SHODDY WORK DANGERSBOLDLY GO WHERE SOMEONE ELSE HAS GONE BEFORE

Mike Trumbature

Anyone remember Star Trek? - BOLDLY GO WHERE NO ONE HAS GONE BEFORE. If you think that's bold, try going behind someone who's worked on a fire pump before you did. Below are some examples of major destruction and an examples of some "near misses" as hidden water damage, loose connections and/or frayed wiring can easily set of an arc, resulting in minor damage to the complete destruction of a controller.

In addition to NFPA 20 and NFPA 25 requiring a certain scope of supply be provided concerning fire pumps, they also require all the work to be done by a "Qualified Person."

2010 NFPA 203.3.39 Qualified Person. A person who, by possession of a recognized degree, certificate, professional standing, or skill, and who, by knowledge, training, and experience, has demonstrated the ability to deal with problems relating to a particular subject matter, work, or project. [1451, 2002]

4.3.4.1 Service personnel shall be qualified and experienced in the inspection, testing and maintenance of fire protection systems. etc..

4.5.2.2 The replacement of components in fire pumps, fire pump controllers, and drivers shall be performed by factory-authorized representatives or qualified persons acceptable to the authority having jurisdiction.

OSHA - Competent and Qualified Person, Interpretation.

SERVICE-FED WATER DAMAGED

ELECTRIC FIRE PUMP CONTROLLER

This service-fed electric fire pump controller had water damage but was superficially-cleaned to the point the hidden danger was unknown. Instead of following NEMA standards for water damaged electrical equipment, it was "cleaned up" and put online. When the controller was energized and the contactor engaged, the contactor reportedly caught fire and the arc propagated above the breaker, melting the wiring inside the conduit and destroying the controller.. One person went to the hospital.

NEMA - Guidelines For Handling Water-Damaged Electrical Equipment

250 HP SERVICE FED CONTROLLER LOOSE ISOLATION SWITCH WIRING

Loose connections on L1 and L2 resulting in discoloration from heat. Excess exposed wiring above the the breaker case insulation. Dust, loose connections and a water leak from incorrect conduit fittings could result in an explosion.

125 HP, 208 VAC SERVICE FED ELECTRIC FIRE PUMP CONTROLLERPreviously replaced pilot relay to the main motor contactor - missing relay retaining clips and frayed wiring on the 120 (red) and line voltage (black) control wiring. If these strands were to come in contact with each other or an adjacent terminal, severe damage and/or a personal injury could result. This could also set off an arc, resulting in the destruction of the controller

DIESEL CONTROLLER - LOOSE BATTERY CHARGER WIRINGThis charger had been replaced before me. These are the battery charger output wires to the controller field terminals and go back to the engine batteries - NO FUSES. Loose connections under load can easily result in a terminal failure. A short could easily result in the controller, field wiring and engine harness being severely damaged and/or destroyed. The alarm wiring on the left is barely making contact and nearly touching.

JOCKEY PUMP OVERLOAD RELAY - LOOSE CONNECTIONNuisance jockey pump overload tripping. The overload was incorrectly replaced due to tripping from short cycling. Whomever replaced it did not tighten the L1 contactor screw completely. Not too long after, it began to overheat and trip even worse, damaging the contactor as well. Replacing the overload and contactor, increasing the pressure switch differential from 10 PSI from 15 and setting the START and STOP settings per NFPA 20, eliminated water hammer and repeat start problems.

250 HP MOTOR LEAD CONNECTION FAILURELoose split-bolt motor lead connector. Unusual heat detected on one phase of the motor contactor and resistance check lead to the motor junction box where part of the electrical tape had melted on the cover. I was able to remove the connector without ever loosening the bolts.

100 HP, 460 VAC PRIMARY RESISTOR CONTROLLER

This resistor cabinet was removed for jobsite shipping then reinstalled in the field with #12 AWG wire. The harness finally failed due to overheating. The enclosure is not secured to the floor or conduit system and the ground wire on the left too small. There were no mounting bolts in the rear of the front-heavy resistor cabinet which easily tilts forward.

75 HP, 208 VAC SERVICE FED CONTROLLER

The conduit on the left is the motor feeder. The NEMA 1 locknut on the outside is upside down and the one on the inside barely catching the threads. The smaller liquid-tight is the alarm conduit There are metal shavings on the outside. There is a sprinkler head about three feet above the conduits and both conduits located directly over the line voltage control power transformers located on the inside. The controller is fed directly from a large utility transformer feeding a hotel.