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FIREPUMP ARRANGEMENTSAT INDUSTRIALFACILITIES
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FIREPUMP ARRANGEMENTSAT INDUSTRIALFACILITIES
ThirdEdition
DENNISP.NOLAN
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Notices
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ListofTablesxv AbouttheAuthorxvii
Preface xix
Acknowledgmentsxxi Notice xxiii Introductionxxv
1.HistoricalApplicationsofFirewaterPumpingSystems1 AncientWaterPumps1 ReciprocatingHandandSteamDrivenFirePumps3 RotaryPumps4 InventionofCentrifugalPump4 ModernFirePumps5 MunicipalWaterPumpingPlantsandMains6 OffshoreFacilities9
2.PhilosophyofProtection11 ProtectionOptions11 RiskAssessments15
3.FirewaterFlowRequirements17 RiskAreas19
ExposureCoolingRequirements20 FireControlRequirements20 SuppressionRequirements20 EgressWaterSprays21 ResidualPressureRequirements21
4.DurationofFirewaterSupplies23 CapabilityofPublicWaterMains23
5.SourcesofFirewaterPumpSupply29 SeasandOceans30 Rivers,Channels,Ponds,andLakes30 WaterWells(NaturalUndergroundReservoirs)31
6.PumpTypesandApplications45
7.PumpInstallation,PipingArrangements,andAccessories67
CheckValves89
AirReleaseValve89
SupervisionofIsolationValves90
InletScreens,Strainers,andFilters90 SubmergedPumpIntakeOpenings92
Cavitation,NetPositiveSuctionHeadandVortices93
WaterHammerorSurge94
PumpingSystemHydraulicDesign96 VibrationLimitation97
FireSprinklerProtection100
8.MaterialsofConstruction103
9.PumpDriversandPowerTransmission109
EngineStartingSystems118
StartingBatteries119
EngineCoolingSystem120
EngineExhaustSystem120
AirSuppliesandVentilation122
InstrumentPanel123
SteamTurbine123
PowerTransmissionOptions124
DriverPumpCoupling125
RightAngleGearDrives125
Lineshafts129
IndirectHydraulicDrive130
AcousticalConcerns134
MaintenanceAccess135
10.FirewaterPumpControllers137
FirewaterPumpControllers138
DieselEngineFirewaterPumpControllers139
ElectricMotorFirewaterPumpControllers140
ControllerPowerSupplies140
DualPowerSourceControllers140
AutomaticTransferSwitches141
RemoteAlarmandShutdownPanelsforFirePumpControllers141
LowSuctionPressureCut-Off141
JockeyPumpControllers142
FoamPumpControllers142
ControllerListingorApproval142
MultipleFirewaterPumpInstallations143
AutomaticActivation143
FiremainPressureSwitchActivation143
RemoteActivation144
LocalActivation144
StartupAttempts144
ColorCodingofPanelIndicators145
PipingandInstrumentationDiagrams145
ControllerIndicators146
First-UpFaultFeature147
CauseandEffectsCharts149
FirewaterPumpShutdown150
SpecializedInstallations151
ControllerLocationandAccessRequirements151
Facility/PlantElectronicMonitoringofFirePumps152
11.Reliability153 FailureCategories154
InsuranceIndustryExperience154 FaultTreeAnalysis155
RelianceonCommercialElectricalPowerSources160
12.ClassifiedAreaPumpInstallations161
DieselEngineIgnitionHazards162 PrimaryIgnitionHazards162
SecondaryIgnitionHazards163 HotSurfaces163
HotExhaustGases164
ExhaustSystem(Muffler)164
ExhaustSystemSparkorFlameDischarge165
EngineOverspeeding165
FlashbackinAirIntake166 MaterialSelection166
RatedInstrumentationandElectricalHardware167 DecompressionPorts167 ElectricMotors167 Controllers167
13.FirewaterPumpAcceptanceandFlowTesting169 SafetyPrecautions170 FactoryAcceptanceTest171
SiteAcceptanceTestandCommissioning172
PumpCurveTestPoints174
FuelExamination177
14.HumanFactors,QualityControl,andAudits185 HumanFactors185 Identification185 Painting186 FlowArrows186 StartingInstructions187 Access187 Guards188 EnvironmentalandHealthFactors(e.g.,NoiseLevels)188 EmergencyandPrefirePlans189 Documentation189 Training191 Security191 QualityControl191 ReportingandInvestigatingFirePumpFailures194 CompanyInspections/AuditsandInsuranceSurveys194 ImplementingandTrackingRecommendationsforImprovements194 RecentMajorIncidentsWhichFirePumpFailuresWereContributingCause195 InternationalStandardsRelatedtoFirePumps195
AppendixA:SelectedMajorIncidentsAffectingthePerformanceofFirewater PumpingSystems197
AppendixB:PurchaseData/SpecificationSheet201 Acronyms205 Glossary209 Bibliography213 Index 217
LISTOFFIGURES
Figure1.1Basicreciprocatingpumpofantiquity2
Figure6.1Horizontalshaftpumpfirepumptypes49
Figure6.2Verticalshaftfirepumptypes50
Figure6.3Characteristicfirewaterpumpcurve55
Figure6.4Foampumpinstallationschematic60
Figure6.5Foampumpinstallationschematic61
Figure7.1Typicalarrangementofseveralfirewatersuppliestoan industrialfacility 76
Figure7.2NFPAhorizontalpumpinstallationfromstoragetank82
Figure7.3Typicalpumppipingarrangements84
Figure9.1Typicalfirewaterpumprightanglegeardrive128
Figure9.2Diesel-drivenlineshaftpumparrangement129
Figure9.3Hydraulicpumpsystemschematic131
Figure9.4Exampleofhydraulicfirewaterpumpsystem132
Figure9.5Hydraulicfirewaterpumpsystemarrangements133
Figure9.6Hydraulicdriverarrangements135
Figure9.7Hydraulicdriverarrangements136
Figure10.1Firewaterpumpcontrollers.(A)Typicaldieselengine firepumpcontroller,(B)Electricalfirepump controller,and(C)Dieselenginecontrollerpanel withlampdisplay 139
Figure10.2TypicalP&IDforoffshorefirewaterpumpinstallation146
Figure11.1Firewaterpumpingsystemfailuremodes156
Figure11.2Flowchartoffirewaterpumpfailures157
Figure13.1Factoryboreholepumptestingarrangements172
Figure13.2Firepumpperformancetestreport175
Figure13.3Firepumpperformancetestreport176
Figure13.4Weeklyfirepumptestsampleform—page1180
Figure13.5Weeklyfirepumptestsampleform—page2181
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LISTOFTABLES
Table4.1Firewaterduration24
Table4.2SurveyofNFPAFireCodesforfirewaterdurations25
Table4.3Surveyofindustrydurationrequirements26
Table7.1FirepumpcomponentstobelistedperNFPA70
Table7.2ULteststandardsforlisteddevices71
Table7.3Comparisonofhorizontaltoverticalsplitcasepumps72
Table7.4Commonspacingdistancesforfirewaterpumps74
Table7.5Atmosphericpressureversusaltitude93
Table8.1Commonfirewaterpumpmaterials107
Table9.1NEMAenclosureclassifications112
Table9.2Pumpdriverfueldurationrequirements116
Table9.3Pump/driverconfigurationoptions125
Table9.4Shaftrotationoptionsforrightanglegeardrives127
Table9.5Comparisonofoffshorepumpdrivers134
Table10.1Dieselenginecontrollerindicators148
Table10.2Causeandeffectschart—firewaterpumpstartup149
Table11.1Failurecausesofcontrolsystem-relatedaccidents160
Table13.1Factoryacceptancetestsandverifications171
Table13.2Comparisonsofpumptestrequirements174
Table14.1Documentsubmittalsandapprovals192
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ABOUTTHEAUTHOR
DennisP.Nolanhasa40-yearcareerdevotedtoriskengineering,fire protectionengineering,losspreventionengineering,andsystemsafety engineering.HeholdsaBachelorofScience(BS)degreeinFire ProtectionEngineeringfromtheUniversityofMaryland,aMasterof Science(MS)degreeinSystemsManagementfromFloridaInstituteof TechnologyandaDoctorofPhilosophy(PhD)DegreeinBusiness AdministrationfromBerneUniversity.HeisalsoaUSregisteredFire ProtectionEngineeringProfessionalEngineerintheStateofCalifornia.
HeiscurrentlyassociatedwiththecorporateFirePrevention EngineeringstaffoftheSaudiArabianOilCompany(SaudiAramco), locatedinDhahran,SaudiArabia.Thisoperationalsocontainsthelargest oilandgasproductionandseparationfacilitiesintheworld.Themagnitudeoftherisks,worldwidesensitivity,andforeignlocationmakethis oneofthehighlycriticalHighlyProtectedRisk(HPR)operationsinthe world.HehasalsobeenassociatedwithBoeing,Lockheed,Marathon OilCompany,andOccidentalPetroleumCorporationinvariousfireprotectionengineering,risk,andsafetyroles.Thesepositionswereinseveral locationsintheUnitedStatesandoverseaslocations.Aspartofhiscareer, hehasexaminedoilproduction,refining,andmarketingfacilitiesinvarioussevereanduniqueworldwidelocations,includingAfrica,Asia, Europe,theMiddleEast,Russia,andNorthandSouthAmerica.His activityintheaerospacefieldhasincludedengineeringsupportforthe NASASpaceShuttlelaunchfacilitiesatKennedySpaceCenter,those undertakenatVandenburgAirForceBase,California,andclassified“Star Wars”defensesystems.
Dr.Nolanhasreceivednumeroussafetyawardsandisamemberof theAmericanSocietyofSafetyEngineers.HewasamemberoftheFire ProtectionWorkingGroupoftheUKOffshoreOperatorsAssociation (UKOOA),NationalFireProtectionAssociation(NFPA),Societyof PetroleumEngineers(SPE),andtheSocietyofFireProtectionEngineers (SFPE).Heistheauthorofmanytechnicalpapers.Hehaswrittenfive otherbookswhichinclude SafetyandSecurityReviewfortheProcess Industries,ApplicationofHAZOP,PHA,What-IfandSVAReviews (1st, 2nd,3rd,and4thEditions), HandbookofFireandExplosionEngineering PrinciplesforOil,Gas,ChemicalandRelatedFacilities(1st,2nd,and3rd
Editions), EncyclopediaofFireProtection,(1st,2nd,and3rdEditions), LossPreventionandSafetyControl,and AppliedOperationalExcellenceforthe Oil,GasandProcessIndustries (coauthor)whicharebothwidelyreferred towithinthepetroleum,chemical,andotherindustries.Dr.Nolanhas alsobeenlistedin Who’sWhoinCalifornia forthelasttenyearsandalso appearsinthe16thEditionof Who’sWhointheWorld.
PREFACE
Thisbookdescribesfixedfirepumpinstallationsforindustrialfacilities fromtheviewpointoftheendusers,fireprotectionengineers,losspreventionprofessionals,andthosejustenteringacareerinwhichdecisions aboutfirepumpinstallationsmustbemade.Therefore,muchbackground informationisgivenforthenecessaryrequirementsandusefulnessofa firepumpandtheservicesthatinterfacewithit.
Itisassumedthatthereaderisgenerallyknowledgeablewithhydraulicsforpumpsandpumpingsystems;therefore,thisbookisnotconcernedwiththosedetaileddesignmathematicalcalculationaspects.Many excellentreferencebooksareavailablewhichprovideadequateguidance inthedesignoffirewaterinstallationstocalculatewaterflow,pressureand otherhydraulicfeaturesandconcernsassociatedwithfirepump installations.
Thisbook’sprimaryobjectiveistheprovisionofpracticalinformation andbasicbackgrounddesignprinciplesontheapplicationoffixedpumps forfirefightingpurposesatindustrialfacilities,bothonshoreandoffshore. Wherespecificdetailsarenecessaryandpertinenttothediscussionthey areprovided,otherwise,thesecanbefoundfromtheapplicablefirecodes andengineeringpracticestobeappliedtothefacility.Experiencefrom theinstallationoffirepumpsinthepetroleumandchemicalindustries, historicaldata,manufacturer’sspecificationsheets,regulatorycode requirements,andhistoricalincidentsrelatedtofirepumps,havebeen drawnuponforthepreparationoftheinformationinthisbook.
Allfirewaterpumpinstallationshouldmeettherequirementsoflocal ordinancesandapplicablefirecodesforthefacility.Thisbookdoesnot intendtoreplaceorsupplementthelegalrequirementsofthosedocumentsandtherequiredresponsibilitytomeetthemrestwiththeowner ofthefacility.
CustomaryU.S.pumpindustrypracticeistoexpressallformsof energy,thatis,head,associatedwithcentrifugalpumpsintermsoffeetof liquid,whileforreciprocating,rotary,orpositivedisplacementpumpsthe practiceistoexpressitintermsofpressure(psi).Thisconventioniscontinuedinthisbook.
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ACKNOWLEDGMENTS
Gratefulacknowledgmentisduetothefollowing,fortheirassistanceor theuseoftheirmaterialinthisbook:
StevenChaloupka,AmarilloGearCompany;SandroPaliotti, ArmstrongDarling,Inc.;AuroraPumpCompany;JohnMcConnell, Chemguard,Inc.;LouisSotis&PamelaJ.Munslow,FactoryMutual (FM);R.V.Stanford,Lloyd’sRegisterofShipping;WarrenE.HillIII, Metron,Inc.;RuneOsmundsen,FrankMohnFlatoyAS;Dennis J.Berry,NationalFireProtectionAssociation(NFPA);HowardCollins, OccidentalPetroleumCorporation;DarrellSnyder,PattersonPump Company.
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Reasonablecarehasbeentakentoassurethatthebook’scontentis authentic,timely,andrelevanttotheindustrytoday;however,norepresentationorwarrantyismadetoitsaccuracy,completeness,orreliability. Consequentially,theauthorandpublishershallhavenoresponsibilityor liabilitytoanypersonororganizationforlossordamagecaused, orbelievedtobecaused,directlyorindirectly,bythisinformation. Inpublishingthisbook,thepublisherisnotengagedinrenderinglegal adviceorotherprofessionalservices.Itisuptothereadertoinvestigate andassesshisownsituations.Shouldsuchstudydiscloseaneedforlegal orotherprofessionallegalassistancethereadershouldseekandengage theservicesofqualifiedprofessionals.
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INTRODUCTION
PhotocopyrightPattersonPumpCompany,reprintedwithpermission
TYPICALFIREWATERPUMPINSTALLATION
Numerousunexpectedfiresoccureveryyearandcausedamage amountstoseveralbillionsofdollars.Fortunately,mostofthesefiresare smallandeasilysuppressedbywaterapplication.Wateristheuniversal agenttocontrolandsuppressunwantedfires,beitasmallincidentora largeindustrialconflagration.Watersuppressesfiresbyoxygendeprivation throughsmotheringandbyheatabsorption.Atotalof,3.8L(onegallon) ofwaterwillabsorbabout1512kcal(6000Btu),whenvaporizedto steaminafire.Itisthemostefficient,economical,andmostreadilyavailablecommodityforextinguishingfiresofageneralnature.
