Pump Operator Ch 16

Question 0

What is the best assurance that apparatus will perform within its design limitations?

Answer 0

An organized system of apparatus testing, plus regular maintenance, is the best assurance that apparatus will perform within its design limitations.
– Furthermore, the insurance industry requires that apparatus be tested in order for the community to receive full credit. This, in turn, affects the insurance rates in the jurisdiction.

Question 1

How often is a fire apparatus tested?

Answer 1

A fire apparatus is tested immediately after its construction – before the purchaser accepts it – to ensure that it performs in the manner for which it was designed.
– Once it is placed into service, it is tested at least yearly to ensure that it will continue to perform properly under emergency conditions.

Question 2

What two basic categories can apparatus testing be grouped into?

Answer 2

– Pre-service tests and service tests.

Question 3

Why must the driver/operator have a basic understanding of the pre-service test?

Answer 3

To be able to appreciate and understand the service tests. The driver/operator will often be required to perform these tests or at least assist mechanics who are doing them.

Question 4

What are the three categories of the pre-service tests?

Answer 4

– Manufacturers tests
– Certification tests
– Acceptance tests
To ensure that they are performed, these tests must be required in the apparatus bid specifications.

Question 5

What is NFPA 1901 deal with?

Answer 5

It’s the standard for automotive fire apparatus.

Question 6

What does NFPA 1906 deal with?

Answer 6

It’s the standard for wildland fire apparatus

Question 7

What does NFPA 414 deal with?

Answer 7

Standard for aircraft rescue and firefighting vehicles

Question 8

NFPA 1901-1906 and 414 are used as a basis for most apparatus bid specifications.

Answer 8

When specifications are written for an apparatus, they should contain a clause that requires them to me the pertinent chapters of these NFPA guidelines.
– The clause should state that failure to meet these requirements will be cause for rejecting acceptance of the apparatus.

Question 9

The manufacturer is required to perform two specific tests in addition to the pump certification test:

Answer 9

The Road test and the hydrostatic test

Question 10

Road test:

Answer 10

NFPA requires the following minimum tests to be conducted on the fire apparatus after its construction is complete. The apparatus is fully loaded in the same manner as it would be once in service. This includes making sure that the water and/or foam tanks are full and the weight of hose and equipment that will be carried on the apparatus are accounted for. The road tests should be conducted in the location and a manner that will not violate any applicable traffic laws or motor vehicle codes. The test surface should be a flat, dry, paved road surface that is in good condition.
– The apparatus must accelerate to 35 mph from a standing start within 25 seconds. This test must consist of two runs, in opposite directions, over the same surface
– The apparatus must achieve a minimum top speed of 50 mph. This requirement may be dropped for specialized wildland fire apparatus not designed to operate on public roadways
– The apparatus must come to a. From 20 mph within 35 feet
– The apparatus parking brake must conform to specifications listed by the braking system manufacturer
Departments that protect hilly for mountainous jurisdictions may have special requirements for apparatus acceleration, deceleration and breaking capabilities on roads with specific degrees of slope. Many prefer to write their own performance-based specifications

Question 11

Hydrostatic testing:

Answer 11

The hydrostatic test determines whether the pump and pump piping can withstand pressures normal he encountered during firefighting operations.
– Pumps are tested hydrostatically at 250 psi for three minutes. The tank fill line, tank to pump line, and bypass lines valves should be closed during this test. Discharge valves should be opened and capped. Intake valves should be closed and/or capped. The test pressure should be maintained on the system for a minimum of three minutes without the failure of any components of the system.

Question 12

Pump certification testing:

Answer 12

Pump certification tests are performed to make sure that the fire pump system operates in the manner for which it was designed after the pump and components are installed on the apparatus chassis. These tests must be conducted by an independent testing organization, such as underwriters laboratories.
– NFPA 1901 requires the following pump certification test for apparatus that are equipped with a 750 GPM or larger fire pump:
– Pumping test
– Pumping Injun overload test
– Pressure control system test
– Priming device test
– Vacuum test
– Water tank to pump flow test
– Internal intake pressure relief valve test – if so equipped –
Apparatus with a fire pump that has a rated capacity of less than 750 GPM are required to undergo the same certification test, with The exception of the pumping Engine overload test. The test may be omitted for smaller pumps.

Question 13

How long does the certification pump testing require the pump be operated at, versus the service pumping test?

Answer 13

Certification pump testing requires the pump be operated for three hours. Versus 40 minutes for the service pumping test per NFPA 1901

Question 14

Acceptance testing:

Answer 14

Acceptance tests are conducted to assure the purchaser that the apparatus meets bid specifications at the time of delivery. A representative of the manufacturer is present during testing.
– The acceptance test should include another pump test, even if a certification test was performed at the factory. Instances have happened where a pump that was certified at the factory failed to perform as desired or rated once it was delivered.
– If the apparatus fails to perform according to the requirements detailed in the bid specifications, it should be rejected. On occasion, the manufacturer or sales person may attempt to offer the purchaser alternative credits, such as chrome wheels or gold Leaf lettering, to compensate for an apparatus that fails to meet all of the performance specifications. It is generally an unwise decision to accept this trade off. The most important factor in making this purchase is getting an apparatus that performs as needed during an emergency.
– An important acceptance testing issue arises when the jurisdiction purchasing the apparatus is located at an altitude in excess of 2000 feet above sea level. In these cases, the pumping engine overload test must be performed during acceptance testing. This ensures that the engine develop the necessary power to operate in the jurisdiction it serves

Question 15

The requirements for fire department service testing are contained in which NFPA guideline?

Answer 15

The requirements for fire department service testing are contained in NFPA 1911, standards for service test of fire pump systems on fire apparatus.

Question 16

Pumper service tests:

Answer 16

According to the standard, a pumper should be given a service test at least once a year for whenever it has undergone extensive pump for powertrain repair. These service tests are necessary to ensure that the pumper will perform as it should and to check for defects that otherwise might go unnoticed until a failure occurred.
– The driver/operator’s need to know how to perform the minimum service test required in NFPA 1911. These tests include the following:
– Engine speed test
– Priming device tests
– Vacuum test
– Pumping test
– Pressure control test
– Gauge and flow meter test
– Tank to pump flow rate test
– Internal intake pressure relief valve test – if so equipped –

Question 17

Site considerations for pumper service tests:

Answer 17

NFPA 1911 says that pumper service test may be conducted using either a fire hydrant or static body of water as a supply source. Most jurisdictions prefer to draft from a static source during testing because this is a true test of the pumps capability. When using a static water supply source, the water must be at least 4 feet deep. The strainer must be submerged at least 2 feet below the surface of the water. The surface of the water may be no more than 10 feet below the centerline of the pump intake, and 20 feet of hard intake hose should be used for drafting during testing.
– The atmospheric air temperature during testing should be between 0°F and 100°F. The water being used for testing should be between 35°F and 90°F because hotter water has less surface tension and could affect test results.
– The barometric pressure should be at least 29 inches of mercury corrected to sea level. This is because a 1 inch drop in barometric pressure reduces a pumpers maximum possible static lift by about 1 foot
– These figures are good for tests that are performed at altitudes of up to 2000 feet above sea level. Beyond that, it may be necessary to increase intake hose diameter of the number of intake hoses used in order to pump the rated capacity.
– Altitude affects the pumps performance: lifting ability drops about 1 foot per 1000 feet increase in altitude; gasoline engines have 3.5% less efficiency per 1000 feet increase in altitude.
– It is necessary to layout a sufficient number of discharge hoses and nozzles to pump the rated capacity of the fire pump. 2 1/2 inch hose is the minimum size hose that may be used for this application. Larger hoses may be used if available. Make sure that whatever hoses used has been tested to ensure that it is capable of withstanding the discharge pressures during the pump test. Scribe a mark where the hose and couplings meet.
– If the scribe Mark moves more than 3/8 of an inch away from the coupling, stop the test and replace the hose.

Question 18

Correcting net pump discharge pressure for the tests:

Answer 18

The pump service tests are to be conducted at 150, 165 – overload –, 200, and 250 psi net pump discharge pressure. Net pump discharge pressure is the total work done by the pump to get the water into, through, and out of the pump. When at draft, the net pump discharge pressure is more than the pressure shown on the discharge gauge. Therefore, when the tests are conducted, the allowances for friction loss in the hard intake hose and the height of the lift must be taken into account.
– The allowances for friction loss are then used to determine the correct pump discharge pressure during each test. The following formulas are used to make this calculation:
Pressure correction = lift (m) + intake hose friction loss / divided by 0.1

Question 19

Equipment needed for service tests:

Answer 19

Equipment for performing service test must be in good condition and be tested regularly. NFPA 1911 requires that all gauges must have been calibrated within 60 days of the testing. Gauges can best be tested for accuracy by an independent third-party using a deadweight tester. The phone equipment is needed to perform the test for pumpers:
– A gauge to check the pump intake pressure. This gauge should have a range of 30 inches. HG vacuum to 150 psi for compound gauges
– A gauge to check the pump discharge. This gauge should be capable of a range from at least 0–400 psi
– Peto tube with knife edge and air chamber rated at least from zero psi – 160 PSI. Note: this is not needed if a flowmeter is used
– Straight stream nozzles of correct sizes to match the volumes pumped for the different tests. Note: if a flowmeter is used, fog nozzles may be used provided they are rated for the necessary flows.
– Rope, chain, or a test stand for securing test nozzles
– Revolution counter or hand tachometer
– Fire department for insurance agency forms. Recommended, but not required, are the following:
– 2 6foot length of quarter inch 300 psi hose with screw fittings. Note: these are used to connect the test gauges to the test gauge fittings at the pump operators panel
– Clamp to hold Peto tube to test nozzle
– Thermometer
– Stopwatch or watch with sweeping secondhand
–

Question 20

What are a Peto tube and gauge used to measure?

Answer 20

The velocity pressure of the stream of water

Question 21

Flowmeters:

Answer 21

A flowmeter, which reads the flow directly into gallons per minute, may be used instead of a Peto gauge to determine the flow from the nozzles. Flowmeters allow much more flexibility and help to complete the test more quickly. When a flow meter is used, all the pump test can be run without shutting down the pump, without changing nozzles and without having to convert Peto pressure readings to GPM. It flow meters are used, they must be calibrated to the manufacturers specifications

Question 22

Safety precautions during service test:

Answer 22

– All personnel should wear protective headgear and hearing protection – if exposed to noise in excess of 90 dB
– Preevent waterhammer: open and close all valves and nozzles slowly
– Do not stand over or straddle hose
– Manipulate the engine throttle slowly. Prevent sudden pressure changes, which can damage equipment and injure personnel
– Tie down test nozzles and devices securely
– Cover all open manholes at the test pit
– Be aware of the location of all personnel in the test area in relation to hoselines

Question 23

Engine speed check:

Answer 23

– Check all fluid levels before the first test – the engine speed check.
– The engine speed should be checked under no load conditions to ensure that it is still running at the same governed speed that it was rated for when the apparatus was new. If it is not running at the correct speed, no further testing should be started until the situation is corrected by a trained mechanic.
– The engine speed may be checked by the tachometer on the engine and/or a properly calibrated and he’ll tachometer or revolution counter

Question 24

Vacuum test:

Answer 24

– The vacuum test is performed to check the priming device,, and hard intake hose for air leaks. Most agencies prefer to perform this test first because it will be difficult to proceed if the apparatus is unable to hold an appropriate vacuum.
Step one: make sure that the pump is completely drained of all water
Step two: inspect all gaskets of intake hose and caps
Step three: look for foreign matter in the intake hose. Clean the hose if necessary
Step four: connect 20 feet of the correct intake hose to the pump intake connection. Check original test records for correct diameter of hose
Step five: cap The free end of the intake hose
Step six: make sure that all intake valves are open and the intake connections are tightly capped. As well, all discharge valves should be closed and they are caps should be removed
Step seven: connect an accurate vacuum gauge or mercury manometer to the threaded test gauge connection on the intake side of the pump.
*Caution: if the gauge is not connected to the intake side, it will be irreparably damaged.
Step eight: check oil level of priming pump reservoir if so equipped. And replenish if necessary
Step nine: make pump packing glands accessible to check for leakage raise floorboards or open compartment doors.
Step 10: run the priming device until the test gauge shows 22 inches of mercury developed. Note: reduce the amount of mercury developed 1 inch for each 1000 feet of altitude.
Step 11: compare readings of the apparatus intake gauge and test gauge. Record any difference
Step 12: shut off the engine. Listen for air leaks. No more than 10 inches of vacuum should be lost in five minutes. Excessive leaks will affect the results of subsequent tests and should be located and corrected before performing the rest of the test.
– If the apparatus is unable to reach 22 inches of mercury, the apparatus should be removed from service and repaired as soon as possible.

Question 25

Testing the condition of hard intake hose:

Answer 25

Step one: make sure that the pump is completely drained of all water
Step two: inspect all gaskets of intake hose, and remove the gasket from the intake cap
Step three: look for foreign matter in the intake hose. Clean the hose if necessary
Step four place a lighted flashlight into the hose, just inside the female coupling, that will be connected to the intake
Step five: connect 20 feet of the correct intake hose to the pump intake connection check original test records for correct diameter of hose. Support the hose on drums or sawhorses so that it is relatively straight
Step six: make sure that all intake valves are open and the intake connections are tightly capped. As well, close all discharge valves and remove their caps
Step seven: connect an accurate vacuum gauge or Mercury manometer to the threaded test gauge connection on the intake side of the pump
Caution – if the gauge is not connected to the intake side, it will be irreparably damaged
– Step eight check oil level of priming pump reservoir if so equipped and replenish if necessary
– Step nine – make pump packing glands accessible to check for leakage. raise floorboards or open compartment doors
– Step 10 – place the Gasket against the mail and of the hose and then use a sheet of 3/8 inch Lexan or other hard, clear plastic, large enough to cover the entire opening against the gasket. Hold the gasket and plastic in place until the priming device is operated
– Step 11 – run the priming device until the test gauge shows 22 inches of mercury developed. 1 inch for each 1000 feet of altitude
– Step 12 – compare readings of the apparatus intake gauge and test gauge. Record any difference
– Step 13– Shut off the engine. Listen for air leaks. No more than 10 inches of vacuum should be lost in five minutes
– Step 14 – looking through the clear plastic, examine the inside of the hose for any signs of bubbling or liner separation. These signs sometimes form slowly

Question 26

After the dry vacuum and or hard intake hose test is completed, prepare the pumper for the remainder of the tests:

Answer 26

– Step one: open a discharge valve to allow the pressure in the pump to equalize
– Step two: replace the Cap at the end of the intake hose with the intake strainer
– Step three: use standard departmental procedure to tie off intake hose in preparation for drafting, then lower the hose into the water. The strainer should be at least 2 feet below the surface. The sides and bottom of the strainer should also have at least 2 feet of water surrounding them
– Step four: connect the discharge pressure test gauge to the pressure side of the pump at the test fitting on the operators panel
– Step five: connect an adequate number of hose lines to carry the capacity of the pump to the test. The test nozzle must be the correct size to handle the capacity of the pump
– Step six: make sure that the nozzle is secured so that it cannot come loose and injure personnel. – Never hold the test nozzle by hand during a test!
– Step seven: connect the Pido gauge and test stand gauges. It is recommended that the Peto gauge be clamped in position at the nozzle

Question 27

Steps to the pumping test:

Answer 27

The pumping test checks the overall condition of the engine and the pump. To obtain the correct engine and nozzle pressures for the capacity test, some adjustments and readjustments have to be made. All changes must be made slowly to prevent damage to the pump and hose and possible injury to personnel and to allow time for the resulting pressure changes to register on the test gauges.
– Step one: gradually speed up the pump until the net pump discharge pressure is 150 psi, adjusted for intake hose friction loss and altitude. If the pump is a two-stage pump, the transfer valve must be in the parallel/volume position.
– Step two: check the flow at the nozzle, using either a Peto gauge or a flowmeter. If the flow is too great, close a valve further. Reduced engine speed to correct discharge pressure. If the flow is too low, open a valve further. Increase engine speed to correct discharge pressure. – Note: all of these adjustments must be made without the engine speed exceeding 80% of its peak performance
– Step three: when both the pump discharge pressure and the volume flowing or satisfactory, the test officially begins. The following readings are made and recorded at the beginning of the test and at five minute intervals thereafter until the 20 minutes for the test are over. – Note: fluctuations in pressure necessitate more frequent readings.
– Pump discharge pressure
– Nozzle pressure or flow
– Engine tachometer
– RPM using portable rpm counter
– Engine coolant temperature – optional –
– Oil pressure – optional –
– Automatic transmission fluid temperature – optional –
– Step for once the 20 minute capacity test has been completed, the net pump discharge pressure should be increased to 200 psi. At this point, the pump should be delivering at least 70% of it’s rated volume capacity. According to NFPA 1911, two stage pump transfer valves may be in either the parallel/volume or series/pressure position for this portion of the test. It is best to see the pump certification paperwork to see which position The transfer valve was in during the certification test and use the same.
– The pump should be allowed to run at this setting for 10 minutes
– Step five: once the 200 PSI test has been completed, the net pump discharge pressure should be increased to 250 psi. At this point, the pond should be delivering at least 50% of it’s rated volume capacity. Two-stage pump transfer valves must be in the series/pressure position for this portion of The test. The pump should be allowed to run at this setting for 10 minutes
– Hold the Peto gauge with the blade opening in the center of the stream with the tip about one half the nozzle diameter from the end of the nozzle. If the Pido is too close to the nozzle, the reading will be erroneously increased
– Keep the engine temperature within the proper range
– Check the oil pressure to be sure that proper engine lubrication is maintained
– Record any unusual vibration of pump or engine
– Record any other defect in the performance of pump or engine. Correct minor defects immediately if possible