CENTRIFUGAL FIRE PUMPS

SEPTEMBER 1992

PAGE 1 OF 39

EGE 15-B-23 1992

TABLE OF CONTENTS 1. 2. 3. 4. Scope References General Design 4.1 Horizontal Pumps and Jockey Pumps 4.2 Vertical Multistage Pumps 4.3 Skid- or Trailer-Mounted Pumps 5. Drivers 5.1 General 5.2 Motors 5.3 Diesel Engines 5.4 Steam Turbines 6. Accessories 6.1 Controls and Instrumentation 6.2 Piping 6.3 Mounting Plates 6.4 Painted Surfaces 6.5 Nameplates 7. Inspection and Testing 7.1 Inspection 7.2 Testing 8. Preparation for Shipment 9. Vendor Data 9.1 General 9.2 Proposal Data 9.3 Contract Data 9.4 Data Book

1. SCOPE This Guide covers basic requirements for the design, fabrication, and performance of horizontal and vertical shaft, single- and multistage centrifugal fire pumps, drivers, and controls, including stationary, skid-mounted, and trailer-mounted pumps. 2. REFERENCES The following publications form a part of this Guide. Unless otherwise specified herein, use the latest edition.
Mobil Engineering Guides EGE 00-B-5 EGE 00-C-4 EGE 15-B-15 EGE 15-B-7 EGE 15-D-23 EGE 16-B-30 EGE 33-B-8 EGE 33-B-9 Equipment Sound Levels Equipment Purchasing General Engineering Requirements General-Purpose Internal Combustion Diesel Engines General-Purpose Steam Turbines Centrifugal Fire Pump Data Sheet Piping Selection and Application of Piping Components and Materials (With Classification Sheets and Appendix) Electrical Motor Control Electrical Induction Motors

ANSI (American National Standards Institute) Standards

MOBIL ENGINEERING GUIDE EGE 15-B-23 1992

B1.1 B1.20.3 B16.1 B16.5 Unified Inch Screw Threads Dryseal Pipe Threads Cast Iron Pipe Flanges and Flanged Fittings Pipe Flanges and Flanged Fittings
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NFPA (National Fire Protection Association) Publications 20 70 1901 1963 Installation of Centrifugal Fire Pumps National Electric Code Pumper Fire Apparatus Screw Threads and Gaskets for Fire Hose Connections

SAE (Society of Automotive Engineers) Standard J1349 Engine Power Test Code

3. GENERAL 3.1 Equipment shall be furnished according to the following: (a) (b) (c) (d) The requirements of this Guide. The purchase order. The attached Data Sheets. The publications in the Reference Section of this Guide.

When local requirements are more stringent, they shall take precedence over the requirements in this Guide. 3.2 Centrifugal fire pumps and drivers shall meet the requirements of NFPA 20 and NFPA 1901, except as modified herein. The pumping units shall be listed for fire pump service by Factory Mutual (FM) or Underwriters Laboratory (UL). Approval and certification are not required unless specified on the Data Sheet. Mobil Technology Company and the Facilities Group should be contacted concerning testing laboratories located outside the United States. 3.3 Equipment shall be suitable for installation and operation in the local environment and hazardous areas as specified on the Data Sheets. 3.4 The equipment shall meet applicable sound levels as specified on the Data Sheets and in EGE 00-B-5.

3.5 Each pump shall be suitably furnished for installation in either a fixed operation or a mobile operation as defined on the Data Sheet. 3.6 Major parts such as casing components and bearing housings shall be designed (shouldered or doweled) and manufactured to ensure accurate alignment on reassembly. The mating faces of the pump casing to the bearing housing assembly shall be fully machined. 3.7 The pump design shall provide hydraulic axial balance at all speeds and pressures. The thrust bearing shall be designed to support the load at all points on the head-capacity curve from shutoff to runout flow requirements (assuming continuous operation). 3.8 Threads for bolts, screws, and nuts shall conform to ANSI B1.1.

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3.9 The pump shall be designed to operate safely at the maximum peak speed of the driver according to Section 5 of this Guide. 3.10 3.11 The rated capacity for pump selection shall be within 10% of the best efficiency point. Stable head-capacity curves gradually rising to shutoff are required (see Figure 1).

3.12 The casing shall include a means to facilitate the disassembly of the casing and the stuffing box cover (if provided), such as tapped holes for jackscrews. The use of wedges as pry bars is not acceptable. 3.13 The minimum dimensions of the passages at the periphery or at any point in the impeller shall be as follows:
TABLE 1 MINIMUM INTERNAL CLEARANCE FOR PARTICLES Passage Size mm 8 13 16 in.
5/16 1/2 5/8

Pump Capacity m/h 114 114 to 170 170 US gpm < 500 500 to 750 > 750

3.14 The repair of leaks and defects in pressure castings by peening or plugging, or by the use of plastic or cement compounds, is prohibited. Cast iron shall not be repaired or welded. 4. DESIGN 4.1 4.1.1 Stationary/Horizontal Pumps and Jockey Pumps General

(a) Stationary pumps shall be of the type specified on the Data Sheets and shall be horizontal, single-stage pumps of split case, end suction, or in-line designs. Single-stage, end suction, and in-line pumps shall be limited to capacities under 1892 L/min (500 gpm). Capacities of 1892 L/min (500 gpm) or higher require a double-suction between-bearing pump. (b) Rated pump capacities shall be as specified by NFPA 20. Figure 1 defines the acceptable parameters relative to the curve shape. (c) Jockey pumps for pressure maintenance shall be of the overhung, single-stage, and centrifugal design.

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NOTE: Listed pumps can have different head-capacity curve shapes for a given rating. Figure 1 illustrates the extremes of the curve shapes. Shutoff head will range from a minimum of 110 percent to a maximum of 140 percent of rated head. At 150 percent of rated capacity, head will range from a minimum of 65 percent to a maximum of just below rated head.

FIGURE 1 PUMP CHARACTERISTICS CURVES

(d)

Jockey pumps shall be furnished mounted on rigid baseplates.

(e) Jockey pumps shall be driven by a horizontal electric motor, unless otherwise specified on the Data Sheets. (f) Where jockey pumps are provided, the minimum size shall be capable of making up the allowable system leakage rate within 10 minutes at a pressure equal to the desired firewater static system pressure. The minimum rated capacity for the pump/driver design shall be 5.7 m/h (25 US gpm). (g) (h) 4.1.2 The driver for jockey pumps shall be rated for continuous operation. Horizontal pumps shall not be specified for systems that require a suction lift. Casings

(a) Flanged connections shall conform to the structural and dimensional requirements of ANSI B16.1 or B16.5, as applicable. Cast iron flanges shall be flat faced and of a minimum thickness equivalent to a 250-pound rated flange. Supplier's standard flanges that are thicker or larger in diameter are acceptable if they are faced and drilled to conform to the required ANSI standard. Suction and discharge nozzles shall be drilled for bolts. Tapped stud holes are not acceptable.

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(b) Suction and discharge flanges shall each have the same rating to permit hydrostatic pressure testing of the entire casing. (c) Pumps shall be equipped with an auto-venting device and connection, unless they are self-venting. Tapped connections for vents, drains, or gages shall be a minimum of NPS 3/4 (NPS = nominal pipe size, inches) and shall be valved. Threaded connections shall be as specified by ANSI B1.20.3. (d) 4.1.3 All pumps except jockey pumps shall have double volutes. Wear Rings

Casings shall be furnished with tongue-and-groove fitted, renewable wear rings. 4.1.4 Impellers

(a) Impellers shall be closed, dynamically balanced, and of one-piece construction. Impellers shall be keyed to the shaft. (b) Balancing of the impeller shall be accomplished by metal removal. The addition of weight is not acceptable. The maximum allowable residual unbalance per plane shall be calculated as follows:

U = 4 W/N Where:
U W N (c) 4.1.5 = maximum component and assembly unbalance (ISO 6.3 as a minimum). = weight of part (lb/kg). = maximum rotating speed (rpm).

Impellers shall be individually secured against axial movement in either direction along the shaft. Shafts and Shaft Sleeves

(a) Shafts shall be designed to transmit full driver output torque during starting. Shaft deflection in the stuffing box area shall be limited to 0.0508 mm (0.002 in.) while operating throughout the entire operating range. (b) Hard faced shaft sleeves are required on all packed pumps in the stuffing box area, and on pumps with shaft diameters exceeding 35 mm (1.37 in.). (c) Shaft sleeves shall be locked or keyed, made of corrosion-erosion resistant material, and replaceable. Sleeves shall be sealed at the inner end, machined, and assembled for concentric rotation. Sleeve ends shall extend 3 mm (1/8 in.) beyond the outer face of the packing or the seal gland. (d) 4.1.6 (a) (b) Horizontal pumps shall have a cylindrical fit at the coupling end. Bearings Bearings shall be oil lubricated. Ring-oiled hydrodynamic-sleeve radial bearings shall be required under any of the following

MOBIL ENGINEERING GUIDE EGE 15-B-23 1992 conditions: (1) For "between bearings" pumps where DN factors are 300,000 or greater. (DN = Diameter in inches x revolutions/minute.) (2) Where antifriction radial bearings fail to meet the minimum AFBMA L-10 rating life of three years or 25,000 hours. (AFBMA = American Federation of Bearing Manufacturers.) (3) (c) Where the driver-rated kW is 300 (400 hp) or greater.
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Each bearing housing shall be provided with: (1) (2) (3) A constant level oiler, 118 ml (4 fl oz), secured to the bearing housing. A housing drain plug with a visible water trap to remove condensation from the oil sump. A top-mounted vent.

(4) A permanent indication of proper oil level, accurately located at the required oil level line, and clearly marked on the outside of the bearing housing adjacent to the constant-level sight-feed oiler. An oil level tag that locates the proper oil level by field measurement below the shaft centerline is not acceptable. (d) Bearing or lubricant temperatures shall not exceed 82C (180 F) at any operating or ambient condition. (e) Sleeve bearings shall be arranged to permit shaft vibration measurements adjacent to the bearing, while the pump is operating. (f) Commercially available, two-piece labyrinth-type bearing isolators shall be used on all bearing housings. 4.1.7 Materials

Unless otherwise specified, pump materials shall be as specified by Table 2.

TABLE 2 PUMP MATERIALS (Horizontal Pumps and Jockey Pumps) Materials Casing Impeller Wear rings Shaft Shaft sleeve Gland Packing Elastomer Fresh Water Cast iron Bronze Bronze 18-8 Stainless or Monel K-500 Bronze Bronze Teflon-graphite fillament braided Viton Brackish/Salt Water Ni-Resist (ASTM A439 type D-2) NiAl Bronze (ASTM B148 type 958) Monel K-500 Monel K-500 Monel K-500 Monel or bronze Teflon-graphite filament braided Viton

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EGE 15-B-23 1992

4.1.8

Shaft Seals and Packing

(a) The stuffing box shall be of sufficient size to allow for installation of cartridge mechanical seals. All seals shall have viton elastomers, be a balanced design, and have carbon/silicon seal faces. (b) Glands shall be designed to ensure that the bolts are retained if the packing becomes loose. Studs that are screwed into the pump case are the preferred gland fastener. (c) The pump and seal shall be designed so that both the inboard seal and sleeve may be removed from the pump without removing the rotating assembly and without moving the pump. (d) An eccentric washer or equivalent reference point shall be provided on the seal plate and shall correspond to a groove or reference point on the sleeve for locating the seal. (e) Ample space shall be provided for packing or mechanical seal replacement. Packing glands shall be split. (f) Stuffing boxes on all packed pumps shall be provided with lantern rings and a tapped connection for flushing the packing. Tapped holes in the lantern ring shall be provided to facilitate removal. (g) Throat bushings shall be of the renewable type and designed so that they cannot be forced out by hydraulic pressure. If the stuffing box is at a higher pressure than the inside area of the casing, the throat bushing should be shouldered on the stuffing box side of the bushing. If the stuffing box is at a lower pressure than the inside area of the casing, the bushing shall be shouldered on the casing side. (h) Drains shall be provided to prevent liquid from collecting around bearing brackets.

4.1.9

Couplings

(a) Couplings shall be nonlubricated. They shall consist of forged steel hubs and spacers with stainless steel or Monel flexible elements. Disk material shall be suitable for the atmospheric environment. Carbon steel disks are not acceptable. (b) Spacer length shall permit removal of the pump rotor, the bearing brackets, or the mechanical seal without disturbing the driver. Minimum spacer length shall be 125 mm (5 in.). The rating of the coupling shall be equal to the maximum driver horsepower, including the service factor. The maximum operating torque load of the coupling shall be limited to 80% of the coupling manufacturers rating. (c) The hub bore and rim of the couplings shall be concentric within 0.0125 mm (0.0005 in.).

(d) Couplings shall be properly keyed in place. The coupling and shaft fits shall be designed according to the following:
TABLE 3 COUPLING AND SHAFT FITS (Horizontal and Jockey Pumps) Shaft Diameter at the Coupling

Interference Fit

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1.0 mil/in. of shaft diameter 0.5 mil/in. of shaft diameter

#50 mm (2 in.)
>50 mm (2 in.)

(e) For horizontal pumps driven by motors rated higher than 75 kW (100 hp) and for pumps driven by turbines, the pump supplier shall deliver a pilot-bored driver half-coupling to the driver manufacturers plant for final boring and mounting. (f) Corrosion-resistant, rigid, sparkproof, removable guards extending to within 13 mm (1/2 in.) of the stationary housings shall be provided on all moving parts that could be hazardous to personnel. Guards shall be provided around all flywheels. All bolting for the shaft guard shall be type 316 stainless steel with a minimum diameter of 10 mm (3/8 in.). Guards shall comply with OSHA standards or with applicable local safety codes, as specified. 4.2 4.2.1 (a) Vertical Multistage Pumps General Vertical pumps shall be furnished with open line shafts and water-lubricated bearings.

(b) Engine-driven pumps shall be driven through a right angle gear. Motor-driven pumps shall be directly coupled. (c) All vertical pumps with mechanical seals shall have a valved vent orifice connection on the seal chamber or shall have flush piping located to provide fluid at the seal face before startup. Orifice calculations shall be provided. The minimum orifice size shall be 3.2 mm (1/8 in.). (d) 4.2.2 The rated speed of vertical pumps shall be 1800 rpm or less. Column Pipe Assembly

(a) The pump length and submerged depth specified on the Data Sheet shall be as indicated in Figures 2A and 2B. (b) If the following conditions exist, column pipes shall not be fabricated in fiberglass: (1) (2) Length exceeds 20 m (65 ft). Internal pressure exceeds 1380 kPa gage (200 psig) at the last stage impeller discharge.

(c) Fiberglass columns shall be fabricated from heavy-wall, marine-grade pipe that has an internal lining in addition to the required external lining. The internal lining shall have a minimum thickness of 0.5 mm (0.02 in.). The external lining shall have a minimum thickness of 0.75 mm (0.03 in.). The internal and external linings shall be specified by the supplier. The supplier shall provide a list of his specific experience with this material in fire pump service. The column pipe design shall account for the linearity changes that will occur due to the following: (1) (2) (3) Pump shutoff pressure. Maximum water temperature. Minimum water temperature.

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(d) Column lengths shall be connected by flanges without gaskets. An insulating gasket shall be provided between the column pipe and the bowl assembly. (e) Bolting of the column pipe shall be by through-bolts with top and bottom washers and threads, as specified by ANSI B1.1. Only the top and bottom assemblies may be furnished with studs. The bolts shall be a minimum of 16 mm (5/8 in.) with a minimum of 12 bolts per flange. Two nuts shall be used. When installed, each bolt or stud shall be flush with the outer end of the nut, in order to avoid marine growth on threaded surfaces. (f) Where fabricated steel is specified, the column shall be Sch 80 pipe (ASTM A53, Grade B or ASTM A106, Grade B) with a flange minimum thickness of 28 mm (11/8 in.). Each section of column pipe shall be sandblasted to white metal and coated. All coated surfaces shall be tested for defects using a holiday pin hole detector. (g) Spider supports are required every 4.6 m (15 ft) of pump length between the column and the stilling tube. (h) A design analysis shall be made of all columns to verify their structural integrity and all vibrating frequencies. As an alternate, the vendor may cite proven experience with the proposed column size and length. 4.2.3 (a) Bowl Assembly The bowls shall be the bolted type with register fits to ensure alignment.

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FIGURE 2A APPLICABLE REFERENCES FOR PUMPS LENGTH AND SUBMERGED DEPTH

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EGE 15-B-23 1992

FIGURE 2B APPLICABLE REFERENCES FOR OFFSHORE ENGINE DRIVEN PUMPS LENGTH AND SUBMERGED DEPTH

MOBIL ENGINEERING GUIDE EGE 15-B-23 1992 (b) (c) 4.2.4 (a) (b) 4.2.5 (a)
PAGE 12 OF 39 SEPTEMBER 1992

Renewable bowl wear rings shall be furnished with an interference fit. The suction bell bearing shall be pressure-fed with water. Impellers The impellers shall be the enclosed type. Impellers shall be secured to the shaft by a key-and-split collar device with positive locking. Line Shaft The minimum shaft diameter shall be 38 mm (11/2 in.).

(b) The shafts shall have key-and-split ring couplings located a maximum of 300 mm (12 in.) from the column pipe flanges. (c) The shafts shall have cutless rubber bearings. The maximum allowable assembled shaft runout shall be 0.13 mm (0.005 in.) per 3 m (10 ft) of shaft length. (d) The bearings shall be supported in spiders machined to fit the register fit of the column pipe flanges. (e) The maximum bearing span shall be 3 m (10 ft).

(f) Shaft sleeves shall be furnished at the bearing location and at the packing or seal areas. Shaft sleeves shall extend to the packing seal gland area as required in Paragraph 4.1.5 (c) of this Guide. 4.2.6 Shaft Seals and Packing

Shaft seals and packing shall conform to Paragraph 4.1.8 of this Guide. 4.2.7 (a) (b) (c) Discharge Head The discharge head shall be the aboveground type. The discharge head bolting shall be a minimum diameter of 25 mm (1 in.). The head shall be equipped with the following: (1) (2) (3) (4) An ANSI B16.5, 150# RF discharge flange. A right angle gear or a motor attachment flange. A connection to the engine cooling loop (where applicable). A pressure gage.

(5) Two access windows and guards, located 90 degrees from the discharge centerline. Guards shall be of nonsparking material. (d) The head shall provide the entire support for the right angle gear or motor, column, line shaft, bowl, assembly, and strainer.

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(e) When steel is specified, the head shall be Sch 80 steel (ASTM A36 WP 275) that has been internally and externally coated. All coated surfaces shall be tested for defects, thereby confirming that they are free of holidays. (f) The stuffing box shall be removable and equipped with a high-pressure head and throat bushing. The stuffing box shall be insulated from the head with a micarta gasket. (g) The stuffing box shall have a register fit on the discharge head.

(h) Stuffing boxes subjected to discharge pressure shall have a bleedoff line to the suction side in order to reduce the differential pressure across the packing. 4.2.8 Materials

Pump materials shall be as specified by Table 4. 4.2.9 (a) Right Angle Gear The supplier shall provide a gear unit that is: (1) (2) (3) (4) (b) Factory Mutual (FM) approved. Right angled. Spiral bevel-geared. High efficiency. (5) (6) (7) Single-reduction. Totally enclosed. Designed with a vertical hollow shaft.

The reduction gear box shall be equipped with: (1) (2) A sprag-type nonreverse ratchet. A flanged coupling spacer for impeller adjustment. (3) (4) An oil sump temperature gage. A 90-10 Cu Ni cooling coil.

(c) The gear ratio shall be suitable for the rated speeds of the pump and the driver. Gears shall be designed to transmit the maximum power capable of being produced by the engine. (d) Gear boxes shall be furnished with a thrust bearing load rating that is equal to 125% of the weight of the rotating pump parts plus the hydraulic thrust, when operating at any point on the curve. Upthrust protection shall be provided for 150 percent of the calculated hydraulic thrust during startup. (e) The selected gear shall be based on using a maximum of 90% of the manufacturers published power rating for that gear. Gear boxes shall be rated for the driver nameplate rating, including any applicable service factors. Unless otherwise stated on the Data Sheets, the minimum gear service factor shall be 1.5.
TABLE 4 PUMP MATERIALS (Vertical Multistage Pumps) Materials Fresh Water Salt Water

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Pump Bowls Bushings Impellers Wear rings Shaft Bearings Bearing spider Column pipe

Cast Iron Bronze Bronze Bronze 18-8 stainless or Monel K-500 Cutless rubber Bronze *Carbon steel coated *Fiberglass: for example, Bondstrand 2000M *Stainless steel ASTM 316/316L 18-8 stainless or Monel K-500

NiAl bronze ASTM B148 type 958 NiAl bronze ASTM B148 type 958 NiAl bronze ASTM B148 type 958 Monel K-500 Monel K-500 Cutless rubber NiAl bronze ASTM B148 type 958 *Carbon steel coated *Fiberglass: for example, Bondstrand 200M *NiAl bronze ASTM B148 type 958 centrifugally cast Monel K-500

All bolts (including and gear head bolting) Strainer

18-8 stainless

NiAl bronze ASTM B148 type 958 or Monel K-500 Bronze ASTM B505 Grade C 93 700 Teflon-graphite braided *NiAl bronze ASTM B148 type 958 *Carbon steel (coated)

Stuffing box

Bronze ASTM B505 Grade C93 700 Teflon-graphite braided *Carbon steel (coated) *NiAl bronze ASTM B148 type 958 *Stainless steel ASTM 316/316L

Packing Discharge head

*As specified on the pump Data Sheet.

(f) Gears and gear bearings shall be arranged for oil lubrication. Antifriction bearings may be provided on gears below 110 kW (150 hp). (g) Gear box oil temperatures shall be a maximum of 82C (180F) at any operating or ambient condition. (h) When pressure lubrication is required or specified, the supplier shall provide a self-contained system complete with the following items: (1) (2) (3) (4) A shaft-driven oil pump. An oil cooler. An oil pressure regulating valve. A pressure switch that initiates an alarm that indicates low oil pressure.

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(5) (6) (7) (8) (9)

An oil pressure gage with a 113 mm (41/2 in.) face. All necessary piping and fittings of 316 L stainless steel. An oil sump temperature indicator. A common audible alarm (110 dB minimum). Indicator lights for alarms.

(i) Antifriction bearings shall be selected to give a three-year (25,000-hour) minimum AFBMA L-10 rating life with continuous operation at all operating conditions. (j) When the vendor cannot demonstrate specific system experience with identical equipment, a complete torsional analysis shall be performed on all vertical multistage pumps driven by engines and gears. 4.2.10 Coupling

(a) The engine-to-gear coupling shall be a double universal joint shaft, complete with shaft flanges for the driver and the driven shaft. (b) The coupling shall allow either the driver or the gearbox to be removed without disturbing the other. The pump-to-gearbox coupling shall be long enough to allow the replacement of the mechanical seal or the packing without moving any other equipment. The minimum length of the pump-to-gear box coupling shall be 125 mm (5 in.). (c) (d) Couplings shall be rated for greater than 120% of the maximum driver horsepower. Couplings shall be dynamically balanced.

(e) A removable, nonsparking shaft guard shall be provided around the coupling. The guard shall be designed to withstand a concentrated load of 90 kg (200 lb) at midspan. The guard shall comply with OSHA or equivalent standards. 4.2.11 Instrumentation

In accordance with NFPA 20, the supplier shall furnish the following instrumentation as a minimum: (a) (b) (c) 4.3 4.3.1 An automatic air release valve. A water level detector. A discharge pressure gage.

Skid- or Trailer-Mounted Pumps Capacity

The rated capacity of the fire pump shall be per NFPA 1901.

MOBIL ENGINEERING GUIDE EGE 15-B-23 1992 4.3.2 Skid-Mounted Units

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(a) Skid-mounted units shall be constructed with a steel frame of sufficient strength to withstand loads imposed when lifting or dragging the unit. The frame shall also have sufficient rigidity to withstand loads from all operating conditions up to engine trip speed without harmful distortions. (b) The skid shall provide adequate support with ample surface area for resting on grade or for hold-down using foundation bolts and clips. (c) The design shall ensure that all parts are readily accessible for maintenance.

(d) Lifting eyes or hooks shall be permanently attached to the frame in order to lift the complete unit. The weight and center of gravity (C.G.) shall be permanently stamped on the skid. 4.3.3 Trailer-Mounted Units

(a) Trailer-mounted units shall be designed so that total axle loads do not exceed the manufacturers rating. Tire loading shall not exceed the recommended load for trucks in highway services. Wheel rims shall be at least 350 mm (14 in.) in diameter. (b) Trailers shall have a minimum road clearance of 200 mm (8 in.) and a maximum road clearance of 300 mm (12 in.). A two-wheeled trailer with adjustable parking legs is acceptable. For all road conditions the center of gravity shall be between the wheels and the hitch. (c) Heavy-duty automotive wheels with tapered-roller bearings shall be provided. Axles shall be of the sturdy tubular type. (d) A heavy gage drawbar and tow hitch shall be provided. The type of hitch shall be as specified on the Data Sheets. (e) A weatherproof, NEMA configuration, three-wire receptacle shall be furnished for the battery charger supply. (f) Tail lights, stop lights, and directional equipment shall conform to local highway regulations.

(g) The body and frame shall be of steel construction with built-in compartments for tools and accessories. The compartments shall accommodate the equipment listed below in Item (h), with the best utilization of space consistent with ease of operation. All compartments shall be self-draining. (h) The following accessories shall be supplied and mounted on the trailer: (1) The manufacturers standard accessories, including special tools required to service and operate the unit. Service tools and operating tools shall be stored in separate compartments. (2) Two 3 m (10 ft) lengths of hard suction hose (diameter as indicated on the Data Sheet). Each hose shall have a long-handled male coupling on one end and a long-handled female swivel coupling on the other end. (3) (4) (5) A corrosion-resistant suction strainer. One double female adapter with swivels to fit the pump suction. Two coupling wrenches for hard suction hose.

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(6) Two coupling wrenches equipped with a hydrant wrench for 63 mm and 75 mm (21/2 in. and 3 in.) hose. (7) 4.3.4 (a) A spare compartment of 0.11 m (4 ft), with a minimum length of 600 mm (24 in.).

Trailer-Mounted Pump Hose Connections Connections for discharge and suction hose shall be furnished for trailer-mounted pumps.

(b) A suction hose connection shall be furnished in the manufacturer's standard size. It shall be suitable for operation with a 3 m (10 ft) suction lift through 6 m (20 ft) of hard hose. A removable suction strainer shall be provided that is suitable for 13.8 bar gage (200 psig) working pressure. (c) Unless otherwise specified, the hose connection threads shall conform to American National Fire Hose Connection Screw Thread (NST) (NFPA 1963). (d) Suction valves for 63 mm or 75 mm (21/2 in. or 3 in.) fire hose shall be quarter-turn ball valves of the same material and type, except that they shall have a swivel coupling for female thread and shall be provided with a plug and chain. One 63 mm or 75 mm (21/2 in. or 3 in.) outlet shall be provided for each 56.7 m/h (250 US gpm) of rated pump capacity. (e) Discharge valves for 63 mm or 75 mm (21/2 in. or 3 in.) fire hose shall have 63 mm (21/2 in.) outlets. One hose shall be provided for each 56.7 m/h (250 US gpm) rated capacity pump. (f) A priming pump controlled from the pump operator's position shall be provided in accordance with NFPA 1901. The pump shall be capable of being primed in less than 30 seconds with a 3 m (10 ft) lift through 6 m (20 ft) of suction hose. (g) Pumps and drivers shall be capable of frequent stopping and starting while operating on runs of short duration. 5. DRIVERS 5.1 General

Drivers shall be electric induction motor or internal combustion engine, as specified on the Data Sheets. Other types of drivers, such as steam turbines, gas turbines, or hydraulic pumps may be considered for specific installations, if approved by Mobil. 5.2 5.2.1 5.2.2 5.2.3 Motors Motors shall comply with EGE 33-B-8, EGE 33-B-9, NFPA 70, and NFPA 20. All motors shall be rated for continuous duty. The maximum locked rotor current for 460V motors shall not exceed the levels stated in NFPA 20.

5.2.4 Motors shall operate successfully under running conditions at rated load when subjected to the voltage and frequency variations noted in EGE 33-B-9. 5.2.5 Electric current limits shall be in accordance with EGE 33-B-9, NFPA 20, and Table 5 of this Guide.

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5.2.6 Current-carrying parts of electric motors shall be installed 300 mm (12 in.) above the floor in conformance with NFPA 20. 5.2.7 Motor drivers for vertical pumps shall be supplied, shop mounted, and aligned by the pump manufacturer. Motor thrust bearings shall be designed to carry the maximum additional upthrust and downthrust that the pump may develop at any time during operation. A nonreverse ratchet is required on all vertical motor drivers above 100 hp. 5.2.8 The maximum upthrust and downthrust to be imposed on the motor thrust bearing shall be specified by the pump manufacturer in the proposal. 5.2.9 Motors shall have nameplate power ratings, not including the service factor, at least equal to the values shown below or to the power rating at the end of the pump curve, whichever is less.

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TABLE 5 DRIVER MOTOR NAMEPLATE POWER RATINGS Motor Nameplate Power Rating 1.25 x pump rated power 1.15 x pump rated power 1.10 x pump rated power

Pump Rated Power 19 kW (25 hp) and less 37 to 75 kW (50 to 100 hp) 90 kW (125 hp) and over

5.3 5.3.1

Diesel Engines General

Diesel engines shall be in accordance with EGE 15-B-15 and NFPA 20 . (a) Fly wheel guards shall have openings with removable covers for barring over the machine and for providing access to the following: (1) (2) (3) Timing marks. The fly wheel center (if available). Any other parts that may require attention.

(b) Four-cycle diesel engines are required. The drive connection shall be designed to absorb the torsional pulsations exhibited by combustion engines. (c) Diesel engines with turbo systems are not acceptable for fire pump services.

(d) When specified on the Data Sheet, the engine shall be protected from spray and rain by a shelter or a sturdy hood. (e) Maximum engine and piston speeds shall be 2100 rpm and 10 m/s (33 ft/s), respectively.

(f) The spark plugs and ignition harness shall be completely protected and sealed against the weather and moisture. Aircraft-type spark plugs and ignition harness may be provided as a substitute for the sealed and protected system. The aircraft-type system requires written Mobil approval. 5.3.2 (a) (b) Rating Engines shall be rated in compliance with NFPA 20. Engines shall be rated by the testing laboratories at the following standard SAE conditions: (1) (2) 7521 mm (29.61 in.) Hg barometer. 25C (77F) inlet air temperature [approximately 91.4 m (300 ft) above sea level).]

Refer to SAE Standard J1349. All Hydraulic Institute ratings shall be based on site-corrected altitude. (c) Engines shall be capable of starting, accelerating to rated speed, and carrying the rated load in less than 20 seconds after actuation of the start signal.

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(d) Except for special cases cited in Data Sheets or specifications, the engine shall have an engine-brake horsepower peak rating at least 10% greater than the maximum horsepower required to drive the pump at the rated speed. The 10% requirement includes an allowance of 5% for accessories. 5.3.3 Speed Control

(a) The engine governor shall be designed to prevent excessive speed if the pump loses suction. Engines shall be provided with a governor that is capable of regulating the engine speed within a range of 10% between shutoff and the maximum load condition of the pump. The governor shall be field adjustable. The governor shall be set and secured to maintain the rated pump speed at maximum pump load. (b) No manual control throttles shall be provided.

(c) The overspeed shutdown device shall operate via a fuel control valve and an air intake shutoff valve. 5.3.4 Fuel System

(a) The fuel tank shall be removable. It shall be fabricated from steel plate that has a minimum thickness of 6 mm (1/4 in.). A minimum eight-hour fuel capacity, based on fuel consumption at the rated engine conditions, shall be provided. (b) Duplex fuel filters shall be per the manufacturers standard with 10 micron nominal, replaceable cartridge elements. (c) A fuel strainer and moisture separator shall be provided between the fuel tank and the engine fuel filter. (d) The tank shall be furnished with a low-level switch to alarm at the skid panel. The low-level switch shall be set at 50% tank capacity. (e) If multiple engines are used, separate fuel tanks and supply lines shall be provided for each engine. 5.3.5 (a) Lube Oil System Engines shall be furnished with a pressure lubrication system that includes the following: (1) (2) (3) (b) (c) (d) Pump. Strainer. Piping. (4) (5) Heat exchanger. Duplex filter equipped with a bypass valve and a pressure gage.

Filters shall be furnished with accessible and easily removable elements. No flexible connections shall be used. The engine sump oil temperature shall meet the following requirements: (1) It shall not exceed the engine manufacturers recommendations.

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EGE 15-B-23 1992

(2)

It shall never exceed 82C (180F) for any operating or ambient condition.

(e) Thermostatically controlled crankcase heaters shall be required for ambient temperatures below 4C (40F). 5.3.6 (a) Cooling System The engine cooling system shall have closed circuits, as specified by NFPA 20.

(b) Cooling for the closed-circuit cooling system shall be as specified on the Data Sheets. Cooling shall be via either: (1) (2) Water/water shell-and-tube exchanger. Air-cooled radiator.

(c) The engine cooling system shall continuously maintain satisfactory engine jacket water temperature when operating at full load at the specified maximum ambient dry-bulb temperature. Jacket water temperatures exceeding 82C (180F) are satisfactory only if the cooling system is pressurized. Backflush piping shall be required on all radiators or exchangers. (d) Water/water exchangers shall comply with NFPA 20. They shall be fabricated as specified on the Data Sheets from either: (1) (2) (3) Red Brass. Copper Nickel. Aluminum Bronze.

(e) Closed loop piping shall be Sch 40 minimum screwed piping. Regulators, valves, and strainers shall have bronze bodies with stainless steel trim. Piping shall be marine bronze. (f) Galvanized carbon steel pipe shall be used for all once-through fresh water cooling requirements. Type 316 L stainless steel piping shall be used for all brackish or saltwater systems. (g) Ball valves shall be provided in the Y-outlet of strainers.

(h) The outlet line from the heat exchanger shall be piped to the edge of the skid and terminated with a union. (i) The cooling water supply to the cooling coil in the right angle gear shall be branched from the cooling loop. (j) Air-cooled, fan type radiator coolers shall be fabricated from corrosion-resistant materials.

(k) A thermostatically controlled electric jacket water heater is required in all locations where the ambient temperature is below 4C (40F). The heater shall maintain the jacket cooling water temperature above 49C (120F) at the minimum ambient temperature. (l) A pressure gage shall be installed in the cooling water supply system on the engine side of the last manual valve.

MOBIL ENGINEERING GUIDE EGE 15-B-23 1992 5.3.7 (a) Air Inlet System The air inlet system shall be either: (1) (2) Naturally aspirated as defined in NFPA 20. Drawn from the outside compartment.
PAGE 22 OF 39 SEPTEMBER 1992

(b) The system shall include ducting, filters, associated flexible connections, and the following items, when specified: (1) (2) Electric heaters upstream of the filters to avoid condensation or freezing on filters. A shutoff valve.

(c) Air filters shall be dry replaceable filters that are suitable for a severe marine environment. A corrosion-resistant filter housing made of 316 stainless steel shall be furnished. When specified, precleaners shall be furnished to remove airborn water contaminants before reaching the main element. (d) An inlet silencer shall be required when the manufacturer cannot meet the sound limit requirement on the Data Sheets. (e) Unless otherwise specified, inlet piping for the air intake filter shall terminate at the edge of the skid with an ANSI B16.5 150# RF flange. (f) (g) 5.3.8 (a) The air intake shall be located in a nonhazardous area. A manometer shall be provided for monitoring the air filter differential pressure. Exhaust System Each engine shall have an independent exhaust system.

(b) The exhaust from the engine shall be piped to a safe point. Exhaust gases shall not be discharged where they will affect persons or endanger buildings. (c) The exhaust pipe diameter shall be no smaller than the engine exhaust outlet diameter and shall be as short as possible. The exhaust pipe shall be covered with high-temperature insulation or otherwise guarded to protect personnel from injury. The exhaust backpressure shall not exceed the engine manufacturers recommendations. (d) Flexible connections between the engine exhaust outlet and the exhaust pipe shall be type 316 stainless steel. A seamless or welded, corrugated, (not interlocked) flexible connection shall be made between the engine exhaust outlet and exhaust pipe. (e) Silencers shall be furnished with: (1) (2) (f) Spark/flame arresters. Support straps with vibration isolators.

The exhaust pipe shall be designed to prevent rain water from flowing into the engine.

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5.3.9

Vibration and Critical Speeds

(a) The vendor shall calculate and assume responsibility for all torsional and lateral studies. The vendor shall eliminate any torsional or lateral structural vibrations that may impair operation of the unit within the specified operating range. (b) Torsional natural frequencies of the engine and driven equipment shall not be closer than 10% to any specified running speed. 5.3.10 (a) Starting System General

The starting system shall be made up of one or a combination of the following types: (1) (2) Pneumatic. Electric. (3) (4) Manual. Nitrogen backup.

Where more than one system is specified, one shall be designated as the main system, with the logic arranged accordingly. System logic shall prevent operation of the starter when the engine is running. (b) Pneumatic Start (1) The pneumatic start system shall include the following: A receiver with a relief valve. A pressure regulator. Pressure gages. A pressurized supply line. (2) The receiver shall include: Capacity for six consecutive cranking periods of 30 seconds' duration each, without recharging. A nameplate specifying the manufacturing and design/hydrostatic test pressure. A level gage, a pressure gage, and a 200 mm (8 in.) hand hole. Valves: Inlet. Outlet. Pressure relief. Drain. Blowdown. (3) The pressure relief valve shall be sized for 120% of the inlet critical flow orifice. Suitable provision shall be made to allow testing of relief valves without depressuring the system, for example, use a three-way switching valve with two 100% relief valves. A control valve with bypass, filter, air motor, and inlet critical flow orifice. Associated piping.

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(4) The flow control valve shall be installed downstream of the supply regulator. The flow control valve shall be an air-operated, two-way high-capacity valve with an auto-manual pilot valve. (5) The air motor shall be sized to provide adequate power for starting the engine. The air motor may be either: Turbo motor (T.D.I. or equivalent). Vane motor (Pow-R-Quik or equivalent). The air motor must be capable of six consecutive starts of 15 seconds' duration at each maximum starting torque. (6) All fittings, tubing, and other instrumentation and valves shall be type 316L stainless steel. An air supply sight glass and lubricator shall be provided. (7) A panel-mounted, low-pressure switch set at 90% of minimum cranking capacity shall be used to operate the starting air low-pressure indicator in the fire pump panel. (8) When air starting is used and air pressure exceeds 7 bar gage (100 psig), air supply tanks shall be placed next to the engine and shielded. (9) The air supply system shall be reliable and independent of any compressor driven by the fire pump engine. (10) If the engine cannot be started after four starts in a 30-minute period, an alarm shall sound. (c) Electric Starting Systems (1) Electric start systems shall be fully self-contained. They shall include a DC motor, batteries, and charger. (2) Batteries and charging systems shall be in accordance with NFPA 20.

(3) Electrical equipment that is not kept inside heated buildings (such as automatic starter relays or battery chargers) shall be installed in stainless steel watertight NEMA type 4X or weathertight NEMA 12 enclosures. Electrical equipment that is kept inside heated buildings shall be mounted in steel NEMA Type 3R painted enclosures. (4) The location of the electric start system shall conform to the electrical classification of the location. All remote pressure switches, flow switches, and control stations in classified locations shall be explosionproof. (5) (d) Maintenance-free, permanently filled batteries shall not be used.

Nitrogen Backup System (1) Nitrogen backup starting systems shall include a minimum of four nitrogen cylinders, each cylinder equipped with individual CGA-580 cylinder valves. (2) (3) All cylinders shall be mounted on a skid in a corrosion-resistant rack. All but one cylinder shall be used for automatic nitrogen discharge, with the remaining cylinder

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reserved for manual operation. (4) A nitrogen backup system shall include the items listed below in Table 6.

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TABLE 6 NITROGEN BACKUP STARTING SYSTEM (For Diesel Engines) Items An isolating valve, check valve, and pressure gage A regulator A pressure gage and needle valve Tubing, type 316L stainless steel, 38 mm (11/2 in.) in diameter A check valve Location Downstream of each cylinder valve

Downstream of the nitrogen header Downstream of the regulator Between the nitrogen cylinder and the inlet-to-air receiver At the inlet-to-air receiver

(e)

Manual System

Manual starting systems, such as hand cranking, shall be used only on small mobile units. 5.4 Steam Turbines

5.4.1 When steam turbine drivers are specified, steam turbines shall be in accordance with EGE 15-B-7 and NFPA 20. (a) (b) (c) For horizontal pumps, horizontal turbines shall be direct-connected to the pump, with no gear box. For vertical pumps, a horizontal turbine driver shall be used, connected through a right angle gear. Vertical steam turbines shall not be used.

5.4.2 Turbine-driven pumps shall be designed to operate continuously at 110% of rated speed. They shall be mechanically suitable to operate safely for brief periods at 115% of rated speed. 5.4.3 Steam turbines shall be rated for 110% of pump rated horsepower, plus any gear losses, while operating at minimum inlet and maximum exhaust steam conditions. The steam conditions shall be defined on the Data Sheets. Provision shall be made in the turbine design for a future increase of 15% in power rating. 5.4.4 5.4.5 Unless otherwise stated on the Data Sheets, turbine drivers shall be field mounted. As a minimum, turbine drivers shall be supplied with a NEMA A oil relay governor.

6. ACCESSORIES 6.1 6.1.1 (a) Controls and Instrumentation General The manufacturer shall furnish all controls and instrumentation specified on the Data Sheet.

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(b)

The method of starting the firewater pumps shall be either: (1) (2) An automatic signal from falling pressure in the main water header. A manually initiated signal (local or remote).

(c) (d)

Backup starting systems shall be actuated by local manual action only. Pumps shall be stopped by local manual action only.

(e) Where more than one pump is furnished, the control logic shall be designed so that if the "lead" engine fails to start after two crank attempts, the "standby" engine will attempt to start. In the event that the "lead" engine starts and header pressure continues to fall to a predetermined setting, the "standby" unit will also start. In any event, both units will continue to crank (an alarm will sound) until the starting system capacity is depleted. (f) Controls and the control panel shall be completely piped and wired, requiring only connection to external piping and wiring circuits furnished by others. (g) Panels located on engines or skids shall be mounted on isolation mounts to prevent vibration damage to instruments. (h) (i) Pressure and temperature gages shall be liquid-filled and shall have stainless steel cases. All pressure gages and switches shall have block and bleed valves.

(j) When specified on the Data Sheet, a circuit breaker shall be provided in the motor branch circuit. No overcurrent or overload protection devices shall be provided in the motor starter. (k) Motor controllers for firewater pump drivers shall be in accordance with NFPA 20 and the requirements of EGE 33-B-9. 6.1.2 Control Panels

(a) A control panel with a stand shall be skid mounted. It shall house the pump unit control logic and instrumentation. (b) Indoor panel enclosures shall be NEMA type 4 steel. They shall be primed and finished with a final coat of paint. (c) Outdoor panel enclosures shall be NEMA type 4X, stainless steel with a brushed finish. All internal braces, enclosure hardware, and instruments shall be type 316L stainless steel. The panel shall have full opening doors with heavy-duty type 316L stainless steel hinges and closures. (d) Panel tubing shall be seamless type 316L stainless steel. Tube wall thicknesses shall be: (1) (2) (3) (e)
1/4

in. O.D. x 0.035 in. W.T. O.D. x 0.035 in. W.T.

3/8 in. 1/2

in. O.D. x 0.049 in. W.T.

All tubing fittings shall be type 316L ferrule compression fittings. Instrument pipe fittings shall be

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type 316L stainless steel with NPT threaded connections. All bulkhead connections shall be provided with female bulkhead fittings. Block valves shall be clamped or mounted on panel braces. Tubing installations shall be neat, plumb, and properly supported. (f) Panel nameplates shall be phenolic, laminated, and engraved. All bulkhead connectors shall have nameplates both inside and outside the panel enclosure. Instruments shall be provided with permanently attached metallic nameplates showing tag numbers. All panel tags and nameplates shall be attached with type 316 stainless steel screws. Minimum lettering size is 1/8 inch. Tags shall be black letters on a white background. (g) Loss of pneumatic supply to the instruments air shall not interfere with safe operation of the fire pump if the pump has started. No engine shutdown device shall trip on the loss of instrument air supply. The overspeed shutdown air valve shall fail open. (h) The panel shall house the driver start/stop control and a key-locked auto/test selector switch with the following functions: (1) While in auto mode, all shutdown devices except overspeed shutdown shall be disarmed. All alarm and indication functions shall operate normally. (2) The panel shall contain all logic necessary to start the pump, if it is not already running.

(i) Control logic shall ensure that, if the engine shuts down under fault conditions, it will be inhibited from restart until the fault is cleared and the system is reset. (j) Relay contacts shall be provided to transmit the pump running status and the general fault signals to a remote panel in the control room or to a main fire alarm panel. The pump running signal shall be generated from a discharge pressure switch set at pump discharge pressure. (k) Panels in humid environments shall be heated or purged with dry air. 6.1.3 Instruments (Diesel Engine Drivers)

(a) Engine drivers shall be furnished with a local gage board containing: (1) A tachometer (range of 0 to 125% rated speed), with an adjustable overspeed trip setting, an overspeed alarm, a digital speed indicator, and a test function. (2) (3) (4) (5) (6) (7) (b) A lube oil pressure gage. An engine cooling water temperature gage. A start air or nitrogen pressure gage. A battery charger ammeter and voltmeter. Fuel tank low level alarms. An engine hour meter.

The manufacturer shall furnish the following independently mounted instruments and controls: (1) A coolant level indicator.

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(2) (3) (4) (5) (6)

A fuel tank level gage. A crank case dipstick. A jacket water inlet and outlet temperature indicator. A coolant flow indicator. A coolant inlet and outlet pressure gage.

(c) Alarm signals shall be located on the control panel. A common relay shall be provided. All shutdowns, except overspeed shutdown, shall be bypassed in auto mode. The following alarms and shutdowns shall be provided:
TABLE 7 ALARMS AND SHUTDOWNS (Diesel Engine Driver Control Panel) Alarm Engine oil pressure low Engine cooling water temperature high Engine overspeed Starting air pressure low Control panel off Fuel level low Battery charger low voltage X X X X X X Shutdown X* X* X

* To be defined on the Data Sheet. These shutdowns should not be specified unless approved by fire and safety personnel at the site. High-high alarms may be substituted for shutdowns.

6.2 6.2.1

Piping General

(a) Piping and fittings shall conform to EGE 16-B-30 (series DB/DA for fresh water and FA for salt water). The discharge piping shall be designed for a minimum working pressure or 2.75 bar gage (400 psig). (b) The manufacturer shall supply and mount the auxiliary piping as specified.

(c) The connecting piping shall be designed to permit field acceptance testing in accordance with NFPA 20.

MOBIL ENGINEERING GUIDE EGE 15-B-23 1992 6.2.2 Screening and Strainers
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Where the water supply is obtained from an open source, such as a pond or wet pit, any materials that might clog the pump shall be prevented from passage. Double removable intake screens shall be provided at the suction intake. These screens shall have an effective open area of 645 mm (1 in.) for each 3.8 L/min (1.0 U.S. gpm) at 150% of rated pump capacity. Screens shall be arranged so that they can be cleaned or repaired without disturbing the suction pipe. A brass, stainless, Monel, or copper wire screen of 13 mm (1/2 in.) mesh and 2.6 mm (0.1019 in.) Brown and Sharpe wire gage shall be secured to a metal frame that slides vertically at the entrance to the intake. The overall area of this particular screen is 1.6 times the net screen opening area. 6.3 6.3.1 Mounting Plates General

(a) All components for fixed pumps shall be mounted on a baseplate provided by the pump manufacturer. (b) In the case of vertical pumps, the strainer, bowl assembly, line shaft, and column pipe shall be suspended from the discharge head and soleplate, after installation of the pump. (c) All components shall be contained within the skid limits. All connections for field tie-ins shall be provided at the edge of the skid. (d) The supplier shall furnish the forces and moments of beam loading, with the load concentrated at the center, based on a safety factor of 2. 6.3.2 (a) Skid The skid shall have full-depth load-bearing members running both longitudinally and transversely.

(b) The skid shall be equipped with four pad eyes that are adequately designed and properly spaced to assure a safe lift. Pad eyes shall be designed using a safety factor of 3.0 times the actual lifting weight. (c) Pad eyes shall be located to provide for lifting a package near level, (the maximum allowable tilt shall be 5% from horizontal). Equipment and facilities shall be located on the skid to avoid interference with slings during lifting operations. If this problem occurs, the manufacturer shall supply a spreader beam for lifting the skid. (d) 6.3.3 The weight and the center of gravity shall be stamped on a skid nameplate. Baseplate

(a) Baseplates for pumps with drivers rated at 7.5 kW (10 hp) or greater shall include horizontal positioning screws for lateral and longitudinal adjustment of the driver position. Vertical leveling screws shall be spaced on the outside perimeter of the baseplate for stability. Stainless steel shims shall be provided. However, in a salt environment, shims shall be Monel . (b) All major elements shall be mounted on fully machined flat surfaces. For all elements except the pump, a maximum total of three individual shims may be used. The total pack height may not exceed 6 mm (1/4 in.). All shims shall provide full foot support. The pump shall be doweled to the baseplate. The base shall not be drilled for driver doweling. The driver shall not be final doweled until

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site-commissioned. The pump shall be mounted without shims. (c) The baseplate and pump supports shall be constructed so that the alignment is not disturbed in any plane under maximum piping-induced nozzle loads. The underside of the fabricated baseplate shall be reinforced by full-depth, welded cross members located under the pump and driver supports. The perimeter members shall be welded steel channel. (d) The minimum anchor bolt hole diameter shall be 19 mm (3/4 in.). The maximum span between anchor bolts shall be 900 mm (36 in.). (e) The vendor shall precoat all the grouting surfaces of the mounting plates with catalyzed epoxy-based primer. (f) The top of the baseplate shall be steel checkerplate, complete with a sufficient number of grout holes that are a minimum of 100 mm (4 in.) in diameter. Holes shall be accessible for grouting with the pump and driver installed. Grout holes shall be arranged so that oil will not accumulate over the open grout. Grout holes in the drip-pan area shall have a 13 mm (1/2 in.) raised-lip edge. Vent holes shall be provided with lips and shall be 6 mm (1/4 in.) minimum. (g) The pump, baseplate, and pedestal support assembly shall be sufficiently rigid to allow mounting without grouting. (h) When specified, the manufacturer shall: (1) (2) (3) (4) Review and comment on the purchasers piping and foundation drawings. Observe a check of the piping by parting the flanges after installation. Recheck the alignment of the pump and the drive train at the operating temperature. Be present during the initial alignment check of the pump and the drive train.

(i) A drain-rim shall be arranged so that it extends beyond the end suction discharge flanges. It shall also be extended to collect leakage from the steam turbine governor assemblies and/or motor bearings. The drain shall be a minimum of NPS 1 (NPS = nominal pipe size, inches). It shall be located to drain the complete base. 6.4 Painted Surfaces

A standard finish is acceptable only if it is suitable for the site environmental conditions and the component design temperature at site ambient temperature. The vendor shall submit the specification for the purchasers review. 6.5 Nameplates (a) All instruments, controls, valves, and hose inlets and outlets shall be identified with nameplates. Nameplate data shall be supplied by Mobil. The nameplates shall be stamped or engraved stainless steel. (b) The pump nameplate shall be stainless steel. The nameplate shall be securely attached to the pump. Included on this or a separate plate shall be: (1) Purchase order number. ( 2 )

MOBIL ENGINEERING GUIDE EGE 15-B-23 1992 Purchasers item number. (3) (4) Capacity. Differential head.
PAGE 32 OF 39 SEPTEMBER 1992

(5) (6) (7) (8)

Speed (rpm). Impeller diameter (actual). Bearing manufacturers identification number. Pump serial number.

The pump serial number shall also be stamped on the pump casing. 7. INSPECTION AND TESTING 7.1 7.1.1 Inspection Equipment shall be inspected and tested according to EGE 00-C-4, except as modified herein.

7.1.2 All work that does not conform with this Guide shall be rejected, and replaced or redone at the vendors expense to the satisfaction of Mobil. 7.1.3 Mobil reserves the right to inspect fabrication and welding of all components prior to the start of coating operations. The contractor shall provide five business days notification prior to initiation of coating operations. 7.1.4 Mobil must be notified of all deviations from the original approved manufacturing drawings specified in Paragraph 9.3(a) of this Guide. Any deviation shall be subject to Mobil approval. 7.1.5 The supplier shall furnish Mobil with certification of materials and with the shop test data verifying that specifications and Data Sheet requirements are being met. 7.2 7.2.1 Testing General

Testing shall occur in accordance with the following: (a) Four weeks prior to testing, the supplier shall submit a detailed testing procedure and checklist for Mobil approval. The supplier shall give Mobil ten business days notice prior to testing. (b) The job seals and piping shall be used during the performance test. The job driver shall be used for testing, when specified on the Data Sheet. (c) All testing shall be conducted using fresh water with a corrosion inhibitor.

(d) After acceptance of each test by Mobil, the water shall be drained and the system shall be blown dry with air. A corrosion-inhibiting oil shall be sprayed into the pump. (e) (f) All instrument air piping shall be tested using air pressure and a soap solution to check for leaks. Motors shall be tested in the manufacturers shop in accordance with EGE 33-B-9.

(g) Engines shall be tested by a testing laboratory in accordance with NFPA 20 and NFPA 1901. The supplier shall furnish Mobil with a certified copy of test results and performance characteristics.

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(h) (i )

Instruments and controls shall be tested at the manufacturers plant. The fuel day-tank shall be pneumatically tested to 0.35 bar gage (5 psig).

(j) The panel, engine, and pump shall be shop tested as an assembly. A characteristic performance curve, which displays pump head, efficiency, brake horsepower, and NPSH vs flow, based upon results of shop tests, shall be submitted. (k) 7.2.2 The control panel and starting systems shall have a complete functional test prior to delivery. Hydrostatic Tests

(a) All pump casings shall be hydrostatically tested with water for a period of 30 minutes. The test pressure shall be 11/2 times the sum of the pumps shutoff head (based on maximum impeller) plus the maximum allowable suction head. The minimum test pressure shall be 1.72 MPa gage (250 psig). Visible leakage or a drop in pressure shall be unacceptable. Cooling passages and jackets for bearings and stuffing boxes shall be tested to a minimum of 793 kPa gage (115 psig). (b) In addition, the pump casing on horizontal pumps, and the pump bowls, column pipe, and discharge heads on vertical turbine pumps, shall withstand a one-minute hydrostatic pressure test at twice the maximum working pressure or 58 kPa (400 psig), whichever is greater, without rupture. For a vertical turbine pump, all bowls shall be tested, including discharge bowls and intermediate bowls. (c) After assembly, and after all leaks have been located and stopped, the hydrostatic testing for piping and vessels shall be done. The testing shall be at 1.5 times design pressure for 30 minutes. Testing against block valves shall not be permitted. After testing, each item shall be drained and air dried. (d) Each test shall be recorded on a calibrated chart recorder. After the hydrotest, the supplier shall furnish Mobil with certification papers. 7.2.3 Performance Tests

(a) All pumps shall be performance tested in the suppliers shop in accordance with this Guide and NFPA 20. The supplier shall submit written verification of the test results to Mobil for approval. Jockey pumps shall be tested if specified on the Data Sheet. All pumps require a one-hour mechanical run test. Vibration and oil temperature shall be recorded and submitted to Mobil for approval. (b) Pump performance shall be guaranteed within the tolerances listed in the Hydraulic Institute Standards for head, capacity, power consumption, and the Net Positive Suction Head (NPSH) at the specified operating conditions. (c) The test points shall be obtained with the pump running at rated speed. A minimum of six test points, that are evenly spaced from 0 to 150% of rated flow, shall be recorded. (d) Underfiling of the impeller vanes to increase head capability shall not be allowed.

(e) A retest is required if the pump has been dismantled for the purpose of machining the impellers to meet the tolerance of differential head or NPSH. 7.2.4 NPSH Tests

An NPSH test is required when the NPSH Available (NPSHA) does not exceed the NPSH Required (NPSHR)

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by more than 0.61 m (2 ft) or when the suction specific speed (NSS) exceeds 12,000. Details of the suppliers proposed testing method shall be included with the proposal. 7.2.5 Vibration Tests

(a) Vibration data shall be taken at each point during the performance test and shall be provided as part of the project document package. (b) For pumps and motors, the measured unfiltered vibration during the shop test at rated speed and at any capacity ranging from the suppliers recommended minimum flow to 150% of rated flow shall not exceed the limits listed in Table 8.

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TABLE 8 MEASURED UNFILTERED VIBRATION LIMITS Antifriction Bearings Housing Velocity Limits Speed, rpm 3600 to 1801 1800 and below
*Including runout.

Sleeve Bearings Shaft Amplitude Limits*

mm/s 5.1 5.1

in./s 0.20 0.20

F
38.1 50.8

mil 1.5 2.0

(c) The filtered velocity measured on the bearing housing shall not exceed 3.8 mm/s (0.15 in./s), peak at running speed, blade passing frequency or frequencies, and other specified frequencies in any plane. (d) (e) A log of vibration data shall be supplied by the pump manufacturer. Steam turbine vibration limits during shop test shall be as given in EGE 15-B-7.

(f) Diesel engine vibration limits shall be measured at the bearings and shall not exceed 9 mm/sec unfiltered and 7.0 mm/sec at any discrete frequency. 7.2.6 Final Acceptance Test

A suppliers representative shall be available to witness the final acceptance test and to ensure that there is compliance with the specification during this test. Final acceptance shall be based on field performance as specified by NFPA 20, for fixed pumping units. For trailer or skid units, a three-hour certification test according to NFPA 1901 shall be performed and witnessed by Mobil when specified by EGE 15-D-23. After installation, the unit shall be field tested under manual and automatic conditions, as follows: (a) The pump shall discharge rated capacity at rated head.

(b) At rated speed, the pump shall discharge at least 150% of the rated capacity at a minimum total head that is 65% of the total rated head. (c) All control equipment shall function properly. Automatic controls shall perform their design function without adjustment or manual attention through at least 10 cycles of actuation. (d) The pump and engine shall be operated at different conditions of load by opening discharge valves in the system to give a maximum discharge flow, and then gradually throttling the main discharge valve until the pump specified minimum flow is achieved. (e) The engine shall not show signs of overload or stress, and its governor shall properly regulate the speed during the test. The acceleration period, from dead rest to rated speed, shall be checked against the manufacturers performance test data after installation. 8. PREPARATION FOR SHIPMENT 8.1 Immediately upon completion of all tests, the manufacturer shall: (a) Protect all machined surfaces with a suitable corrosion preventive that is long-lasting and weather-

MOBIL ENGINEERING GUIDE EGE 15-B-23 1992 resistant. (b) (c) (d) Remove the packing from the stuffing box that was used during the test. Thoroughly air blow dry all internal parts. Use a rust-preventive oil to thoroughly flush the stuffing box of pumps.
PAGE 36 OF 39 SEPTEMBER 1992

(e) Motor drivers for horizontal pumps that exceed 75 kW (100 hp) shall be field mounted. Motors 75 kW (100 hp) and below shall be shipped to the pump manufacturers shop for mounting. Vertical motors, turbine drivers, and engines shall be shop mounted, aligned, match marked, and shipped separately from each other to the field. 8.2 The manufacturer shall provide two complete sets of packing for all pumps that utilize packing. The packing shall be shipped separately to the job site for installation. 8.3 The manufacturer shall seal the openings as follows: (a) Provide 6 mm (1/4 in.) thick metal closures for all untapped and flanged openings. Bolt these closures in place with a minimum of four bolts and full rubber gaskets. (b) Disconnect and plug all tapped openings (for shipping purposes). Use solid, long-shank steel plugs. (c) Plug all tapped openings that are normally open during service. Use solid, long-shank steel plugs coated with C-100 or equivalent antiseize compound. The following materials are unacceptable for plugs: cast iron, brass, plastic, Teflon tape. (d) Plug all tapped openings in stainless steel valves, such as needle valves and gage valves, with type 316 stainless steel plugs. (e) Plug all open-end tubing at bulkhead connections, at panel connections, and at end device connections with type 316 stainless steel plugs. (f) Identify all connections, including those for instruments and instrument leads, with a securely attached type 316 stainless steel metal tag. Indicate the following on the tag: (1) (2) (3) The type of connection. The instrument. The line description of the connecting piping.

8.4 Each major component shall be properly identified with the item and serial numbers. All material that is shipped separately shall be properly tagged with stainless steel tags and marked with the item and serial number of the equipment for which it is intended. 8.5 All items that can be damaged by water shall be coated with suitable preservative and securely wrapped in plastic prior to being placed in wooden crates. 8.6 Wooden crates shall be prepared as follows:

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(a) (b) (c)

Fabricate crates from 13 mm (1/2 In.) thick marine-grade plywood. Reinforce crates with 50 mm x 100 mm (2 in. x 4 in.) members. Space reinforcing members a maximum of 600 mm (24 in.) center to center.

(d) Use boards to brace each item placed in the crate so that the item cannot be damaged by rolling or sliding inside. (e) (f) Securely nail the crate shut. Band the crate in at least three locations. Space the bands a maximum of 1.5 m (5 ft) apart.

(g) Attach blocks under the crate to elevate it a minimum of 100 mm (4 in.). This will allow the crate to be accesible by forklift and to be protected from wet ground. 8.7 8.8 A copy of the equipment data book shall be packaged with the equipment. The assembly shall be prepared according to EGE 00-C-4 for long- or short-term storage.

9. VENDOR DATA 9.1 9.1.1 General The supplier shall submit drawings and data as specified by EGE 00-C-4 and the purchase order.

9.1.2 All data shall reference the project number, location, and purchase order number. The manufacturer shall submit approval drawings, vendor data, etc., in accordance with project specifications, this Guide and the Data Sheets contained in the inquiry. 9.2 9.2.1 (a) Proposal Data The following information shall be submitted with the bid: Completed data/requirements sheets.

(b) A general arrangement drawing showing the overall dimensions, weights, foundation bolting layout, and center of gravity. (c) (d) A P&ID of starting and cooling systems. A guaranteed performance curve.

(e) A sketch that details the fabrication of the column pipe and flanges, including type of welding, machining, and coating details. (f) (g) (h) Coupling drawings. A bill of material for all major equipment items. A list of special tools, including coupling tools.

MOBIL ENGINEERING GUIDE EGE 15-B-23 1992 (i) (j) (k) (l) (m) (n)
PAGE 38 OF 39 SEPTEMBER 1992

A spare parts list for two years operation (price and delivery). Expected and guaranteed sound levels. A complete list of exceptions to all inquiry documentation. A list of instrumentation. References listed by installation, client, model, service, brake horsepower, and driver. A method of preservation and the cost of providing for long-term outdoor storage.

(o) When materials are coated, a copy of the NDT procedure used to assure 100% holiday-free coating. (p) A seal drawing and calculations indicating the deflection of the shaft at maximum and minimum flow. 9.2.2 If a skid- or trailer-mounted unit is being quoted, drawings shall also include the arrangement of all facilities, and the controls on the pump and at the pump operators position. 9.3 Contract Data

The following information shall be submitted to Mobil for approval prior to the start of any material procurement for fabrication: (a) Drawings (1) (2) (3) Mechanical flow diagrams of all systems. A general arrangement and piping drawing. An outline dimensional drawing for the pump, driver, gearbox, and skid baseplate assembly.

(4) A structural skid and pad eye drawings with the unit center of gravity, foundation bolt holes, and weight indicated. (5) (6) (7) (8) (9) (b) Vessel drawings. Piping plans and sections. A firewater pump panel layout and detailed control system schematics. Fuel tank drawings. A coupling drawing and alignment procedures, with allowable tolerances.

Calculations (1) A structural skid and pad eye design.

(2) Vessel calculations, including sizing, wall thickness for shell and heads, nozzles, internals, saddles, and reinforcing pads.

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(3) 9.4

Fiberglass column pipe linearity and clearance calculations.

Data Book

Four weeks prior to completion, a detailed table of contents for job books and first drafts of all startup, operating, and maintenance instructions shall be provided to Mobil. The data book shall be submitted to Mobil for approval. It shall include the following: (1) (2) (3) Completed instrument specification Data Sheets (ISA standard). Bills of material and descriptive literature on every item. Certified shop test curves and test logs for all pump installations.

(4) Spare parts list with ordering instructions and the actual part number for ordering replacement parts. (5) (6) (7) (8) (9) (10) (11) Recommended Preventive Maintenance Schedule for the entire assembly. Cross-sectional drawings. Seal drawings. General vendor information. A completed Data Sheet, marked as-built. Copies of all Guide comments and exceptions. A material list.

(12) A drawing that illustrates all clearances associated with the pump assembly. This should include impeller, seal, coupling, and bearing fits.