DRIVER OPERATOR Page 1 of 10 APPARATUS SERVICE TESTING Pump Testing Pumps test are generally classified into two types based on when they are performed. The first is the Acceptance Test. The Acceptance Test is performed at the manufacturer or the purchasing agency to determine if the pump performs up to specifications. Passing the Acceptance test is required by the purchasing agency before taking possession of the apparatus. The second type of pump test is the Annual Pump or Service Test. Engineers perform daily, weekly and monthly checks of pump components. The Annual Test is a more comprehensive test of the pump. This test is completed on all units with pumps including the Brush units. The purpose of the Annual Pump Test is three fold. First it identifies the current status of the pump as compared to its rating. Second it allows charting the pump s performance over its life time and lastly it helps identify repair and maintenance needs. Besides the annual tests, a pump should be fully tested after major pump repair. This condition would most likely occur after a catastrophic failure during operations or a major repair need identified during the Annual Test. Due to the complexity and time required Annual Pump Tests at the Escondido Fire Department are performed by designated people. This provides consistency conducting the test and a single point of contact who can facilitate and follow up on needed repairs. The draft pit at Fire Station One is where the tests are performed. Before the test we must ensure there is adequate water in the draft pit. Normally there should be 7 to 8ft. vertical distance from the surface of the water to the eye of the pump. The water level must be monitored during the test. Do not use foam discharges or cause foam to enter the pit. Excessive foam in the drafting pit make certain parts of the test impossible. The hard suction hose can be used from the drafting horn or placed directly into the manhole cover. Material and Equipment List 10' of hard suction hose with a cap Mallet 2 1/2" Stream Shaper Three 3" X 50' Hose Lengths Test Gauges (Vacuum and Pressure) Stop Watch
DRIVER OPERATOR Page 2 of 10 Pitot Pressure gauge with appropriate smooth bore tips Test Tachometer Clipboard with a Test Sheet Form Deluge Gun with the Appropriate Tip Thermometers (Air and Water) Measuring Tape Personnel Roles Timer/Recorder: Takes all the readings and records the information on the test sheet. Pump Operator: Operates all equipment, valves, etc. Assistant: Helps as necessary. TEST PROCEDURE No Load Engine Speed 1. Close tank-to-pump valve and drain pump Note: If you open a discharge valve while the pump is draining it will allow air to enter the pump, thereby making it drain faster. Remember to close it. 2. Start the engine and engage pump 3. Throttle up the engine to full RPM with hand throttle. Note: The pump is running dry so the test should be completed in a timely manner to reduce any chance of damage to the pump packing or seals. (Usually less than one minute) 4. Record findings. The test RPM should meet or exceed the No Load Governed Speed listed on the Underwriter s plate Dry Vacuum 1. Remove Keystone completely from pump panel 2. Close all ports, drains, bypasses, etc. 3. Disconnect all hoses and remove all discharge caps 4. Connect the vacuum and PSI test gauges (use nylon tape around threading) 5. Hook up 10' of hard suction hose and cap it
DRIVER OPERATOR Page 3 of 10 Note: Having the hard suction hooked up during the dry vacuum test allows you to check the couplings for leaks. Use the mallet to tighten as necessary. Note: In order to increase battery life, it is recommended that all engines be run at approximately 1000+ rpm when operating priming pumps. Once the main pump is evacuated, you should shut off the engine to listen and/or feel for any leaks. 6. Engage the priming pump - pull a minimum of 22" of vacuum within 45 seconds Note: Apparatus that utilize Automatic Pressure Governors MUST be set in the RPM mode to pull draft. When the pump is empty in pressure mode, it will default to show no possible increase in pressure and therefore, disengage the throttle. Once draft has been achieved in RPM mode, water can be discharged and the pump switched back to the Pressure mode. This is the dry vacuum portion so water will not flow but during the capacity tests, this can become an issue if not in the proper setting. 7. The vacuum must not drop more than 10" in 5 minutes 8. Record the information on the test sheet 9. Release the vacuum slowly through a discharge port Setting up the test pit and Engine for the Pump Test 1. Connect a second 10 section of hard suction to the previous dry vacuum section 2. Install the pitot onto the deluge stream shaper and the pitot hose to the test gauge. 3. Hook up three 3 hoses to the apparatus discharges and deluge pump manifold Note: Apparatus with 500-750 gpm capacity will only need two 3 lines 4. Start the engine and engage the pump 5. Using the primer, pull a draft and flow water to the deluge 6. Check for leaks and kinks in hose lines 7. Shut down all flowing water and prepare to move to the capacity tests Note: Engine should not lose prime at this point. If it does, continue to the next test and begin with re-pulling prime until water flows
DRIVER OPERATOR Page 4 of 10 100% GPM Capacity at 150 PSI: Note: Make sure the pressure relief device is set to the required flow of 150 psi. Make sure a two-stage pump is in volume (parallel) or Pressure Mode. 1. Install the proper nozzle tip into the pitot for the 100% test using the nozzle tip size chart for reference. Operate the throttle and open or close discharges as necessary. 2. Using the valves, set the GPM (per the discharge gauge and the test gauge) and the PSI (per the pitot gauge) as required. Each discharge pressure is not part of the test. Pump each line based on an accurate GPM and pitot pressure. Note: Refer to the factory Underwriters test plate on the pump panel as an indication of the engine rpm necessary. 3. This test is for 20 minutes 4. Record the information every 5 minutes on the test sheet 5. Go directly to the relief valve test without shutting down the engine Relief Valve Test: 1. Engage and set the pressure relief device at 150 PSI if not already set 2. Close all discharges slowly, 4 to 10 seconds each, the increase may not be over 30 PSI when all discharges are closed 3. Record the information on the test sheet 4. Open the discharges slowly 5. Throttle down to 90 psi 6. Set relief valve to 90 psi 7. Close all discharge valves slowly, 4 to 10 seconds each, the increase may not be over 30 PSI 8. Throttle down to an idle and record the information on the test sheet 9. Go directly to the next test 70% GPM Capacity at 200 PSI: 1. Install the proper nozzle tip into the pitot for the 70% test using the nozzle tip size chart for reference. Operate the throttle and open or close the discharges as necessary. Remember to reset your relief valve to 200 psi or higher
DRIVER OPERATOR Page 5 of 10 2. Using the valves, set the GPM (test gauges) and the PSI (pitot gauge) as required Note: Only one or two lines are required for this test 3. This test is for 10 minutes 4. Record the information on the test sheet every 5 minutes 5. Throttle down and close discharges slowly 6. Go directly to the next test 50% GPM Capacity at 250 PSI: Note: With a two-stage pump, this test must be performed in pressure (series). 1. Install the proper nozzle tip into the pitot for the 50% capacity test using the nozzle tip size chart for reference 2. Operate the throttle and open or close the discharges as necessary. Remember to set your relief valve to 250 PSI 3. Using the valves, set the GPM (test gauges) and the PSI (pitot gauge) as required Note: only one line is required for this test 4. This test is for 10 minutes 5. Record the information on the test sheet every 5 minutes. Relief Valve Test 1. Set the relief valve to 250 PSI if not done already 2. Close the discharge slowly, 4 to 10 sec., the increase may not be more than 30 PSI 3. Throttle down to an idle
DRIVER OPERATOR Page 6 of 10 After The Test: 1. Let the engine warm down (especially turbos) 2. Reset the engine to go back into service 3. Make sure the pump is full of water; reset the pressure relief device, the tank to pump valve, etc. 3. Put all the equipment away and clean up your mess 4. Type up the test sheet and log it into the S drive 5. Type up a Vehicle Condition Report and email it if any failures or faults found with the apparatus during the test Suggested Nozzle Tip Size per Pump Tests Net Pump Pressure Nozzle Tip Size Pitot Pressure PSI GPM 500 GPM Pumper 100% capacity 70% capacity 50% capacity 150 200 250 1 ½ 1 1/8 1 1/8 58 88 68 508 351 254 750 GPM Pumper 100% capacity 70% capacity 50% capacity 150 200 250 1 ¾ 1 ½ 1 1/8 68 62 100 750 525 374 1500 GPM Pumper 100% capacity 70% capacity 50% capacity 150 200 250 2 ¼ 2 1 ¾ 100 78 68 1505 1050 750
DRIVER OPERATOR Page 7 of 10 Trouble Shooting: PROBLEM POSSIBLE CAUSE REMEDY Air leak(s) Suction gauge reading low vacuum Defective priming valve Engine speed too high or low Make sure all the valves are closed; listen for air leaks; the problem could be in the clapper valves or the check valves A worn or damaged priming valve may leak and cause the pump to lose prime Mechanically operated primers are designed to operate at certain speeds; check instruction manual Note: One method to locate leaks in the pump and plumbing is to connect to a hydrant, disengage the pump, shut off the engine, and, using hydrant pressure, check for water leaks. Low pump capacity End of suction hose not deep enough High point in suction hose Debris on the strainer Engine and pump speed too low Engine and pump speed too high Make sure the end of the hose is at least 2' deep to prevent whirlpools which allow air to be drawn into pump Do not place any part of the suction hose higher than the pump inlet to prevent air pockets from forming in the hose Check and clean the strainer(s) Lack of engine horsepower; may involve major repairs; the throttle not operating properly; problem with the fuel; engine over heating road transmission in wrong gear Suction is restricted; clean the suction Lift too high; adjust the baffle Water too warm (over 85 F) Collapsed or defective suction hose
DRIVER OPERATOR Page 8 of 10 PROBLEM POSSIBLE CAUSE REMEDY Low pump pressure Pump capacity limits pump pressure Exceeding the pump capacity will reduce pressure in an inverse ratio; surpassing the maximum recommended pump speed will cause cavitation and impair pump efficiency Pump speed too low Check the engine speed governor if so equipped; check for clutch slippage Guide for Annual Pumper Service Test (How to complete the Annual Pumper Service Test form.) 1. The date will be filled in at the time of the test. 2. The vehicle numbers and unit description lines will be filled in on the work sheet by the equipment officer 3. On the line "Tested By", enter the name of the officer or acting officer who conducted the test. This person shall also be the recorder during the test. 4. On the line "Operated By", enter the engineer or acting engineer who operated the engine and pump. 5. On the line "Test Equipment", mark the tip size or flow meter used. 6. Time Column: Record the time of day and at five minute intervals. Use the 24 hour clock system. Example: 1323, 1328, 1333, etc. 7. RPM Panel Tach Column: Record the tach reading at the engineer's panel. 8. PSI Test Gauge Column: Record indicated pressure. 9. PSI Apparatus Gauge Column: Record indicted pressure on the main pump pressure gauge. 10. Pilot Gauge Column: Record the pressure indicated on the pilot gauge or the indicated GPM on the flow meter. 11. Lift Feet Column: Record the number of feet between the center of the suction inlet and the water level in the drafting pit. 12. Vacuum In. Hg. Column: Record indicated inches of mercury on the test gauge.
DRIVER OPERATOR Page 9 of 10 13. Eng. Temp., Oil Pressure, Pit Temperature, Air Temperature Columns: Record readings at the start and finish of the test. 14. Remarks: Record any useful information. 15. After completing the work sheet, type the information on a blank form for placing into the unit's permanent records and save it to the S drive under fire/operations/apparatus/apparatus pump tests/year. Rename your file as the City ID and Unit Designator. Also, this should be forwarded to the Apparatus Battalion Chief for further documentation. ESCONDIDO FIRE DEPARTMENT ANNUAL PUMPER SERVICE TEST TESTED BY: ENG MILEAGE: DATE: OPERATED BY: ENG HOURS: CITY ID NO: ATMOSPHERIC PRESSURE: 14.7 PUMP HOURS: UNIT #: CHASSIS MFG.: MODEL: ENGINE MFG.: MODEL PUMP MFG.: MODEL: GEAR RATIO: TEST LOCATION: LISTED NO LOAD ENGINE SPEED: SUCTION SIZE: LENGTH: 10 + PIT MANIFOLD PANEL RPM DRY VACUUM TEST (W/10 Hard Suction): Inches Vacuum in Sec. Drop Inches In Min TIM E 100% CAP. TEST (20 MIN.) @ 150 PSI. - 1500 GPM - 2 ¼ TIP - (3) 3 LINES - 50 LONG TE ST TA CH APP TACH PAN EL CAB TEST E APP E PITO T GAU GE LIF T FE ET VAC E ENG PAN EL CAB OIL PRESS PANE L CAB PIT AIR RELIEF VALVE TEST: RISE IN PRESSURE @ 90 PSI. @150 PSI & Pumping at Capacity. RISE IN PRESSURE
DRIVER OPERATOR Page 10 of 10 TIME 70% CAP. TEST (10 MIN.) @ 200 PSI. - 1050 GPM - 2 TIP - 3 LINES - 50 LONG TE ST TA CH APP TACH TEST APP PITOT LIF T VAC ENG PANEL CAB E E E FE ET E PAN EL CA B OIL PRESS PAN EL CA B PIT TEM P AIR TEM P TIM E 50% CAP. TEST (10 MIN.) @ 250 PSI. - 750 GPM - 1 ¾ TIP (1) 3 LINE - 50 LONG TE ST TA CH APP TACH TEST APP PITOT LIF T VAC ENG PANEL CAB E E E FE ET E PAN EL CA B OIL PRESS PAN EL C A B PIT AIR TEM P RELIEF VALVE TEST: RISE IN PRESSURE @ 250 PSI & 50% Capacity. COMMENTS: #M-227