Examples of the dangers of working on equipment that others have serviced or installed.

1. SHODDY WORK DANGERS
BOLDLY 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 20
3.3.39 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.

2. 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

3. 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.

4. 125 HP, 208 VAC SERVICE FED ELECTRIC FIRE PUMP CONTROLLER
Previously 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

5. DIESEL CONTROLLER - LOOSE BATTERY CHARGER WIRING
This 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.

6. JOCKEY PUMP OVERLOAD RELAY - LOOSE CONNECTION
Nuisance 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.

7. 250 HP MOTOR LEAD CONNECTION FAILURE
Loose 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.

8. 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.

9. 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.