Firewater Pumps at Industrial Facilities

199 Pages·2011·3.221 MB·English

by  Dennis P. Nolan (Auth.)

HISTORICAL APPLICATIONS OF
FIREWATER PUMPING SYSTEMS
1.1. INTRODUCTION
Apumpisadevicethatutilizesenergytoraise,transportorcompressfluidsandgases.
Thetermpumpisusedforliquidhandlingdevices,whereasacompressorisusedwhen
thepressureofagasisincreased.Theterm‘‘fireengine’’wasclassicallyreferredto
anydevicethatwasusedtoextinguishfires.CurrentEnglishlanguagelinguisticsrefer
to a fire engine as a mobile fire apparatus (i.e., pumper), while firewater pumping
systemsarecommonlyreferredtowhenfixedinstallationsareinvolved.
Pumpingdeviceshavebeeninuseforthousandsofyearsandappliedtoavarietyof
uses.Mostofthetechnologicalimprovementsmadeinwaterpumpingsystemshave
occurred within the last 100years. The version of the pump that is commonly
employed today for firewater service is the centrifugal pump, which was invented
duringtheIndustrialRevolutionofthe1800sandisnowalmostuniversallyadopted.
Priortothis,reciprocatingorrotarywaterpumpswereusedwhichwereoperatedby
hand,wind,orsteampower.
1.2. ANCIENT WATER PUMPS
The first type of ‘‘pump’’ was probably used by the ancient Egyptians sometime
around 2,000 BC. They used waterwheels with buckets to provide for agricultural
irrigation.InthethirdcenturyBC,CtesibiusofAlexandriainventedawaterpumpfor
fire extinguishment. Apparently, Alexandria had some type of hand-operated fire
engine, similar to those used in Europe and America in the eighteenth century.
Subsequently,ataround200BC,theGreeksinventedareciprocatingpump.
In the first century BC, Heron of Alexandria was credited with producing an
improvedtypeofreciprocatingfirepumpbasedonthepumpinventedbyCtesibius.
Thispumpwasessentiallyasuctionliftpump,butmodifiedtoacylinderforcepump.
The pump had two pistons, each within its own cylinder that had a foot valve. The
pistonswereconnectedbyarockerarmthatpivotedonacenterpost.Thecylinders
weresuppliedwithwaterthroughafootvalvelocatedatthebottomofthecylinder.By
liftingandforcingthepistonsdownwiththerockerarm,waterwasliftedandforcewas
appliedsothatitcouldbe‘‘pushed’’outofanozzleconnectedtothetopofthecylinder.
Thenozzlewasmountedsothatitcouldpivotandswivelinanydirection.Thisallowed
forwaterapplicationonanearbyfireincident(seeFigure1-1).Pistonpumpswerealso
reportedlyusedasflamethrowerswhichGreekshipsusedasweapons,whichprobably
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Figure1-1 AncientPumpofAntiquity
usedapetroleum-basedliquidthatwasignited.Pliny(23-79AD)alsomentionstheuse
of‘‘fireengines’’inancientRomeforfire-fightingpurposes.
With the fall of the Roman Empire, large cities disappeared in the West and
therefore the simultaneous destruction of a large number of buildings by large fires
did not occur. The development of a fire pump was therefore not in demand. When
larger cities again appeared in the Middle Ages, the destruction of cities by confla-
grationresumed.Itwasnotuntiltheendofthefifteenthcenturythatthereciprocating
firepumpwasre-invented.Therapidindustrializationoftheseventeenth,eighteenth
andnineteenthcenturies,andtheensuing,frequentconflagrationsoflargecities,saw
the development of many types and applications of pumps and water distribution
systemsspecificallyforfire-fighting.
1.3. RECIPROCATING HAND AND STEAM-DRIVEN FIRE PUMPS
ThereciprocatingwaterpumpremainedinserviceuntillateintheIndustrialRevolu-
tion. The main reason for this was the lack of a high power source. Most industrial
energysources at that timewere of approximately 7.5 kilowatts (10 horsepower) or
lesscapacity(i.e.windmills,waterwheels,animalandhumanefforts,etc.).Withouta
sufficientpowersourcetorapidlymovewatersupplies,onlylimitedcapacitiescould
beachieved.
HistoricalApplicationsofFirewaterPumpingSystems 3
Thefirepumpofthistimewascommonlymountedonacartorcarriageandbrought
tothesceneofafirebyateamofhorses.Atuborreservoirofwaterwasprovidedon
the carriage atthe baseofthepump.This reservoirwasfilledbymeansofabucket
brigade by the local populace. Later, with the provision of street water mains, fire
enginesconnecteddirectlytofirehydrants.Thistypeofmobilefirepumpwasused
and improved upon until the late 1800s. When steam power was developed, it was
appliedtodrivethereciprocatingfirewaterpumpinlieuofmen.
Reciprocatinghandpumpsforsupplyingwatertoextinguishfires(ortopumpbilge
water/wash the decks) were also an essential part of the fittings available to late
eighteenth-centuryEnglishships(i.e.c.1772).ThefirstfireboatsintheUnitedStates
appeared in 1800 for New York City. They used a hand-operated pump and were
importedfromEnglandatacostof,atthetime,$4,000each.
ThefirstfireenginemadeinAmericawasbuiltforthecityofBoston.Itwasmade
in1654byJosephJencks,anironmakerofLynn,Massachusetts,andwasoperatedby
relays of men using handles. The production of this fire engine was the result of a
disastrous fire suffered by the city in January 1653. By 1715, Boston had six fire
companies with engines of English manufacture. The steam-pump fire engine was
actuallyintroducedinLondonin1829byJohnEricssonandJohnBraithwait.Itwasin
use in many large cities by the 1850s. Most steam pumpers were equipped with
reciprocatingpistonpumps,althoughafewrotarypumpswerealsoused.Somewere
self-propelled,butmostusedhorsesforpropulsion,conservingthesteampressurefor
the pump. The first practical fire engine in America was the ‘‘Uncle Joe Ross’’,
inventedbyAlexanderBonnerLatta.Itwasconstructedin1852inCincinnati,Ohio.
Itweighedapproximatelyfourtonsandrequiredfourhorsestopullit,anduseditsown
power.Itcouldprovideuptosixstreamsofwater.Asinglestreamhada4.4cm(13/ inch)
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diameter,andithadareachof73meters(240ft.).ThefirststeamfireengineinAmerica
wasactuallydesignedandbuiltin1841byPaulR.Hodge.Itwas4.3meters(14ft)long
andweighed7257kgs(eighttons).Becauseofitsweightandthesparksproducedfrom
its stack, it was later abandoned. A steam fire engine used by the New York Fire
Departmentremainedinserviceaslateas1932.
1.4. ROTARY PUMPS
Anearlycentrifugaltyperotarypumpwasmadeintheearlyseventeenthcentury.It
couldpumpwateraboutninemeters(30ft).Amoreeffectiverotarypumpwasmade
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byaFrenchmannamedDietzinthelatenineteenthcentury.ApumpsimilartoDietz’s
wasshownattheLondonGreatExhibitionof1851andreceivedwideacclaim.
1.5. INVENTION OF THE CENTRIFUGAL PUMP
The true centrifugal pump was not developed until late in the 1600s. Denis Papin
(1647-c. 1712), a French physicist and inventor, produced a centrifugal pump with
straightvanes.In1851,JohnG.Appold,aBritishengineerandinventor,introduceda
curved-vane centrifugal pump. Finally, another British engineer, Osborne Reynolds
(1842-1912), built the first turbine or centrifugal pump in 1875. Reynolds is more
famousforhisstudyoffluiddynamics,havingthe‘‘ReynoldsNumber’’namedafter
himinrelationtohisstudiesonturbulenceinwaterflowanalysis.
In general, modern centrifugal water pumps operate at speeds much higher (e.g.
1800 or 3600rpm) than were typically obtainable before the advent of steam or
internalcombustionenginesandelectricalmotors.Therefore,centrifugalpumpswere
not technologically feasible or commercially viable before these devices were
inventedandreadilyavailable.
1.6. MODERN FIRE PUMPS
Initially,thefirstindustrialfirewaterpumpswereofthewheelandcrankreciprocating
modelthatweredrivenbymillmachinery,poweredbyawaterwheelorwindmill.This
arrangement was not very practical, because if the mill waterwheel or windmill
stopped, the fire pump would also stop. The English engineer, Thomas Savery
(c.1650-1715),patentedthesteampumpin1698afterDenisPapindevelopedafirst
crudemodelin1690.Thesefirststeam-drivenpumpswereinitiallyappliedtoremove
water from coal mines in England, but were later adapted to a wide variety of uses
includingasfirewaterpumpsformunicipalandindustrialapplications.
ThefirststeamengineinAmericawasimportedfromEnglandin1753.Itwasusedto
pumpwaterfromacoppermineinNewJersey.In1795,thefirstpracticalsteamengine
wasmanufacturedinAmericabyOliverEvansofPhiladelphia,Pennsylvania.Helater
improvedonitin1799withahigh-pressuresteamengine.Itwasparticularlysuitedto
the needs of the ‘‘colonial’’ industries of the time. Steam generation soon replaced or
supplementedwaterwheelsorharnessedanimalsasanindustrialpowersource.
Up until the late 1800s, almost all industrial firewater pumping systems were
supplied with reciprocating steam-driven water pumps. The reciprocating steam
enginedominatedpowergenerationforstationaryandtransportationservicesformore
thanacentury,untilthedevelopmentofthesteamturbineandtheinternalcombustion
engine.Theseengineswereofheavycastironconstruction,andhadarelativelylow
piston speed (600to1,200ft/m)andlowturning speeds(50to500r/min),butwere
availablewithcapacitiesofupto18,642kilowatts(25,000hp).
HistoricalApplicationsofFirewaterPumpingSystems 5
Withthedevelopmentandprovisionofautomaticfiresprinklers,requiringamore
reliablewatersource,rotarypumpsthatwereconnectedtothewaterwheelofthemill
wereused.Whensteamsupplieswereprovidedattheselocations,itreplacedthewater
driveforthepumpsandthereciprocatingsteampumpcameintouse.Asaresult,the
‘‘Underwriters duplex’’, a double acting, direct steam-driven pump was universally
provided as the standard fire pump for industry. As the name implies, these pumps
wereendorsedbytheinsurancecarriersofthetimeandthereforewerequitepopular
withindustrialusers.
When practical, large capacity, electrical motors and internal combustion engines
becameavailableintheearly1900s,thecentrifugalpumpcameintofullindustrialuse.
Internalcombustionenginesormotorswerereadilyappliedasthedriverofcentrifugal
firewaterpumpsduetotheirhighspeedofrotationandeaseofinstallation.
Today, the centrifugal firewater pump is considered the most practical type of
pump.Ithasthecompactness,reliability,lowmaintenance,hydrauliccharacteristics
andflexibilitythathavemadeearlierpumptypesobsoleteforfirewateruse.Centrif-
ugalfirewaterpumpsareroutinelyspecifiedfortheprotectionofindustrialfacilities
worldwide. Theyare found in both onshore and offshore facilities and may evenbe
locatedunderground.
1.7. MUNICIPAL WATER PUMPING PLANTS AND MAINS
Ancientcivilizationsgenerallyusedwaterbucketsorlarge‘‘syringes’’tocarrywater
from rivers or wells to a fire. When no readily available source was available, they
probablydidwhatfiremeninLondondidintheearlyfourteenthcentury—theyduga
holeinthestreetandwaitedforittofillwithgroundwater.
In 1562, the first municipal pumping waterworks was completed in London,
England.Awaterwheelpumpedriverwatertoareservoirabout37m(about120ft)
abovetheleveloftheRiverThames.Waterwasthendistributedbygravityfromthe
reservoir through lead pipes to buildings in the vicinity. By the late 1700s, steam
engines pumped water in most European cities. The first water pumping plant to
supply water for municipal purposes in the Americas was installed in Bethlehem,
Pennsylvaniain1755.Thewaterwaspumpedintoawatertowerthroughwoodenpipes
madefromhemlocklogs.
WoodenlogshadbeeninuseasamethodforsupplingwatersincetheMiddleAges.
HollowbamboowasalsousedintheFarEast(theChineseevenusedbamboopipeto
transmitnaturalgastolighttheircapital,Peking,asearlyas400BC).Afterthedecay
oftheRomanEmpire,theChurchtookovertheresponsibilityforsupplyingwaterand
maintainingtheoldRomanaqueductsinsomeareas.Becauseofthetremendoussize
ofthetask,theaqueductsfellintodisrepairafterafewhundredyears;however,under
theprotectionoftheChurch,aguildofspecialistsinwatersupplyhadbeencreated.
TheirtechnologyspreadoverEuropealongsidethesimultaneousspreadofthemonas-
tic orders. Their system of water pipelines from a source of supply, was made from
hollowed-outlogsconnectedwithacastironcollar,orthenarrowendsofsomelogs
fittedintothewiderendsofothers.Insidebuildings,pipesofleadorbronzewereused,
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acarryoverfromRomandays(leadisapoisonousmaterial,anditissuspectedthatlead
poisoningwasacommoncauseofdeathinRome).
The first municipal water supply system in America was built in Boston,
Massachusettsin1652.Aseriesofwoodenpipeswasusedtoconveythewaterfrom
anearbyspringtoacentralreservoir.By1800,some16Americancitieshadwater-
supply systems. Primitive fire hydrants on public mains in America began to be
installedinthe1830sand1840s.Priortothistime,thereweresomewoodenwater
pipeswithplugsatintervalswhichcouldberemovedtoobtainfire-fightingwater.
ThereisevidencethatcastironpipeswereusedinaGermanCastlein1455and
werealsoinuseatVersailles,Francearound1600.Castironpipesforcitywatermains
intheUnitedStateswerefirstusedin1817inPhiladelphia,Pennsylvania.Thepipeline
was 122 meters (400ft) long and was 11.4cm (4 1/ inches) in diameter. The pipes
2
wereimportedfromEnglandandweresuchanimprovementontheexistingwooden
pipes(woodenpipestendtorotandcannotholdmuchpressure)thatthecitydecidedto
adoptthemforallfutureinstallations.Ithasbeenstatedthatthelimitationsofwooden
pipes hampered early attempts to pump water by steam and held back water supply
technologyingeneral.
In the eighteenth century, metal pipes were manually made and could withstand
onlyalimitedamountofpressure.Theadvent,inthenineteenthcentury,ofsteelpipes
greatly increasedthe strengthof pipes ofall sizes. Initially, allsteel pipes hadtobe
threadedtogether.Thiswasdifficulttodoforlargepipes,andtheywerealsoapttoleak
under high pressure. The application of welding to join pipes in the 1920s made it
possibletoconstructleakproof,high-pressure,large-diameterpipelines.Sincethen,
carbonsteelpipefiremainshavebeenroutinelyprovided,thatwerecementlinedto
limitinternalcorrosion.Unfortunatelyforsomesystems,thecementliningshavebeen
found to deteriorate after many years due to improper or poor initial application or
materials, high water velocities or aging of the system. Copper-Nickel alloys (i.e.
Kunifer 90/10) have found favor for use offshore since the 1970s due their high
corrosionresistanceandlowweight.
Thelatest trendforindustrialfacilitiesistousereinforcedfiberglasspiping(e.g.
Reinforced Thermosetting Resin (RTR)) for underground firewater mains and spe-
cializedfire-rated(includingprotectionagainstjetfires)fiberglassmaterialsforallthe
firewaterpipingonoffshorestructures.Thisofferstheadvantageofsuperiorcorrosion
HistoricalApplicationsofFirewaterPumpingSystems 7
resistanceandtheweightsavingdesiredforoffshorefacilities(fiberglasspipeweight
isapproximatelyonesixththatofsteelpiping).Averylargewallthicknessandwater
flowing through the pipe, allows the fiberglass pipe to withstand hydrocarbon fire
exposures,includingjetfires,foralimitedduration.
AlmosteverycityandtowninAmericahasbeenprovidedwithmunicipalwater-
works,mostofthempubliclyownedandoperated.Thesepublicwatermainsserveto
providewater toindustriesandcommunitiesfordomestic consumptionand alsofor
fire-fightingwater.Additionally,hydrantsareroutinelyprovidedonallcityandprivate
firemainsforthepurposesoffire-fightingsupport.
1.8. OFFSHORE FACILITIES
Firewaterpumpsforoffshoreoilandgasinstallationsneedtobesubmergedinwater
becauseofthehighleveloftheworkplatformsabovethesealevelandinadequatelift
available for the pumps if located at the platform level (see Figure 1-2). Therefore,
‘‘down-hole’’verticalturbinelineshaftfirewaterpumpswerecommonlyadoptedasan
extension of onshore well pumps during the beginning of the offshore industry and
until the early 1980s. They are a standard type of pump used to supply offshore
firewater systems. Several variations in driveand configuration are used to improve
economics,easeofinstallation,weightimpactsandreliability(SeeChapter9).
As offshore platforms moved into deeper waters and harsher environments, they
becamemorecomplexandtheuseofobsoletetankersordedicatedshipsasoffshore
processing facilities evolved. The constraints of space, weight and electrical area
classificationofthefacilityhadtobeconsideredmorecarefully.Electro-submersible
and hydraulic-driven pumps gained considerable favor for offshore use because the
power could be supplied from a dedicated generator or hydraulic power pack posi-
tioned inaconvenientlocationandsomeofthetopside drivehardwaretothepump
could be eliminated, allowing a space or weight savings. Only high integrity and
durable pump driving systems (i.e. electro-submergible or hydraulic motors) should
8 FireFightingPumpingSystemsatIndustrialFacilities
Figure1.2 GulfofMexicoShallowWaterPlatform
be selected for underwater use, otherwise continual repair and downtime of the
firewaterpumpingsystemwilloccur.
Anelectro-submersible pumporhydraulic drivesystemstillrequires adedicated
topside power generation system, which increases its cost compared to a directly
driven diesel engine line shaft pump. Because of this, the use of diesel-driven line
shaftpumpshasagainbeenfavored,especiallywheremarginalreturnsareexpected
fromsomeoilandgasproductionfields.
PHILOSOPHY OF PROTECTION
2.1. INTRODUCTION
Beforetheconsiderationoftheinstallationofafirewaterpumpisundertaken,theneed
foritshouldbefirmlyestablished.Thisneedshouldbeestablishedonthebasisonthe
fireprotectionorriskphilosophypromulgatedforthefacilitybyseniororexecutive
managementduringitsdesign.
In some cases, a firewater system is not absolutely necessary in the protection
measures provided for a facility. Therefore, a firewater pump is not an absolute
requirementforallindustrialfacilities.Furthermore,othermechanismsmayprovide
adequate sources of firewater flow that make the provision of a firewater pump
irrelevant. It should also be remembered that a fire suppression system is used in
the last stages of a fire emergency or explosion event. Other highly effective fire
protectionmeasuresmayalreadyhavebroughtanincidentundercontrol(e.g.process
emergency shutdown and isolation, depressurization, blowdown, etc.) before a fire
suppressionsystemisnecessary.
Also,remote,non-criticalorlowvaluefacilitiesmaynotrequireafirewatersystem
sincethecostofprotectingthesefacilitiesoutweighstheirvaluetotheorganization.
2.2. PROTECTION OPTIONS
2.2.1. PROCESSEMERGENCYCONTROLMEASURES
The primary process emergency control methods are process controls, isolation and
depressurization.Thesemeasures,ifproperlyprovided,shouldcontrolandextinguish
anincidentrelativelyquickly.Althoughthesesystemsprovideforprocesscontroland
incident minimization, they do not cater for fire control and suppression needs.
Therefore,additionalmeasuresmustbeprovidedtoaccommodatethefireprotection
aspectsrequired.
2.2.2. INCIDENTFUELCONSUMPTION
One avenue ofprotectionfor afacilityis toallowa fire incidenttoresolveitself by
allowing the fire to consume all the available fuel to it. This allows conservation of
watersupplysourcestothosefacilitiesthathavenotbeendamagedandrequirecooling
water or exposure protection. It is the simplest and most economical of protection
measures,howevertheincidentitselfmaycauseconsiderablymoredamageunlessitis
terminated at the earliest opportunity (i.e. additional product and facilities may be
destroyed).Insomeinstances,theamountoffuelavailabletoanincidentmaypreclude
theconsiderationofthisoption(i.e.wellblowout,largestoragetankinventory,etc.),as
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thefiremaycontinuetoburnforaconsiderabletime,resultinginadditionalfactorsfor
consideration(i.e.pollution,publicresponse,longtermreputation,businessinterrup-
tionlosses,increasedcostofincidentcontrol,etc.).
2.2.3. PROVIDEPROTECTIVEMEASURES
The best option is to provide some amount of protection features to an installation
basedonthecost/benefit,orcommensuratewiththeriskinvolved.Nationalorlocal
codesmayalsorequiretheinstallationoffireprotectiondevices.Theseareusuallya
combination of passive and active systems. This provides a balanced approach to
protectveryhighriskareaswithsuitableprotectivemeasures,whilelowerriskareas
receivelessinstalledprotectivemeasures.
2.2.4. PASSIVESYSTEMS
Passivefireprotectionfeaturesarenormallypreferredoveractivesystemsduetothe
inherent safety they providewithout the need for additional intervention by manual
means,orfordetectionandcontrolsystemsthatmaymalfunctionorbeimpaireddueto
the incident. The primary passivemeasures include spacing and installed protective
barriers, limitation of fuel sources and utilization of inherently less hazardous pro-
cesses. Passive systems cannot always be provided to some equipment, because of
other inspectionsorconditionsimposed onthe facility,e.g.provision ofvesselfire-
proofingversustheneedtoconductaccuratemetalthicknesschecksforcorrosion.
2.2.5. ACTIVESYSTEMS
Active systems are provided to automatically or manually detect and apply fire
protection measures. These systems usually employ an extinguishing agent that is
usedatthetimeofthefireincident.Commonsystemsincludefirehydrants,monitors
and hose reels for manual applications, and automatic water spray and deluge fire
protectionorwaterexposurecoolingsystems(seeFigure2.1).Automaticsystemsare
arranged in combination with detection and control systems. Firewater pumping
systemsformpartoftheactivefireprotectionsystemprovidedforaninstallation.
2.3. INSURANCE REQUIREMENTS
Industrial insurance underwriters have a vested self-interest in preventing losses at
facilities they insure, even though most large industrial facilities may have a large
deductible. Evidence of application of common industry practices to avoid major
losses (from small incidents) will be investigated during evaluation of the property
duringtheannualsurveyor’sinspectionsorinitialassessmentofthefacilitiespriorto
issuingapolicy.Theinsurer’ssurveyors’assessmentandrecommendations(ifany)to
reducelossesatthefacilitywillbereviewedduringtheinsurancepremiumdetermi-
nation.Ifariskisconsideredbelowthenormalstandardsexpectedforthetypeofplant