TRAINING MANUAL REQUIREMENTS AND

FORMAT

Document Change history

Version Date Author Description of Changes

0 01 Aug 2023 AA Initial Document

 1. Purpose
The purpose of this document is to provide guidance on the training manual submission,
review and contents to be provided by VENDORS / SUPPLIER to Hilton.

2. DOCUMENT SUBMISSION REQUIREMENT

1. Each training manual must be submitted in two versions:

 Version 1 - Before the commencement of the training (For those who attend the
training):

Soft copies of the approved training manuals must be submitted for each system/discipline at
least 1 Week prior to the commencement of training programme. Training will not be started
without submitting the same.

 Version 2 - After the Completion of the training:

Upon the completion of the training programme, one soft copy of the training manuals shall be
submitted to Hilton. This must include, in addition to the above submittal (Version 1):

i. The attendance sheet signed by the participants and trainers

ii. Video record for both class room and on-the job training

iii. Any other hand outs, data sheets and related references distributed during the
training.

3. Document Review Requirements

Hilton will review some selected Training manuals out of the submitted ones. Both Hilton
and consultants shall comment on the training manual submittals. The comments must be
incorporated by the contractors in the training manuals. After the incorporation of comments,
these manuals will be accepted by Hilton as a minimum standard format and must be used
as a template, adhered by all the packages, trades and discipline in the Project.

- The Consultant needs to make sure that all other submitted training manuals meet
the “minimum Hilton acceptable standard”

- All Training Manuals must be submitted for Consultant’s review and acceptance.
Each manual shall be reviewed and approved by the consultant with the approval
cover sheet included.

- All comments made on any section of the training Manual, shall be addressed
properly and accurately prior to the submission.

- Failure to incorporate comments shall require an immediate further revised issue, in

addition to those stated above.

4. Document Content Requirement

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The documents submitted by Vendors shall contain sufficient detailed information to provide
the Operator with a complete understanding of the installed equipment / system training. The
following are the minimum general requirements for the training manual which needs to be
followed:

4.1 The Training Manual Cover Sheet:

This should contain the following information’s as a minimum:

 Project name

 Subject of training

 Name of contractor/consultant/other information related to site installation

team, etc. wherever relevant or applicable.

4.2 The Training Manual Contents/Index:

This should include reference page or section reference for easy

access/understanding

4.3 Training Aids, Syllabus, and Program:

- Introduction: (introduction about the training, who is going to conduct the

training, what are the basic understandings the trainee/participant will have
after the completion of the training, etc.)

- Training Aids: the training aids required to deliver the training program such as
(whiteboard and markers, laptop/PC and Multimedia Projector, Paper and pens
for trainees, flipchart, etc.)

- Training Syllabus: the training outlines/activities which will be followed during

the training which must contain but not limited to the following sections:

 Complete and sign attendance sheet.

 System overview, purpose & compatibility

 Detailed description of the installed system

 Orientation of materials & tools used for installing the equipment’s

 System Operation: (Installed Equipment’s Operation, Start Up & Shut

Down Procedure)

 Maintenance requirements of the installed equipment to include:

Preventive Maintenance, Routine Maintenance & Cleaning Process

 Trouble shooting: Identify common problems & solutions

 Site Walk & Practicable Demonstration (On-the-Job Training)

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  Interactive Question & Answer secessions.

- Training Program: must contain the detailed itinerary of the training to be

conducted.

4.4 Training Attendance Sheet:

The attendance sheet must contain the logos of the subcontractor, main contractor,
consultant, project management, and the client.

At the end of each training session (classroom and field demonstration/on-the-job

training) the attendance sheet must be duly signed by each trainer conducting the
training and the training coordinators.

A complete & signed attendance sheet must be included in the training manual
(Version 2) upon satisfactory completion of each and every training conducted

4.5 Power Point Presentation

Soft copy of the individual presentation provided by the subcontractors and will be
presented during the training course must be included in the training manual
submission (Version 1)

4.6 Training Video

Once the training was conducted satisfactorily the training video will be provided at
the end of the training day and/or upon completion of training or as agreed by all
parties involved.

The training video must be Windows format and Windows compatible using VLC
software.

4.7 Contents of Training Manuals Soft Copy:

PDF Copy of the Training Manual Version (2)

4.8 Training synopsis

The training Synopsis must contain the following section as a minimum

requirement:

 System Description
 Schedule of Equipment
 Operation details (This section should contain the Introduction, General
Operating Mode, Control Data, Start –Up & Shutdown Procedures, Standby
Operation and Hazards & Precautions).
 Maintenance Details (This section should contain the Introduction,
Preventive Maintenance Activities, Corrective Maintenance Activities, Routine
Maintenance which includes periodic inspection, Cleaning Process,

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 Recommended Maintenance Schedules and Fault Finding Table).
 Interface details with other systems
 Manufacturers Literature
 Schematic Drawings/Single Line Diagrams

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 HILTON GARDEN INN & EMBASSY SUITES

TRAINING MANUAL

FIRE PUMP

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Contents
1. SYSTEM DESCRIPTION..................................................................................................7
2. EQUIPMENT SCHEDULE................................................................................................7
3. OPERATION DETAILS....................................................................................................9
4. MAINTENANCE DETAILS & TROUBLESHOOTING....................................................18
5. INTERFACE DETAILS WITH OTHER SYSTEMS:........................................................30
6. MANUFACTURE /SUPPLIER DETAILS........................................................................32
7. SCHEMATIC DRAWINGS/SINGLE LINE DIAGRAMS.................................................33
8. TRAINING AGENDA......................................................................................................39
9. TRAINING AIDS.............................................................................................................39
10. TRAINING RECORDS................................................................................................40

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1. SYSTEM DESCRIPTION
The Fire Protection System is designed to safeguard the property from the hazard of fires in any
event. The supplied fire pumps are suitable for supplying the fire protection system with water at
various pressures in the event of a pressure drop in the line. The arrangement of the fire pump
configuration is such that the main pump has an electric motor, and the stand-by pump is a diesel
pump which receives is coupled to a diesel engine. At the initial stages, if there is any leakage in the
piping network of the system, the jockey pump or the pressure maintenance pump will start at its cut
in set pressure to make up for the loss in pressure and will run until the system pressure has been
restored. If the pressure has gone below the cut in pressure of the jockey, the pressure transducer
senses the pressure drop and signals the main pump to start and again if the pressure drops below
the cut in pressure of the main pump, the stand-by pump starts. The stand-by pump starts in the event
of a power failure too.

Aurora Fire Pump System(s) complete with pump, driver, controller, and accessories. The pumping
unit shall be listed by Underwriters' Laboratories, Inc. and/or shall be fully approved by the Associated
Factory Mutual Fire Insurance Companies, where applicable. The pumping unit shall meet all
requirements of UAE Fire and Life Code of Practice 2018 Ed. and the National Fire Protection
Association Pamphlet No.20 which is,

1. The Fire Pump shall deliver the rated capacity when operating at the rated head.
2. The pump shall also deliver not less than 150% of rated capacity at a pressure not less than
65% of rated pressure.
3. The shut off pressure shall not exceed 140% of rated pressure.

2. EQUIPMENT SCHEDULE
The supplied fire pump capacities for this project for the respective floors is as per the table given
below,

Basement Pump

S/N Type of Fire Pump Design of Pump Capacity Model

1 Electric Fire Pump-Main Horizontal Split Case Pump 1000GPM@16BAR 5-481-15A
2 Diesel Fire Pump-Stand-by Horizontal Split Case Pump 1000GPM@16BAR 5-481-15A
3 Jockey Pump Vertical Multistage 15GPM@16BAR PVM 3-36

Mechanical Floor Pump

S/N Type of Fire Pump Design of Pump Capacity Model

1 Electric Fire Pump-Main Horizontal Split Case Pump 750GPM@14BAR 6-485-12
2 Diesel Fire Pump-Stand-by Horizontal Split Case Pump 750GPM@14BAR 5-481-15A
3 Jockey Pump Vertical Multistage 15GPM@14BAR PVM 3-36

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FIRE PUMP SET (1000GPM@16 BAR)

Description Model Make Location Application

Electrical Fire Pump, Horizontal Split Basement
5-481-15A Aurora
case 2
Electrical Motor, 250 HP Basement
ODP USEM
2
Electrical Fire Pump Controller Basement
GPS Tornatech
2
Diesel Fire Pump, Horizontal Split Basement
case 5·481-lSA Aurora
2
Diesel Engine, 275 HP Basement
JU6H-UF84 CLARKE Supply for Sprinkler & FF
2
System
Diesel Fire Pump Controller Basement
GPO Tornatech (Basement 2-Level 18)
2
Jockey Pump, 5.SHP Basement
PVM 5-29 Aurora
2
Jockey Pump Controller Basement
JP3 Tornatech
2
Diesel Tank 320 GAL Basement
(Usable) 2
Flow Meter Basement
G-1000 GV
2

FIRE PUMP SET (1000GPM@14 BAR)

Description Model Make Location Application

Electrical Fire Pump, Horizontal Split case 6-485-12 Aurora Level 19

Electrical Motor, 250 HP ODP GP5 Marathon Level 19

Electrical Fire Pump Controller 6-485-12 Tornatech Level 19

Diesel Fire Pump, Horizontal Split Level 19

case 5-481-15A Aurora

Diesel Engine, 216 HP JU6H-UF54 CLARKE Level 19

Supply for Sprinkler & FF System
(Level 19-Level 30)
Diesel Fire Pump Controller
GPD Tornatech Level 19
Jockey Pump, 5.5 HP
PVM 3-36 Aurora Level19
Jockey Pump Controller JP3 Tornatech Level 19

Diesel Tank 270 GAL Level 19

(Usable)
Flow Meter G-750 GV Level 19

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3. OPERATION DETAILS
START –UP & SHUTDOWN PROCEDURES

1- START UP PROCEDURE

ELECTRIC DRIVEN

 Open suction gate valves.

 Pump must be filled with water & air contained in the pump should be release in the air
release valve.
 Press packing evenly with gland.
 The main disconnect switch should be in an "ON" position.
 Circuit breaker in "ON" position.
 Check direction of the driver by pressing the "Start" and then after a moment press "Stop" in
the controller.
 Open system Butterfly valve.
 Run the system valve by the opening the valve on the pressure sensing line to create a
pressure drop.
 As the fire pump starts, check the electric motor nameplate if it is in full load current value.
 Adjust the packing and let it leak slightly (1 drop/sec).
 Stop the pump with "ST OP" button after maximum 10 minutes. (set time)
 Run again until desired start-up pressure is reached.

DIESEL ENGINE DRIVEN

 Open suction gate valves.

 Pump must be filled with water & air contained in the pump should be release in the air
release valve.
 Press packing evenly with gland.
 Close casing relief valve using maximum spring pressure.
 Start engine manually on battery.
 Adjust Casing Relief valve spring to allow valve to fully open.
 Stop engine and then open system butterfly valve.
 Run the system valve by the opening the valve on the pressure sensing line to create a
pressure drop.
 As the fire pump starts, check the engine speed and adjust the pump rated speed with
throttle.
 Adjust the packing and let it leak slightly (1 drop/sec).
 Stop the pump with "STOP" button after maximum 30 minutes. (set time)
 Run again until desired start-up pressure is reached.
 Allow Jockey pump to automatically stop at pressure switch setting.

2- AUTOMATIC OPERATION

 Open system butterfly valve and turn all the isolating valves to the fully open position.
 Turn main disconnect switch into "ON" position.

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  Switch fire pump circuit breaker to "ON" position.
 Switch Jockey pump to "AUTO".

If the operating differential of pressure switches do not permit the following settings, the setting should
be close as the equipment will permit. The setting should be established by the pressures observed in
the test gauges. All devices are preset at the factory and normally do not require any adjustments. A
final adjustment may be made on any control to match the exact system requirements.

 REMINDERS

 After the start -up, make sure to open the system butterfly valve,
 Make sure to bring minimum run timer back to 30 minutes.
 The valve on the pump suction must be fully open as the throttle on the suction side is harmful to
the pump.
 Make sure that the pump will not run dry. Centrifugal pump has close clearances and cannot run
dry without serious damages.

3- FLOW TEST PROCEDURE

 Close system butterfly valve

 Open gate valve to hose outside header for flow test or flow meter discharge valve.
 Start the pump by pressing start button.
 Adjust hose by the quantity of hose, valves open or with pump discharge valve if using low meter.
 Take gauge and ammeter reading at 150%of rated flow, shutoff and other intermediate flow.
 Close the gate valve after the test

4- STANDBY and OPERATION

This document covers the philosophy of operation of the Fire Pump System. The system uses
centrifugal pumps to supply water to the Fire Water system, and is designed for unattended operation

SYSTEM DESCRIPTION

The system is comprised of the following equipment:

A. Maintained Pump: Jockey Pump with wall mounted Controller.

B. Duty Pump: Electric Driven Pump with free stand Controller.
C. Stand by: Diesel Driven Pump with wall mounted Controller.

1- Fire Fighting Pump set: 1000GPM @ 16BAR

In case of any miner water leakage in the system, the pressure in the system will be released and it
will start decreasing. Jockey pump will start automatically at 15 Bar and try to maintain this small
pressure loss and it will stop automatically once reaches to the system pressure (16 Bar).
In case of more demand due to the opening of a fire hydrant, Landing valve, actuation of sprinkler
head etc. and the pressure drops to 14 Bar, then the main electric pump will start automatically and it
will stop automatically once the system pressure reaches 16 Bar + 10 Minutes. (Once started and
after reaching to the system pressure, the timer starts with the countdown for 10 minutes then the
main electric pump will stop automatically).
If main electric pump stops due to interruption in the power supply and the pressure drops to 13 Bar,
then the Diesel pump (Standby pump) will start automatically to provide the required flow and
pressure and it will run until stopped manually or it will stop automatically once the system pressure

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reaches 16 Bar + 30 Minutes depending on the entered settings (Both of two options acceptable for
NFPA so the setting of the diesel pump based on the concerned person requirement).

Table: - System Set Pressure: 16 Bar

Pump Cut-In Cut-off

Jockey Pump 15 Bar 16 Bar
Diesel Pump 14 Bar 16 Bar
Electric Pump 13 Bar 16 Bar

1- Fire Fighting Pump set: 1000GPM @ 14BAR

In case of any miner water leakage in the system, the pressure in the system will be released and it
will start decreasing. Jockey pump will start automatically at 13 Bar and try to maintain this small
pressure loss and it will stop automatically once reaches to the system pressure (14 Bar).
In case of more demand due to the opening of a fire hydrant, Landing valve, actuation of sprinkler
head etc. and the pressure drops to 12 Bar, then the main electric pump will start automatically and it
will stop automatically once the system pressure reaches 14 Bar + 10 Minutes. (Once started and
after reaching to the system pressure, the timer starts with the countdown for 10 minutes then the
main electric pump will stop automatically).
If main electric pump stops due to interruption in the power supply and the pressure drops to 11 Bar,
then the Diesel pump (Standby pump) will start automatically to provide the required flow and
pressure and it will run until stopped manually or it will stop automatically once the system pressure
reaches 14 Bar + 30 Minutes depending on the entered settings (Both of two options acceptable for
NFPA so the setting of the diesel pump based on the concerned person requirement).

Table: - System Set Pressure: 14 Bar

Pump Cut-In Cut-off

Jockey Pump 13 Bar 14 Bar
Diesel Pump 12 Bar 14 Bar
Electric Pump 11 Bar 14 Bar

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Controls and Displays Standard Features
Model GPD Diesel Engine Fire Pump Controllers

Standard Features • ViZiTouch V2 operator interface • NEMA 2 assembly • Pressure and

event recorder • Battery voltage and amperage display • Run Test push button • HAND -
OFF - AUTO selector switch • Manual crank pushbuttons (2) • Stop pushbutton • Remote
start / deluge valve start provision • Pressure transducer and run test solenoid valve
externally mounted • Gland plate • Audible alarm • Alarm contacts for remote indication •
Weekly exercise programmable time clock • Crank cycle • Programmable automatic
shutdown (minimum run timer) • Programmable sequential start timer (delay start timer)

1. Alarm bell
2. Externally mounted pressure transducer
and run test solenoid valve with
protective cover
3. Key lock
4. ViZiTouch V2 operator interface
5. Exterior USB Port (Interior USB port
also supplied)
6. HAND OFF-AUTO selector switch
7. Remote alarm contacts with removable
terminals
8. Gland Plate
9. Automotive type engine connections
10. Battery chargers

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Model GPx Series - Electric Fire Pump Controllers

• ViZiTouch V2 operator interface • NEMA 2 assembly • Pressure and event recorder •

Voltage and amperage display • Single operator for both isolating • switch and circuit breaker
• Surge arrestor
• Lifting lugs • Run test push button • Available with automatic power • transfer switch •
Emergency start handle • Start and stop pushbuttons • Locked rotor protector • Phase
reversal indication • Remote start / deluge valve start provision • Pressure transducer and
run test solenoid valve externally mounted

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• Gland plate • Audible alarm • Alarm contacts for remote indication • Available with full
voltage and reduced voltage starting

1. Alarm bell
2. Externally mounted pressure transducer and
run test solenoid valve with protective cover
3. Lifting Lugs
4. ViZiTouch V2 operator interface
5. Exterior USB Port (Interior USB port also
supplied)
6. Custom designed Isolation switch / Circuit
breaker operator handle
7. Key lock
8. Remote alarm contacts with removable
terminals
9. Surge arrestor
10. Custom designed emergency start
mechanism with integrated limit switch
11. Gland plate
12. Automatic power transfer switch

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OPERATING MODES
METHODS OF STARTING / STOPING for the Diesel engine driven pump controller
The controllers are available as combination automatic / non-automatic with provision for
manual or automatic shutdown (an automatic shutdown is only possible after an automatic
start).
 METHODS OF STARTING
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 • AUTOMATIC START
The controller will start automatically on low pressure detection by the pressure sensor
when the pressure drops below the cut-in threshold.
• MANUAL START
The engine can be started by pressing the CRANK 1 or and/or CRANK 2 push button,
regardless of the system pressure, when the Main Selector switch is in the HAND position.
The Fuel Solenoid Valve will open as soon as a CRANK button is pressed and will remain
in this state.
• REMOTE MANUAL START
The engine can be started from a remote location by momentarily closing a contact of a
manual push button.
• REMOTE AUTOMATIC START, DELUGE VALVE START
The engine can be started from a remote location by momentarily opening a contact
connected to an automatic device. The controller must be in automatic mode.
• SEQUENTIAL START
In case of a multiple pump application, it may be necessary to delay the starting of each
motor when there is a water pressure drop to prevent simultaneous starting of all motors.
• FLOW START, HIGH ZONE START
The pump can be started by opening/closing a contact on the FLOW/ZONE START/STOP
input.
• WEEKLY START
The engine can be started (and stopped) automatically at the preprogrammed time.
• TEST START
The motor can be started manually by pressing the run test button.

 METHODS OF STOPPING

• MANUAL STOP
Manual stop is done by pressing the STOP push button. Note that pressing the stop push
button will stop the engine only if all starting causes have disappeared.
• AUTOMATIC STOP
The automatic stop is possible only after an automatic start and this function has been
activated. When this function is Enabled, the motor is automatically stopped 30 minutes
(adjustable) after the restoration of the pressure (above the cut-out threshold) given that no
other run cause is present.
• FLOW STOP, HIGH ZONE STOP
If the controller has been started by the FLOW/ZONE START/STOP input and the signal
has returned to normal, the motor will be stopped given that no other run cause is present.
• EMERGENCY STOP
The emergency stop is always possible in any running condition and is done by positioning
the main selector switch to the OFF position.

METHODS OF STARTING / STOPING for the electrical motor driven pump controller
The controllers are available as combination automatic / non-automatic with provision for
manual or automatic shutdown (an automatic shutdown is only possible after an automatic
start).

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  METHODS OF STARTING

• AUTOMATIC START
The controller will start automatically on low pressure detection by the pressure sensor when
the pressure drops below the cut-in threshold.
• MANUAL START
The motor can be started by pressing the START push button, regardless of the system
pressure.
• REMOTE MANUAL START
The motor can be started from a remote location by momentarily closing a contact of a
manual push button.
• REMOTE AUTOMATIC START, DELUGE VALVE START
The motor can be started from a remote location by momentarily opening a contact connected
to an automatic device.
• EMERGENCY START
The motor can be started manually by using the emergency handle. This handle can be
maintained in a closed position.Important: to avoid damaging the contactor, it is
recommended to start the motor in this manner:1) Shutdown the main power by using the
main disconnect means,2) Pull the emergency handle and lock it in closed position,3) Turn
the power back on by using the main disconnect means.
• SEQUENTIAL START
In case of a multiple pump application, it may be necessary to delay the automatic (pressure
drop) starting of each motor to prevent simultaneous starting of all motors.
• FLOW START, HIGH ZONE START
The pump can be started by opening/closing a contact on the FLOW/ZONE START/STOP
input.
• WEEKLY START
The engine can be started (and stopped) automatically at the preprogrammed time.
• TEST START
The motor can be started manually by pressing the run test button.

 METHODS OF STOPPING

• MANUAL STOP
Manual stop is done by pressing the priority STOP push button. Note that pressing the stop
push button will prevent the motor from restarting as long as the button is pressed, plus a two
second delay.
• AUTOMATIC STOP
Automatic stop is possible only after an automatic start and this function has been activated.
When this function is enabled, the motor is automatically stopped 10 minutes after the
restoration of the pressure (above the cut-out threshold) given that no other run cause is
present.
• FLOW STOP, HIGH ZONE STOP
If the controller has been started by the FLOW/ZONE START/STOP input and the signal has
returned to normal, the motor will be stopped given that no other run cause is present.
• EMERGENCY STOP
The emergency stop is always possible in any starting condition and is done by using the
main
disconnecting means located on the door.

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METHODS OF STARTING / STOPING for the Jockey pump controller

 METHODS OF STARTING

• AUTOMATIC START
The controller will start automatically on low pressure detection by the pressure
sensor when pressure drops below the cut-in threshold.
• MANUAL START
The motor can be started by pressing the START push button, regardless of the
system pressure.
 METHODS OF STOPPING
• MANUAL STOP
Manual stop is done by pressing the priority STOP push button. Note that pressing
the stop push button will prevent the motor from restarting as long as the button is
pressed, plus a two seconds delay.
• AUTOMATIC STOP
The motor is automatically stopped after the restoration of the pressure (above the
cut-out threshold), after a programmable run period timer.
• EMERGENCY STOP
The emergency stop is always possible in any starting conditions and is done by
using the disconnect switch located on the door.

4. MAINTENANCE DETAILS & TROUBLESHOOTING

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4.1. PREVENTIVE MAINTENANCE ACTIVITIES, CORRECTIVE MAINTENANCE
ACTIVITIES, ROUTINE & MAINTENANCE WHICH INCLUDES PERIODIC
INSPECTION, CLEANING PROCESS.

This chapter shall provide the minimum requirements for the routine inspection, testing, and
maintenance of fire pump assemblies.
Table 4.1 shall be used to determine the minimum required frequencies for inspection,
testing, and maintenance.
Alternative Inspection, Testing, and Maintenance Procedures. In the absence of
manufacturer’s recommendations for preventive maintenance, Table 4.2 shall be used for
alternative requirements.

Auxiliary Equipment.
The pump assembly auxiliary equipment shall include the following:
1. Pump accessories as follows:
A. Pump shaft coupling
B. Automatic air release valve
C. Pressure gauges
D. Circulation relief valve (not used in conjunction with diesel engine drive with heat
exchanger)
2. Pump test device(s)
3. Pump relief valve and piping (where maximum pump discharge pressure exceeds the
rating of the
system components or the driver is of variable speed)
4. Alarm sensors and indicators
5. Right-angle gear sets (for engine-driven vertical shaft turbine pumps)
6. Pressure maintenance (jockey) pump and accessories

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Table 4.1 Alternative Fire Pump Inspection, Testing, and Maintenance
Procedures

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Page 21 of 42
Page 22 of 42
Table 4.2 Summary of Fire Pump Inspection, Testing, and Maintenance

A preventive maintenance program shall be established on all components of the pump

assembly in accordance with the manufacturer’s recommendations or Table 4.1.
Records shall be maintained on all work performed on the pump, driver, controller, and
auxiliary equipment.
The preventive maintenance program shall be initiated immediately after the pump assembly
has passed acceptance tests.
Whenever a component in a fire pump is adjusted, repaired, rebuilt, or replaced, the tests
required to restore the system to service shall be performed in accordance with Table 4.3
NFPA 20 shall be consulted for the minimum requirements for design, installation, and
acceptance testing. Replacement parts shall be provided that will maintain the listing for the
fire pump component assembly whenever possible. If the part is no longer available from the
original equipment manufacturer, then an approved like part shall be permitted to be used

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Table 4.3 Summary of Component Replacement Testing Requirements

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4.2. RECOMMENDED MAINTENANCE SCHEDULES AND FAULT FINDING
TABLE. & TROUBLESHOOTING

This chapter contains a partial guide for locating pump troubles and their possible causes The causes
listed here are in addition to possible mechanical breakage that would be obvious on visual
inspection. In case of trouble, it is suggested that those troubles that can be inspected easily should
be corrected first or eliminated as possibilities.

1. Air Drawn into Suction Connection Through Leak(s).

Air drawn into suction line through leaks causes a pump to lose suction or fail to maintain its
discharge pressure. Uncover suction pipe and locate and repair leak(s).
2. Suction Connection Obstructed.
Examine suction intake, screen, and suction pipe and remove obstruction. Repair or provide screens
to prevent recurrence.
3. Air Pocket in Suction Pipe.
Air pockets cause a reduction in delivery and pressure similar to an obstructed pipe. Uncover suction
pipe and rearrange to eliminate pocket.
4. Well Collapsed or Serious Misalignment.
Consult a reliable well drilling company and the pump manufacturer regarding recommended repairs.
5. Stuffing Box Too Tight or Packing Improperly Installed, Worn, Defective, Too Tight, or of
Incorrect Type.
Loosen gland swing bolts and remove stuffing box gland halves. Replace packing.
6. Water Seal or Pipe to Seal Obstructed.
Loosen gland swing bolt and remove stuffing box gland halves along with the water seal ring and
packing. Clean the water passage to and in the water seal ring. Replace water seal ring, packing
gland, and packing in accordance with manufacturer’s instructions.
7. Air Leak into Pump Through Stuffing Boxes.
Same as possible cause in 1.6.
8. Impeller Obstructed.
Does not show on any one instrument, but pressures fall off rapidly when an attempt is made to draw
a large amount of water. For horizontal split-case pumps, remove upper case of pump and remove
obstruction from impeller. Repair or provide screens on suction intake to prevent recurrence.
For vertical shaft turbine-type pumps, lift out column pipe and pump bowls from wet pit or well and
disassemble pump bowl to remove obstruction from impeller. For close-coupled, vertical in-line
pumps, lift motor on top pull-out design and remove obstruction from impeller.
9. Wearing Rings Worn.
Remove upper case and insert feeler gauge between case wearing ring and impeller wearing ring.
Clearance when new is 0.0075 in. (0.19 mm). Clearances of more than 0.015 in. (0.38 mm) are
excessive.
10. Impeller Damaged.
Make minor repairs or return to manufacturer for replacement. If defect is not too serious, order new
impeller and use damaged one until replacement arrives.
11. Wrong Diameter Impeller.
Replace with impeller of proper diameter.
12. Actual Net Head Lower Than Rated.
Check impeller diameter and number and pump model number to make sure correct head curve is
being used.
13. Casing Gasket Defective, Permitting Internal Leakage (Single-Stage and Multistage
Pumps).
Replace defective gasket. Check manufacturer’s drawing to see whether gasket is required.
14. Pressure Gauge Is on Top of Pump Casing.
Place gauges in correct location.
15. Incorrect Impeller Adjustment (Vertical Shaft Turbine-Type Pump Only).

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Adjust impellers according to manufacturer’s instructions.

16. Impellers Locked.

For vertical shaft turbine-type pumps, raise and lower impellers by the top shaft adjusting nut. If this
adjustment is not successful, follow the manufacturer’s instructions. For horizontal split-case pumps,
remove upper case and locate and eliminate obstruction.
17. Pump Is Frozen.
Provide heat in the pump room. Disassemble pump and remove ice as necessary. Examine parts
carefully for damage.
18. Pump Shaft or Shaft Sleeve Scored, Bent, or Worn.
Replace shaft or shaft sleeve.
19. Pump Not Primed.
If a pump is operated without water in its casing, the wearing rings are likely to seize. The first warning
is a change in pitch of the sound of the driver. Shut down the pump. For vertical shaft turbine-type
pumps, check water level to determine whether pump bowls have proper submergence.
20. Seal Ring Improperly Located in Stuffing Box, Preventing Water from Entering Space to
Form Seal.
Loosen gland swing bolt and remove stuffing box gland halves along with the water-seal ring and
packing. Replace, putting seal ring in proper location.
21. Excess Bearing Friction Due to Lack of Lubrication, Wear, Dirt, Rusting, Failure, or
Improper Installation.
Remove bearings and clean, lubricate, or replace as necessary.
22. Rotating Element Binds Against Stationary Element.
Inspect clearances and lubrication and replace or repair the defective part.
23. Pump and Driver Misaligned.
Shaft running off center because of worn bearings or misalignment. Align pump and driver according
to manufacturer’s instructions. Replace bearings according to manufacturer’s instructions.
24. Foundation Not Rigid.
Tighten foundation bolts or replace foundation if necessary.
25. Engine-Cooling System Obstructed.
Heat exchanger or cooling water systems too small. Cooling pump faulty. Remove thermostats. Open
bypass around regulator valve and strainer. Inspect regulator valve operation. Inspect strainer. Clean
and repair if necessary. Disconnect sections of cooling system to locate and remove possible
obstruction. Adjust engine-cooling water-circulating pump belt to obtain proper speed without binding.
Lubricate bearings of this pump. If overheating still occurs at loads up to 150 percent of rated
capacity, contact pump or engine manufacturer so that necessary steps can be taken to eliminate
overheating.
26. Faulty Driver.
Inspect electric motor, internal combustion engine, or steam turbine, in accordance with
manufacturer’s instructions, to locate reason for failure to start.
27. Lack of Lubrication.
If parts have seized, replace damaged parts and provide proper lubrication. If not, stop pump and
provide proper lubrication.
28. Speed Too Low.
For electric motor drive, confirm that rated motor speed corresponds to rated speed of pump, voltage
is correct, and starting equipment is operating properly. Low frequency and low voltage in the electric
power supply prevent a motor from running at rated speed. Low voltage can be due to excessive
loads and inadequate feeder capacity or (with private generating plants) low generator voltage. The
generator voltage of private generating plants can be corrected by changing the field excitation. When
low voltage is from the other causes mentioned, it can be necessary to replace transformer taps or
increase feeder capacity. Low frequency usually occurs with a private generating plant and should be
corrected at the source. Low speed can result in older type squirrel-cage-type motors if fastenings of
copper bars to end rings become loose. The remedy is to weld or braze these joints. For steam
turbine drive, confirm that valves in steam supply pipe are wide open; boiler steam pressure is
adequate; steam pressure is adequate at the turbine; strainer in the steam supply pipe is not plugged;
steam supply pipe is of adequate size; condensate is removed from steam supply pipe, trap, and
turbine; turbine nozzles are not plugged; and setting of speed and emergency governor is correct. For
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internal combustion engine drive, confirm that setting of speed governor is correct; hand throttle is
opened wide; and there are no mechanical defects such as sticking valves, timing off, or spark plugs
fouled, and so forth. The latter can require the services of a trained mechanic.
29. Wrong Direction of Rotation.
Instances of an impeller turning backward are rare but are clearly recognizable by the extreme
deficiency of pump delivery. Wrong direction of rotation can be determined by comparing the direction
in which the flexible coupling is turning with the directional arrow on the pump casing. With poly phase
electric motor drive, two wires must be reversed; with dc driver, the armature connections must be
reversed with respect to the field connections. Where two sources of electrical current are available,
the direction of rotation produced by each should be inspected.
30. Speed Too High.
See that pump- and driver-rated speed correspond. Replace electric motor with one of correct rated
speed. Set governors of variable-speed drivers for correct speed. Frequency at private generating
stations can be too high.
31. Rated Motor Voltage Different from Line Voltage.
For example, a 220 or 440 V motor on 208 or 416 V line. Obtain motor of correct rated voltage or a
larger size motor.
32. Faulty Electric Circuit, Obstructed Fuel System, Obstructed Steam Pipe, or Dead Battery.
Inspect for break in wiring open switch, open circuit breaker, or dead battery. If circuit breaker in
controller trips for no apparent reason, make sure oil is in dash pots in accordance with
manufacturer’s specifications. Make sure fuel pipe is clear, strainers are clean, and control valves
open in fuel system to internal combustion engine. Make sure all valves are open and strainer is clean
in steam line to turbine.

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Possible Causes of Fire Pump Troubles.

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Maintenance of Fire Pump Controllers After Fault Condition.

• Introduction.
In a fire pump motor circuit that has been properly installed, coordinated, and in service prior
to the fault, tripping of the circuit breaker or the isolating switch indicates a fault condition in
excess of operating overload. It is recommended that the following general procedures be
observed by qualified personnel in the inspection and repair of the controller involved in the
fault. These procedures are not intended to cover other elements of the circuit, such as
wiring and motor, which can also require attention.
• Caution.
All inspections and tests are to be made on controllers that are de-energized at the line
terminal, disconnected, locked out, and tagged so that accidental contact cannot be made
with live parts and so that all plant safety procedures will be observed.
• Enclosure.
Where substantial damage to the enclosure, such as deformation, displacement of parts, or
burning has occurred, replace the entire controller.
• Circuit Breaker and Isolating Switch.
Examine the enclosure interior, circuit breaker, and isolating switch for evidence of possible
damage. If evidence of damage is not apparent, the circuit breaker and isolating switch can
continue to be used after the door is closed. If there is any indication that the circuit breaker
has opened several short-circuit faults, or if signs of possible deterioration appear within
either the enclosure, circuit breaker, or isolating switch (e.g., deposits on surface, surface
discoloration, insulation cracking, or unusual toggle operation), replace the components.
Verify that the external operating handle is capable of opening and closing the circuit breaker
and isolating switch. If the handle fails to operate the device, this would also indicate the
need for adjustment or replacement.
• Terminals and Internal Conductors.
Where there are indications of arcing damage, overheating, or both, such as discoloration
and melting of insulation, replace the damaged parts.
• Contactor.
Replace contacts showing heat damage, displacement of metal, or loss of adequate wear
allowance of the contacts. Replace the contact springs where applicable. If deterioration
extends beyond the contacts, such as binding in the guides or evidence of insulation
damage, replace the damaged parts or the entire contactor.
• Return to Service.
Before returning the controller to service, inspect for the tightness of electrical connections
and for the absence of short circuits, ground faults, and leakage current. Close and secure
the enclosure before the controller circuit breaker and isolating switch are energized. Follow
operating procedures on the controller to bring it into standby condition.

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5. INTERFACE DETAILS WITH OTHER SYSTEMS:
Terminal Strip Descriptions for Diesel controller

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Terminal Strip Descriptions for Electrical controller

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6. MANUFACTURE /SUPPLIER DETAILS

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7. SCHEMATIC DRAWINGS/SINGLE LINE DIAGRAMS

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8. TRAINING AGENDA
The instruction program consists of two sessions, class room and field sessions. During the class
room session all the trainees will get the information regarding the type of Fire Pumps installed, how it
operates, how it is to be maintained. In the field session, the trainees will familiarize with the location
of the fire pump Upon completion of both class room and field sessions all the trainees will have
thorough information regarding the operation and maintenance of the system.

MAX NO OF TRAINEES
TRAINING SUBJECT DURATION
PER SESSION
Introduction 1 Hour 10 People
System Description & Equipment
Schedule
Operation with Schematic 1 Hour
Questions
Site Presentation operations and 1 Hour
maintenance)
Questions

9. TRAINING AIDS

Training aids consist of the following listed items:

 Approved Operation and Maintenance Manuals

 Training Manuals including outline, basic test of instructions modules and trainee workbook, films,
slides, charts, models, handouts, catalogues, samples and other visual and written aids to
complement instruction.
 As Built Drawing
 Training Presentations

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10. TRAINING RECORDS

ATTENDANCE SHEET

SN NAME COMPANY DESIGNATION SIGNATURE

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