Firemiks
Firemiks
Firemiks
MANUAL
FIREMIKS – GP
GEAR PUMP TYPE
WITH AUTOMATIC FLUSHING
Original English version
Date: 2016-03-29
Document: FiremiksInstructionManual-AutoFlushing-GP
Firemiks AB
P.O. Box 8155, 104 20 STOCKHOLM, Sweden
phone +46-8-551 196 10 - [email protected] - www.firemiks.com
Page 2/42
TABLE OF CONTENTS
1 EC Declaration of conformity
According to European Directive 2006/42/EC
Manufacturer:
Firemiks AB
P.O. Box 8155
SE-104 20 STOCKHOLM, Sweden
Tel: +46-8-551 196 10
www.firemiks.com, [email protected]
2016-03-29
Firemiks AB
Mikael Aredal, Managing Director
3 General description
3.1 FIREMIKS® is designed with two displacement units direct coupled to
each other through a flexible drive coupling. FIREMIKS dosing system is
driven solely by the existing extinguishing water flow - no additional
energy is required.
The extinguishing water flow from a main water supply/pump goes
through the FIREMIKS water motor which powers the concentrate gear
pump. The power of the water flow generates a circular rotor motion,
which is transferred to the concentrate gear pump over the direct drive
coupling. The concentrate pump pumps concentrate into the water
motor outlet creating the water/concentrate mixture.
Since the water motor and the concentrate pump are directly connected
with the drive coupling, the system is by that flow-proportional. Dosing is
automatically adjusted from the amount of water that goes through the
FIREMIKS.
3.2 FIREMIKS is a dosing system which uses an atmospheric concentrate
tank. Equipped as standard with a Manual air relief valve. Flushing of
the concentrate pump is done automatically when the concentrate inlet
is closed with 3-way ball valve. Optional: Automatic air relief valve,
suitable for installations with suction from below the unit.
The above is to give a general idea and is not binding. In case of doubt, always
refer to the chapters that follow.
4 Installation
Please refer to the European standard EN 13565-2 for general requirements on
fixed foam systems for fire-fighting. Any Foam Fire Protection System must be
designed in accordance with the Authority Having Jurisdiction whether it is the
Insurance Carrier, Fire Marshal, end user or the relevant NFPA Fire Code(s.)
4.1 Storage
4.1.1 Respect the temperature limits as specified on the data sheet. Standard is 5
to 50 °C
4.1.3 Protection caps: Let the yellow plastic protection caps and plugs remain on
the unit until it is installed unless you need to use the threads for installation.
4.3 Requirements for the equipment before and after the FIREMIKS:
4.3.1 FIREMIKS is designed to operate with clean water. Water must be free
from sand, gravel and other debris that may wear out the volumetric water
motor quickly. In most cases the FIREMIKS can cope with occasional
instances of isolated foreign objects up to 2 mm size. If there is an acute risk
of particles entering the FIREMIKS or when polluted or contaminated water is
used, the piping system must be designed so that there is a suitable filter or
strainer where this pollution can be collected fully, placed before the
FIREMIKS. We refuse any responsibility for blockage or damage of the
water motor by any foreign objects in the water, whatever their size.
Please contact us if you need further guidance in this subject.
4.3.2 Note! Any new piping system before the FIREMIKS must be flushed out
thoroughly before the assembly of the FIREMIKS in the system. (There
are often foreign particles from the welding etc., left). Take care so other
foreign particles do not come into the unit during installation. Keep the
protection caps and plugs on the unit on as long as possible. Also take note
of the requirements on clean water for any discharge devices mounted
downstream of the FIREMIKS also. NFPA 11 etc. also requires the foam
delivery system and main water supply system to be flushed before activating
the foam delivery system.
4.3.3 No minimum length of straight piping for the water supply before or after the
FIREMIKS is required, although a sharp bend just before the unit may give an
additional increased pressure drop with a more uneven flow through the unit.
4.3.4 Maximum flow in the system must be checked with a flow meter if water
source pumping capacity is higher than the max flow of the FIREMIKS. If
there is a risk that the water flow could exceed the stated max. flow, there
should be some kind of flow limiter placed before the unit. Exceeding
maximum flow of the unit may lead to damage and failure of the unit.
4.3.5 Overspeeding at start-up. Even if the main water pump has a capacity
equal or below the max flow capacity of the FIREMIKS, over-speeding can
happen at the start if the main pipes are empty and the flow-limiting parts are
located after the unit. This risk for over-speeding could be minimized if the
FIREMIKS and the piping are completely filled with water up to the flow-
limiting parts. Gently filling the piping before the flow limiting parts, is also
helpful to prevent over-speeding of the FIREMIKS, i.e. not suddenly starting
the main flow.
4.3.8 In the case that the pressure capacity of the pumping system is higher than
the maximum rated pressure of the FIREMIKS unit, it is recommended that a
pressure-relief valve is installed in the main system.
4.3.9 If the installation is to operate for an extended period of time (more than 10
minutes) with extinguishing water only, a by-pass should be installed and
used around the FIREMIKS system to avoid unnecessary wear of the
volumetric water motor and to avoid damaging the gear pump that relies on
the concentrate for optimal lubrication.
4.3.11 For wet pipe systems it is recommended to install a drain valve after the
FIREMIKS unit with a capacity of about 100 - 200 lpm to facilitate the rotation
of the water motor according to the maintenance instructions, see 7.3
4.3.12 It is possible, with only one main water pump, to design the piping system so
there is plain water from some outlets in the system and at the same time
additive admixed water from other outlets. The requirement is that the
minimum and maximum flow limits on the FIREMIKS are kept.
4.3.13 The outlet system after the FIREMIKS can be divided in many different ways,
also vary in heights, as long as the min. and max. flow limitations of the
FIREMIKS are kept.
4.4 Concentrates:
4.4.1 The FIREMIKS can be used with all common foam liquids/fire-fighting
additives. As for example standard detergents, synthetic AFFF, AFFF-AR and
protein based FP, FFFP and FFFP-AR. Should there be any questions and
thoughts about different additives, please contact us and state additive type
and brand. Note: Minimum water flow rate with correct dosing varies
depending on viscosity properties of the foam concentrate and system
pressure.
4.4.2 For concentrates with low viscosities close to water, we recommend the PP
(Piston Pump) type FIREMIKS.
4.4.3 This FIREMIKS type is NOT suitable for Gel Forming additives. Contact your
distributor or Firemiks AB for a special version of the FIREMIKS that can
handle these additives.
There are two basic designs for the supply of concentrate to the FIREMIKS
unit. The preferred one is the gravity feed scenario, the other one is the suction
priming scenario.
The NPSHR at the concentrate inlet of the FIREMIKS at max water flow and
viscosity 50 cSt is approximately 5m. Priming capability and possible suction
height depends on suction pipe design and associated losses, the viscosity
and steam pressure of the concentrate liquids to be used and the water flow
used at start-up (for priming). Always test your installation that priming of the
concentrate pump is possible at the lowest start-up water flow to be used and
that suction height (when the tank is almost empty) does not adversely affect
the admixture rate.
The most common mistake when installing a FIREMIKS is to rely too much
on the suction capability. Suction side is inherently much more sensitive than
the pressure side of the pump. It is strongly recommended to have the
concentrate tank in the immediate vicinity of the FIREMIKS and with a
minimized suction height for the whole tank as this will always give the best
performance (reliability of suction and start-up time). A longer suction line will
create higher flow losses and increase the risk for leaks that hugely impact on
suction capability.
After initial priming, if there is no leakage in the suction line and the main
system is pressurized, the concentrate should remain in the suction line and
the unit should start dosing immediately when resuming water flow. However,
if this is to be relied upon in order to avoid priming in a critical emergency
situation, a foot valve must be installed at the bottom of the suction line in the
concentrate tank. This will assure the suction line remains filled with
concentrate liquid once the system is primed over longer time periods.
However, this foot valve can in its turn make suction more difficult and
therefore the system must always be primed manually before the system is
stand-by.
Always aim to have as short and easy flowing foam concentrate feed to
the FIREMIKS as possible as it is critical for reliable performance of the
FIREMIKS.
The concentrate feed line connects the concentrate tank with the Selector
valve Dosing/Flushing (No. 4 on Flow chart) on the concentrate pump inlet.
The internal diameter on concentrate feed system must have equal diameter
as the inlet of the Selector valve Dosing / Flushing(No. 4 on Flow chart), or
one size larger (see also Appendix 2, Dimensional Drawing).
Avoid sharp 90-degree bends and keep the concentrate feed line as free as
possible from other flow restrictions (bends, bottom valves, unnecessary
filters).
Avoid elevation changes in the line where air bubbles may stagnate and
cause head losses and cavitation. Any other check valves, ball valves, etc.
should also have at least the same internal diameter as the Selector valves.
Additional valves are discouraged as they increase the risk of operator error
and could cause dry running (see 4.9) if a valve is unintentionally closed.
It is very important that there are no air leakages in the concentrate feed line
anywhere between the tank and the concentrate pump. The system should
be pressure tested (preferably with a manual hand pump up to about 2 Bar)
before the start, to expose possible air leakages, and designed in such a way
that its seal is guaranteed to last in time.
Example of a good installation with gravity feed and short distance from
concentrate tank to the FIREMIKS.
4.6.1 FIREMIKS – GP is provided with a gear pump and is particularly suited for
use in systems with higher flow rates (such as deluge systems), in addition
also very suited for extinguishing concentrates with high viscosity. It is used
with preferably gravity feed of a concentrate liquid from an atmospheric
concentrate tank and provides admixture to e.g. foam nozzles, sprinklers,
foam monitors etc. Alternatively, the unit can be equipped with an automatic
air relief valve making it possible to suck concentrate liquid from below the
concentrate pump inlet (see 4.5.2 for more info).
4.6.2 The unit itself does not require any welding or painting for installation, suitable
pipe connections are to be bolted (cut groove) or threaded (BSP) and the unit
is held in place with screws, see 4.6.7. However, the supporting installation
can require welding and painting, in such case be careful not to contaminate
the in- and outlets of the FIREMIKS unit.
4.6.3 The unit should as a rule be installed with the inlet and outlet of the
water motor and the pump shaft in horizontal positions. Other
configurations of the FIREMIKS are possible but must be configured and
approved by Firemiks AB.
4.6.4 The unit should preferably be installed and used in a frost-free environment. If
this is not possible it is important to drain the unit completely before frost
season. It should not be exposed to higher temperature than 50 degree
Celsius, even when the unit is not in use. This is both valid for the ambient
temperature and for the water temperature.
Note! Be observant for direct solar radiation that can heat up the unit
above 50 degrees C, in these cases use a sun roof. Contact us if higher
temperature tolerances, above 50 degree C, are needed.
4.6.5 If the unit has been contaminated during storage, see also 4.1, make sure to
carefully clean the inside of the unit before installation. If contamination is
especially aggravated and/or temperature limits have been exceeded, please
contact your distributor or Firemiks AB on how to proceed.
4.6.6 The water flow must be in the direction shown by the arrow on the upper side
of the water motor (Note! The direction of rotation of the drive shaft is
reversed compared with the direction of the water flow arrow). The unit can
optionally be configured with the water flow in the opposite direction. See also
Appendix 2, Dimensional Drawing.
4.6.7 The FIREMIKS complete unit must be held in place ONLY by using the
mounting plane with four (or six) threaded holes on the bottom of the water
motor. See Appendix 2, Dimensional Drawing for the key dimensions of the
mounting interface. It is advisable to have a support under the concentrate
pump bracket to balance the weight. NOTE! The support must not be
bolted or fixed to the concentrate pump bracket, to avoid any movement
in the drive gear alignment that can come from even the slightest movement
in the water line. Failure to follow this instruction can result in uneven rotation
of the concentrate pump or the water motor, and possible failure of the unit.
For alternative ways of fixating the unit, contact us. Exceptions apply, see
Dimensional drawing.
4.6.8 It is very important that there are no movements on the water main line that
could create tensions between the water motor inlet and outlet. If any such
movement exists on the connecting pipes, separate support(s) must be made
to stabilize the connection pipes before connecting to the FIREMIKS.
Alternatively, a flexible hose connection to the FIREMIKS is also a possibility.
4.6.9 Make sure there is enough space around the unit to enable easy access for
service and maintenance, especially on the back gable side of the water
motor (opposite side of the concentrate pump).
For the operating instruction of when the valves must be operated, refer to
section 6.1. This section considers the function of the valves.
The unit comes equipped with a manual selector valve for Dosing or
Flushing.
Warning: Always make a fast and determined switch with the
selector valve (No. 4 on Flow chart), leaving it only at its end
positions.
Otherwise, if the selector valve is left between its two end positions,
the valve may be open for both flushing and dosing and thus
pressurized flushing water can enter the suction line and pollute or
even overflow the concentrate tank.
Flushing Dosing
The end user, if necessary for the installation, may automate the
selector valve Dosing/Flushing (No. 4 on Flow chart). When
automating the existing three-way valve, whatever the chosen method
of automation, make sure that the actuator is fast and able to make a
switch under one second. Otherwise, if the selector valve is left
between its two end positions, the valve may be open for both flushing
and dosing and thus pressurized flushing water can enter the suction
line and pollute or even overflow the concentrate tank.
If the chosen actuator works slowly leaving the valves open for some
time between its two end positions, an alternative is to install a check
valve to avoid the risk for pressurized water to enter the concentrate
tank. This check valve should then be of the swing type / flapper type,
not spring loaded. Make sure it works properly and does not interfere
with gravity feed.
4.7.6 Filter
The flushing line is equipped with a filter so that no debris may enter
the pump during flushing. There are two types of filters used on a
Firemiks, check which type your Firemiks is equipped with and learn
how to clean it.
On this filter type, the system must be made pressure free before
opening the filter cap. This filter type is used on smaller units and is
fool proof as no valve is involved.
With this filter type, there is no need to make the system pressure
free to open the filter. The filter can be cleaned with pressure in the
system by closing the valve (handle is put perpendicular to the pipe,
in the ‘OFF’ position) and opening the filter cap.
WARNING!: Only close the filter valve for cleaning the filter. In
all other circumstances, be sure this valve is always OPEN
(handle parallel to the pipe, in the ‘ON’ position)! Otherwise
during operation no flushing can be done and the pump will run
dry if attempting to flush the system.
4.8.1 Some units are equipped with an optional dosing return valve. This valve is
not to be used during regular operation and its handle should remain
positioned for dosing into the main water line only. The valve should
only be operated by qualified maintenance personnel for
maintenance/testing purposes.
4.8.2 A return hose or pipe to the concentrate tank can be connected to the Dosing
Return Valve, making it possible to run the unit with concentrate without
creating any mixture and without consuming any concentrate, for testing
purposes. It is strictly forbidden to include any valves in this return line
or piping as a mistakenly closed valve can lead to dangerous pressure
build-up. If a valve is included in the return line, it is mandatory to order
the FIREMIKS with an optional pressure relief valve in the dosing line.
4.8.3 Note!: Beware that with the Dosing Return Valve in the return position,
any flushing done (Selector valve Dosing / Flushing in flushing position
(No. 4 on Flow Chart)) will result in water being added into the
concentrate tank and possibly make it overflow.
4.8.4 For regular operation, it can be advisable to remove the handle of the valve in
order to avoid unauthorized operation of the Dosing Return Valve. Warning!:
when remounting the handle, be sure reassembled in the same orientation as
when it was removed. Incorrect installation can lead to a total blockage of the
dosing line and lead to dangerous pressure build-up (see 4.8.2).
5.1.2 Check that the drain valve on the water motor is closed (no drain valve on FM 400
size)
5.1.3 NOTE! Make sure that the cover over the drive shaft and the protection cap
on the back gable side are in place.
5.1.1 On units equipped with an Automatic air relief valve, make sure that
the yellow protection cap is removed.
5.1.2 Follow the instructions for first start-up in the next chapter.
6 Operation
The FIREMIKS is designed to serve in fire emergencies. It is not suitable for
continuous use.
On the next page a tabled summary is presented for operating the FIREMIKS.
Wet system There is always pressurized water in the main piping and the
Firemiks
Dry system Main piping and Firemiks are filled with water at start-up
Gravity feed A steady and sufficient supply of concentrate by gravity to the inlet
of the Firemiks.
Suction The atmospheric concentrate container is below the inlet of the
priming Firemiks which will need to suck the concentrate to the inlet
Flushing Selector valve in flushing position*
Dosing Selector valve in dosing position*
6.1.2 Warnings:
Warning: Do not operate the Firemiks with only flushing for extended times, the
pump needs the concentrate for lubrication, see also 4.3.9
Warning: Never use water instead of a concentrate for dosing. The FIREMIKS
gear pump type will not dose correctly with water. More importantly, the pump
needs the concentrate for lubrication and attempting to dose with water only may
seriously damage the pump.
Warning: with the optional Dosing return valve connected to the concentrate tank,
be careful not to use flushing when the Dosing Return is open, this will fill you
concentrate tank with water! See also 4.8.3
Warning: Do not let the pump run dry. If the concentrate is finished, switch over to
flushing! See also 4.7.1 and 4.7.6.2. Or stop the whole system altogether.
Firemiks AB
still dry, e.g. after that the pump and piping is wetted by pressurised flushing water, pressurised flushing water, then immediately after select
installment or then immediately after select the dosing position. Check if dosing the dosing position and open the manual air relief valve to
moving the unit.) is working correctly. If the unit is equipped with a manual air relief start suction of the concentrate. Close the air relief valve
valve (or the optional dosing return valve), shortly open the valve to when concentrate comes out, then the pump is primed
see if concentrate comes out. and ready for use. If the pump does not suck the
concentrate up to the inlet, intermittently flush the unit for a
second to improve the suction. Suction will be stronger at
higher main water flow rates (within the approved range).
Start-up in a Just let the water flow through Gently start the main water flow Just let the water flow Gently start the main water flow
the unit, dosing starts through the piping to prevent through the unit, dosing through the piping to prevent
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6.2.2 The unit is equipped with a label showing min. and max. flow, max. pressure
and nominal admixture. It is placed on the upper side of the water motor.
6.2.3 Different nozzles in the system after the FIREMIKS can be opened and
closed independently of each other without affecting the admixture, as long
as the min. and max. limits in pressure and flow of the FIREMIKS are kept.
6.2.4 An admixture test can be made in several different ways, for example with a
refractometer or by measuring the sucked concentrate at a defined water
flow.
Tests must be made with the actual concentrate liquid, as plain water will give
too low admixture, especially on low flows and high pressures. This is due to
the fact that the concentrate gear pump is designed to seal with higher
viscosity than water. More importantly, the pump needs the viscous
concentrate for lubrication and attempting to dose with water only may
seriously damage the pump after some time. Dosing with water is not the
same as flushing, as flushing puts no load on the pump.
6.3.1 When the Selector valve Dosing / Flushing on the concentrate pump inlet
(No. 4 on Flow Chart) is closed for Dosing it automatically opens for flushing
with water of the concentrate pump. It means you may temporarily (max 10
minutes, see also 4.3.9) stop producing admixture and only use plain water
for fire-fighting. Note! The selector valve handle must only be positioned
in its two end positions.
6.4 Note! Never let the FIREMIKS run dry without concentrate or
flushing water, this will damage the concentrate pump.
6.4.1 The concentrate pumps can withstand some dry running without damage for
a limited time, dry running must however never be purposely chosen or relied
upon.
6.4.2 When all concentrate liquid is finished, always switch to Flushing with
the Selector valve Dosing / Flushing on the concentrate pump inlet (No.
4 on Flow Chart). Or stop the FIREMIKS altogether by shutting down the
main water flow.
6.5.1 After use of the unit in a fire, or in a test with large water flows; check the
function according to paragraph 7.3
6.5.2 Preventive maintenance measure: when the unit has served in a major fire
and the operator wants to ensure optimum future functioning, it may be
appropriate to change the Vanes in the unit. Contact your distributor or
Firemiks AB for spare parts and instructions.
FIREMIKS with the aluminum water motor must always be flushed with
fresh water after use. This is to avoid excessive corrosion of the aluminum
housing.
FIREMIKS with the bronze water motor must also be flushed with fresh
water if salt water is allowed to drain from the water motor and/or the
concentrate pump. If not flushed with fresh water, crystallizing salt will impair
the correct function of the water motor and the concentrate pump.
7 Maintenance
For maintenance of your complete installation surrounding the
FIREMIKS, please refer to European standard EN 13565-2 for general
requirements.
7.1.1 Close completely a shut-off valve in the main water supply before the unit and
make sure it cannot be opened while you are working on the unit, see also
4.3.7.
7.3.2 Wet pipe system. Let a small water flow go through the unit for about 30
seconds (see also 4.3.11) and check rotation of the unit.
7.3.3 Check the filter on the flushing line for cleanliness. There are two filter types,
see 4.7.6 for more information. If the filter is clogged, make sure that it is
emptied and returned to its previous placement.
Or
Ball valve with integrated filter: close ball valve and open filter cap, no
depressurization necessary.
7.4.2 Complete function test, letting the unit function by mixing additive. This is to
check the function of the system. It should be controlled that (i) rotation is
smooth, (ii) suction is immediate, and (iii) dosing is within the tolerance. If the
unit is not working satisfactorily, read section 8. Troubleshooting.
7.4.2.1 Optional dosing return valve This valve may be used to check the
function and dosing of the unit. See 4.8 for more information.
8 Troubleshooting
8.2 NOTE! There is a risk for powerful jet streams of water at leakages
when the system is under pressure. Be sure to make the unit (and if
necessary the system) without pressure when performing service
on the unit.
8.3 If the water motor and the concentrate pump is rotating but there is
no suction of fire-fighting additive, or the admixture is too low:
b) Check if there are any valves in the suction line that are closed or
partly closed.
8.5 Leakage between gable and middle part on the water motor:
b) If this is not sufficient the O-rings between gable and middle part
must be replaced. See 9.1 Water motor spare parts overview.
8.6 Leakage between connection pipe and middle part on the water
motor:
a) See 8.5 a)
8.7 Water motor rotor and additive pump is difficult to rotate with crank
on the rotor shaft end:
a) This is normal in a wet pipe system where a unit which is filled with
pressurized water and is attempted to be manually rotated. It is
possible to check rotation if there is no pressure in the system and
a drain valve according to section 4.3.11 is opened.
c) Check if any filter or other valves in the main line is filled with
pollution. Clean if necessary.
d) Check that the main water pump is working correctly and that
there are no air leakages affecting this pump.
9 Spare parts
9.1 Water motor spare parts overview
(4) Installation
(4.2.1) For weight see Appendix 1, Data sheet. Suitable points to lift the unit are
shown in Appendix 2, Dimensional Drawing. Units from size 3200-12000 Lpm
also have holes for lifting eyes shown on the Dimensional Drawing. The unit
should not be exposed to strokes or knocks.
(4.6.9) Make sure there is enough space around the unit to enable easy access
for service and maintenance, especially on the back gable side of the water
motor (opposite side of the concentrate pump).
(4.8.1) Some units are equipped with an optional dosing return valve. This valve
is not to be used during regular operation and its handle should remain
positioned for dosing into the main water line only. The valve should only
be operated by qualified maintenance personnel for maintenance/testing
purposes.
(4.9.1) Note! Never let the FIREMIKS run dry without concentrate or
flushing water. See 6.4.1 for more info.
(5.1.3) NOTE! Make sure that the cover over the drive shaft and the protection
cap on the back gable side are in place.
(6) Operation
(6.2.2) The unit is equipped with a label showing min. and max. flow, max.
pressure and nominal admixture. It is placed on the upper side of the water
motor.
(6.6.1) Some units are equipped with an optional dosing return valve. This valve
is not to be used during regular operation and it should remain with the valve
positioned for dosing into the main water line only. The valve should only be
operated by qualified maintenance personnel for maintenance/testing purposes.
See 4.8 for more information.
(7) Maintenance
(7.1.1) Close completely a shut-off valve in the main water supply before the unit
and make sure it cannot be opened while you are working on the unit, see also
4.3.7.
(8) Troubleshooting
(8.2) NOTE! There is a risk for powerful jet streams of water at leakages when
the system is under pressure. Be sure to make the unit (and if necessary the
system) without pressure when performing service