Fire Fighting Systems AS

Document No: FFS-667 Revision 01

Installation Instruction
SFP Pump/Bell housing/Caterpillar Marine Diesel Engine assembly
Caterpillar C32, C18 or C9.3 engines
Document no. : FFS-667 Document control
Version Description Written Approved Date
by by
01 Added C9.3 engine HMP RAS 05/07/2017
00 First Release HMP PHR 02/03/2017

Contents
1  GENERAL DESCRIPTION AND PURPOSE OF THIS DOCUMENT 1 
1.1  Disclaimer 2 
2  REFERENCE DRAWINGS/DOCUMENTATION 3 
3  SAFETY PRECAUTIONS 4 
General Safety Precautions 4 
4  LIFTING AND TRANSPORTATION 5 
5  INSTALLATION 5 
5.1  Structural installation 5 
5.2  Fuel system and connections 5 
5.3  Coolant connections and filling 6 
5.4  Exhaust system and air inlet 6 
5.5  Lubrication system/oil filling 7 
5.6  Electrical installation 7 
5.7  Start air installation 7 
5.8  FiFi system water temperature switch installation (Option) 7 
5.9  FiFi system water pressure transmitter installation (Option) 8 
5.10  Engine accessories and documentation 9 

1 General description and purpose of this document

 This procedure is to be used during installation engineering & design phase as well as
installation of the relevant FFS system subassembly covered by this document – at
customer/shipyard/end-user site/vessel/works.
 The customer, shipyard or party responsible for installation (hereafter referred to as
customer) is requested follow this procedure and confirm accordingly in the document
FFS-254 - Installation confirmation before Start-up and Commissioning for the relevant
item. Adherence to this document is a pre-requisite for FFS warranty validity and
commissioning attendance.

Fire Fighting Systems AS Tel: +47 69 24 49 90

Tykkemyr 27 Fax: +47 69 24 49 95
N-1597 MOSS e-mail: ffs@fifisystems.com
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 Fire Fighting Systems AS
Document No: FFS-667 Revision 01

1.1 Disclaimer

The present installation instruction is an integral part of the purchase agreement and project
documentation. FFS general terms and conditions given in the project-/order -relevant Order
Acknowledgement are applicable to the delivery under consideration. In the event that, at the
time of installation, technical alternatives are considered, or the instructions concerned as
interpreted by the client seem at risk of giving rise to misunderstandings, the client is under the
obligation to contact FFS without delay. Under all circumstances, at the same time, excluding
any form of product liability if this provision is not complied with. Recommendations of a
general nature included in our installation instructions, such as personal protection and safety
advice, can under no conditions whatsoever be invoked, nor does FFS accept any liability
whatsoever for any consequential loss.

The installation of the delivered equipment is subject to requirements in order to ensure the
best and safest possible operation of the installation. These requirements are binding for the
commissioning of syste m/delivered equipment and the basis of the warranty. Deviation
from the instructions is only possible following consultation and with the prior permission in
writing from FFS. All data and specifications may be modified by FFS and/or PON/Caterpillar
without prior warning.

Fire Fighting Systems AS Tel: +47 69 24 49 90

Tykkemyr 27 Fax: +47 69 24 49 95
N-1597 MOSS e-mail: ffs@fifisystems.com
NORWAY www.fifisystems.com

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 Fire Fighting Systems AS
Document No: FFS-667 Revision 01

2 Reference drawings/documentation
 The relevant FFS project documentation/working drawings package is to be available to
the personnel carrying out the installation, and its contents must be read and
understood.
 FFS project Item 00, Item 02, Item 06 and Item 08 are the core chapters in the FFS
documentation relevant to this installation.
 FFS project Item 00 contains the Engine room arrangement drawing, with main
dimensions, footprint and information for foundation
 FFS project Item 02 contains the control system drawings for electrical installations.
However, in general the cable between engine and its control cabinet is an FFS supply
cable with readily made termination to the engine’s contact, with marked conductors
for termination in the relevant cabinet.
 FFS project Item 06 contains documentation for the pump unit, regarding piping and
installation.
 FFS project Item 08 contains documentation for the engine.
 PON/CAT publication no 2010 V.03_EN of “INSTALLATION GUIDE – Caterpillar
Marine Diesel Engines”, hereafter referred to as PON_INST_GUIDE (under FFS
project Item 08)
 Caterpillar Performance data for the supplied engine (under FFS project Item 08)
hereafter referred to as Performance Data
 Caterpillar Systems data for the supplied engine (under FFS project Item 08) hereafter
referred to as Systems Data
 Caterpillar Operation and Maintenance Manual no SEBU8775-02 (CAT C32) hereafter
referred to as C32 Manual
 Caterpillar Operation and Maintenance Manual no SEBU9044-03 or SEBU8245-02
(CAT C18) hereafter referred to as C18 Manual
 Caterpillar Operation and Maintenance Manual no SEBU9251-02 (CAT C9.3) hereafter
referred to as C9.3 Manual

Fire Fighting Systems AS Tel: +47 69 24 49 90

Tykkemyr 27 Fax: +47 69 24 49 95
N-1597 MOSS e-mail: ffs@fifisystems.com
NORWAY www.fifisystems.com

Page 3 of 9
 Fire Fighting Systems AS
Document No: FFS-667 Revision 01

3 Safety Precautions
 All safety directions must be respected in order to avoid damage to personnel,
environment and equipment. In this document, the following annotations are used
with belonging signification:

Warning
Indicates possibilities for hazards or unsafe practices, which COULD result
in fatal or severe personnel injuries or substantial product or property
damage, if the required precautions are not taken.

CAUTION!
Indicates possibilities for hazards or unsafe practices, which COULD result in minor
personnel injuries and/or property damage, if the required precautions are not taken.

Note
Draws attention to specific information of technical significance which might not be
obvious to specialist personnel, or points at important remarks in the procedures to
follow.

General Safety Precautions

 Use only suitable, approved and certified lifting gear for performing lifting
operations.
 Take care when handling and lifting the unit/assembly. Avoid abrupt landing and
shocks to the unit when lifting onboard vessel or installation, as well as during
transport.
 Electrical and mechanical connections, as well as lifting operations are to be carried
out by qualified personnel only.
 Proper procedures on safety and personal protection equipment when filling fluids
and installing equipment must be adhered to.
 Refer to C32, C18 or C9.3 Manual under “Safety Section”

Fire Fighting Systems AS Tel: +47 69 24 49 90

Tykkemyr 27 Fax: +47 69 24 49 95
N-1597 MOSS e-mail: ffs@fifisystems.com
NORWAY www.fifisystems.com

Page 4 of 9
 Fire Fighting Systems AS
Document No: FFS-667 Revision 01

4 Lifting and transportation

 The assembly is delivered on transport pallet covered with plastic. Lift and transport the
assembly by suitable equipment and procedures, ensuring stabilizing moment always
exceeds heeling moment.
 Carefully remove plastic and remove fastening bolts to the transport pallet.
 The assembly is to be lifted in the two engine lifting lugs marked on the top of the
engine, by suitable lifting gear to the application and weight.
 Do not split the pump/bell housing from the engine without consulting FFS. If this is
Note absolutely necessary for the installation process, FFS can provide detailed information
and guidance to customer relevant to this.
 Refer to C32, C18 or C9.3 Manual under “Lifting and Storage”

5 Installation

5.1 Structural installation

 Place the pump/engine assembly at the designated location at the vessel structure or
baseplate.
 Refer to FFS Engine Room Arrangement drawing (under FFS project Item 00, typically
drawing number suffix E1) for fastening to structure. Select bolts/nuts/washers of
closest dimension to given free holes, or proper thread standard if applicable. Bolt
grade metric standard 8.8 or higher/US equivalent bolt grade or higher. Tighten
fasteners to proper torque corresponding to size and grade, typically obtained from
fastener supplier.
 Refer to FFS project Item 06 for considerations around piping. In general, no pipe-
stress is to be transferred to the pump via the flanges, ie. all piping must be fully self-
supported. Dynamic forces from water at full nominal flow and pressure, and if
applicable - vessel movements, must be taken into consideration.

5.2 Fuel system and connections

 Dimension, design and connect fuel system and its lines/components according to
PON_INST_GUIDE and Systems Data. Systems Data parameters overrules
PON_INST_GUIDE if discrepancies.
 Refer to FFS project Item 08 for connection details
 Prescribed counterpressure/fuel system back pressure must not be allowed exceeded.
 Highest fuel level in the relevant tank is generally not to exceed the vertical height of
the engine’s injectors, due to risk of oil dilution by internal fuel leakage.

Fire Fighting Systems AS Tel: +47 69 24 49 90

Tykkemyr 27 Fax: +47 69 24 49 95
N-1597 MOSS e-mail: ffs@fifisystems.com
NORWAY www.fifisystems.com

Page 5 of 9
 Fire Fighting Systems AS
Document No: FFS-667 Revision 01

5.3 Coolant connections and filling

 FFS normally delivers the engine drained of coolant (to lowest practical level/drain
point) due to transport regulations.
 Refer to PON_INST_GUIDE and Systems Data. Systems Data parameters overrules
PON_INST_GUIDE if discrepancies.
 Refer to C32, C18 or C9.3 Manual
 If expansion tank is present on the engine, connect the supplied additional expansion
tank to engine by the supplied rubber hose to the filler neck, with its bottom 100-
300mm higher than the highest point of the engine.
 Note that the raw(/sea) water side cooling system on FFS pump/bell housing/engine
assembly generally is a closed system mounted on the complete unit from FFS works.
Note This neither requires nor allows any customer adaptations or modifications. If the
purchased unit is supplied with raw water pump and no FFS integrated seawater
cooling system, refer to PON_INST_GUIDE

5.4 Exhaust system and air inlet

 Dimension, design and connect the exhaust system and engine room air supply
according to PON_INST_GUIDE and Systems Data. Systems Data parameters
overrules PON_INST_GUIDE if discrepancies.
 Use values in Performance Data for guidance.
 Prescribed counterpressure/exhaust back pressure must not be allowed exceeded.
 Proper countermeasures preventing water ingress into the exhaust system and
subsequently the engine must be designed and executed.
 All FFS supplied protective covers must be left fully attached and sealed on the exhaust
outlets and air filters until exhaust system final assembly and before first start (air
filters). No foreign objects, dust or debris of any kind is allowed to enter the engine
exhaust outlets or air inlets, during storage, installation or commissioning.

Fig. 5.4.1 – protective covers of air filter and exhaust shown

Fire Fighting Systems AS Tel: +47 69 24 49 90

Tykkemyr 27 Fax: +47 69 24 49 95
N-1597 MOSS e-mail: ffs@fifisystems.com
NORWAY www.fifisystems.com

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 Fire Fighting Systems AS
Document No: FFS-667 Revision 01

5.5 Lubrication system/oil filling

 FFS normally delivers the engine drained of oil due to transport regulations.
 Refer to PON_INST_GUIDE and Systems Data. Systems Data parameters overrules
PON_INST_GUIDE if discrepancies.

5.6 Electrical installation

 Refer to FFS project Item 02 and PON_INST_GUIDE

 In general, FFS supplies the communication cable between the engine socket and the
FFS supplied engine control cabinet, with connector plug terminated. The customer is
then to complete terminations in the engine control cabinet.
 If electric start, FFS in general do not supply the battery package. The customer is then
to design, execute and terminate the battery package and relevant wiring to the electric
starter terminals on the engine.
 Circuits are not to be energised before FFS commissioning attendance or FFS approval
of such, in the event the system/project is sold without FFS commissioning.

5.7 Start air installation

 Refer to FFS project Item 08 and PON_INST_GUIDE

 In general, FFS in not supply the air supply system. The customer is then to design,
execute and terminate this to the air starter connection on the engine.

5.8 FiFi system water temperature switch installation (Option)

 Refer to FFS project Item 02

 If a temperature switch for high water temp alarm in the fifi system is supplied, this is
to be terminated in the FFS main control system cabinet acc, to supplied drawings.
 The temp switch is in general packed in the FFS main control system cabinet and
delivered ready calibrated. The sensor pocket(thermowell) is in general mounted from
FFS works in either the pump casing top, bottom or in FFS supplied spool piece on the
pump discharge side.
 FFS instruction/drawing no 4008630 shows the steps, where generally the steps
regarding setting are to be bypassed and steps 2-3 followed. Then followed by
customer’s electrical connections according to FFS supplied wiring diagrams.

Fire Fighting Systems AS Tel: +47 69 24 49 90

Tykkemyr 27 Fax: +47 69 24 49 95
N-1597 MOSS e-mail: ffs@fifisystems.com
NORWAY www.fifisystems.com

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 Fire Fighting Systems AS
Document No: FFS-667 Revision 01

Fig. 5.8.1 – Fifi system water temp switch sensor pocket (thermowell) exhaust shown in
top of pump casing (C32-SFP300x400 pump application)

5.9 FiFi system water pressure transmitter installation (Option)

 Refer to FFS project Item 02

 If a pressure transmitter for water pressure reading/control in the fifi system is supplied,
this is to be terminated in the FFS main control system cabinet acc, to supplied
drawings.
 The pressure transmitter is in general packed in the FFS main control system or engine
control cabinet. The sensor location is in general in FFS supplied spool piece on the
pump discharge side, in the same tee piece as the standard local reading main discharge
pressure gauge. Then followed by customer’s electrical connections according to FFS
supplied wiring diagrams.

Fire Fighting Systems AS Tel: +47 69 24 49 90

Tykkemyr 27 Fax: +47 69 24 49 95
N-1597 MOSS e-mail: ffs@fifisystems.com
NORWAY www.fifisystems.com

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 Fire Fighting Systems AS
Document No: FFS-667 Revision 01

5.10 Engine accessories and documentation

 Refer to FFS project Item 00 and Item 08

 In general, dry exhaust elbow(s) and exhaust compensator(s) are delivered by FFS.
Exhaust elbows are in general mounted from FFS works, compensators delivered on the
engine’s transport pallet.
 The engine’s hard copy manual in addition to accessories not applicable for mounting
until at customer’s works (eg. exhaust counter flanges, gaskets etc.) are in general
delivered in box on the engine’s transport pallet.

Fire Fighting Systems AS Tel: +47 69 24 49 90

Tykkemyr 27 Fax: +47 69 24 49 95
N-1597 MOSS e-mail: ffs@fifisystems.com
NORWAY www.fifisystems.com

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