ieee-ias 2012.02.18 presentation - fire pump engine controllers

Diesel Drive Fire Pump ControllersPrepared IEEE - IAS-by-

Jim Nasby – Columbia EngineeringSkokie, Illinois USA

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From a presentation to the

Chicago Fire Department Fire Prevention Bureau

Topics to be Covered1. Fire Pump - General2. Fire Pump Installation Elements - Overview3. Engine Drive Fire Pumps in General4. Diesel Drive Fire Pump Controllers5. Operating Margins

Fire Pump Installation Considerations

• Pressure Sense Lines

• Jockey Pump Relief Valve ?

• Engine Room Ventilation

• Pump House Heating

FirePumpControllerPressureConnection(PressureSense Line)

SeparatePressureSenseLines-for-EachPump

Fire Pump Driver Types• Diesel Drive -- U.L. & F.M.

– Fixed Speed– Variable Speed (Pressure Limiting) - PLD

• Right Angle Gear Drive• Vertical Engine (Stewart & Stevenson)

Models DCFRA & DCMRA – 1973 - 2008

Model DCM - 2008

Model DCM – Display Panel Prototype

Controller Enclosure TypesEnclosure TypesType 2 Indoor Only - Vertical Dripproof onlyType 3R Outdoor - Rain or Dripping water up to 45 degreesType 12 Indoor - Protection against dripping water and dust.Type 4 Outdoor - Protection against water, dust, & hosedown.Type 4X — Corrosion Resistant – Special Paint or Stainless SteelNote: Unofficial (J.S.N.) Designations: 4XA = Organic, 4XB = 304 S/S, 4XC = 316 S/S & 4XCL = 316L (Low Carbon) S/S.

Note: These Ratings are all useless unless:U.L. “Type” Labeled ("NEMA" Label is not meaningful) -and-Proper Conduit Hubs are used.

Common Controller Options - Functional

- Automatic Stop Timer Note: This is not allowed to be used, per NFPA-20, on “Sole Source Pumps”, nor by F.M. as a matter of course, even if present.

- Sequence Starting (Multiple Pumps)- Pump Lockout (Multiple Pumps)- Remote Start and/or Deluge Valve Start

Controller Options -for- Enhanced Fire Protection

- Pump House (Pump Room) Alarms- 5 Year Warrantee Models

- Space Heater and Humidistat- Better Types of Enclosures

Common Pump House Alarms- Low Pump Room Temperature Low- Low Fuel Level (Now Mandatory)- Main Relief Valve Open- Water Reservoir Low- Water Reservoir Empty- Flow Meter On- Other Tamper Alarms

Enhanced (Digital) Pressure and Alarm Recorders

Better Controllers Include

- 4 x 40 (160) Character Display- Separate Pressure and Alarm Memories*- At least 2,000 pressure readings stored- At least 300 Alarm Events stored- Front Panel Access to All Data -and-- No Passwords to Access Data- No Paper, Floppy Disks, etc.- Read Pressure 3 Times per Second- Use Data Reduction for More Storage

* So that Alarm Event Data doesn’t over-write Pressure Data and vice versa.

Typical Paperless (Digital) Recorder Panel

M.C.S. Model PR4001 Recorder

Typical PR4001 Recorder Pressure Plot

Expanded, showing 137 out of 4095 total points (7 hours).

Where is the glitch?

Typical PR4001 Recorder Pressure Plot

Expanded, showing 90 out of 4095 total points (1-3/4 hours).

See the glitch?

Typical PR4001 Recorder Pressure Plot

Expanded further, showing 46 out of 4095 total points (232 Sec.)

Shows that Pump was cavitating.

SIX Automatic Start Attempts

NFPA Requirements - Cont'd

- The controller does SIX Automatic cranks and Five Rests of 15 Seconds each on alternate battery banks.- After the 6th Crank, controller signals Failure to Start Alarm.-If one battery bank fails, the controller Cranks using the Other Battery Bank for All Remaining Cranks.

24 Hour Recharge Time

NFPA Requirements - Cont'd

The battery chargers are required to:

- Charge 100% of both battery banks’ ampere hour capacity in 24 hours

- Avoid Battery Boiling- Reduce to ½ Amp or Less into Battery

- Chargers are a major differentiator among controller manufacturers.

Engine will be "Run to Destruction"

Engine is Sacrificial

Engine is NOT protected from:- Low Oil Pressure -or-- High Water Temperature, Except during testing.

- E.G.: It will run to destruction under fire demand.

- Shutdown only on: - Overspeed (Imminent Destruction) - Failure to Start

• Pressure switch starting -or-

• Pressure Transducer & Circuitry (This also differentiates mfr's.)

• Pressure recorder on the pressure sensing line.

• Weekly test by pressure drop

– Weekly Test Timer

– Drain (Test) Solenoid Valve

NFPA Requirements - Cont'd (for pressurized systems)

• Auto On

• Low Oil (LOP)

• High Water (HWT)

• Failure to Start (FTS)

• Low Fuel (LFL)

• Overspeed (OVS)

• Low Eng. Temp.**

NFPA Requirements - Cont'd

• Battery No. 1 Failure (B1F)

• Battery No. 2 Failure (B2F)

• -or- Low Air or Hydraulic Pressure *

• Charger Failure

• ECM Alarms (2 alarms) *

• Overpressure *

* Some Engines

Visual Indication and Common Audible Alarm for and Common Alarm Contacts for:

** Added in NFPA-20 2010.

• Engine Run

• Switch Off

• Engine Failure Consisting of:

– the Above Listed 9 (up to 12) Signals

– Optional Pump House Trouble Alarms

–F.M. Required Additional Alarms• Weekly Test Enabled

• Loss of Battery Power (B1F and B2F)

NFPA Minimum Required ContactsRemote Alarm Contacts for:

Other Diesel Controller Options- Power Failure StartingPower Failure Starting

- Keep Pump Room warm -or-Keep Pump Room warm -or-- Charge Battery(s) -or-Charge Battery(s) -or-- For risks with high temp. processesFor risks with high temp. processes

- RecorderRecorder- Additional AlarmsAdditional Alarms- Low Suction Shutdown (Ohio)Low Suction Shutdown (Ohio)

Note: “Interlocking” (Lockout) is a common option on both diesel and Motor Drive Controllers, even though prohibited by NFPA-20.

Typical D.F.P.C. RatingsNameplate

Operating Margins (Parameters)• A.C. Voltage Margin +/- 10%

(105 to 130 Vac ) Minimum for best results.

• High D.C. Voltage Margin: +25% (15 / 30 Vdc) Minimum for Continuous Thermal and Circuit Reliability (Typical Alternator Output or Ni-Cad Equalize Voltage)

• Low D.C. Voltage Battery Margins (Assume Single Battery Operation, E.g.: One Battery Dead or Missing):– 9 / 18 Vdc Cranking (3/4 of Nominal)

– 6 / 12 Vdc Breakaway (1/2 of Nominal) for at least ½ Second

Questions ?