Self-testing and self-calibrating fire sprinkler system, method of installation and method of use

• US 20120298381A1
• Filed: 01/27/2012
• Published: 11/29/2012
• Est. Priority Date: 01/27/2011
• Status: Active Grant

• Current Assignee: W.S. Darley & Co.
• Original Assignee: W.S. Darley & Co.
• Inventors: Taylor, Jeremy
• Granted Patent: US 9,375,595 B2
• Time in Patent Office: Days
• US Class Current: 169/13
• CPC Class Codes: A62C 35/64 pressurised
• CPC Class Codes: A62C 37/50 Testing or indicating devices for determining the state of readiness of the equipment

Abstract

A Self-Testing and Self-Setting residential fire pump system for residential fire protection. The system is designed to boost pressure into a residential sprinkler system when water supply is insufficient to meet the sprinkler system'"'"'s design requirements. The system comprises an in-line vertical multi-stage, centrifugal pump connected to an electric motor with horsepower ranges from ¾ to 10, a flow rate range of 15 gpm-200 gpm, and pressure ranges of 20 psi-238 psi. The system also comprises a controller assembly which is programmed to Self-Test and Self-Calibrate to most residential fire sprinkler systems with the push of a button, and a manifold made from brass or stainless steel pipe fittings connected to the pump'"'"'s suction and discharge ports, allowing water to flow from an existing water supply through the pump to either the test loop or existing residential fire sprinkler system. The pump and controller can be mounted on an ABS base.

Claims

1. An automatic, self-calibrating, self-testing fire sprinkler system comprising:

a pump;

an electric motor engaged to the pump;

a control panel engaged to a controller assembly;

and a suction manifold, the suction manifold comprising a solenoid test valve, a suction pressure sensing line, and a discharge pressure sensing line.

2. The automatic, self-calibrating, self-testing fire sprinkler system of claim 1 wherein the pump is connected to a water supply, the water supply being selected from group consisting of pressurized domestic supply and water tank.

3. The automatic, self-calibrating, self-testing fire sprinkler system of claim 1, wherein the system further comprises an ABS base capable of supporting and housing the assembled system.

4. The automatic, self-calibrating, self-testing fire sprinkler system of claim 1 wherein the pump is a vertical multistage pump.

5. The automatic, self-calibrating, self-testing fire sprinkler system of claim 1 wherein the controller assembly comprises a Programmable Logic Controller, a suction transducer, a discharge transducer, test solenoid outputs, a motor contactor, a disconnect lever, multiple light-emitting diode lights, multiple dry contacts for power failure, a pump failure alarm, and a remote start.

6. The automatic, self-calibrating, self-testing fire sprinkler system of claim 1 wherein the controller assembly comprises a pre-programmed control board, a suction transducer, a discharge transducer, test solenoid outputs, a motor contactor, a disconnect lever, multiple light-emitting diode lights, multiple dry contacts for power failure, a pump failure alarm, and a remote start.

7. A method of installing the automatic, self-calibrating, self-testing fire sprinkler system of claim 1 comprising:

a. connecting a pump to a water supply;

b. connecting the water supply to a suction manifold;

c. connecting an empty sprinkler system to a discharge valve;

d. connecting a controller assembly to an electrical power source; and

e. connecting power to a control panel.

8. A method of calibrating the automatic, self-calibrating, self-testing fire sprinkler system of claim 1 comprising:

a. verifying that the discharge valve is closed;

b. opening the suction valve thus alloing water to flow freely into the pump system from the supply side;

c. priming the pump'"'"'s vent by opening it to insure the pump is full with water;

d. visually checking the system for leaks;

e. turning the system on in order to allow calibration to an existing sprinkler system;

f. turning the controller assembly handle to the on position;

g. waiting about 3 seconds to determine whether an audible alarm sounds, signalling that the system is not calibrated;

h. pushing the test button so that the pump motor receives electrical power sufficient to turn on from the controller assembly so that, during the first 5 seconds of pumping, the pump pushes water against the closed discharge valve thus allowing pressure to be sensed by the suction and discharge pressure transducers located in the controller assembly by means of the suction and pressure sensing lines;

i. allowing the information gathered by the transducers to be sent to the controller assembly;

j. allowing the controller assembly to learn the system suction pressure and the “

no flow”

discharge pressure capabilities of the pump at which time the pump is pumping against a closed valve, resulting in the pump running under no flow conditions;

k. allowing the controller assembly to send a signal to a check light located on the controller so that the light starts blinking on the control panel, signalling that the discharge valve is ready to be opened;

l. opening the valve allowing the discharge transducer to sense and relay to the controller an instant drop in pressure as the sprinkler system piping begins to fill, so that when the sprinkler system piping is full the pump returns to “

no flow”

conditions;

m. allowing the controller to recognize the state of the system by means of constant pressure readings being sent to it by the discharge pressure transducer;

n. allowing sufficient time to elapse to achieve a no-flow pressure reading at which time the controller will send a power to the test solenoid valve allowing it to open;

o. allowing the discharge pressure transducer to sense the resulting drop in water presure resulting from the test solenoid valve opening which in turn relays that information to the controller PLC which is capable of sensing that water is being pumped;

p. allowing sufficient time to elapse during which time water is being pumped with an open solenoid so that the controller PLC, by means of the pressure readings being sent by the suction and discharge pressure transducers, senses and records the suction and discharge pressure under pump running with flow conditions;

q. allowing sufficient time to elapse so that the system produces stable pressure reading under flow conditions and the controller stops sending power to the test solenoid valve thus resulting in the valve closing;

r. allowing the pump to continue pumping against what are now no flow conditions;

s. allowing the controller, by means of the pressure transducers, to verify no flow conditions; and

t. allowing the controller PLC to send electrical power to a green check LED which will turn solid green indicating that they system is calibrated and ready for use.

9. A method of automatically testing the self-calibrating, self-testing fire sprinkler system of claim 1 comprising:

a. setting an automatic test interval;

b. obtaining suction and discharge pressure readings at static conditions by means of the suction and discharge pressure transducers reading line pressure;

c. relaying that information to the controller;

d. allowing the controller, by means of readings sent by the pressure transducers, to verify that the static suction and discharge pressure are as they were at calibration;

e. if either suction or discharge pressures are higher or lower than they were at calibration, then the test fails and the system stops;

f. if the suction and discharge pressures are the same as they were at calibration, then the test continues;

g. allowing the controller to send a signal to the solenoid test valve telling it to open;

h. as soon as the solenoid valve is open, allowing the controller, by means of pressure information sent to it by the discharge pressure transducer, to detect an instant drop in pressure which indicates that because the solenoid valve has opened there is demand for water;

i. programming the controller to start the pump at an adjustable percentage below the set discharge pressure;

j. if the discharge pressure transducer does not send a drop in pressure to the controller, then the solenoid valve has failed and the test will stop;

k. if the controller reads a “

start point”

pressure, the controller turns on the pump;

l. allowing the transducers to send pressure reading to the controller and allowing the controller to verify that the readings are the same as the readings taken during the calibration step;

m. if the readings from the calibration and test steps are the same, then the pump is deemed to be working correctly which will result in the system being started at the first sign of pressure drop, which simulates an open sprinkler in the house; and

n. if the pressure readings during the test are higher or lower than the reading during the calibration step, then the test is deemed to have failed.