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Suction Booster Pump for Fire Apparatus

Submitted to: Professor Howard Pearlman The Senior Design project Committee Mechanical Engineering and Mechanics Department Drexel University

Team Number: MEM-13

Team Members:

Kevin Dinshah Mechanical Engineering Jason Grote Mechanical Engineering Soren Hasselbalch Mechanical Engineering Paul Pisarski Mechanical Engineering

Submitted in partial fulfillment of the requirements for the Senior Design Project

November 24, 2002

Table of Contents

Introduction

Problem Statement

Method of Solution

Manufacturing

Environmental and Social Impacts

Additional Targets of Success

Team Responsibilities

References

Appendices:

Timeline

Pump Performance Curve

Pump Lift Curve

Page

1

Background 1

3

3

Objectives 4

Design 4

Analysis 4

5

Testing 5

Marketing 5

Economic Analysis 6

6

Measurement of Success and Deliverables 6

7

7

8

I

II

III

Abstract:

Firefighters are always searching for new and inventive ways to improve the capability of

their equipment to better accomplish their job. Frequently fire trucks use the pump intake (i.e.

suction port) located on the front bumper so they can gain access to the drafting source such as a

lake, without endangering the truck itself. The current state-of-the-art device available to

overcome frictional losses while using the front suction requires setup time and the unnecessary

usage of manpower. We propose to improve the front suction on the trucks by adapting the

current state- of-the-art device within the vehicle to allow the trucks to overcome the frictional

losses of the internal piping while drafting, and avoid using valuable set-up time and manpower.

Our approach is to design a booster pump within the piping that boosts flow by sending a high

velocity jet in the positive flow direction. Anticipated results include the completion of the original

objective stated earlier in addition to the adherence of the system to the NFPA requirements.

Introduction:

Firefighters are always searching for new and inventive ways to improve the capability of their

equipment to better accomplish their job. Setup time and efficiency is vital in their line of work.

When a department is dispatched to a scene the lines must be laid for the intake of the truck’s

pump using a hydrant or “Drafting” from an alternate water source such as a lake or river, and for

the discharge lines that will be deployed to fight the fire. The term drafting means the pump is not

using a positive pressure source and must rely on atmospheric pressure and the power of the

pump itself to draw in water. The intent of this project is to reduce the set up time and increase

efficiency, allowing firefighters to deliver the required rate of water to extinguish fire.

Background:

Frequently fire trucks use the pump intake (i.e. suction port) located on the front bumper

so they can gain access to the drafting source without endangering the truck itself. A soft

shoreline or wooded areas are common scenarios where the side intake ports are impracticable.

The distance the bumper extended beyond the front axle allows these trucks to remain at a safe

distance from a soft shoreline. Since the front of the vehicle is narrower than the side, it can gain

better access to the drafting source, for instance a wooded area. The draw back of using of the

front suction adds considerable losses to pump performance, due to the additional twists in the

piping needed to make the connection from the front bumper to the pump located midship on the

vehicle. Below is a diagram of a typical drafting setup using the front suction port:

1

The diagram to the right is an

illustration of a current product called the

“TurboDraft”. This device is attached to the

end of a suction line and lies with the suction

line in the water source. It requires a

discharge line from the truck that is used to

induce the water flow using a nozzle as

shown. The operation of this device is one

way of increasing the flow of water to the

pump under less than ideal drafting

conditions. The draw back to this device is

the setup time and difficult operation added

when arriving on the scene. The device is

bulky and heavy. With the weight of the

TurboDraft and the attached suction line it

becomes difficult to manage the system

when a clog occurs. If debris were to

become lodged in the TurboDraft it would

have to be unclogged by moving the setup

around which takes time. Time is precious

since most fire trucks only carry 500 to 750

gallons of water, which depending on the

intensity of the fire and number of discharge

lines, could be used in a few minutes. This

means the drafting setup must be ready by

the time the tank is empty.

2

Problem Statement:

When using the front suction port for drafting on a fire apparatus lack of water flow is

caused by frictional losses added by the bends and twists in additional piping that is not required

when using the side port. An easy to use, instantaneously available device needs to be designed

in order to overcome the losses in pump performance during this condition.

Method of solution

The frictional losses incurred while drafting through the front suction can be overcome by

designing a similar device as the TurboDraft that is easier to use and available instantaneously.

The device could be mounted within the truck at the truck manufacturer or possibly sold as a

retrofit. The device would require some modifications in the way trucks are piped and a discharge

line available at the front bumper. The basic concept is illustrated below.

3

This solution must be based on the rules and regulations of the National Fire Protection Agency

or NFPA.

Objectives:

Design an internal device mounted, or “Booster Pump” on a fire apparatus that

overcomes pressure drops due to curves and bends in piping as well as reducing the risks of

cavitations and reduced flows when drafting from front suction.

Design:

The design of the suction booster pump will adapt existing technology to generate an

inducer located in-line with the suction piping of the fire apparatus as shown on page 3. Designs

may consist of a permanent suction booster pump system, integrated during the manufacturing

process of the truck or as a retrofit to an existing truck. Construction must be robust and firmly

adhere to the regulations of the N.F.P.A. The design will use the given constraints such as the

volume, velocity, and change in pressure over the pump required to meet NFPA regulations. With

these givens we can determine our variables, namely the nozzle, nozzle pipe dimensions and

location of device on truck.

Analysis:

The pump performance curves can be found in appendix II. The pump performance curve

based on the use of the side suction shows the required RPM and Horsepower required to

generate the required flows. The lift curve, found in appendix III, shows the potential of the pump.

Based on these sources we will calculate the required energy to overcome frictional losses due to

bends in piping and to overcome less than perfect drafting conditions. Theoretical calculations of

pressure drops throughout the induction device will be carried out; as well as minimizing further

losses due to new device will be performed. Theoretical calculations for the increase of

horsepower for the additional flow to the booster pump will be performed. In other words, if the

pump is rated for 1000GPM and our device is powered by 150GPM, then the pump must produce

4

a total of 1150GPM to reach full pump performance and power the booster pump. Most pump

models will perform well above there rating. Those that cannot reach the required flow due to

mechanical limits will not see a full performance rating which will be noted. Also, locate a

maximized position within the truck to position the device. In addition, research will be made on

the efficiency of modern pumps and establish practical design limitations. FEA analysis of

prototype for structural capability of device will be performed.

Manufacturing:

Create a prototype of a booster pump with materials satisfactory for fire apparatus

implemented by the N.F.P.A. All pieces are to be welded and machined, little if any plastic parts

will be essential for this device. There may be possible uses for investment casting for the

prototype or mass production. The machining will be performed by manual milling and turning

machines at Hale Product’s facility. All welding will be sent out to a vendor who will determine the

proper method according to the material and construction.

Testing:

A test will be performed on a fire truck using the front suction with no additional

equipment. This will establish a base line for comparison when the time comes to test the booster

pump. Testing will be performed on a prototype based on the design parameters mentioned

above using an “in house” testing facility at Hale Products. These tests could be done by testing

the side suction port with and without the device at certain performance points and measuring the

difference, or by using a mock-up of the fire trucks piping to determine the difference. Pressure

losses will be measured across the device as well as the pressure differential gained by the

device. Testing

Marketing:

Each truck with a front suction port experiences frictional losses that reduce pump

performance during drafting, consequentially reducing performance. The internal booster pump

5

may overcome these frictional forces and could be made enclosed in the truck (during production)

or as a retrofit for an existing truck that attaches on the front suction and utilizes the front fire

hose line, known as the “trash line” as a source of energy for induction.

Economic analysis:

Engineering costs for the suction booster pump are based on a current average rate of

$39.00 /hr, including overhead. An estimated time of development is 6 months of engineering

design and testing. Shop time necessary to prototype our design is approximately 100 hrs (or 2.5

weeks), at a shop rate of $33.00 /hr. An extra 120 hrs (or 3 weeks) of is estimated for testing and

modifications once the prototype is manufactured. Material costs are anticipated to be $1000,

based on prior Hale products.

Team Total Hours/Week Weeks Members Total Hrs Rate Cost

Engineering cost 20 26 4 2080 $39 $81,120 Shop Time 40 5.5 220 $33 $7,260 Materials Cost $1,000

Total Cost $89,380

Environmental and Social Impacts:

The act of putting out a fire, not only saves lives and property, but as fire burns, it launches an

extensive variety of gases and ash into the environment. The only adverse effects this product

would add to the environment is: the increase of horsepower that will be required to run it. As a

result, a small increase in fuel consumed and burned, thus increasing the percentage of CO

(carbon monoxide)

Measurement of success and deliverables:

As part of a successful conclusion to this project, a working prototype will be produced for

testing and an evaluation of performance increase with the addition of the booster pump.

6

The evaluation of the prototype will be based on the theoretical calculations performed prior to the

manufacture of a prototype.

Additional targets of success:

Further success will be measured on performance of prototype and its ability to overcome the

frictional losses within in the truck, as well as the additional losses than may occur in the field due

to less than perfect conditions. A working prototype will demonstrate the benefits, on the behalf of

society, with the increased protection of its homes and industry.

Team Responsibilities:

Although every team member is ultimately responsible for the individual work assigned;

each team member has input on all aspects of this project.

Jason Grote: FEA structural analysis, Technical Drawings, NFPA requirements,

Database for test results.

Soren Hasselbalch: Scheduling, Nozzle pipe design and calculations, Project economics.

Kevin Dinshah: Piping fluid flow analysis, Material Requirements, Enforce Ethical

Practice.

Paul Pisarski: Nozzle Design, Calculations, and Testing,

Time-Line:

See Appendix I

7

References:

1 . Hale Products; Engineering Dept., 700 Springmill Rd., Conshohocken PA

2. National Fire Protection Agency (NFPA) Rules and Regulations 1901

3. Schutte & Koerting; Turbodraft Division; http://www.turbodraft.net/

8

Task Due Date 10/6 10/13 10/20 10/27 2003

11/3 11/10 11/17 11/24 1/5 1/12 1/19 1/26 2/2 2/9 2/16 2/23 2004

3/1 3/8 3/15 3/22 3/29 4/5 4/12 4/19 4/26 5/3 5/10 5/17

Pre-Proposal

Written Proposal

Proposal Oral

Research

20-Oct-03

24-Nov-03

1-Dec-03

5-Jan-04

Theoretical Calculations 19-Jan-04

Design 2-Feb-04

Prototype 1-Mar-04

Progress report presentation 1-Mar-04

SD Project Abstract 8-Apr-04

Testing/Data aqusition 12-Apr-04

Modifications 26-Apr-04

Final Product 3-May-04

Final Report 10-May-04

Final report Presentation 17-May-04

Monday, April 01 , 2002 08:52:27

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