FIREWATER PUMPS WEEKLY INSPECTION & TEST

Transcription

1 Effective 08/06/10 Page 1 of 11 Rev: 07/30/2010 FIREWATER PUMPS WEEKLY INSPECTION & TEST SAFETY INSTRUCTIONS AND PROCEDURES Document Revision Change Table Revision Number Revision Description Revised By Revision Date Rev. 02 Considered as starting document for revision change table BASF CORPORATION AGRICULTURE PRODUCTS BEAUMONT PLANT Approved By:

2 Effective 08/06/10 Page 2 of 11 Rev: 07/30/2010 Raw Water Storage Area A-445A - Electric 500 gpm (Jockey Pump) A-441A - Electric 1500 gpm A-441C - Electric 1500 gpm A-441D - Electric 1500 gpm A-441B - Diesel 2000 gpm A-441E - Diesel 2000 gpm

3 Effective 08/06/10 Page 3 of 11 Rev: 07/30/2010 Purpose To provide the minimum requirements as stated in the NFPA 25 section 8.1 for the routine inspection, testing, and maintenance of the BASF Beaumont Site firewater pumps and assemblies. Inspection. The purpose of inspection shall be to verify that the pump assembly appears to be in operating condition and is free from physical damage. The pertinent visual observations specified in the following checklists shall be performed weekly: Electrical system conditions: a) Controller pilot light (power on) is illuminated. b) N/A - Transfer switch normal pilot light is illuminated. c) N/A - Isolating switch is closed standby (emergency) source. d) Reverse phase alarm pilot light is off or normal phase rotation pilot light is on. (A- 441A pump only) e) Oil level in vertical motor sight glass is normal. Diesel engine system conditions: a) Fuel tank is two-thirds full. b) Controller selector switch is in auto position. c) Batteries (2) voltage readings are normal. d) Batteries (2) charging current readings are normal. e) Batteries (2) pilot lights are on or battery failure (2) pilot lights are off. f) All alarm pilot lights are off. g) Engine running time meter is reading. h) Oil level in right angle gear drive is normal. i) Crankcase oil level is normal. j) Cooling water level is normal. k) Electrolyte level in batteries is normal. l) Battery terminals are free from corrosion. m) Water-jacket heater is operating

4 Effective 08/06/10 Page 4 of 11 Rev: 07/30/2010 Testing A weekly test of fire pump assemblies shall be conducted without flowing water. This test shall be conducted by starting the pump automatically. The electric pump shall run a minimum of 10 minutes. The diesel pump shall run a minimum of 30 minutes. A valve installed to open as a safety feature shall be permitted to discharge water. N/A - The automatic weekly test timer shall be permitted to be substituted for the starting procedure. Weekly Tests. Qualified operating personnel shall be in attendance during the weekly pump operation. The pertinent visual observations or adjustments specified in the following checklists shall be conducted while the pump is running: Pump system procedure: a) Record the system suction and discharge pressure gauge readings b) Check the pump packing glands for slight discharge c) Adjust gland nuts if necessary d) Check for unusual noise or vibration e) Check packing boxes, bearings, or pump casing for overheating f) Record the pump starting pressure Electrical system procedure: a) Observe the time for motor to accelerate to full speed b) N/A - Record the time controller is on first step (for reduced voltage or reduced current starting) c) N/A - Record the time pump runs after starting (for automatic stop controllers) Diesel engine system procedure: a) Observe the time for engine to crank b) Observe the time for engine to reach running speed c) Observe the engine oil pressure gauge, speed indicator, water, and oil temperature indicators periodically while engine is running d) Record any abnormalities e) N/A - Check the heat exchanger for cooling water flow

5 Effective 08/06/10 Page 5 of 11 Rev: 07/30/2010 (Electric) A-441A Pump Test 1) With system in normal run condition, (jockey pump on and firewater header pressure at set point of psig) contact the W.O.D. Control Operator to monitor underground firewater line pressure from the DCS and notify Boiler House Operator of test. DCS Firewater Line Pressure psig Controller Indicator Pressure Local Line Gauge Pressure psig psig 2) Lower firewater line pressure controller to psig 3) When firewater line pressure reaches psig this will start the delay start switch for A-441A, A-441C and A-441B pumps. A-441A pump should respond to pressure drop with in 10 seconds and energize. A-441A pump should start and pressure up firewater line and reset A-441C and A-441B timers before either pump is to respond. 4) As soon as A-441A pump responds adjust line pressure controller set point to psig and allow firewater line pressure to balance. Did A-441A pump start within 10 seconds after line pressure reached psig? (Circle one) YES or NO (If No record time: seconds) Did A-441C pump start? (Circle one) YES or NO Time A-441A pump started DCS Firewater Line HIGH Pressure psig 5) While A-441A pump is running conduct weekly inspection of pump. (follow the check list set up in SAP) 6) Allow A-441A pump to run for at least 10 minutes 7) After A-441A pump has run for10 minutes shut down pump from electric motor control panel. Pull handle to shut down position and leave A-441A pump off line while conducting weekly testing of other pumps. Time A-441A pump stops (Electric)

6 Effective 08/06/10 Page 6 of 11 Rev: 07/30/2010 A-441A off line Notice: Never leave firewater pump area without placing all operable pumps back in ready-standby condition. A-441C Pump Test 8) Allow firewater line pressure to line out at psig 9) Lower firewater line pressure controller to psig 10) When firewater line pressure reaches psig this will start the delay start switch for A-441C, A-441B pumps and A-441D. A-441C pump should respond to pressure drop with in 20 seconds and energize. A-441C pump should start and pressure up firewater line and reset A-441B and A-441D timer before either pump is to respond. 11) As soon as A-441C pump responds adjust line pressure controller set point to psig and allow firewater line pressure to balance Did A-441C pump start within 20 seconds after line pressure reached psig? (circle one) YES or NO (If No record time: seconds) Did A-441B pump start? (Circle one) YES or NO Time A-441C pump started DCS Firewater Line HIGH Pressure psig 12) While A-441C pump is running conduct weekly inspection of pump. (Follow the checklist set up in SAP) 13) Allow A-441C pump to run for at least 10 minutes 14) After A-441C pump has run for10 minutes shut down pump from electric motor control panel. Pull handle to shut down position and leave A-441C pump off line while conducting weekly testing of other pumps. Time A-441C pump stops A-441A, and A-441C, are off line Notice: Never leave firewater pump area without placing all operable pumps back in ready-standby condition.

7 Effective 08/06/10 Page 7 of 11 Rev: 07/30/2010 (Electric) A-441D Pump Test 15) Allow firewater line pressure to line out at psig 16) Lower firewater line pressure controller to psig 17) When firewater line pressure reaches psig this will start the delay start switch for A-441D and A-441B pumps. A-441D pump should respond to pressure drop with in 20 seconds and energize. A-441D pump should start and pressure up firewater line and reset A-441B timer before A-441B pump is to respond. 18) As soon as A-441D pump responds adjust line pressure controller set point to psig and allow firewater line pressure to balance Did A-441D pump start within 20 seconds after line pressure reached psig? (Circle one) YES or NO (If No record time: seconds) Did A-441B pump start? (Circle one) YES or NO Time A-441D pump started DCS Firewater Line HIGH Pressure psig 19) While A-441D pump is running conduct weekly inspection of pump. (Follow the check list set up in SAP) 20) Allow A-441D pump to run for at least 10 minutes 21) After A-441D pump has run for10 minutes shut down pump from electric motor control panel. Pull handle to shut down position and leave A-441D pump off line while conducting weekly testing of other pumps. Time A-441D pump stops A-441A, A-441C, and A-441D are off line Notice: Never leave firewater pump area without placing all operable pumps back in ready-standby condition.

8 Effective 08/06/10 Page 8 of 11 Rev: 07/30/2010 (Diesel) A-441B Pump Test 22) Allow firewater line pressure to line out at psig 23) Lower firewater line pressure controller to psig 24) When firewater line pressure reaches psig this will start the delay start switch for A-441B pump. A-441B pump should respond to pressure drop with in 60 seconds and energize. A-441B pump should start and pressure up firewater line. 25) Adjust firewater line pressure to psig and allow firewater line pressure to balance. Monitor engine temperature and oil pressure. Time A-441B pump started Did A-441B pump start within 60 seconds after line pressure reached psig? (Circle one) YES or NO (If No record time: seconds) DCS Firewater Line HIGH Pressure psig 26) While A-441B pump is running conduct weekly inspection of pump. (Follow the check list set up in SAP) Notice: It is recommended to wear proper hearing protection when diesel pumps are running while performing this task. After 15 minutes of run time record engine temperature and oil pressure. A-441B normal run temperature is 180 deg. F Circle one Temp. = LOW Normal High Engine Oil Pressure psig 27) Allow A-441B pump to run for at least 30 minutes 28) After A-441B pump has run for30 minutes shut down pump from motor control panel. Place switch in off position and leave A-441B pump off line while conducting weekly testing of other pumps. Time A-441B pump stops Is A-441B Diesel Fuel Tank Level at least 2/3 s full? YES or NO (If NO - Recharge Tank)

9 Effective 08/06/10 Page 9 of 11 Rev: 07/30/2010 (Diesel) A-441A, A-441B, A-441C, and A-441D are off line Notice: Never leave firewater pump area without placing all operable pumps back in ready-standby condition. A-441E Pump Test Do Not Allow Both Diesel Pumps to Run Through Firewater Header Kickback Valve at the Same Time. 29) Isolate A-441E pump from firewater line header system using 6-inch butterfly valve on discharge side of pump. This valve is locked in the open position and must be unlocked before changing its position. 30) Open manual kick-back valve to allow line pressure to decrees below 125 psig and allow firewater to discharge back to Raw Water Storage Canal. 31) When firewater line pressure reaches psig this will start the delay start switch for A-441E pump. A-441E pump should respond to pressure drop with in 120 seconds and energize. A-441E pump should start and discharge back to Raw Water Storage Canal. Adjust kick back valve so pump discharge pressure is at local gauge. Run A- 441E pump for 30 minutes. Time A-441E pump started Did A-441E pump start within 120 seconds after line pressure reached psig? (Circle one) YES or NO (If No record time: seconds) After 15 minutes of run time record engine temperature and oil pressure. Circle one Temp. = LOW Normal High Engine Oil Pressure 32) While A-441E pump is running conduct weekly inspection of pump. (Follow the check list set up in SAP) Notice: It is recommended to wear proper hearing protection when diesel pumps are running while performing this task. 33) Allow A-441E pump to run for at least 30 minutes 34) After A-441E pump has run for 30 minutes shut down pump from motor control panel. Place switch in off position.

10 Effective 08/06/10 Page 10 of 11 Rev: 07/30/2010 A-441E Pump Test cont d Time A-441E pump stops Is A-441E Diesel Fuel Tank Level at least 2/3 s full? YES or NO (If NO - Recharge Tank) A-441A, A-441B, A-441C, A-441D, and A-441E are off line Notice: Never leave firewater pump area without placing all operable pumps back in readystandby condition. Placing Pumps and System back in Ready Standby Mode 35) Make sure firewater line pressure is at psig before proceeding. DCS Firewater Line Pressure psig Controller Indicator Pressure Local Line Gauge Pressure psig psig 36) Close kickback valve on A-441E and line up pump back to the firewater line header by opening the 6-inch butterfly valve and locking it back using its yellow chain and firewater lock in the open position. 37) Place A-441E control switch to AUTO position. 38) Place A-441B control switch to AUTO position. 39) Place A-441-D Handle on control panel to AUTO position. 40) Place A-441-C Handle on control panel to AUTO position. 41) Place A-441-A Handle on control panel to AUTO position.

11 Effective 08/06/10 Page 11 of 11 Rev: 07/30/2010 Please record all deficiencies and take corrective actions to resolve. Action Item Corrective Action Date Completed Date: Signature: Ops Maint Unit Oper