Abstract:
A flow test device for diminishing and diverting the flow of a high pressure stream of water while testing a fire pump has a hollow diverter tank supported on a trailer for receiving a high pressure stream of water forced by the fire pump through one or more pipes and nozzle tips retained in a stable position adjacent the diverter tank. Diffusers within the tank divert the flow of water as it enters the tank with the water subsequently exiting through an open bottom of the diverter tank. One or more support panels maintain the pipes in a generally horizontal orientation in relation to the diverter tank. A valve and gauge board enables a user to control the testing and provides for easy positioning in the vicinity of the fire pump to be tested while avoiding splash and spray from the diverter tank discharge.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application is based upon and claims benefit of copending and co-owned U.S. Provisional Patent Application Ser. No. 61/140,135 entitled “System and Method for Testing Fire Pump Full Capacity Flow”, filed with the U.S. Patent and Trademark Office on Dec. 23, 2008 by the inventor herein, the specification of which is incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates to water flow measuring devices, and more particularly, to water flow measuring devices for use with fire-fighting equipment such as fire hydrants or building fire pumps. 
         [0004]    2. Background 
         [0005]    In the construction of most buildings, UL and/or FM approved fire pumps are incorporated. The pumps provide water pressure for fire sprinklers, hydrants, or a standpipe system where the available source of water pressure is inadequate. Building sprinkler systems designed for extinguishing fires within the building and fire standpipes often carry extremely high water pressures. All approved fire pumps are constructed and factory tested pursuant to the National Fire Protection Association (“NFPA”) regulations. Most state and local fire and building regulatory agencies, as well as insurance underwriters, have adopted the NFPA regulations or code for testing fire pumps. 
         [0006]    It is necessary to test the water pressure in the building fire suppression systems periodically to meet fire and safety codes. The NFPA code requires field testing of each new pump and annual testing of existing pumps. Under supervision of local building and fire authorities, the pumps are tested with full water flow to verify that the pump, the supply piping, and the water source meet the design demand of the fire suppression system of the building. 
         [0007]    To test a typical system, the sprinkler system or standpipe is usually connected to a hose and a playpipe to allow the free flow of high pressure water through the system and out the playpipe. Typically, temporary hoses are attached to an available connection and the water is released. A playpipe or flow diverter may be connected to the end of the hose to allow flow measurements at the exiting water stream. A measuring device, such as a pitot tube, determines the flow of water exiting the hose/playpipe. During pressure tests, water may be allowed to discharge from these systems for anywhere from a few minutes to half-an-hour or more. 
         [0008]    The water discharged from the playpipe typically cannot be directed with any great specificity or accuracy to a particular area, but instead flows primarily outdoors in the immediate vicinity of the building that contains the system under test. The water is often discharged adjacent to the building wall or hydrant. Additionally, when water under high pressure is released to atmospheric pressure, considerable forces are in play on the discharge stream. High-pressure water spraying from the hose releases very strong forces that are difficult to control and tend to cause the hose and playpipe to swing from side to side and whip violently. Typically, the playpipe or flow diverter needs to be restrained during testing. Extreme care must be exercised with regard to where the water is discharged. The high-pressure water from the playpipe may dig holes in streets, driveways, parking lots, and lawns, with results very similar to hydraulic mining. Damage to the ground, surrounding landscaping, and harm to individuals in the path of the water can occur due to a misdirected water stream. 
         [0009]    Building sites and crowded city locations rarely afford sufficient spray areas without interrupting traffic for long periods or without potential harm to pedestrians and nearby property. Many new pump installation tests are conducted on dirt pad sites of new building construction. Such sites typically cannot handle the high-pressure sprays and large volume of water runoff for the full duration of the flow test. Thus, the tests are often shorter in length than necessary and cannot provide accurate results because the tester is unable to provide flow for the appropriate time. Other sites may not have the physical space necessary to accommodate the full spray of water under high pressure without damage to surrounding property. 
         [0010]    As safety codes and standards have improved over the years, accuracy in testing is of an increasing importance. To perform a flow test properly using current methods the following must take place.
       1. Typically, three persons are required. One person is located at the fire pump inside the building performing tests, one person is located at the fire pump&#39;s flow test header on the building, and one person is located at the flow point of discharge. The person at the flow test header and the person at the flow point of discharge must communicate with each other to accurately adjust the flow pressure to required levels. When multiple flows are required to meet a certain demand, the task gets much more difficult. When the volume of one flow device is adjusted higher, the other flow devices decrease in volume, thus requiring much more time to set all flow devices to required pressures accurately.   2. The area at the flow point of discharge, the majority of the time, could exceed 30 yards in diameter. Bridge devices are sometimes used to stack flow discharge units where several units can flow at one location. However, in most conditions, more than three discharge flow devices are required thus making it difficult to accurately measure flows. The person at the flow point of discharge will need to walk back in forth from one test point to the other, communicating with the person at the flow test header to open or close valves to increase/decrease flows, back and forth several times to verify all flow points of discharge are reading the required pressures. After verification, the person at the flow point of discharge moves away from the test area allowing the person at the fire pump to perform tests. In some cases, the hose valves at the flow test header, due to heavy vibration, will slowly open creating inaccurate flows at the flow point of discharge. This is common, and the person at the test header must watch the valve handles to make sure this does not happen. Even when watching closely, if the handle moves in the slightest way, the flows are compromised. Having the person at the flow point of discharge not continuously watching the pressure gages because the person has moved from his position, can result in the flow test results not being accurate.   3. Having to move back in forth several times to measure flows at the point of discharge requires excessive time and excessive water usage.   4. The difficulty of providing unrestricted access to the test equipment is that water backsplash is difficult to control. The difficulty increases as the size of the device reduces. An unrestricted access flow diverter must allow the operator access to the measurement and control devices without getting him wet in the process. The device should prevent any backsplash of the fluid in the area where access is required. The person at the flow point of discharge, at 90% of the flow test locations, gets soaking wet from the knees down.   5. Excessive turbulence will greatly affect flow readings. Unfortunately, it is practically impossible to eliminate water turbulence. Fire hoses used are typically 2½-inch size. Any bends, curves, and/or kinks in any fire hose will create water turbulence thus resulting in inaccurate measurements.       
 
         [0016]    There is a need for a high-pressure water testing apparatus that is easy to control; that dissipates the pressure from the system under test; and that is easy to use. 
       SUMMARY OF THE INVENTION 
       [0017]    Accordingly, it is an object of the present invention to provide a flow capacity test device that avoids the disadvantages of the prior art. 
         [0018]    Another object of the present invention is to provide a flow capacity test device that is effective and easy to use. 
         [0019]    Yet another object of the present invention is to provide a flow capacity test device to improve testing accuracy. Another object is to provide a flow capacity test device enabling an easier means for testing fire pumps. A related object is to provide a flow capacity test device that saves costs and water. 
         [0020]    Still another object of the present invention is to provide a flow capacity test device to be as maintenance free as possible, uses less area to flow water, decreases labor costs, increases productivity, and uses less water during testing. 
         [0021]    These and other objects of the present invention are attained by the provision of a flow capacity test device having a diverter tank mounted on a portable trailer. A plurality of pipe sections connects to the diverter tank through pitotless nozzles having direct connections to a valve and gauge board. Support panels may be used to support and maintain alignment of the pipe sections between the diverter tank and the valve and gauge board. The diverter tank has an open bottom and includes one or more flow diffusers. A user at the valve and gauge board can control flow from a plurality of fluid sources and simultaneously measure the pressure while avoiding splash and spray from the diverter tank discharge. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0022]    The above and other features, aspects, and advantages of the present invention are considered in more detail, in relation to the following description of embodiments thereof shown in the accompanying drawings, in which: 
           [0023]      FIG. 1  is a rear perspective view of a flow capacity test device according to an embodiment of the present invention. 
           [0024]      FIG. 2  is a front perspective view of a flow capacity test device according to an embodiment of the present invention. 
           [0025]      FIG. 3  is a side elevation view of a flow capacity test device according to an embodiment of the present invention. 
           [0026]      FIG. 4  is a top plan view of a flow capacity test device according to an embodiment of the present invention. 
           [0027]      FIG. 5  is an elevational view of hose and gauge connection panel for a flow capacity test device according to an embodiment of the present invention. 
           [0028]      FIG. 6  is a perspective, cutaway view of the interior of a diverter box for a flow capacity test device according to an embodiment of the present invention. 
           [0029]      FIG. 7  is an enlarged view of a flow diverter for a flow capacity test device according to an embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0030]    The invention summarized above and defined by the enumerated claims may be better understood by referring to the following description, which should be read in conjunction with the accompanying drawings. This description of an embodiment, set out below to enable one to build and use an implementation of the invention, is not intended to limit the invention, but to serve as a particular example thereof. Those skilled in the art should appreciate that they may readily use the conception and specific embodiments disclosed as a basis for modifying or designing other methods and systems for carrying out the same purposes of the present invention. Those skilled in the art should also realize that such equivalent assemblies do not depart from the spirit and scope of the invention in its broadest form. 
         [0031]    Referring to the drawings,  FIGS. 1-4  shows a flow capacity test device, indicated generally as  10 , according to the present invention. The test device  10  is mounted on a portable trailer  13  and has a diverter box  16 . The portable trailer  13  enables accurate flow testing in any test location. In a preferred embodiment, the trailer  13  includes a frame  14  mounted on heavy payload tires  15  to support the weight of the test device  10 . 
         [0032]    The trailer  13  may include vertical barriers on three sides and a rear gate (not shown). The side barriers and rear gate may be selectively moveable between an open and a closed position. In some embodiments, the side walls of the trailer  13  may be constructed of heavy angle framing with expanded metal infills. Additionally, the rear gate, if included should have double door latched gates made of heavy angle framing and expanded metal. The floor of the trailer  13  may be made of heavy duty expanded metal, except under the diverter box  16 . 
         [0033]    Further included in the test device  10  are one or more fluid conduits  25 . The conduit  25  is connected on one end to the diverter box  16  by a pitotless nozzle  28  and on the other end to a test header  31 , best seen in  FIG. 5 . The conduit  25  between the pitotless nozzle  28  and the rear of the trailer&#39;s remote test header  31  has been designed to greatly reduce water turbulence from the fire hoses and valve  52  located on the trailer remote test header  31 . Conduit  25  may be approximately seven feet of steel 2½-inch pipe with a smooth brass extension downsizing to an appropriate diameter for the pitotless nozzle  28 . In a preferred embodiment, the fluid conduit  25  starts at the remote test header  31  with a 2½-inch diameter section  33  approximately 4 inches in length, then upsizes using a first 2½×4-inch eccentric reducer/expander  34  to an elongated 4-inch diameter section  35  approximately 35-inches in length, then reduces through a second 2  1 / 2 ×4-inch eccentric reducer/expander  34  back to a 2½-inch diameter section  37  approximately 16 inches in length. (The change in diameters is best seen in  FIG. 3 .) In a preferred embodiment, the conduit  25  uses a smooth brass 2½-inch female NPT to hose threaded adapter to join the conduit  25  to the pitotless nozzle  28 . The overall dimension of conduit  25  is approximately 67-inches in length. Other lengths and diameters may be used. This design removes approximately 95% of the water turbulence, thus allowing true flow readings. The increased pipe size and volume absorbs most of the turbulence and allows a smoother flow pattern prior to flowing through the pitotless nozzle  28 . Also connected to the remote test header  31  are one or more 2½-inch valves  52  that can be connected to a fluid flow system for connecting the test device  10  to a hose from the system to be tested. 
         [0034]    The test device  10  includes a pitotless nozzle  28  and insert  40 . In a preferred embodiment a suitable pitotless nozzle  28  and insert  40  is manufactured by Hydro Flow Products, Inc. of Arlington Heights, Ill. The pitotless nozzle  28  includes a gauge port  43 . Fluid enters the nozzle  28  as turbulent flow. As the fluid passes through the nozzle  28 , the turbulent flow is converted to laminar flow due to the shape of the nozzle  28 . Once in laminar flow, the pressure at that point in the nozzle is constant, and therefore the pressure, and thus flow rate, can be measured with greater accuracy. A pitotless nozzle is described in U.S. Pat. No. 6,874,375 to Grenning, the specification of which is included herein by reference, in its entirety. The design of the pitotless nozzle  28  keeps the measuring point out of the direct path of water flow, thus the possibility of damaging the unit by rocks, debris, etc. is not a factor. A gauge line  46  extends from the gauge port  43  on the pitotless nozzle  28  to the remote test header  31 , shown in  FIG. 5 . A gauge connection  49  on the remote test header  31  is used to attach a pressure gauge (not shown) to indicate pressure, which can be correlated to flow in the conduit  25 . One or more support panels  55 ,  56  prop up and maintain alignment of the fluid conduit  25  between the remote test header  31  and the diverter box  16 . In some embodiments, one or more support bars  58  may extend between the support panel  55  and the rear wall  62  of the diverter box  16 . 
         [0035]    In a preferred embodiment, the diverter box  16  includes one or more flow diffusers  19 . The diverter box  16  comprises a rigid enclosure with an open bottom  22 . In some embodiments, the diverter box  16  comprises a steel enclosure approximately 30-inches long, 36-inches tall and 77-inches wide. A plurality of strengthening tubes  64  may extend between the front wall  60  and rear wall  62  of the diverter box  16 . 
         [0036]    Referring to  FIG. 6 , the diverter box  16  is the water discharge area for flow testing. Inside the diverter box  16 , in the direct path of each water flow, a flow diffuser  19  is placed. In some embodiments, the flow diffuser  19  includes a manufactured steel arrow shaped head  20  and a wire mesh portion  21  at each stream location. As shown in  FIGS. 6 and 7 , the arrow shaped head  20  may be formed by a rectangular pyramid approximately 2-inches on each side and 2-inches long. Preferably, the wire mesh portion  21  should be approximately 6-inches square located about 2-inches behind the base  65  of the arrow shaped head  20 . The length of each of the plurality of flow diffusers  19  can vary from as short as about 10- or 11-inches to as long as about 18- to 22-inches. During test flows, the water is then distributed in numerous directions within the diverter box  16  and then directed downwards by gravity in a safe, less forceful manner. 
         [0037]    Flows are measured through the pitotless nozzle  28  and inline unit  40 . The inline unit  40  is used to eliminate vacuum problems during testing. The water gauge port  43  on the pitotless nozzle  28  is connected to a pressure gauge that may be connected at the gauge connection  49  at the rear of the trailer next to each hose valve  52 . This will allow one person to adjust flows and observe flow pressure reading in one general location that is safe. This design will reduce labor costs because the third person is no longer required (person at the pumps test header), will ensure accurate testing because the person at the rear of the trailer (remote test header) is now capable of observing all pressure readings to ensure all flows are not disturbed or changed, being at one safe location the person is no longer subjected to water damage to self, testing area has been reduced considerably and now can be performed in tight areas such as busy town, cities, businesses, testing procedures and actual time in testing has been reduced by 50%, by reducing the time in testing more pumps can be tested in a single day, by reducing the time required to conduct the testing, up to approximately 50% of the water usage can be saved, making this unit ‘green’. 
         [0038]    The invention has been described with references to a preferred embodiment. While specific values, relationships, and materials have been set forth for purposes of describing concepts of the invention, it will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the spirit or scope of the basic concepts and operating principles of the invention. It should be recognized that, in the light of the above teachings, those skilled in the art can modify the specifics without departing from the invention taught herein. Having fully set forth the preferred embodiments and certain modifications of the concept underlying the present invention, various embodiments as well as certain variations and modifications of the embodiments herein shown and described will obviously occur to those skilled in the art upon becoming familiar with such underlying concept. It is intended to include all such modifications, alternatives and other embodiments insofar as they come within the scope of the appended claims or equivalents thereof. It should be understood, therefore, that the invention may be practiced otherwise than as specifically set forth herein. Consequently, the present embodiments are to be considered in all respects as illustrative and not restrictive.