locks include “hard shank” and “break-away shank” types. The hard shank lock requires a key or bolt cutters to remove the lock. The break-away lock behaves similar to a seal as it can be readily removed by breaking the shank if a key is not available. A hard shank lock should be considered a lock; while, a break-away lock should be considered a seal.

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Electrically supervised valves include an electric tamper switch connected to a fire alarm system. When a valve is operated, the tamper switch detects the valve movement and signals the fire alarm system that the valve is no longer in the intended position. Ideally, electronic supervision includes a printed or digital record of signal activity to provide a visual means to confirm a valve has not experienced operation since the last inspection.

Shut PIV with the valve wrench locked in place. (Photo source: Rich Gallagher, Zurich)

Electrically supervised valves are typically designed for supervision in the “open” position. In some cases, such as valves controlling a fire pump flow test line, valves may be supervised in the “shut” position. It is important to realize that in reality these valves may only be proving they are not fully open rather than proving they are actually shut. For example, a butterfly valve will typically only contain one switch arranged to operate as the valve is moved from the full open position. This switch cannot be used to prove the butterfly valve is fully shut.

Each valve type listed above has its operating handle or wrench permanently fixed to the valve except for:

• Gate valve located underground

• Gate valve located in a pit

• Post indicator valves

Gate valves located underground or in a pit are operated using a T-handle wrench. The T-handle wrench should be mounted in an accessible location near the gate valve. The T-handle wrench can be sealed or locked to its mounting bracket. A sign near the valve should clearly indicate the location of the T-handle wrench.

Post indicator valves are equipped with an “L” shaped wrench hung from the valve. When the wrench is not in use, it is to be sealed or locked to the valve post. When stowed correctly, the short leg of the wrench covers the valve operating nut. This makes the wrench part of the seal or lock systems. When the valve is operated, the long leg of the wrench is positioned on the operating nut. In this position, the handle extends out from the valve providing leverage for valve operation. Whenever the PIV is not fully open, the wrench should be left in the operating position as an added indication the valve is not fully open.

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Provide an appropriate sign for each control valve. Appropriate includes:

• Identification (e.g. number or letter) consistent with fire alarm control unit indications as well as site diagrams or block plans

• Purpose (e.g. area or function controlled by the valve)

Testing On an annual basis, test each control valve by moving it through its full range of operation. Typically this means moving from “open” to “shut” back to “open”.

As control valves are tested, count the number of turns to “shut” and the number of turns to “open”. Having the same number of turns is an important indication the valve has returned to the open position.

Control valves are subject to internal mechanical failure. For example, the gate inside of a gate valve can separate from the valve stem. When this occurs, the valve stem may indicate the valve is “open” when in fact the gate is obstructing the valve waterway.

After each control valve operational test, conduct a water flow test downstream to verify there is no abnormal pressure drop due to a failed control valve. As an example, after operating a sprinkler system control valve, perform a main drain test. Compare the main drain test results with past results. Any significant pressure drop could indicate a serious obstruction of the water supply to the system. See “5.2 Main drain” for further information about main drain tests.

A.3 Pipe, fittings, and supports – water based systems

Inspection Inspection of pipe, fittings, and supports is limited to above ground sections that can be safely accessed for observation.

On an annual basis, inspect pipe and fittings to identify leaks, physical damage, and corrosion.

Pipe leaks and physical damage should be scheduled for prompt repair.

Corrosion may range from superficial surface rust to serious structural deterioration. All corrosion identified should be evaluated by a fire protection professional.

Pipe with pinhole leak in heat effect zone at pipe continuous weld (Photo source: Rich Gallagher, Zurich)

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Deep structural corrosion (Photo source: Rich Gallagher, Zurich)

Inspection of pipe and fitting supports is intended to identify concerns such as missing, broken, physically damaged, or corroded support features. Inspection should also identify floor settlement compromising the performance of pipe stands. Pipe and fitting support features include: hangers, pipe clamps, riser clamps, pipe stands, and earthquake sway bracing.

Examples of pipe support – Riser clamp (Photo source: Rich Gallagher, Zurich)

Examples of pipe support - Pipe stand (Photo source: Rich Gallagher, Zurich)

Examples of pipe support - Pipe hanger (Photo source: Rich Gallagher, Zurich)

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Examples of earthquake bracing (Photo source: Mike Widdekind, Zurich)

Testing No specific tests are stipulated for pipe, fittings, and supports.

Hydrostatic testing of pipe is conducted for new or modified fire protection piping. Hydrostatic testing is not otherwise performed unless there is a specific concern with system integrity

Water flow through pipe and fittings can provide insights into the condition of fire protection pipe and fittings. This is discussed further in section 3.5 Private fire mains including hydrants.

A.4 Check valve and Backflow prevention assembly

Description Many water-based fire systems will have two or more water supplies. As an example, a system may be supplied by a fire pump and tank and a jockey pump.

When water is flowing into the system, it will often be the one water supply providing the greatest pressure that supplies the system. All other water supplies will remain static unless a pressure balance develops allowing two or more supplies to contribute water flow at a common pressure.

To avoid losing water pressure from a higher pressure supply back into a lower pressure supply, each supply is to be equipped with a non-return valve. The non-return valve used in a fire system will be either a check valve or backflow prevention assembly.

Check valves are the simplest form of non-return valve. They include swing check valves or wafer check valves as shown in the following photos.

Swing check valve (Photo source: Rich Gallagher, Zurich)

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Wafer check valve (Photo source: Rich Gallagher, Zurich)

Others authorities, such as public water utilities, may require the use of more complex non-return valves that also provide backflow prevention for public health purposes. The following are two examples of these more complex devices.

Double check valve (Photo source: Rich Gallagher, Zurich)

Reduced pressure backflow prevention assembly with vented intermediate chamber (Photo source: Rich Gallagher, Zurich)

Reduced pressure backflow preventers may include a vented intermediate chamber. Where a vented intermediate chamber is provided, it will periodically discharge a limited amount of water when waterflow stops. This discharge is intended to drain the chamber between the two check valves. This forms an air gap in the pipe intended to reduce any change of water backflow from the fire system into a potable water system.

The concern with backflow preventers equipped with vented intermediate chambers is the vent valve could fail to close and continue discharging water. Under full water source pressure, the discharge from a vent valve could exceed 3,000 lpm (800 gpm). Considering this flow rate, considerable drainage is needed for these vent valves.

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Inspection Reduced pressure backflow prevention assemblies with a vented intermediate chamber are to be inspected weekly to detect a failure of the relief vent valve.

All check valves and backflow prevention assemblies are to be internally inspected on a 5 year basis to verify internal components are in good condition. This includes verifying internal components move through their full range of motion, are not corroded, and have no mineral deposit accumulations. In addition, the valve body should be free of corrosion affecting valve integrity or the operation of internal components.

Testing On an annual basis, conduct a full flow test of each backflow prevention assembly to verify the assembly can deliver the largest fire protection demand supplied by the device.

A.5 Pressure reducing or regulating valves

Description Pressure reducing or regulating valves (PRV’s) are used to control fire system water pressure in sections of systems where the water pressure would otherwise exceed the rated working pressure of fittings, valves, or other components.

Ideally, system pressures should be designed not to require the need for PRV’s; however, when they are installed, inspection and testing is essential.

There are two types of PRV’s; pilot operated and direct acting. Pilot operated PRV's use a pilot regulator on a pilot line outside of the main valve body to control the

Strainer and meters

There are occasions when a water supply may be equipped with a strainer or

meter. A strainer may be provided to protect a fire system from debris in a

non-potable source of water or to protect small sprinkler or nozzle orifices

from obstruction. Strainers may also be provided to protect meters required

by a public water utility to measure fire water usage.

Strainer, meter, and check valve assembly (Photo source: Rich Gallagher, Zurich)

Where strainers and meters are present, annual full flow tests should be

conducted. As a note, UL listed meters and strainers are available for fire

system use.

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regulating action of the main valve. Direct acting PRV's incorporate a spring or piston inside the valve to directly regulate the valve operation.

Pilot operated pressure reducing valve. The photo shows an unacceptable shutoff valve in the pilot line which if shut could impair valve operation.(Photo source: Rich Gallagher, Zurich)

Pilot operated pressure reducing valve. This photo is a cut-away view of the valve. (Photo source: Stuart Lloyd, Zurich)

Direct acting pressure reducing valve – angle-tye valve (Photo source: Rich Gallagher, Zurich)

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Direct acting pressure reducing valve - straight-type valve (Photo source: Rich Gallagher, Zurich)

Pilot operated PRV’s are field adjustable. Direct acting PRV's may be either factory set or field adjustable. When a factory set PRV is found not meeting the required outlet flow and pressure, replacement is the only option.

Inspection Inspect PRV’s on a quarterly basis to verify there is no physical damage, no leaks, and the downstream pressure gauge reading is normal. PRV’s that fail to control their static outlet pressure can expose downstream fittings and component to excessive pressures and possible system failure.

For PRVs serving as hose outlets, verify hose adapters and caps are in place.

Testing Full-flow test PRV’s on an annual basis to verify they will meet the greatest downstream fire system flow and pressure demand.

A.6 Fire department connection

Inspection Inspect fire department connections on a quarterly basis. Inspections verify the connection is visible and accessible, the sign and caps are in place, the hose connections are not damaged and are operable, and there are no signs of leaks.

Where caps are missing, it is possible that foreign material may have been introduced to the fire system. Foreign material could then be propelled further into the system should the fire service use the connection. This could lead to an obstruction of fire system piping.

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Fire department connection with cap out of place (Photo source: Rich Gallagher, Zurich)

Fire department connection with cap missing and foreign matter introduced (Photo source: Rich Gallagher, Zurich)

Fire department connection obstructed by vegetation (Photo source: Rich Gallagher, Zurich)

Testing The fire department connection typically contains no water between the connection and its check valve. This means the integrity of this section of a system is unsupervised by pressurized water or air. To verify the integrity of this piping, pressure we recommend testing the pipe to 10 bar (150 psi) every five years.

3.2 Water storage

3.2.1 ITM Checklist Include all items from 3.1 General along with the following items.

B. Water supply ITM – Water storage


B.1 Water storage – all methods

I W

(1)

Water level okay ☐ Yes ☐ No

Water temperature okay ☐ Yes ☐No

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http://www.faithfabric.com/tbh/history/images/drexel/0202drexelfire.jpg


Water heating system okay (2) ☐ Yes ☐ No

Tank exterior okay (2) ☐ Yes ☐ No

I 3 Interior okay (for steel tanks with no cathodic protection or no butyl rubber liner) ☐Yes ☐No

I 5 Interior okay (for all other tanks) ☐ Yes ☐ No

T V (3)

Tank fill flow test okay ☐ Yes ☐ No

Measured flow rate _________

Required flow rate _________

T A Level indicator is functional ☐ Yes ☐ No

Tank fill mechanism is functional ☐ Yes ☐ No

B.2 Water storage - pressure tank

I W

Air pressure okay ☐ Yes ☐ No

Air pressure reading __________

Normal air pressure __________


Frequency: W = Weekly M = Monthly Q = Quarterly S = Semi-annual A = Annual V = Varies 5 = 5 year

Table notes:

(1) Where water level and temperature are electronically monitored via a fire alarm system at a constantly attended location, these inspection elements may be extended to monthly.

(2) For open reservoirs, there typically will be no water heating system to assess and no “tank” exterior elements to inspect.

(3) A tank fill flow test is to be conducted for reduced capacity tanks to verity the fill rate will provided the additional water volume needed to support the fixed fire protection demands for the full system design duration. Conduct flow tests on a frequency compliant with local standards which may be as often as quarterly. As a minimum, conduct flow tests on an annual basis.


B.1 Water storage – all methods

Inspection On a weekly basis, check each water storage tank to verify water level is normal and the tank exterior is visually in good condition. Good condition means no physical damage, no corrosion, and no leaks.

July 2016 23


Water storage tank with visible external corrosion (Photo source: Stuart Lloyd, Zurich)

On a weekly basis during cold weather, verify tank temperature is normal and the tank heating system is operating.

Where tank water level and water temperature are monitored at a constantly attended location, these inspections can be increase to monthly.

Reservoirs; open water sources such as ponds, lakes, and rivers; and tanks located in climates not subject to freezing may not include heat sources to be monitored and inspected. Monitoring normal water level remains important.

Water storage tank corrosion failure with fire pump house damage. (Photo source: Malcolm Davies, Zurich)

Elevated reservoir (Photo source: Rich Gallagher, Zurich)

July 2016 24


Steel tanks are subject to corrosion and warrant periodic internal inspections. Conduct internal inspections at least every three years. Where a tank is equipped with cathodic protection maintained in accordance with manufacturer’s instructions, the internal inspection can be extended to every five years.

Fire pump ground water tank (Photo source: Stuart Lloyd, Zurich)

Where a tank is approved for a specific service frequency – such as an LPCB approved LPS 1276 10-year steel tank – internally inspect the tank in accordance with its approval as well as its manufacturer’s guidelines.

Testing Conduct a water supply flow test of the tank fill for each reduced capacity water tank. A reduced capacity water tank is a tank that relies upon an automatic fill to meet the full water supply duration of the fire systems supplied. Conduct the flow tests at the locally required frequency which may be as often as quarterly. As a minimum, conduct a water supply flow tests annually.

On an annual basis, verify the tank level indicator is functional. Mechanical level indicators may use floats, cables, and pulleys which are subject to binding and sticking. Pressure gauge may be out of calibration.

On an annual basis, verify the tank fill mechanism is functional. The tank fill may be controlled by a manual valve, a float operated valve, or an pressure operated altitude valve. In each case, all manual and automatic valves associated with a tank fill are to be tested to verify their functionality.

B.2 Water storage – pressure tanks

Inspection On a weekly basis, verify air pressure is normal. Air pressure provides the energy needed to deliver water to open sprinklers or other flowing outlets.

July 2016 25


3.3 Fire pump weekly

3.3.1 General information The following photo is marked to show common components of an electric fire pump installation.

Electric fire pump (Photo source: Rich Gallagher, Zurich)

1. Fire pump

2. Coupling guard

3. Electric motor

4. Grouted base (wood forms still in place to retain curing grout)

5. Plinth or housekeeping pad

6. Fire pump suction valve (gate type valve)

7. Fire pump suction gauge (not visible)

8. Automatic air release

9. Circulation relief valve

10. Fire pump discharge gauge

11. Discharge check valve

12. Fire pump pressure sensing line (location show with green line)

13. Fire pump discharge valve (butterfly type)

14. Bypass supply valve (butterfly type)

15. Bypass check valve

16. Bypass system valve (butterfly type)

17. Flowmeter isolation valve (butterfly type)

18. Flowmeter

19. Flowmeter throttling valve (butterfly type)

July 2016 26


The following photo is marked to show common components of a diesel fire pump installation.

Diesel fire pump (Photo source: Rich Gallagher, Zurich) 1. Fire pump

2. Coupling guard

3. Electric motor

4. Grouted base (wood forms still in place to retain curing grout)

5. Plinth or housekeeping pad

6. Fire pump suction valve (OS&Y type)

7. Fire pump suction gauge (not visible)

8. Automatic air release

9. Engine cooling water line with bypass

10. Engine heat exchanger

11. Engine heat exchanger discharge line

12. Fire pump discharge gauge

13. Discharge check valve

14. Fire pump pressure sensing line (location show with green line)

15. Fire pump discharge valve (butterfly type)

16. Bypass supply valve (butterfly type)

17. Bypass check valve

18. Bypass system valve (butterfly type)

19. Flowmeter isolation valve (butterfly type)

20. Flowmeter

21. Flowmeter throttling valve (butterfly type)

22. Batteries

July 2016 27


The following photo is marked to show common components of a diesel fire pump fuel tank installation.

Example of a diesel fuel tank (Photo source: Rich Gallagher, Zurich)

1. Tank fill

2. Tank vent

3. Tank secondary containment space vent (where provided)

4. Tank level indicator

5. Tank level float switch (where provided)

6. Fuel supply line and manual shutoff valve

7. Fuel return line

July 2016 28


The following photo is marked to show common components of a jockey pump installation.

Jockey pump installation (Photo source: Rich Gallagher, Zurich)

1. Jockey pump suction valve

2. Jockey pump

3. Jockey pump discharge check valve

4. Jockey pump pressure sensing line (location show with green line)

5. Jockey pump discharge valve

6. Jockey pump controller

July 2016 29


The following photo is marked to show common components of an UL-listed electric fire pump controller common to the US.

Electric fire pump controller (Photo source: Rich Gallagher, Zurich)

1. Operating handle (single handle for both the manual isolation switch and circuit breaker disconnecting means)

2. Start pushbutton

3. Stop pushbutton

4. Emergency stop

5. Test pushbutton

6. Emergency run handle

The following photo is marked to show common components of an electric fire pump controller common to the UK.

July 2016 30


Electric fire pump controller common to the UK (Photo source: Rich Gallagher, Zurich)

1. NA

2. NA

3. Operating handle for manual isolation switch

4. Start pushbutton (break glass)

5. Stop pushbutton

July 2016 31


The following photo is marked to show the components of an Australian Standard AS2941 electric fire pump controller common to Australia.

Electric fire pump controller (Photo source: Peter Boyle, Zurich)

1. NA

2. NA

3. Operating handle (single handle for manual isolation switch)

4. Start pushbutton

5. Stop pushbutton

July 2016 32


The following photo is marked to show common components of a UL-listed diesel fire pump controller common to the US.

Diesel fire pump controller (Photo source: Rich Gallagher, Zurich)

1. Crank engine using battery set 1


3. Stop engine

4. Break glass access to selector switch (manual – off – auto) and engine test

Diesel fire pump controller selector switch (Photo source: Rich Gallagher, Zurich)

5. LCD display

6. LED indicator lamps

July 2016 33


The following photo is marked to show common components of a diesel fire pump controller common to the UK.

Diesel fire pump controller (Photo source: Rich Gallagher, Zurich)

1. Switch to select cranking engine using battery set A

2. Switch to select cranking engine using battery set B

Note: Switch at 1 & 2 also isolated DC power

3. Stop engine

4. Switch (AC power isolator)

5. Indicator lamps (trouble conditions)

July 2016 34


The following photo is marked to show the components of an Australian Standard AS2941 diesel fire pump controller common to Australia.

Diesel fire pump controller (Photo source: Peter Boyle, Zurich)



3. Stop engine

4. LCD display

5. LED indicator lamps

July 2016 35


3.3.2 ITM Checklist Include all items from “3.1 General” along with the following items.

C. Water supply ITM – Fire pump weekly


C.1 Water supply

I W Water supply tank full ☐ Yes ☐ No

I W Water supply tank fill source available ☐ Yes ☐ No

I W Water supply pressure normal ☐ Yes ☐ No

C.2 Suction valve I W

Valve open, sealed, locked or electrically supervised ☐Yes ☐ No

I W Valve not leaking ☐ Yes ☐ No

C.3 Discharge valve

I W Valve open, sealed, locked or electrically supervised ☐ Yes ☐ No


C.4 Bypass supply valve



C.5 Bypass system valve



C.6 Flowmeter isolation valve

I W Valve shut ☐ Yes ☐ No


C.7 Flowmeter throttling valve



C.8 Test header valve



C.9 Pump room or house

I W Room dry ☐ Yes ☐ No

I W Room drainage okay ☐ Yes ☐ No

I W Room heat okay ☐ Yes ☐ No

I W Room ventilation okay ☐ Yes ☐ No

I W Room lighting okay ☐ Yes ☐ No

I W No vermin (insects, rodents, etc.) ☐ Yes ☐ No

July 2016 36




C.10 Fire pump

I W Pump clean ☐ Yes ☐ No

I W Pump dry (no leaks) ☐ Yes ☐ No

I W Coupling guarded ☐ Yes ☐ No

I W Plinth (housekeeping pad) okay ☐ Yes ☐ No

I W Pump base grouted ☐ Yes ☐ No

I W Vertical turbine lubrication oil level okay ☐ Yes ☐ No

C.11 Electric fire pump motor

I W Fire pump motor clean ☐ Yes ☐ No

I W Fire pump motor dry (no leaks) ☐ Yes ☐ No

C.12 Electric fire pump controller

I W Controller clean ☐ Yes ☐ No

I W Controller dry (no leaks) ☐ Yes ☐ No

I W Isolation switch closed (On) ☐ Yes ☐ No

I W Circuit breaker disconnect closed (On) ☐Yes ☐No

I W Power available ☐ Yes ☐ No

C.13

Electric fire pump emergency transfer switch

I W Isolation switch closed (On) ☐ Yes ☐ No

I W Circuit breaker disconnect closed (On) ☐Yes ☐No

I W Emerg. transfer switch power available ☐Yes ☐No

C.14 Diesel engine I W

Engine clean ☐ Yes ☐ No

Engine dry (no leaks) ☐ Yes ☐ No

Engine fuel tank level okay ☐ Yes ☐ No

Engine battery terminals clean ☐ Yes ☐ No

Engine battery fluid level okay ☐ Yes ☐ No

Engine batteries raised above floor ☐ Yes ☐ No

Engine crank case oil level okay ☐ Yes ☐ No

Engine coolant fluid level okay ☐ Yes ☐ No

Fuel tank above ¾ full ☐ Yes ☐No

Engine hours (record) __________

Diesel engine combustion air

Fans operate ☐ Yes ☐No

Louvers operate ☐ Yes ☐No

July 2016 37




C.15 Diesel controller

I W Controller clean ☐ Yes ☐ No

I W Controller dry (no leaks) ☐ Yes ☐ No

I W Controller in automatic ☐ Yes ☐ No

C.16 Jockey pump

I W Jockey pump suction valve open ☐ Yes ☐ No

I W Jockey pump discharge valve open ☐ Yes ☐ No

I W Jockey pump controller clean ☐ Yes ☐ No

I W Jockey pump controller dry (no leaks) ☐ Yes ☐ No

I W Jockey controller automatic ☐ Yes ☐ No

T W

Jockey pump started automatically ☐ Yes ☐ No

Start pressure normal ☐ Yes ☐ No

Start pressure __________

T W

Jockey pump automatic stop okay ☐ Yes ☐ No

Stop pressure normal ☐ Yes ☐ No

Stop pressure __________

C.17 Fire pump

T W

Fire pump starts upon drop in pressure ☐ Yes ☐ No

Start pressure normal ☐ Yes ☐ No

Start pressure __________

T W Cooling water discharge okay (1) ☐ Yes ☐ No

T W

Main relief operating ☐ Yes ☐ No

Main relief pressure normal ☐ Yes ☐ No

Main relief pressure __________

T W Water passing shaft packings (2) ☐ Yes ☐ No

T W No unusual noise or vibration ☐ Yes ☐ No

T W Bearing temperature okay ☐ Yes ☐ No

T W Pump suction gauge reading __________

Pump suction gauge reading normal ☐ Yes ☐ No

T W Pump discharge gauge reading __________

Pump discharge gauge reading normal ☐ Yes ☐No

T W Fire pump running alarm signal okay ☐ Yes ☐ No

July 2016 38




C.18 Fire pump electric motor

T W Motor run for at least 10 minutes ☐ Yes ☐ No

C.19 Fire pump diesel engine

T W Diesel engine starting battery set (3) ☐ Set 1 ☐ Set 2

T W Engine cooling water discharge okay ☐ Yes ☐ No

T W Engine temperature okay ☐ Yes ☐ No

Engine maximum temperature __________

T W Engine oil pressure okay ☐ Yes ☐ No

Normal engine oil pressure __________

T W Engine run for at least 30 minutes ☐ Yes ☐ No


Frequency: W = Weekly

Table notes:

(1) Cooling water for an electric motor driven fire pump is provided by a circulating relief valve located at the fire pump discharge. Cooling water for a diesel engine driven fire pump is provided by an engine cooling line supplied from the fire pump discharge.

(2) Shaft packings should pass 1 to 3 drips of water per second when the pump is running.

(3) For each weekly test, alternate battery sets for diesel engine start.


C.1 Water supply

Inspection On a weekly basis, verify each water supply tank is full. This may be evident by:

• Reading the fire pump suction pressure gauge

• Reading the tank level indicator

• Overflowing the tank

July 2016 39


Fire pump suction gauge (Photo source: Rich Gallagher, Zurich)

Water tank mechanical level indicator (Image source: Rich Gallagher, Zurich)

Water tank overflow (Photo source: Stuart Lloyd, Zurich)

On a weekly basis, verify each water supply tank fill source is available. This may be evident by:

• Reading the supply pressure gauge on the fill pipe

• Overflowing the tank

On a weekly basis, verify the water supply pressure from the tank is normal. This includes normal water pressure being available in the:

• Water tank discharge line

• Fire pump supply (or suction) line

July 2016 40


C.2 Suction valve For discussion see item “A.2 Control valves” in this chapter.

C.3 Discharge valve For discussion see item “A.2 Control valves” in this chapter.

C.4 Bypass supply valve For discussion see item “A.2 Control valves” in this chapter.

C.5 Bypass system valve For discussion see item “A.2 Control valves” in this chapter.

C.6 Flowmeter isolation valve For discussion see item “A.2 Control valves” in this chapter. This is a normally shut valve.

C.7 Flowmeter throttling valve For discussion see item “A.2 Control valves” in this chapter. This is a normally shut valve.

C.8 Test header valve For discussion see item “A.2 Control valves” in this chapter. This is a normally shut valve.

C.9 Pump room or house On a weekly basis, verify the room or house is:

• Secure against unauthorized access.

• Free from storage

• Dry, specifically this means no standing water

• Drainage is provided and unobstructed

• Ventilation is sufficient to control dampness

Motor-operated combustion air damper - The damper is held closed by electric power. The damper opens upon diesel engine start or loss of power. (Photo source: Rich Gallagher, Zurich)

• Heat is adequate to maintain the temperature above 4°C (40°F) for electric motor driven pumps and 10°C (50°F) for diesel engine driven pumps (or higher temperature per the diesel enginer manufacturer guidelines)

• Lighting is sufficient to allow signs and indicators to be read

• No infestation by insects, rodents or other vermin

July 2016 41


C.10 Pump On a weekly basis, verify the fire pump is clean and dry. Some water discharge may be present at pump shaft packings.

Verify the coupling or flexible shaft guard is provided and secured in place.

Right, fire pump coupling; left, fire pump flexible shaft (Photo source: Rich Gallagher, Zurich)

The above photos show a coupling guard - left disassembled reveling coupling within, and right in place guarding the coupling (Photo source: Rich Gallagher, Zurich)

Flexible shaft guard in place with yellow pictograph warning sticker (Photo source: Rich Gallagher)

Plinths (raised housekeeping pads) should be in good condition with no evidence of structural duress such as cracking or settlement. Verify the grouting of the pump base is also sound.

For vertical turbine pumps, visually check the lubricating oil level is in the intended range.

July 2016 42


Vertical turbine lubricating oil site glass (Photo source: Rich Gallagher, Zurich)

C.11 Electric fire pump motor On a weekly basis, verify the motor is clean and dry.

C.12 Electric fire pump controller On a weekly basis, verify the control panel (or controller) is clean and dry. UL listed fire pump controllers will have the automatic start pressure switch located within the control panel. Any sign of water dripping from the controller indicates a need for prompt service by a qualified person as the water leak is occurring inside a live electrical panel!

Left photo shows a UL listed control panel with a mercury-type pressure switch. Right photo shows a UL listed controller with an automatic start pressure transducer. In each case, water is brought into a 480VAC control panel. (Photo source: Rich Gallagher, Zurich)

July 2016 43


UK fire pump installations provide two, redundant automatic start pressure switches for each fire pump and locate them outside of the fire pump control panel (Photo source: Stuart Lloyd, Zurich)

On a weekly basis, also verify the electric power isolation switch handle is in the closed or “On” position, the circuit breaker disconnecting means handle is in the closed or “On” position, and power is available as indicated by the power indicator light or other visual display. For some UL listed controllers, one single handle is provided to operate both the isolation switch and the circuit breaker disconnecting means. For some LPCB approved controllers, there will be a single On/Off switch provided to control electric power.

C.13 Electric fire pump emergency transfer switch On a weekly basis, verify the electric power solation switch handle is in the closed or “On” position, the circuit breaker disconnecting means handle is in the closed or “On” position, and emergency transfer switch power is available. For some UL listed emergency transfer switches, one single handle is provided to operate both the isolation switch and the circuit breaker disconnecting means.

C.14 Diesel engine On a weekly basis, verify the diesel engine is clean and dry. Leaks may include water, diesel fuel, lubricating oil, and engine coolant.

Verify the fuel tank level is okay. The tank should be at least two thirds full or at a level that will provided at least an eight hour supply. An eight hour supply is typically equal to 3.8 L (1 gal) per horsepower of the engine.

July 2016 44


Examples of fuel tank visual level indicators - left photo indicating 3/4 tank and right photo indicating 1/8 tank (Photo source: Rich Gallagher, Zurich)

On a weekly basis, verify battery terminals are clean, battery fluid levels are okay, and batteries are rack supported above the floor. Placing batteries on support racks is intended to keep current carrying parts at least 0.3 m (1 ft.) above the floor and to aid in housekeeping (specifically , avoiding batteries sitting in water).

Batteries raised off the floor (Photo source: Rich Gallagher, Zurich)

For non-sealed batteries, use appropriate acid-resistant personal protective equipment while checking each battery cell to verify battery plates are covered with dielectric fluid. Where plates are exposed, add distilled water using a dispenser intended for the purpose.

Example of apron, arm sleeves, gloves, safety glasses, and face shield used during battery cell inspection. Also, shown is a distilled water battery fill container. (Photo source: Rich Gallagher, Zurich)

July 2016 45


On a weekly basis, also verify the crank case oil and coolant fluid levels are in the appropriate ranges.

On a weekly basis, verify sufficient combustion air is provided for the diesel engine. Verify active ventilation features such as fans and motor-driven louvers operate as intended. Finally, on a weekly basis, record the engine hours. This is evidence that weekly tests are being performed.

C.15 Diesel fire pump controller On a weekly basis, verify the controller is clean and dry, and the selector switch is in the automatic position.

The discussion regarding water leaking from electric fire pump control panels also applies to diesel fire pump control panels. Of course, voltage levels will be lower for the diesel control panel. For discussion see “C.12 Electric fire pump controller”.

C.16 Jockey pump On a weekly basis, verify the jockey pump suction and discharge control valves are open. Also, verity the controller is clean, dry, and in the automatic mode.

The discussion regarding water leaking from electric fire pump control panels also applies to jockey pump control panels. For discussion see “C.12 Electric fire pump controller”.

Test the jockey pump automatic start by slowly dropping the system pressure. Record the start pressure, and verify it is normal.

Allow the jockey pump to restore the system pressure until the pump stops, record the stop pressure, and confirm the stop pressure is normal.

C.17 Fire pump On a weekly basis, start the fire pump by slowly dropping the system pressure. This is a test of the fire pump automatic start feature. Record the start pressure, and verify it is normal.

Where redundant automatic start pressure switches are provided (e.g. in the UK), test each switch. The UK fire pump redundant automatic start pressure switches are specifically arranged to allow independent testing of each switch.

Whenever the fire pump starts and no water is flowing in the system, immediately verify the circulating relief valve is discharging water to cool the fire pump.

Example of fire pump circulating relief valve (Photo source: Rich Gallagher, Zurich)

July 2016 46


If the fire pump is equipped with a main relief valve, verify whether it is operating. If it is operating, recording its pressure setting. This will be the same as the pressure displayed on the fire pump discharge gauge.

Right, direct acting relief valve; left, pilot operated relief valve (Photo source: Rich Gallagher, Zurich)

Verify water is passing the shaft packing on both sides of a fire pump at a rate of 1 to 3 drips per second. This dripping provides lubrication and cooling of the pump shaft and shaft packing. It also aids in avoiding air being drawn in to the pump.

Shaft packing is located on either side of the pump (Photo source: Rich Gallagher, Zurich)

Verify the pump is not experiencing any unusual noise or vibration.

Check the temperature of the pump bearings. Do not use a hand to sense the bearing temperature by touch. Allowable bearing operating temperatures may be as high as 93°C (200°F). Use a device such as a non-contact infrared thermometer for this check.

July 2016 47


Orange arrows point to the inboard and outboard bearing caps. The green arrow points to the inboard bearing surface where temperature should be measured. A similar surface is should be checked on the outboard bearing. (Photo source: Rich Gallagher, Zurich)

Read the pump suction and discharge gauges, record the values, and verify they are normal compared to past weekly tests. See the discussion in item “A.1 Water pressure and flow” for additional information.

Verify the fire pump running alarm is received at the building fire alarm control unit and at the fire alarm monitoring station.

C.18 Fire pump electric motor On a weekly basis, run an electric motor driven fire pump for at least 10 minutes. This allows the electric motor to dissipate heat associated with the motor inrush current when the motor starts.

C.19 Fire pump diesel engine On a weekly basis, run a diesel engine driven fire pump for at least 30 minutes. This allows the engine to thoroughly circulate lubricating oil to all internal engine surfaces, reach operating temperature, and drive moisture from the crankcase. The 30 minute run is intended to mitigate internal engine corrosion.

During the weekly run, monitor the engine temperature and lubricating oil pressure. Confirm they remain within the normal range for the duration of the test.

July 2016 48


Left photo shows a diesel engine control panel with mechanical gauges. Right photo shows a diesel engine control panel with digital display. (Photo source: Rich Gallagher)

3.4 Fire pump semi-annual and annual

3.4.1 ITM Checklist Include all items from checklist “A. Water supply ITM - General” and checklist “C. Water supply ITM - Fire pump weekly” along with the following items.

D. Water supply ITM – Fire pump annual


D.1

Annual fire pump test – pump start methods

(Test all

methods

present)

T A

All fire pumps:

Drop-in-pressure ☐ Yes ☐ No

Electric motor driven fire pumps:

Manual electric at controller ☐ Yes ☐ No

Manual mechanical at controller ☐ Yes ☐ No

Diesel engine driven fire pumps:

Controller switch in “manual 1” ☐ Yes ☐ No

Controller switch in “manual 2” ☐ Yes ☐ No

Controller switch in “test” ☐ Yes ☐ No

Engine manual 1 ☐ Yes ☐ No

Engine manual 2 ☐ Yes ☐ No

Other fire pump start methods:

Remote manual start ☐ Yes ☐ No

Fire system start signal ☐ Yes ☐ No

Other (describe): ☐ Yes ☐ No

July 2016 49




D.2 Annual fire pump test – pump signals

T A

All fire pumps:

Pump running ☐Yes ☐No

Electric motor driven fire pumps:

Electric power phase failure ☐Yes ☐No

Electric power phase reversal ☐Yes ☐No

Diesel engine driven fire pumps:

Diesel controller off automatic ☐Yes ☐No

Diesel trouble ☐Yes ☐No

D.3 Annual fire pump test - flow test

T A

Test point #1 (no flow):

Discharge pressure __________

Suction pressure __________

Speed __________

Main relief valve operating ☐Yes ☐No

Amps (electric)

__________ , __________ , __________

Volts (electric)

__________ , __________ , __________

Engine oil pressure (diesel) __________

Engine water temperature (diesel) __________


Test point #2, #3, #4, and #5:

Ideally, conduct four flowing test points spread out across the range of fire pump operation

Discharge pressure __________

Suction pressure __________

Speed __________

Flow __________


Amps (electric)

_________ , __________ , __________

July 2016 50




Volts (electric)

_________ , __________ , __________

Engine oil pressure (diesel) __________

Engine water temperature (diesel) __________


Overall results:

Test result okay ☐ Yes ☐ No

D.4 Fire pump and

driver mounting

I S Mount and bolts free of physical damage ☐ Yes ☐ No

Mount and bolts free of corrosion ☐ Yes ☐ No

T S Mounting bolts torque okay ☐ Yes ☐ No

D.5 Fire pump I A

Pump bearings okay ☐ Yes ☐ No

Pump shaft end play okay ☐ Yes ☐ No

M A Lubricate bearings ☐ Yes ☐ No

D.6 Coupling T S Alignment okay ☐ Yes ☐ No

M S Lubricate ☐ Yes ☐ No

D.7 Flexible drive shaft


D.8 Right angle gear drive


D.9

Fire pump controller

(see discussion in Chapter 4 regarding arc-flash hazard)

I S Wire insulation not cracked ☐ Yes ☐ No

Circuit boards no corrosion ☐ Yes ☐ No

T S Volt and amp meters okay ☐ Yes ☐ No

M S Calibrate pressure switch ☐ Yes ☐ No

Tighten wire connections ☐ Yes ☐ No

D.10 Electrical motor

M V Grease bearings ☐ Yes ☐ No

D.11 Diesel engine I S

Diesel exhaust system okay ☐ Yes ☐ No

Crankcase breather clear ☐ Yes ☐ No

Circuit boards no corrosion ☐ Yes ☐ No

Check engine fuel lines and filters ☐ Yes ☐ No

July 2016 51




T S

Volt and amp meters okay ☐ Yes ☐ No

Fuel tank free of water ☐ Yes ☐ No

Alternate battery start logic ☐ Yes ☐ No

Six start attempt failure logic ☐ Yes ☐ No

Engine combustion air louvers open upon power failure ☐ Yes ☐ No

M S

Check and top off oil level ☐ Yes ☐ No

Check and top off antifreeze level ☐ Yes ☐ No

Supply air louvre cleaned ☐ Yes ☐ No

Tighten wire connections ☐ Yes ☐ No

Clean cooling water lines ☐ Yes ☐ No

Clean engine air filter ☐ Yes ☐ No

Adjust engine drive belts ☐ Yes ☐ No

M A

Oil and filter changed ☐ Yes ☐ No

Fuel filters changed ☐ Yes ☐ No

Check heat exchanger zinc anode ☐ Yes ☐ No

M 2

Replace engine hoses ☐ Yes ☐ No

Replace engine coolant ☐ Yes ☐ No

Replace engine thermostat ☐ Yes ☐ No

Replace engine air filter ☐ Yes ☐ No

Replace engine drive belts ☐ Yes ☐ No

D.12 Wet pit or jack well

I A Clean wet pit screen and strainers ☐ Yes ☐ No


Frequency: W = Weekly M = Monthly Q = Quarterly S = Semi-annual A = Annual V = Varies 5 = 5 year


D.1 Annual fire pump test – start methods A number of methods are available to start a fire pump. During the annual test, test each method provided.

July 2016 52


Automatic fire pumps will typically start upon a drop in system pressure. Test this start method weekly.

Electric fire pump controllers may have an electric manual start pushbutton which engages the motor starter magnetically using the controller circuitry. In addition, the controller may include a mechanical manual start handle that bypasses the controller circuitry and manually engages the motor starter mechanically.

Diesel engine electronic control module (at the engine) with pushbuttons to crank "Batt A" or "Batt B" (Photo source: Rich Gallagher, Zurich)

Diesel engine controllers will include an electric pushbutton that uses the diesel controller circuitry to manually crank the engine for starting using either battery set 1 or battery set 2. These battery sets may be designated as battery set A and battery set B. In addition, electric pushbuttons may be provided at the engine control panel.

Should the automatic start and electric pushbuttons fail, handles may be provided on each starter motor contactor to allow manual mechanical engine cranking using either battery set 1 or battery set 2.

Diesel engine motor starter contactors with manual operating handles (Photo source: Rich Gallagher, Zurich)

Other possible fire pump start methods include:

• Remote manual start

• Fire system start signal

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A remote manual start is often located at an on-site security station where security staff may manually start a fire pump without the delay of traveling to the fire pump controller.

A fire system start signal is an automatic signal generated by a fire extinguishing system release panel. The signal is intended to start the fire pump without waiting for a drop in system pressure. For example, a fire detection system that releases a water spray deluge system may also send a remote start signal to the fire pump.

D.2 Annual fire pump test – pump signals During the annual test, test each fire pump signal monitored at a constantly attended location. Signals may be monitored by a fire alarm system or a remote fire pump annunciator panel. Typically signals include:

All fire pumps • Pump running (NFPA) or Pump on demand (Europe) – This signal indicates the fire

pump has been commanded to run

• Pump running (Europe) – This signal indicates the fire pump has actually started and has caused an increase in water pressure at the fire pump discharge

Pump running pressure switch at fire pump discharge - European arrangement (Photo source: Rich Gallagher, Zurich)

Electric motor driven fire pumps • Electric power phase failure

• Electric power phase reversal

Diesel engine driven fire pumps • Diesel controller off automatic

• Diesel trouble

Additional signals • Fire pump installation valve tamper

• Fire pump room or house low temperature

• Fire pump ground water tank low level

• Fire pump ground water tank low temperature

• Diesel fire pump low fuel tank level

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D.3 Annual fire pump test – flow test During the annual fire pump capacity or flow test, collect test data at no flow (churn) and at least four additional test points evenly spaced across the range of the fire pump curve. The test should achieve at least the greatest fire protection design flow supplied by the fire pump. In other words, there is no requirement to flow the greatest flow rate shown on the fire pump nameplate.

The five test points are intended to facilitate the graphing of a fire pump test curve. This curve is to meet or exceed all fire system demands supplied by the fire pump. Where fire pump curve has deteriorated, and specifically if fire system demands are no longer being met, the test results should lead to fire pump maintenance to restore fire pump performance.

At each test point, the following readings will be collected for all fire pumps:

• Discharge pressure

• Suction pressure

• Pump speed

• Main relief valve operating (yes/no)

For electric motor driven fire pumps, the following additional readings are collected:

• Volts (three readings, one for each phase)

• Amps (three readings, across the phases)

For diesel engine driven fire pumps, the following additional readings are collected where suitable indicators are provided:

• Engine coolant temperature

• Engine lubrication oil pressure

Operation of the main relief valve, where present, actually interferes with the annual test as water discharging from the main relief valve is not measured. Only those test points where the main relief valve is not discharging are valid test points. It is ideal to turn the main relief valve off during the annual flow test; however, if this will result in excessive system pressures, the operation of the main relief valve will have to be tolerated.

For UL listed electric fire pump motors:

• Voltage readings should remain between 95% and 110% of motor nameplate volts.

• Amperage readings should not to exceed the motor nameplate full load motor amps times the motor name plate service factor (which is typically 1.15 for fire pump motors).

D.4 Fire pump and driver mounting

Inspection On a semi-annual basis, verify the fire pump and driver mount and mounting bolts are free of physical damage and corrosion.

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Mounting bolts shown with red circles and arrows (Photo source: Rich Gallagher, Zurich)

Test On a semi-annual basis, verify the torque of the fire pump and driver mounting bolts are within manufacturer’s specifications

D.5 Fire pump Annually, inspect pump bearing and lubricate them in accordance with manufacturer’s instructions.

Check fire pump shaft end play or end float. This is axial movement of the pump shaft, and it should not exceed manufacturer’s allowances. Excessive end float can allow rotating pump parts to clash with stationary parts. In addition, it can adversely affect coupling and flexible drive shafts.

D.6 Coupling Couplings may be found in used with either electric motor or diesel engine driven fire pumps. Annually, verify coupling alignment. Coupling alignment includes angular alignment, parallel alignment, and axial alignment.

Parallel alignment is checked with a straight edge as shown in the following image.

Coupling parallel alignment check with a straight edge (Image source: Rich Gallagher, Zurich)

Angular alignment is checked with feeler gauges (or a taper gauge) as shown in the following image. The gauge is inserted at four points 90 degrees apart.

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Coupling angular alignment check with feeler gauges (Image source: Rich Gallagher, Zurich)

An accurate alignment check can be made using a dial indicator as shown in the following image. The dial gauge in position “1” checks parallel alignment. The dial gauge in position “2” checks angular alignment. For each check, the dial gauge is attached to one side of the coupling, positioned, and zeroed. A mark is then placed on the other coupling half opposite the dial gauge mounting point. Both halves of the coupling are rotated together (dial mount and mark kept adjacent to each other). Check alignment at four locations 90 degree apart such as with the dial mount at the top, bottom, and both sides. The dial will indicate if adjustments are needed (e.g. raise, lower, or side-to-side movement of driver).

Coupling parallel and angular alignment check with a dial gauge (Image source: Rich Gallagher, Zurich)

Axial alignment is the gap provided between coupling halves that allow for end play or float of the shafts on either side of the coupling. Coupling manufacturer’s instructions apply including minimum shaft end engagement of the coupling halves to the shaft ends.

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Lubricate the coupling in accordance with manufacturer’s instructions. This includes use of the specific lubricant recommended by the manufacturer.

Example of an all-metal tapered grid-type coupling with cover halves removed and no g

Inspection, testing, and maintenance (ITM) · 2021. 1. 11. · Inspection, testing, and maintenance...

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