Diesel Drive Fire Pump Controllers

Prepared IEEE - IAS-by-

Jim Nasby Columbia Engineering
Skokie, Illinois USA
---
From a presentation to the
Chicago Fire Department Fire Prevention Bureau
Topics to be Covered
1. Fire Pump - General
2. Fire Pump Installation Elements - Overview
3. Engine Drive Fire Pumps in General
4. Diesel Drive Fire Pump Controllers
5. Operating Margins
Fire Pump Installation Considerations
Pressure Sense Lines
Jockey Pump Relief Valve ?
Engine Room Ventilation
Pump House Heating
Fire
Pump
Controller
Pressure
Connection
(Pressure
Sense Line)
Separate
Pressure
Sense
Lines
-for-
Each
Pump
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 Types
Enclosure Types
Type 2 Indoor Only - Vertical Dripproof only
Type 3R Outdoor - Rain or Dripping water up to 45 degrees
Type 12 Indoor - Protection against dripping water and dust.
Type 4 Outdoor - Protection against water, dust, & hosedown.
Type 4X Corrosion Resistant Special Paint or Stainless Steel
Note: 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 doesnt 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 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 Contacts
Remote Alarm Contacts for:
Other Diesel Controller Options
- Power Failure Starting
- Keep Pump Room warm -or-
- Charge Battery(s) -or-
- For risks with high temp. processes
- Recorder
- Additional Alarms
- 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.
Ratings
Nameplate
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 Second
Questions ?