LPS 1240 Issue 1.2 Requirements for LPCB approved fire sprinkler pump sets used in automatic sprinkler installations

This standard specifies LPCB’s requirements for the approval of Fire Pump Sets for use in sprinkler systems conforming to sprinkler system installation standards, for example the “LPC Rules for automatic sprinkler systems” (incorporating EN 12845:2003)

This standard is not intended to cover all aspects of the design and build of a pump set. It is limited to addressing certain critical areas, which are known to affect the ability of sprinkler systems to perform.

The requirements for both diesel fire pump sets and electric fire pump sets are covered in this standard.

This standard specifies the fire pump set requirements by:

Referencing the relevant standards

Detailing pump set requirements which are not covered by other fire protection standards (eg. engine protection during weekly test, couplings, base plates and installation requirements)

The detailing requirements in this standard will take precedence (with the exception of regulatory requirements, which must always take precedence) over any other requirements.

Suppliers of LPCB Approved Fire Pump Sets shall control and be responsible for the design, construction, testing, performance, provision of installation instructions and commissioning of their fire pump sets.

The installer of the approved fire pump set is responsible for the installation of the pump set in strict accordance with the manufacturer’s installation manual and procedures. An LPCB approved sprinkler system installer, with sufficient knowledge and training in relation to the manufacturer’s product, should always be used.

Fire pump set – An assembly comprising at least a pump, driver or motor, partial wiring loom, drive coupling and a mounting and/or base, which is intended to supply water to an automatic sprinkler installation.

Installer – The installer of the approved fire pump set is responsible for the installation of the pump set in strict accordance with the manufacturer’s installation manual and procedures. (An LPCB approved sprinkler system installer, with sufficient knowledge and training in relation to the manufacturer’s product, should always be used.)

Supplier – Supplier of LPCB Approved Fire Pump Sets shall control and be responsible for the design, construction, testing, performance, provision of installation instructions and commissioning of their fire pump sets.

Prerequisites

The pump set manufacturer should be able to demonstrate to LPCB at least 3 years previous experience of fire pump set manufacture, or heavy duty process pump set manufacture.

The pump set shall use LPCB approved components, where available (for example diesel driver, bare-shaft pump and control panel). Where approved components are not available, components suitable for the intended installation code must be used.

Table 1 – pre-requisite component approvals.

Documentation

Each fire pump set shall be supplied with a set of comprehensive documentation as follows:

Where installation, service or maintenance operations described are sequential, this should be identified and each stage should be presented in the correct sequential order.

Note: It is permissible & preferable for the information to be divided up between different sets of documents (e.g. User manual, installer manual, service manual).

The following items marked with bullets identify general headings and specific items of critical importance which shall be clearly presented in the pump set manufacturer’s documentation.

A list of suggested general headings are provided below as a guide (but not a complete list of all items):

Commissioning and operation

Maintenance and service

Faults and remedial action

Pump dimensions

Pump connections

Pump sections and parts list

Documentation must contain all required information, also specific, detailed information about the following items:

Pump set component details

Coupling misalignment tolerance dimensional limits (in x, y, z plane & angular)

Transport, handling and storage procedures

Site assembly and installation of pump set. Specifically the following items should be included as part of a pre-commissioning checklist :

Foundation and mounting plinth details for pump set base – dimensions,

material, reinforcing rod details o Foundation bolt hole size and positioning, and bolt fixing (if applicable) Positioning and mounting instructions for pump base plate, with initial levelling and alignment instructions, and;

Details of shimming, packing or wedge materials, sizes and exact positioning (with diagrams)

Bolt grouting requirements (if applicable)

Fixing base plate to plinth – bolt tightening procedure (sequence and torque)

Bolt requirements (size and type)

Connection of suction and delivery piping (including maximum allowable misalignment which can be tolerated by the pump set)

Final alignment and levelling instructions (if applicable), with;

Final shimming/packing materials, sizes and positioning, with diagrams (if

different from above)

Grouting the base plate at the relevant stage (if applicable)

Operating and maintenance instructions shall include all aspects of the servicing and maintenance of the unit and have a declaration of life expectancy, for specified loading conditions and degrees of misalignment.

The hydraulic characteristic curve for the pump shall be provided by the manufacturer with the pump set.

Details of all pump set labels shall be supplied to LPCB.

Design and Construction

Fire pump sets shall be designed to comply with the client’s performance requirements and the applicable installation standard, for example The LPC Rules. The pump and driver shall be sized accordingly.

Fire pump sets shall comprise major component parts which are LPCB approved to the following standards (where approved components are available).

For Diesel Fire Pump Sets:

LPCB approved pump, in accordance with LPS 1131

LPCB approved diesel engine, in accordance with LPS 1239

LPCB approved controller, in accordance with LPS 1236

For Electric Fire Pump Sets:

LPCB approved pump, in accordance with LPS 1131

LPCB approved controller, in accordance with LPS 1237

Protection of the diesel engine during the weekly test

No measures to protect the driver or motor by shutting down the driver or motor during the weekly test are permitted. Outputs to allow for audible and visual alarms for the following conditions are permissible: over speed, low oil pressure or high coolant temperature.

Base plate / supporting chassis

The base plate and supporting chassis or equivalent assembly shall:

• Support the pump and driver assembly and allow the pump set assembly to operate as intended
• Ensure the pump set retains correct alignment, once mounted, as specified by the manufacturer.

This clause will require design calculations (verified by an independent chartered engineer) to be supplied to LPCB. LPCB may in turn appoint an independent expert to review these design calculations if LPCB deem this to be necessary.

Driver or motor and pump mounts

Driver or motor and pump mounts shall be capable of withstanding expected loadings and shall be manufactured from materials appropriate for use in a machinery room.

This clause will require design calculations (verified by an independent chartered engineer) to be supplied to LPCB. LPCB may in turn appoint an independent expert to review these design calculations if LPCB deem this to be necessary.

Batteries

Two separate battery power supplies shall be provided for engine starting and control panel backup. They shall be used for no other purpose.

Batteries shall be either:

Open nickel – cadmium prismatic rechargeable cells complying with BS EN 60623 (Secondary cells and batteries containing alkaline or other non-acid electrolytes. Vented nickel-cadmium prismatic rechargeable single cells ) (or BS 6260 (Specification for open nickel-cadmium prismatic rechargeable single cells – withdrawn).

Lead-acid Plante positive batteries complying with BS EN 60896 part 1 Stationary lead-acid batteries. General requirements and methods of test. Vented types (or BS 6290 part 1 – withdrawn) and BS 6290 Part 2.

Wiring loom

Wiring provided by the pump set engine manufacturer shall be adequately rated for its purpose, in accordance with BS 7671 (Wiring Regulations).

Shielded wire or some other type of EMF protection is to be used for the circuit between terminals 2, 3 and 20 which are the magnetic pickup signal wires.

The cable insulation and any conduit used shall be oil, gas and fuel resistant and it shall be rated in excess of the expected temperature conditions it will be exposed to. The bundle of wires should be protected in some sort of loom, and should be routed away from hot areas of the engine.

For electric motors, requirements are given in the LPC Rules for automatic sprinkler systems, BS EN 12845 clause 10.8 and Technical Bulletin 220 clause 2.11.

Fuel System

The fuel plumbing between the tank and engine shall be of all metallic design or steel braided reinforced hose with an independent fire resistance approval to BS EN ISO 7840 or BS EN ISO 15540.

The fuel supply shall have a lockable on-off valve sized according to the engine manufacturer’s recommendations. Galvanized metal piping shall not be permitted (diesel fuel and zinc react causing the plating to detach).

Cooling Water Lines – Heat Exchanger Cooling

Cooling water lines to the heat exchanger are to be a minimum 15 mm nominal bore copper taken from the discharge side of the pump, prior to the pump discharge valves. The piping shall incorporate a strainer of at least one pipe size larger than the pipe work, a pressure regulator (if required), pressure gauges and automatic flow valve.

Components shall be assembled in the following order (in the direction of flow): a manual shut-off valve, strainer (as detailed above), pressure gauge, manual shut-off valve, automatic flow valve, pressure regulator (if required) and pressure gauge. A full sized by­pass line shall allow isolation of the strainer and manual shut-off valve, for maintenance purposes only.

In normal operation, cooling water flow shall be through the strainer with the by-pass line secured closed. This strainer shall be capable, by type or use of unions, of being easily removed for maintenance, during which time the by-pass line shall be opened.

Cooling system

Where the heat exchanger is cooled by sprinkler water, the cooling water flowing through the heat exchanger shall discharge into an open tundish and be clearly visible. The tundish shall be at least 150 mm diameter, and connect to a drain of at least 80 mm diameter.

Exhaust

The exhaust piping and silencer shall be sized to not exceed the engine manufacturer’s exhaust back pressure limits.

Power transmission – Driver to pump couplings

Driver or motor to pump coupling arrangements shall be capable of being serviced. When following the manufacturer’s service and maintenance documentation, the coupling shall:

Be ‘fail safe’ – of a design that provides emergency drive capability if flexible elements fail

Be misalignment tolerant, within limits specified by the manufacturer (see section 3.2)

Have a declaration of life expectancy, given loading conditions and degrees of misalignment (see section 3.2)

Have dampening characteristics

Have an adequate means of attachment to shafts, given expected loadings and permissible misalignment [1]

Factory Testing.

The requirements for factory testing are defined by BS EN 12845 & LPC sprinkler rules clause 10.9, 13.1, which is repeated here for ease of reference:

“Supplier’s test and certification of results. Each complete engine and pump set shall be tested by the supplier for no less than 1%. hrs at the rated flow. The following shall be recorded on the test certificate:

Site Installation – Base Plate Fixing

The method of base plate fixing shall be detailed in the Instruction Manual (ref.3.2). Where shimming locations are critical, these shall be specified by the manufacturer, and marked clearly and permanently (paint resistant to water and diesel) on the base plate.