Fire Water Pump Replacement

Please email [email protected] to declare interest

A) Introduction

LondonEnergy Ltd (The Company) own and operate the EcoPark Energy Centre located in Edmonton, London. The Energy Centre has five boilers burning approximately 500,000 tonnes of domestic refuse per year in a continuous 24-hour operation, 7 days per week. The waste is delivered by road via the weighbridges/gate house by various types of transport. The waste is tipped and held in storage bunkers. Waste is fed by three 5m3 grabbing cranes from the storage bunkers to the feed chutes of each boiler. Each of the water tube boilers is operated to achieve an evaporation rate of 40 tonnes per hour, at a steam pressure of 41.5 Bar and temperature of 415 OC. Material which remains after the incineration process is transferred to the residual conveyors for onward transfer for further treatment and recycling.

Within the EcoPark, there is a firewater ring main system consisting of:

1. 2 x Firewater Pumps
2. 1 x Sprinkler Header with level control (float switch start)
3. 1 x Fire Water Ring Main (with pressure-controlled start capability)
4. 40 x Isolation Valves
5. 18 x Fire Hose Points
6. 18 x Fire Hose Connections
7. 20 x Fire Hydrants
8. 1 x Crossover Pipeline (for pressure compensation - to be decommissioned and replaced with the jockey pump)

The Eco Park Firewater Pump Project aims to install two new diesel firewater pumps and integrate them with the London Energy DCS system. This will enhance the control, monitoring, and visibility of the fire protection system compared to the currently installed setup. Additionally, a new jockey pump will replace the existing crossover system to maintain pressure in the Firewater Ring Main.

In addition to the installation of two new firewater pumps and a jockey pump, this project requires enhanced visual, audible, and control capabilities. All components and alarms must be integrated with the SCADA system, ensuring seamless monitoring and control.

B) Project Scope

1. Replace the existing firewater pumps with two new diesel driven firewater pumps. Disconnection of the existing cables from the current firewater pumps and re-termination into the new firewater pump panel. Extending the existing cables via a JB or cable joint. Installation of any additional cables (to be specified and installed by the contractor).
2. Select, procure and install a new jockey pump to maintain Ring Main pressure. Installation of any additional cables (power and control) for the jockey pump.
3. Upgrade repeater panels to communicate all alarms and faults to the SCADA system.
4. Implement DCS-based control and monitoring of the firewater pumps and jockey pump through SCADA.
5. All technical documentation and drawings are to be provided to LEL by the selected contractor for upload to the London Energy SharePoint, by LEL.

C) Control Specifications

This section outlines the existing control and installation configurations, as well as the required upgrades.

Existing Control and DCS Specifications (Electrical):

• Auto Start: Currently initiated via the "Firewater Pump Test Panel" located on the turbine mezzanine level and from the Sprinkler Header Level Switch.
• Manual Start: Operated through local control panels at each pump and at various push buttons throughout site. Manual stop is only available via the engine choke on the diesel engine.
• Indications Available:

o Pump running

o Battery circuit healthy

o Battery charger healthy

o Pump on demand

o Fail to start

o Low oil pressure

o High water temperature

o Lamp test

o Alarm acknowledgement

All above indications are repeated on remote repeater panels located in the Turbine Hall (East end).

• Audio and visual alarms: Present on both local and remote panels.
• No current control or status indication is available in the CCR via SCADA

Fault Indication and Alarms (Current Local Control Panel):

o High water temperature

o Low oil pressure

o Battery charger failure

o Battery circuit failure

o Fail to start

o Pump on demand

o Alarm acknowledgment

o Repeater panels provide remote visual and audible alarms.

o The local test panel enables auto start/stop of firewater pumps

o No current DCS connectivity or SCADA monitoring of pump operation

Fault Indication and Alarms (New Local Control Panel to be installed):

The new firewater pump control panel (provided by SPP Pumps) will use a volt-free contact for a common fault alarm. Individual alarm indications will be shown locally via the HMI. Features include an integrated PCB board with volt-free contacts and designated inputs, dual 10A battery chargers and 12V DC batteries for ignition coil and motor starter.

Alarm and Status Indications:

o Not in Auto Mode

o Pump Running

o Pump on Demand (via Float, Pressure or Manual Start request)

o Failed to Start

o Mains Supply Failure

o High Water Temperature

o Low Oil Pressure

o Low Engine Cooling Water Flow

o Low Fuel Level

o Low Engine Temperature

D) New Control Specifications

This section outlines the specifications for the new firewater pump control system to be installed by the selected contractor, including all hardwired electrical requirements, the selected contractor is expected to incorporate the existing manual and automatic start functions.

New Control System Specifications:

1. Auto/Remote Start

Auto or remote start will be initiated from the Firewater Pump Test Panel. Interconnections required to enable this function are shown in the associated project drawings.

o All interconnection work will be carried out by the selected contractor.

2. Manual Start

Manual start shall be initiated locally via push buttons installed on the new control panel at each firewater pump. These panels include an integrated HMI display.

3. Local Indication and Fault Display

The new control system shall provide local indication of the following conditions via LEDs installed on the new repeater panels.

o Pump Running

o High Water Temperature

o Low Engine Temperature

o Low Cooling Water Flow

o Remote Start Active

4. Repeater Panel Signal Integration

Pre-existing repeater panel cables will be reused. These will be terminated in the new repeater panels, which will display:

o Pump Running

o Fault Alarm

o Not in Auto Mode

o Pump on Demand

o Mains Failure

o Failed to Start

Interconnection between the new firewater pump control panel and repeater panels will be made using an IP67-rated polycarbonate junction box, installed locally at the new firewater pump.

o All terminations will be completed by the selected contractor

5. Repeater Panel Construction

Repeater panels will be built on-site by a LEL-specified technician.

o All components must comply with the appropriate SIL (Safety Integrity Level) as defined by selected contractor.

6. SWA Cable - Mezzanine Floor

A single 3-core cable, conforming to LPC Technical Bulletins 210 and 236 (TB210 and TB236), shall be routed between the junction box and the relay/start push-button station on the Mezzanine Floor for each firewater pump shall be installed by the contractor.

7. SWA Cable - Firewater Pump Control Panel

A single 19-core SWA cable conforming to LPC Technical Bulletins 210 and 236 (TB210 and TB236), shall be routed between the junction box and the control panel on each firewater pump.

8. Sirens

Existing orange mineral-insulated cables for the sirens on Panel 1 and Panel 2 must be reinstalled on top of the new control panels.

9. A LPCB flow meter is to be provided and installed in accordance with LPC rules (technical bulletins) incorporating BSEN12845, with an integral "self-test" return loop for both pumps.

Existing Repeater Panel - Indications and Installation (Turbine Hall):

Current repeater panels provide the following indications:

1. High Water Temperature
2. Low Oil Pressure
3. Battery Charger Failure
4. Battery Circuit Failure
5. Fail to Start
6. Pump on Demand
7. Alarm Acknowledgement
8. Visual and audio alarms for remote fault indication
9. Local Test Panel for auto start/stop control

No DCS or SCADA connectivity for pump status or alarms

New Repeater Panel - Indications and Installation (Turbine Hall):

1. Common Fault Alarm - Visual and audible indication
2. Not in Auto Mode
3. Failed to Start
4. Pump on Demand
5. Pump Running
6. Mains Failure

Full DCS/SCADA Integration - All alarms and remote start/stop functions to be extended to SCADA, existing cabling will be reused for connectivity between new firewater pump control panels and repeater panels, Sirens to be reinstalled on top of new control panels

E) Jockey Pump Specifications

This section outlines the installation requirements for the jockey pump, including electrical, control, and mechanical specifications

1. Decommissioning:

o Two "Dust Extraction Pump Discharge" pumps are to be disconnected, removed, and associated cables made safe.

2. Installation:

o A Jockey Pump will be installed in place of the "TY192 Dust Extraction Pump Discharge" pump.

o Jockey pump to replace cross over pipeline for pressure compensation. Installation to be carried out by the selected contractor.

3. Electrical Supply:

o A new 415V 3-phase supply is required.

o One of:

 4-core Conforming to LPC Technical Bulletins 210 and 236 (TB210 and TB236), , or

 3-core with bare copper earth, Conforming to LPC Technical Bulletins 210 and 236 (TB210 and TB236),

from an appropriate designated distribution board. Location to be determined by contractor.

o A lockable isolator must be installed near the jockey pump on a suitable stand. The appropriate loading and size of the jockey pump motor to be designed, selected, procured, installed and commissioned by the contractor.

4. Pump Specification:

o The motor nameplate details must be provided to the E&I technician.

o Final pump sizing is to be determined by the selected contractor.