Necessary Instructions for Installation, Commissioning, Operation and Maintenance of Containerized FireFighting Pump Package

This document includes the necessary instructions for installation, commissioning, operation and maintenance of containerized firefighting pump package. For the individual component specific instruction, we refer to the IOM manuals of the various components.

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1.1 System Description

The Installation of Stationary Pumps for Fire Protection shall be performed in accordance with NFPA20 indications.

The system consists of one or more fire pumps driven by electric motor or diesel engine and/or jockey pumps driven by electric motor aimed to maintain water pressure in the firefighting system.

At site, each fire pump shall be connected to the firefighting system and shall be commissioned properly to grant the operation in accordance to the standards.

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1.2 Locating Fire Pump Cabinets

Fire Pump Cabinets shall be installed in a Safe Area. A proper placement of a fire pump and related equipment is also intended to provide a relatively safe environment for the equipment operator. Fire pumps must not be located in mechanical equipment spaces, which would expose the fire pump and operator to damage and potential injury.

General requirements:

• The fire department should plan ahead with the location and access to the fire pump room.
• The Fire pump, driver, controller, water supply, and power supply should be safeguarded from any potential disruption of service caused by explosion, fire, flood, earthquake, rodents, insects, windstorm, freezing, vandalism, and other adverse conditions.
• Fire pump units should be placed at least 50 ft (15.3 m) away from the building they are protecting.
• Fire pump units should be separated from the hazard they are protecting in a way that will prevent direct exposure of the pump unit to a fire related to the hazard.
• Except for what is strictly allowed, rooms that contain fire pumps should not have any storage, equipment, or penetrations that are not essential to the operation of the pump and related components.
• The location of the pump unit is very important for its operation and maintenance. The following factors should be considered when choosing a location for your pump unit:

1. Put the pump unit in a way that makes it easy to access for maintenance, inspection, and possible repair activities.
2. Make sure there is enough space around and above the pump for a lifting device such as a crane or a winch that can lift the whole unit.
3. Locate the unit logically with respect to the water reservoir and the system connections. Make sure that the pipework needed for the connection to the system is designed as efficiently as possible to allow for minimal head loss.
4. When feasible, do not install the unit in locations with a high risk of damage. Avoid installation in areas with heavy traffic (human or vehicle). If the unit is placed in a location with heavy traffic, make sure to install proper protection against collisions.

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1.3 Pre‐Installation

One of the most important factors to successful operation and maintenance of your pump unit is a correctly performed installation of the unit. A pump unit that has been installed correctly will remain aligned better in the long run, will show less leakage of casing as well as flanges, will show less vibration and will demand less servicing.

Another aspect that will be influenced by the installation of your pump unit is its service‐life. A correctly performed installation will prolong the pump's service‐life and diminish the risk of failures in emergencies.

A bad performed installation may damage a new pump unit severely within a relatively short time.

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2. HANDLING & TRANSPORT

2.1 General

The cranes and other hoisting‐devices used must have enough capacity to lift skids, pumps and auxiliary equipment without risk. Each component must be hoisted following all relevant local laws / directions. Only trained personnel should do the hoisting and transporting. Handling must be done safely and with caution.

2.2 Pump Room Skids

Each Pump Room is designed for 8‐point lifting from the lifting provisions located on Pump Room Skid Baseplate. lifting provisions can be removed for transportation purposes and shall be properly connected to the baseplate prior lifting. Adequate means for verifying the tightening torque shall be used. hoisting shall be done taking care walls and accessories are not damaged during lifting.

WARNING

Always use certified and regular inspected hoisting equipment only!

WARNING

Never stand under the load while hoisting. Hard hats and safety shoes are mandatory!?

2.3 Vertical Pump & Submersible Pumps

Please refer to pump manual for specific instruction on handling and installation of the pumps.

WARNING

Submersible Pumps need to be installed in water reservoir with the relevant electric motor flushing jacket.

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2.4 Right‐Angle Gear Box

If the Right‐Angle Gear Box is not already mounted on the pump, handling of Right‐Angle Gear Box on the Pump shall be done using the correct provisions:

• Remove Gear Box Cover‐Hood bolts and take off the cover‐hood.
• Under the hood there are two tapped holes for lifting lugs. Screw in the lifting lugs (not included in the scope of supply).
• The lifting lugs to be used should naturally have the same screw thread as the tap holes have and should be sufficiently strong to carry the entire gearbox‐weight.

If present, Gearbox Non‐Reverse Provision is installed under the Gear Box Cover‐Hood, this should be removed to make sure it will not be damaged during gearbox installation. When removing Gearbox Non‐Reverse Provision make sure the non‐reverse pins do not fall off.??

3. INSTALLATION

3.1 Fire Pump Cabinets Foundation

When designing Fire Pump Cabinet Foundation, consider these factors:

• Dimensional Requirements

Please refer to the GAD drawing for the required space and the required positions of pipe work (discharge piping, pump positions, relief valve discharge positions and test line)

Generally, slab shall be more 1 meter larger than Fire Pump Cabinets edge.

• Foundation Strength

The concrete slab foundation must be strong enough to support the whole skid with all its equipment, to reduce any vibration and to give a permanent solid base.

Detailed information regarding loads are contained on GAD and/or Foundation layout.

Typical Fire Pump Cabinets Load is 1.000 kg/m2.

• Foundation Levelling

Fire Pump Cabinet shall be installed on a flat and uniform slab. Suggested tolerance is ±0.5mm/m for the concrete foundation; acceptable tolerance is ±1mm/m for the concrete foundation. In case of needs, use Fire Pump Cabinet levelling plates and shim plates to correct Fire Pump Cabinet Levelling.

• Foundation Fixing Points

After Levelling, Fire Pump Cabinet Fixing Points shall be properly tightened to the slab and tightening torque verified.

3.2 Pumps

After Fire Pump Cabinet is properly fixed to the slab, Fire Pumps can be installed. Prior Fire Pumps Lifting, remove the Removable Roof Fixings of the Fire Pump Cabinet and move the removable roof using the 4 lifting points. Once finalized pump lifting, Removable Roof shall be fixed again in position checking that the seals are adequately compressed to avoid water infiltration inside the cabinet.

Warning

Before stating any activity verify that pumps are free from dirt and debris. Check discharge head, suction bell and filter. In case dirt or debris are present, clean and remove the dirt and debris. If necessary, dismantle the pump to clean it.

Warning

Vertical pumps shall be carefully hoisted to avoid deflections to shaft and column pipes. Proper handling will avoid high shaft vibration and premature failures.

Once each pump is hoisted into its place, fix it on its pump plate. Fixing Points shall be properly tightened to the pump plate and tightening torque verified. Flange bolts and gasket can be installed, and flange bolts tightening can be performed only after pre-alignment verification.

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3.3 Mounting the Right‐Angle Gear Box

If the Right‐Angle Gear Box is not already mounted on the pump, right‐angle gear can be mounted onto the discharge head. Right‐Angle Gear Box should be hoisted according to the directions given above paragraph 2.4. Prior Lifting, remove the Removable Roof Fixings of the Fire Pump Cabinet and move the removable roof using the 4 lifting points. Once lifting is finalized, Removable Roof shall be fixed again in position, checking that the seals are adequately compressed to avoid water infiltration inside the cabinet.?

Warning

Before placing the Right‐Angle Gear Box on the discharge head make sure the gearbox bottom and discharge head top surfaces are clean and undamaged. Never mount the gearbox when either of the surfaces is dirty or damaged. This will cause misalignment.

Warning

Before mounting the Right‐Angle Gear Box, the pump shaft and the hollow shaft gearbox should be inspected for damage and cleanliness.

Place accurately and carefully gearbox over the pump shaft. Bolts shall be properly tightened to Pump Discharge Head and tightening torque verified.

If present, Gearbox Non‐Reverse Provision is installed under the Gear Box Cover‐Hood, this should be installed again. Check Non‐Reverse Pins are all placed properly in the coupling and are clean and undamaged.

Placing the coupling over the shaft should be done with care. If resistance is met never mechanically force or hammer the coupling onto the shaft; this can cause damage to the bearings or gears.

After the coupling has been placed, the key to fix the shaft to the coupling should be placed. Mounting the key should be done with care ; make sure the shaft‐thread is not damaged.

After coupling has been placed, shaft top nut has to be installed and the shaft's vertical position shall be adjusted.

Warning

Shaft Vertical Position shall be adjusted properly, if not correctly performed, pump will be damaged.

When shaft adjustment is done the gearbox hood can be installed.

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3.4 Submersible pumps

Typically, jockey pumps are submersible type. If practical, Submersible jockey pumps are shipped completely assembled. ?

Before installing the pump check that:

• discharge pipes are attached (discharge pipes fixing must prevent unscrewing due to the starting and stopping torques)
• cables are intact and that cable insulation is not damaged
• electric motor cooling jacket is installed

Prior Lifting, remove the Removable Roof Fixings of the Fire Pump Cabinet and move the removable roof using the 4 lifting points. Once lifting is finalized, Removable Roof shall be fixed again in position, checking that the seals are adequately compressed to avoid water infiltration inside the cabinet.

Warning

The pump is to be carefully hoisted to its vertical position.

Before lowering the pump into position carefully check the bottom of the discharge pipe mounting flange and remove any dirt. Check the pump plate and remove any dirt.

Once the pump is hoisted into its place, check electric cables are correctly positioned onto the pump plate. After bolts shall be properly tightened to plate and tightening torque verified.

Protect cables to avoid damages to cable insulation.

3.5 Spool Piping Installation

Some Spool Piping are shipped separately for transportation limits. Each Spool Piping is marked with clear indication for installation at site.

Where applicable, install gaskets, flanges and/or grooved connections according to normal practices. All bolts shall be properly tightened to plate and tightening torque verified. Spool supports shall be properly installed at site.

3.6 Electrical Connections (Power Distribution Panel)

Warning

Check wiring diagrams before making any connections.

Warning

Connections of electrical power systems must always be performed by trained electricians.

Warning

Connecting must be done in accordance with applicable legal safety regulations and local codes and standards.

Each Fire Pump Cabinet is provided with the Power Distribution Panel. Power Distribution Panel shall be fed by main power supply and to emergency power supply.

All equipment inside the Fire Pump Cabinet (except the Electrical Fire Pump Controllers) are fed by Power Distribution Panel.

Each electrical equipment is already wired to Power Distribution Panel or to Controllers.

Sole exceptions are:

• Each Submersible Motor which shall be wired to relevant Jockey Pump Controller.
• Each Electrical Fire Pump Controllers which shall be wired to Plant Grid.
• Each Set of Diesel Engine Battery which shall be wired to Diesel Engines Battery Cables.
• Each Set of Notifier Battery which shall be wired to Notifier Battery Cables.

Warning

It is recommended to keep Diesel Engines Battery Cables disconnected during installation procedure to avoid unwanted start-ups. Diesel Engine Batteries connection shall be done only when required during Diesel Engine commissioning.

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3.7 Electrical Connections (Electrical Fire Pump Controllers) - Driver Direction of Rotation

Provided the provision of paragraph 3.6, before connecting Electric motor to Pump shall be checked the direction of rotation. Pump Controllers manuals (Jockey or Main Electric) provide detailed sections.

Warning

For safety reasons, it is suggested to perform rotation test prior to engaging the coupling.

Warning

Jockey pumps direction can be checked operating pumps near to “no-flow capacity” for few seconds. If discharge pressure reaches a level close to the one expected (see Jockey Pump Curve at “no-flow capacity”), direction of rotation is correct. On contrary, switch off the control panel and swap two phases and re-test.

3.8 Coupling Installation

Warning

For safety, before starting any activity on Couplings and/or Driveshafts, make sure that control panels are securely locked in “off” position and that Diesel Engines Battery Cables are disconnected.

Warning

Gearbox and electric driver must be engaged after having verified the correct direction of rotation.

Each Coupling-Half has a slide: one is installed on pump shaft (or on gear box shaft); second coupling-half is engaged on electric motor shaft (or on Diesel Engine SAE Flange). Slide pump coupling-half over the shaft to engage it with driver coupling-half. Be careful not to damage the flexible elements. Once in place lock the coupling using the two grub screws.

For the diesel pumps there is no need to check the direction of rotation. After step “3.3 Mounting the Gearbox” the engine can be connected with the gearbox by mounting the universal shaft.

Before and during installation the following points must be taken care with:

• Before the shaft may be mounted, first check it for possible damage and failing components such as balance plates.
• Clean the flanges of the shaft and the counter flanges of gearbox and engine so that they are completely free of corrosion preventing agents, dirt, grease and paint, so that the surfaces of shaft and contra flanges can be connected properly.

3.9 Alignment

Warning

Proper operation of the system is strongly related to a proper alignment.

Warning

Alignment must be regularly checked according to NFPA25 as minimum.

After installation of the couplings the alignment must be checked. Correct, if a misalignment is higher than maximum allowable misalignment or if RMS vibration levels on pump are higher than 11,2 mm/s. Please revert to coupling manual for maximum allowable misalignment.

After alignment, coupling guards must be installed.

3.10 Cooling systems

Gear boxes and diesel engines (not radiator type) are provided with heat exchangers for cooling lubrication oil with pumped fluid. For proper operation, to avoid overheating and damages to the equipment, heat exchangers cooling loops need to be connected to pumps discharge after pump installation.

• Each cooling water loop have a pressure reducer which have been pre‐set during FAT.
• Each cooling water loop have a filter which need to be regularly cleaned to avoid low flow.

3.11 Exhaust systems (for diesel drive pump only)

Exhaust silencers are preferably installed in the cabinet or, where not feasible, on cabinet roof. In case Exhaust silencers are mounted on roof follow dedicated instructions.

For transportation, exhaust terminals are shipped separately and shall be installed with bolts and gaskets provided. Exhaust terminals shall be installed before diesel engine start-up.

3.12 Pressure relief valve

For transportation, pressure relief piping spool are shipped separately and shall be installed with bolts and gaskets provided.

Where foreseen, pressure relief valves discharge spool shall be installed. ?Verify that provided supports are fixed to pipes spools.

Where applicable, install gaskets, flanges and/or grooved connections according to normal practices. All bolts shall be properly tightened to plate and tightening torque verified. Spool supports shall be properly installed at site.

Verify pressure relief valve operation in accordance with NFPA25 and check maintenance requirements on pressure relief valve manual.

3.13 Tank Filling and Ventilation Procedure for Diesel Pumps

Diesel engines are equipped with tanks and have specific protocols for ventilation and filling to ensure safety and operational efficiency. The following details outline the procedure for both ventilation and filling, emphasizing the importance of avoiding positive pressure within the tanks and preventing overfilling.

Ventilation:

1. Ventilation Cap Installation: The diesel container is equipped with a specialized flame arrestor ventilation cap. This cap includes a piece of pipe and is designed to be screwed into the ventilation connection located on the side of the container. Ensure that the flame arrestor cap is securely fastened to provide adequate ventilation and prevent the ingress of flames.

Filling:

1. Direct Filling: Filling can be performed directly through the filling connections on the side of the container. Use appropriate hoses and connectors to ensure a secure and leak-free filling process.
2. Remote Filling: Alternatively, the tanks can be filled using a remote system. The remote filling system must be designed to connect to the container’s filling connection safely.
3. Avoid Positive Pressure: The internal tanks are not designed to withstand positive pressure. During filling, ensure that the filling pressure is controlled and does not exceed the tank's design limits to avoid damaging the tanks.
4. Overfill Prevention: The external filling system must be integrated with the high-level switch on the tank. This high-level switch will trigger an alert or shut off the filling process to prevent overfilling. Regularly check and maintain the high-level switch to ensure it functions correctly.

Safety Considerations:

• Always follow the manufacturer’s guidelines and safety protocols during filling and ventilation operations.
• Inspect all connections and equipment before use to ensure they are in good working condition.
• Use personal protective equipment (PPE) such as gloves and safety goggles to protect against spills and splashes.
• Ensure that fire extinguishers and other safety equipment are readily accessible in case of emergencies.

3.14 Installation Instructions for Cabinet Roof Hatches

1. Preparation:

• Ensure that all necessary safety measures are in place, including proper personal protective equipment (PPE) such as gloves, helmets, and safety boots.
• Confirm that you have all the required tools and equipment, including adjustable chains, lifting lugs, and appropriate connectors for the electric fans.

2. Hatch Removal:

• The hatches come pre-installed and need to be removed for the pump installation.
• Locate the threaded holes on the hatches, which are used for attaching the lifting lugs.
• Securely attach the lifting lugs to the threaded holes.

3. Hoisting the Hatches:

• Connect adjustable chains to the lifting lugs. Make sure the chains are adjusted to balance the hatch during the hoisting process.
• Using an appropriate hoisting mechanism, carefully lift the hatch from its position on the container roof.
• Ensure the hatch is balanced and stable during the entire lifting process to avoid any accidents or damage.

4. Installation of Equipment:

• With the hatch removed, proceed with the installation of the pumps or other equipment as required.
• Follow the manufacturer’s instructions for the installation of the equipment to ensure it is securely and properly installed.

5. Reinstalling the Hatches:

• Once the equipment installation is complete, carefully lower the hatch back into position using the adjustable chains and hoisting mechanism.
• Ensure the hatch is properly aligned and securely seated.

6. Ventilation Louvres and Electric Fans:

• The hatches are equipped with ventilation louvres and electric fans.
• Connect the louvres and fans by plugging the connectors into the roof-mounted sockets.
• Verify that all electrical connections are secure and properly insulated.

7. Final Checks:

• Conduct a thorough inspection to ensure that the hatches are securely in place and that all equipment, louvres, and fans are correctly installed and connected.
• Test the electric fans to confirm they are functioning correctly.

8. Safety and Maintenance:

• Regularly inspect the hatches, louvres, and electric fans for any signs of wear, damage, or malfunction.
• Ensure ongoing maintenance is performed according to the manufacturer’s recommendations to maintain optimal operation and safety.

3.15 Connecting discharge piping

Connecting discharge piping involves several steps to ensure a secure, efficient, and leak-free connection. Here’s a general guide on how to connect discharge piping, often used in contexts such as plumbing, HVAC systems, or industrial applications:

Materials and Tools Required:

1. Discharge Pipe: Appropriate type and size (e.g., PVC, copper, steel).
2. Fittings: Elbows, couplings, adapters, etc.
3. Pipe Supports and Clamps: To secure the piping.
4. Sealant/Thread Tape: For threaded connections.
5. Solvent Cement/Primer: For PVC connections.
6. Wrenches and Pliers: For tightening fittings.
7. Pipe Cutter/Saw: To cut the pipe to the desired length.
8. Measuring Tape: To measure pipe lengths and distances.
9. Safety Gear: Gloves, goggles, etc.

Steps to Connect Discharge Piping:

1. Plan the Layout: Determine the route of the discharge piping. Identify the connection points (from the discharge outlet to the final discharge point).
2. Measure and Cut the Pipe: Measure the required lengths of pipe. Use a pipe cutter or saw to cut the pipe to the necessary lengths. Ensure cuts are clean and straight.
3. Prepare the Pipe and Fittings: Clean the ends of the pipes and the insides of the fittings. For threaded connections, wrap thread tape around the male threads. For PVC pipes, use primer on the pipe ends and fittings before applying solvent cement.
4. Assemble the Piping: Start at the discharge point and work towards the final discharge location. For threaded pipes, screw the fittings onto the pipe ends and tighten with wrenches. For solvent-welded pipes, apply solvent cement to the primed areas and quickly join the pipe and fitting, holding them together for a few seconds to set. For push-fit or compression fittings, insert the pipe into the fitting until it locks or tightens with compression nuts.
5. Support the Piping: Secure the piping with pipe supports and clamps at regular intervals to prevent sagging and movement. Ensure that the piping is properly aligned and sloped (if required, such as for drainage).
6. Test the Connection: Once all connections are made, test the system for leaks. Gradually introduce the discharge (fluid or gas) and check all joints and fittings. If any leaks are detected, tighten the fittings or redo the connections as necessary.
7. Final Inspection: Perform a final inspection to ensure all connections are secure and there are no visible leaks. Verify that the discharge system functions correctly under operating conditions.

Safety and Best Practices:

• Always follow manufacturer instructions for the materials and fittings used.
• Wear appropriate safety gear to protect yourself from sharp edges and chemicals.
• Ensure proper ventilation if using solvent cement or other chemicals.
• Use the right tools for cutting and joining pipes to avoid damage and ensure a good fit.

4. COMMISSIONING / OPERATING

Before Operation

1. Installation Check Carefully inspect the complete installation.
2. Fluid Levels Check all liquid levels, including oil and coolant in the diesel engine and right-angle gear. If oil is absent, refer to document MD3/BZ-00/FF-M-06-JG5-003 "Lubricant Schedule" for details on the required quality and quantity of oil.
3. Fuel System Check fuel level in the fuel tank. Inspect fuel supply and return piping.
4. Mechanical Fasteners Ensure all bolts and nuts are properly tightened.
5. Electrical Systems Verify battery connections and battery condition. Check electric supply to the controller. Ensure the battery charger is functioning properly.
6. Pump and Water Levels Ensure the pump shaft can rotate freely. Check water level to confirm it is sufficient for operation.
7. Valves Ensure discharge valves, test line valves, and test valves are closed.

First Starting (On Site)

1. System Pressurization It is recommended to pressurize the system using the jockey pumps for a smoother start.
2. Manual Start Start the pump by initiating a manual start on the controller. Observe the pump for easy start-up and smooth operation without unusual vibrations.
3. Initial Flow Adjustment If starting difficulties or excessive vibrations occur, stop the driver immediately and determine the cause. Slowly open the valve to the test line. Slowly open the test valve and adjust to create the required flow, aiming for approximately half of the rated capacity for the initial test.
4. Gland Nut Adjustment Gradually adjust (tighten) the gland nuts over an extended period. Monitor leakage from the stuffing box, ensuring it is between 40 to 60 drops per minute. Leakage should only occur between the shaft-sleeve and soft packing-rings, not between the stuffing box and soft packing rings. Adjust stuffing box leakage as necessary, following gland packing instructions as detailed in the pump manual.
5. Rated Capacity Testing Continue to open the test valve until the rated capacity is reached. During the first operation period, monitor and note all gauge readings. Compare them with values in the pump, engine, and gearbox manuals. Investigate and correct any significant deviations from the manual guidelines.

Pressure Settings

• Pressure Transducers and Switches Set the pressure transducers and pressure switches to the desired operating pressures during commissioning. Adjust pressure accumulator set pressures if necessary. Follow the control panel manuals for instructions on adjusting the starting set pressure of the fire/jockey pumps.

References

• For set pressures, refer to document MD3/BZ-00/FF-I-06-JI5-101 “Instrument List”.
• For oil quality and quantity, consult document MD3/BZ-00/FF-M-06-JG5-003 “Lubricant Schedule”.
• For gland packing instructions, see the pump manual.
• For guidelines on pressure adjustment, follow the relevant control panel manuals.

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4.1 Operating / weekly test

Standard Operating Procedure (SOP) for Weekly Testing of Pumps per NFPA-20

Before Each Start

1. Check Control Panel Displays: Ensure all status indications are normal.
2. Check Gearbox and Engine Lubricant Levels: Verify lubricant levels are within acceptable ranges.
3. Check Valve Positions: Confirm all valves are in their correct positions.

Weekly Test Procedure

1. Isolate the Pump: Close the discharge flange of the pump to be tested. This action isolates the pump from the system, leaving the system standby on other pumps.
2. Relieve Test Valve Pressure: Open the test valve slightly to relieve any pressure, then close it again.
3. Create Pressure Drop: Open the valve to the test line. This action will create a pressure drop at the pressure transducer of the pump to be tested.
4. Check Control Panel: Verify that the “pump on demand” light comes on at the control panel display.
5. Automatic Pump Start: After a preset start delay of 3 seconds, the pump should start automatically.
6. Achieve Full Speed: Once the pump reaches full speed, slowly open the test valve.
7. Adjust for Rated Capacity: Adjust the valve setting to achieve the rated capacity. Check and record the flow and discharge pressure.
8. 30-Minute Operation: Allow the pump to run at rated conditions for approximately 30 minutes. During this time, check the following: Stuffing box leakage Gearbox cooling Engine cooling Engine temperatures Ensure all signals and indicators provide consistent levels with each test run.
9. Conclude the Test: After 30 minutes, slowly close the test valve. Avoid closing it too swiftly to prevent pressure spikes. Close the valve to the test line. Verify the control panel to ensure the “pump on demand” light is off. Manually stop the pump.
10. Restore Normal Operation: Slowly open the discharge valve to the main system. Briefly open the test valve to relieve any remaining pressure from the test line.
11. Repeat Procedure: Repeat the above procedure for each pump in the system.

Notes

• Ensure all safety protocols are followed during the test.
• Record any anomalies or irregularities encountered during the testing process.
• Maintenance personnel should be trained and familiar with this procedure.

By following this SOP, you will ensure the reliability and performance of the pumps in compliance with NFPA-20 standards.?

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5. MAINTENANCE

Maintenance Program for Pump Unit?

This chapter outlines the essential inspection and maintenance tasks required as part of a preventive maintenance program. Regular maintenance is crucial to ensure the efficient functioning and extended service life of the pump unit. All inspection, maintenance, and testing activities must be documented and kept for future reference. The latest inspection/maintenance report should be stored in the container.

Preventive Maintenance Program

A well-planned and regularly executed maintenance program is key to the long-term operation and longevity of the pump unit. The following guidelines provide a basic maintenance framework for average operating conditions. Adjustments to the maintenance schedule should be based on operating conditions and the results of previous inspections. Maintaining a clean environment around the pump unit is critical before, during, and after all maintenance activities.

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Weekly Maintenance Tasks Before Each Operation

1. Diesel Engine Walk-around Inspection: Check for debris, foreign objects, loose or broken fittings, guards, and components. Repair as needed. Belts: Inspect for wear, damage, or looseness. Cooling System: Ensure proper coolant level. Air Cleaner Indicator: Check and replace air cleaner elements if the indicator diaphragm remains locked. Engine Crankcase: Maintain oil level between the "add" and "full" marks on the dipstick. Fuel System: Check for leaks, drain water separator, and keep fuel tank full. Check fuel filter indicator if equipped. Batteries: Maintain electrolyte level, clean batteries, and check connections. Gauges: Inspect all gauges for proper condition and replace or repair any broken ones. Battery Charger: Ensure proper operation. Exhaust System: Drain exhaust condensate if equipped.
2. Electric-Motor Check cable glands for proper installation and elastomer condition.
3. Pump Walk-around Inspection: Check for leakages, loose bolts, corrosion, and debris or foreign objects.
4. Deran Right-Angle Gear Drive Walk-around Inspection: Check for leakages, cleanliness, and loose bolts. Address any issues found. Oil Level: Ensure the proper oil level. For drives with a sight gauge, it should be at the marked level. For those without, the level should be about half an inch below the filler hole. Adjust as necessary using the correct oil quality.

During Operation

1. Diesel Engine Start the Engine: Run for approximately 30 minutes while performing checks. Oil Pressure: Verify proper operating oil pressure. Speed (RPM): Check and record readings. Leaks and Noises: Inspect for leaks and unusual noises. Stop the engine before making repairs.
2. Electric-Motor Start the Motor: Run for approximately 30 minutes while performing checks. Speed (RPM): Check and record readings. Noises: Inspect for unusual noises.
3. Pump Noises/Vibrations: Check for unusual noises and vibrations. Stuffing Box: Ensure leakage is between 40 to 60 drops per minute. Adjust as necessary following gland packing instructions. Stuffing Box Drain: Ensure free flow of stuffing box waste pipes.
4. Deran Right-Angle Gear Drive Noises/Vibrations: Check for any deviations from normal noise and vibration levels and correct them promptly. Cooling System: Verify that all valves are in the correct positions and check the pressure gauge. Oil Distribution: Ensure proper oil distribution by removing the oil system test plug while operating.
5. Universal Shaft Noises/Vibrations: Inspect for unusual vibrations or noises and address immediately.

After Stopping

1. Diesel Engine Automatic Switches: Ensure all switches are correctly set for automatic start.
2. Fuel Level: Refill if below 50% full.
3. Malfunctions: Report and repair any malfunctions.
4. Battery Charger: Record the charging amperage reading.