METHOD STATEMENT FOR TESTING & COMMISSIONING OF FIRE PUMP
TOOLS / EQUIPMENTS / TEST INSTRUMENTS
START – UP AND COMMISSIONING
INSPECTION & RECORDS
The purpose of this procedure is to define the step by step method to implement the correct practices for the pre-commissioning & commissioning of “Fire Pumps” through the guidelines contained herein so as to ensure that the job execution complies with the project requirements and serves the intended function to satisfactory level.
The scope of this Method Statement is to define the method of Testing and Commissioning of Fire Pumps installed within the project in accordance with the a part of commissioning checks at site.
3.1 Contract Specifications and Approved Shop Drawing
3.2 Approved Material Submittals
3.3 Manufacturer’s Instructions
4.0 TOOLS / EQUIPMENT /MATERIAL /TESTING INSTRUMENTS
4.1A .Consists of Electrical, Diesel and Jockey Pump (Vertical Turbine Pump – 1E+1D+1J)
4.1B. Pump and motor assembled on a separate base frame, coupled using suitable coupling arrangement by the manufacturer.
4.1C. OS & Y valves, NRV, flexible connectors and piping accessories as per approved submittals.
4.1D. Pump foundation as per manufacturer’s recommendations and approved shop drawings.
4.1E. Autotransformer type Control Panel.
4.2 Digital Multimeter
4.3 Clamp Meter
5.0 QUALITY CONTROL
In general, it shall be ensured by site engineer that product manufacturer’s recommendations are followed
Engineer shall further oversee the Pre-commissioning and commissioning activity as per the approved method statement for Start-up and Commissioning of Fire Pumps
The Fire Pump shall be tested and Commissioning under direct supervision of manufacturer / local dealer’s representatives.
6.0 START – UP AND COMMISSIONING
Pre – Commissioning Mechanical:
6.1.1 Check and inspect the installation of Fire Pump is complete; verify the installation as per approved drawings.
6.1.2 Verify compliance to the manufacturer’s installation instructions.
6.1.3 Obtain installation certification from manufacturer or their authorized local representative.
6.1.4 Check and ensure adequate clearance available for service and maintenance of pumps and motors.
6.1.5 Check the installation is coordinated with other services.
6.1.6 Ensure the shipping bolts / clamps are removed.
6.1.7 Check all nuts, bolts, screws, fasteners etc., are fixed and tightened as required.
6.1.8 Ensure the piping is pressure tested. Verify test certificates.
6.1.9 Check all piping connections are complete at pumps, flow meter and pressure relief line
6.1.10 Check and ensure the piping is flushed and cleaned.
6.1.11 Check the alignment is completed as per manufacturer’s instructions.
6.1.12 Check and verify the water level in the water tank is full.
6.1.13 Check and ensure the safety guards are in place and secure.
6.1.14 Adjust desired cut-in and cut off pressure as per requirements.
6.1.15 Ensure the pumps are cleaned prior to start-up and all identification labels and tags are in place.
6.2 PRE – COMMISSIONING ELECTRICAL
6.2.1 Check all power cabling and control wiring is completed and dressed neatly.
6.2.2 Check the power isolator is fixed close to the pump motor for emergency stop and power isolation, as per approved drawings / details.
6.2.3 Check all terminations are completed and tightened as required.
6.2.4 Check the grounding connections are completed and tightened as required.
6.2.5 Ensure the overload protections are set correctly as per the pump motor load current.
6.2.6 Ensure all identification tags and labeling works are complete.
6.3 ELECTRIC DRIVEN FIRE PUMP
6.3.1 Open suction gate valves
6.3.2 Check that pumps are full of water and that all air contained in pump has been allowed to escape through the air release valve.
6.3.3 Lower setting of pressure switch (senses discharge pressure) to prevent pump from starting.
6.3.4 Place the main disconnect switch in the ‘ON’ position.
6.3.5 Place circuitry breaker in the ‘ON’ position and check if POWER ON light is illuminated.
6.3.6 Check direction of driver rotation by pressing momentarily the ‘Start’ and then ‘Stop’ push buttons on the controller (proper direction is indicated by arrow on pump casing), for in-line pump use a light on shaft to see rotation (this is clockwise looking down from top of motor). If rotation is wrong interchange motor leads in panel per instructions in panel.
6.3.7 Bring the timer setting down to one (1) minute for automatic start test purpose.
6.3.8 Open system valve.
6.3.9 Bleed the system by opening a valve on the pressure sensing line to create a pressure drop.
6.3.10 As soon as fire pump starts check if full load current value is within the electric motor nameplate rating with service factor taken into account
6.3.11 Check packing adjustment to obtain slight leak of approximately 1 drop per second.
6.3.12 After running for one minute (time set on the running period timer), stop pump with stop button. If you try stopping it before the time set on the timer, the pump will not stop.
6.3.13 Bleed again until desired start-up pressure is attained.
6.3.14 Allow jockey pump to stop automatically at pressure switch setting.
6.4 AUTOMATIC OPERATION
6.4.1 Open system butterfly valve and turn all the isolating valves to the fully open position.
6.4.2 Place the main disconnect switch one the ON position.
6.4.3 Switch fire pump circuit breaker to the ON position.
6.4.4 Switch the jockey pump to AUTO (the Power ON light must be lit).
6.4.5 Record all pump and motor nameplate data in the commissioning format.
6.4.6 Ensure compliance to all manufacturer’s start-up and commissioning instructions, as applicable.
7.0 INSPECTION & RECORD
7.1 Request for Inspection shall be raised for Consultants inspection.
7.2 Signed-off pre-commissioning check lists.
7.3 Commissioning reports.
7.4 Calibration certificates of testing instruments.
8.1 All safety precautions shall be followed as per the established Project Safety Plan.
8.2 Only experienced and skilled technicians shall be engaged for carrying out Start-up and Commissioning of Fire Pumps.
8.3 Safety Guards shall be in place and secured prior to start-up.
8.4 Cable test reports shall be verified prior to energisation.
8.5 Appropriate Warning signs and tapes shall be placed during start-up and commissioning as required.
8.6 All PPE shall be worn as appropriate according to the nature of the job.
8.7 Work area shall be maintained neat and clean.
9.1 Schedule of Fire Pumps.
9.2 Pre commissioning check sheet for Fire Pumps.
9.3 Fire Pump Commissioning sheet.
9.4 Test Certificate for Fire Pump.