METHOD STATEMENT FOR INSTALLATION, TESTING & COMMISSIONING OF FIRE PUMPS SET

CONTENTS

1.0 PURPOSE

2.0 SCOPE

3.0 REFERENCES

4.0 DEFINITIONS

5.0 RESPONSIBILITIES

6.0 EQUIPMENT

7.0 PROCEDURE

8.0 ATTACHMENTS

1.0 PURPOSE

The purpose of generating this method statement is to define the procedure & work sequence for the correct practices for the Installation, Testing & Commissioning of Fire Pumps Set through the guidelines contained herein so as to ensure that the job execution complies with the requirements of the contract specification & approved shop drawings to which will serve for the intended function to the satisfactory level for all applicable areas in the project.

2.0 SCOPE

This method statement covers all processes related to Installation, Testing & Commissioning of Fire Pumps Set.
This procedure is to be read in conjunction with the relevant ITP, outlining the responsibility and the quality verification to be performed by various parties.

3.0 REFERENCES

Latest Approved shop drawings for the required and applicable areas for Fire Fighting System.
Specifications
Project Quality Plan

4.0 DEFINITIONS:

PQP : Project Quality Plan

PSP : Project Safety Plan

QCP : Quality Control Procedure

HSE : Health, Safety and Environment

MS : Method Statement

ITP : Inspection Test Plan

QA/QC : Quality Assurance / Quality Control Engineer.

WIR : Work Inspection Request

MIR : Material Inspection Record.

5.0 RESPONSIBILITIES:

5.1 Project Manager

5.2 Construction Manager

5.3 Site Engineer

5.4 QA/QC Engineer (MEP):

5.5 Site Foreman

5.6 Safety Officer

5.7 Store Keeper (SK)

6.0 EQUIPMENT:

7.0 PROCEDURE

7.1 Safety

· Ensure only trained persons shall operate the power tools.

· Ensure all concerned personnel shall use PPE (Personal Protective Equipment) and all other items as required.

· Ensure adequate lighting is provided in the working area whenever required.

· Ensure service area/work area openings are provided with barricade, tape, and safety nets.

Ensure that all people engaged in the Installation of Fire Pumps are experienced & have received proper & adequate training related to the activity.
Access to the work area shall only be permitted when an assistant is available & work permit has been issued to perform such activity.

7.2 INSTALLATION PROCEDURE

Move the assembled Pump set in the common base frame to the Pump Room. Fork lift will be used for shifting the pump sets to the Pump Room.

Mark the location of Anchor Bolts as per the Approved Drawings. Only approved Anchor Bolts shall be used. Rubber pad shall be provided between the plinth & base frame for vibration isolation.
After the anchor bolt holes have been located, check to ensure that they match pump bolting position. Then fix the anchor bolts as per manufacturer’s recommendations.

When anchor bolts are inserted in the bolt holes on the plinth, position the pump set on the plinth with rubber pads in between. Chain block of adequate capacity will be used for the same.

Connect the suction & discharge piping to the pump set header as per the approved shop drawings.

Connect the piping between the pump headers to the pressure switches as per the manufacturer’s recommendations.

Connect Exhaust pipe from the diesel engine up to the discharge point as per the approved shop drawings.

Complete electrical & BMS connections to the control panel & from the control panel to the pumps as applicable to the project specifications & manufacturer’s recommendations.

After work completion, inspection will be raised for consultant’s approval & recommendations.

7.3. TESTING & COMMISSIONING PROCEDURE

7.3.1. PRE-START UP

7.3.1.1 Visual inspection shall be done for the oveall pump assembly.

7.3.1.2 Ensure that there is no visible signs of cracks, damages or rust on the pumps.

7.3.1.3 Ensure that all mechanical & electrical installation has been done according to the approved shop drawings & manufacturer’s recommendations.

7.3.1.4 Ensure that pumps assembly base are securely anchored with foundation bolts on the concrete floor.

7.3.1.5 Ensure that pumps assembly base is grouted sufficiently to absorb any vibration.

7.3.1.6 Ensure that pumps assembly base level & aligned with all connecting piping.

7.3.1.7 Ensure that pumps rotates freely when turned by hand.

7.3.1.8 Ensure that pumps are installed in the proper direction of flow in relation to the system and the suction & discharge.

7.3.1.9 Suction & discharge piping supports with rigid stand independent of the pump assembly.

7.3.1.10 Eccentric reducer installed on the pump suction side.

7.3.1.11 OSY gate valve installed on the suction side of the pump.

7.3.1.12 Control Valve & Check valve installed on the pump discharge line.

7.3.1.13 Ensure that the following are installed properly & correctly:

Casing relief valve before check valve.
Drain pipe for stuffing box.
Automatic air release valve.
Compound vacuum suction gauge.
Discharge gauge.
Pressure relief valve for diesel pump.

7.3.1.14 Sensing lines are connected to their respective controllers.

7.3.1.15 All motors and control wirings are connected.

7.3.1.16 Water tank & Diesel tank is filled.

7.3.1.17 Battery filled with acid.

7.3.1.18 Oil level in engine crank case is verified.

7.3.1.19 Engine cooling system is filled with coolant.

7.3.1.20 Cooling water inlet & outlet are connected.

7.3.1.21 Cooling loop waste outlet is piped to drain.

7.3.1.22 Exhaust pipe is connected.

7.3.1.23 Fuel line is properly connected to the engine.

7.3.1.24 Air inlet filter is installed in the engine.

7.3.1.25 Fresh air supply is adequate for engine combustion and room ventilated.

7.3.1.26 Flow meter is installed with two butterfly valves before and fter.

7.3.2 SEQUENCE OF OPERATION

ELECTRIC PUMP:

A.1. Open suction valves.

A.2. Check that pump is full of water and that all air contained in the pump been escape through the air release valve.

A.3. Compress packibng evenly with gland (hand tight).

A.4. Lower setting of pressure switch to prevent pump from starting.

A.5. Check incoming voltage for all phases.

A.6. Place islotaor and breaker in “ON” position & check “Power ON” light is illuminated.

A.7. Press start the stop to check the direction of rotation and adjust.

A.8. Bleed the system to create pressure drop.

A.9. When the pump start, check if full load current value is within the electric motor name plate rating.

A.10. Check packing adjustment to obtain slight leak.

A.11. Stop the pump & allow jockey pump to pressuring the system again.

B. DIESEL PUMP:

B.1. Open suction valves.

B.2. Check that pump is fill of water and that all air contained in the pump been escape through the air release valve.

B.3. Compress packing evenly with gland.

B.4. Close the pressure relief valve using maximum spring pressure.

B.5. Lower setting of starting pressure.

B.6. Start engine manually on either battery.

B.7. Adjust relief valve to open at tested pressure of the system.

B.8. Stop engine and open system valve.

B.9. Bleed the system to create pressure drop.

B.10. When the pump start check the following:

Engine Speed.
Oil pressure
Fuel Pressure
Abnormal noise or vibration
Cooling water drain

B.11. Check packing adjustment to obtain slight leak.

B.12. Stop the pump by putting selector switch “OFF” Position and allow jockey pump to pressurize the system again.

7.3.3 FLOW TEST

ELECTRIC PUMP

A.1. Close system valve.

A.2. Open gate valve for flow meter discharge valve & keep buttrfly valve after flow meter fully close.

A.3. Press start button to start the pump.

A.4. Adjust flow by butterfly valve after the flow meter.

A.5. Take suction & discharge pressure and ampere readings at shut off rated, 150% of rated flowand another intermediate flow.

A.6. Plot the pump curve and match it with the factory test curve.

DIESEL PUMP

B.1. Close the system valve.

B.2. Open gate valve for flow meter discharge valve & keep butterfly valve after flow meter fully close.

B.3. Press start button to start the pump.

B.4. Adjust flow by butterfly valve after the flow meter.

B.5. Take sectional discharge pressure and RPM of the engine at shut off, rated, 150% of the rated flow and another intermediate flow.

B.6. Plot the pump curve and match it with the factory test curve.

7.3.4. AUTOMATIC OPERATION

7.3.4.1 Open system valve & turn all isolating valves to the fully open position.

7.3.4.2 Set pressure switches to the following setting valves:

All fire pump stop pressure = fire pump shut off pressure + minimum suction pressure.
Jockey pump start pressure = stop pressure – 10 psi
Electric pump start pressure = jockey start pressure- 5 psi
Diesel pump start pressure = electric pump start pressure- 10 psi

Use 10 psi for each additional pump

The final pressure should not exceed the pressure rating of the system.

7.3.4.3 Place all switches for all control panels to the auto mode.

7.3.5 CONTROL PANELS

Control panels are designed to operate by three methods as follows:
Automatic Mode
Manual Mode
Emergency Start

7.3.5.1 Automatic Mode

In case of any pressure drop in line due to hose reel, fire hose, sprinkler opening or any small leak in the lines & or if the pressure reach to the cut-in- pressure point for the jockey pump it will start automatically and stop automatically at cut-off pressure. If the jockey pump couldn’t maintain the pressure in the system & pressure drop to cut-in pressure of the duty pump it will start automatically & stop manually or automatically after 10 minutes if the pressure reached to the cut-off point.
In case of electric supply failure or mechanical failure of the electric pump, then the diesel engine pump will start automatically when the pressure in the system reach to cut-in pressure of the standby pump and it should stop manually from the control panel after assuring there is no requirement of fire pump to keep running or automatically after 30 minutes if the pressure reached to the cut-off point.

7.3.5.2 Manual Mode

In case of emergency, the pumps can run in manual mode function for jockey pump by placing selector switch in “hand mode”. Electric pump by depressing the “start” push button and diesel pump it can start either from control panel or engine itself by putting selector switch in “Manual” mode and depressing “crank push button” for a few second (3-4 second only just to reach firing condition of the engine) or from the engine instrument panel. All pumps should stop manually if run in manual mode by returning switch to OFF position or depress stop push button.

7.3.5.3 Emergency Start

In case of any problem in the control circuit of Electric & Diesel Controller, fire pumps can run through emergency start handle to mechanically close the contactor.