Dealing With the Omega Sprinkler Issues
Central
Sprinkler and UL Urging Omega Sprinkler Sample Testing
Subject:Omega Sprinkler
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Patterson, New York March 4, 1998 - The National Fire Sprinkler
Association (NFSA) has announced that today’s action of the U.S.
Consumer Product Safety Commission (CPSC) demonstrates support for the
excellent record of fire sprinkler protection. This morning the CPSC
released its decision to sue for recall of all "Omega" model sprinklers
produced by Central Sprinkler Corporation, one of eight sprinkler
manufacturers in the U.S.
According to NFSA President John Viniello, "The CPSC action is aimed at
preserving the excellent reputation fire sprinklers have earned over the
past 100 years. Fire sprinklers are more than 99% effective in
controlling fires. Both Central Sprinkler and the Consumer Product
Safety Commission have indicated their commitment to address the problem
and to ensure that fire sprinklers maintain their reputation as the most
effective and reliable defense against unfriendly fire. We are confident
that the two organizations will reach an agreement on an appropriate
solution."
Of approximately 600 million sprinklers installed in the United States,
it is estimated that 10 million are Central Omegas. In the past two
years there have been reports of several fires in which at least one
Omega sprinkler did not operate at the available system pressure. No
injuries or deaths resulted, since in most cases adjacent sprinklers
operated properly to control the fire. The problem with the sprinklers
is believed to be an O-ring that sometimes sticks, binding the sprinkler
as it activates to distribute water over the fire. In June of 1996,
Central Sprinkler replaced the rubber O-rings with silicone O-rings in
an attempt to correct the problem. The CPSC action, however, affects
even newer Omega sprinklers, because the agency apparently does not
believe the problem has been fully resolved by the change in O-ring
material.
Viniello urges that the issue be kept in perspective.
"The action on the
part of CPSC deals with only one product line of one manufacturer.
Unlike the safety issue with automobile air bags, no one has been
injured or killed by sprinklers failing to operate when needed.
Automatic sprinklers are proven life-safety devices, and their record of
success is unparalleled when matched against any fire safety device."
Individuals or organizations that have questions regarding
Omega
sprinklers are encouraged to call Central Sprinkler at 800-523-6512 or
Underwriters Laboratories at 800-758-1794.
Established in 1905, the National Fire Sprinkler Association is a trade
association comprised of installers and manufacturers of fire sprinklers
and related equipment and services. Professional, Subscriber, and
International memberships are also available. NFSA provides
publications, seminars, representation in codes and standards-making
market development, labor relations, and other services to its
membership. Headquartered in Patterson, New York, NFSA has regional
offices throughout the country.
Dealing With the Omega Sprinkler Issues
The following article is reprinted from the NFSA publication Grassroots
- Volume XIV - Number 9 - September 1997, Russell P. Fleming, P.E.,
Editor
In April of 1997, NFSA Chairman Claude Chafin appointed a special
Contractor Liaison Committee to work with Central Sprinkler Corporation
on the Omega sprinkler problem. The purpose of forming the committee was
to provide a sounding board for Central Sprinkler and a conduit to other
fire sprinkler contractors as information became available on properly
addressing the problem.
The members of the committee include:
•Bill Oliver, Chairman Oliver Sprinkler Company, Philadelphia, PA •David
Dixon Security Fire Protection, Memphis, TN •Jay Livingston Livingston
Fire Protection, Hyattsville, MD •Wayne Gey Wayne Automatic Fire
Sprinklers, Ocoee, FL •Russ Fleming National Fire Sprinkler Association,
Patterson, NY
This special issue of GrassRoots constitutes an interim report of the
committee, an attempt to communicate to the entire NFSA membership what
has been determined so far to be the facts of the Omega sprinkler
situation, and suggestions on dealing with the issues from a contractor
perspective. In preparing this report, the Committee has met several
times with representatives of Central Sprinkler, and has attempted to
focus on the key questions facing sprinkler contractors. A question and
answer format has been selected for use in addressing the most
commonly-asked questions.
Background: Four instances have been reported in which an Omega model
sprinkler closest to a fire did not operate at the available system
pressure. Fortunately, no one was injured in any of the four fires,
which were controlled by adjacent sprinklers and responding
firefighters. In each case, the Omega sprinklers fused due to the heat
of the fire as expected, but did not fully operate due to sticking of an
O-ring assembly seal made of EPDM rubber. The first two incidents, which
took place in 1995 in a Veterans Administration hospital and a Marriott
hotel, were blamed on improper use of stop-leak products. Subsequent
testing has shown that there are various reasons why the O-ring assembly
might stick, including swelling of the O-ring due to reaction with
residual hydrocarbons from cutting oils. In the case of copper tube
systems or nonmetallic piping served by copper piping, there have been
cases found in which de-dezincification of the brass sprinkler body has
apparently permitted the formation of deposits that prevent the O-ring
from releasing freely.
Question: What changes have resulted from the identification of this
problem?
Answer: Beginning in June of 1996, Central changed the O-ring material
from EPDM to silicone so as to eliminate the hydrocarbon swelling
problem. In June of 1997, Underwriters Laboratories acted to add tests
to UL 199 to investigate the potential adverse effects of residual
cutting oils or antifreeze solutions on internal components of
sprinklers, as well as a test to check for potential dezincification of
brass parts.
Question: What is Central Sprinkler's policy for dealing directly with
building owners on Omega issues?
Answer: Central's position is that the key to identifying problem Omega
sprinklers is through the testing of random samples taken from
individual sprinkler systems. The initial contact for a given facility
with Omega sprinklers may be the building owner, the management company
of a given property, or the fire protection contractor that originally
installed the system or that has a service contract.
Individuals wishing to have Omega sprinkler testing completed for a
given facility should call the Omega Sprinkler Customer Service
Department at 1-800-523-6512. The contact person will be asked to
provide system specific information. Typically, a building owner letter
and questionnaire is then faxed or mailed to the building owner or
building representative to provide Central Sprinkler with information
regarding the sprinkler systems and the type of sprinklers installed.
Once this information is received by fax or by telephone, Central
Sprinkler will forward the appropriate test kits to the building owner
or designated representative. The test kits contains instructions,
replacement Omega sprinklers, wrenches for removal of sprinklers, female
threaded caps, and packaging for the return of the sprinklers, and water
bottles for the collection of sprinkler drop water, if required. Once
the sample sprinklers are returned, the testing as outlined in the test
protocol is conducted at no expense to the building owner or
representative.
After the test results are forwarded to the building owner or
representative, Central Sprinkler will offer resolution/remedy for
installed sprinklers that are identified to be impaired by hydrocarbon
contamination. The remedy proposed will be either the installation of
the UL listed spring collar or the replacement of sprinklers. Central
Sprinkler will determine if a remedy is required, the type of remedy and
time frame for the progress.
Although the sprinkler contractor can be designated as the owner's
representative, it is not expected. Central believes that, in most
cases, the contractor does not want to be informed of the resolution of
site specific issues given the complexity, time requirements, and the
desire to distance his/her company from the negative association with
remedial actions.
Question: What is the protocol used for sampling sprinklers?
Answer: Central Sprinkler is requiring that NFPA 25 be followed for the
random selection of sample sprinklers for testing, but specifically
recommending that two (2) percent of the installed sprinklers be removed
from any building containing Omega sprinklers manufactured between 1983
and June 6, 1996 and installed in steel pipe systems. The removed
samples must be returned with the sprinkler bodies capped and with the
system water maintained in the bore of the sprinkler to prevent the
O-ring assembly from drying during transit and test and to preserve the
water source from the sprinkler drops to identify, if required, the
presence of excessive hydrocarbons or other foreign substances.
Central Sprinkler logs every field return in its Return Authorization
system, approved to ISO 9000 quality standards, to allow for quick
computer tracking of test results. Once the sample sprinklers are
received, Central Sprinkler inspects the sprinklers for physical damage,
notes the condition and finish of the sprinklers, and collects the water
from the bores of the sprinklers for possible outside independent
laboratory testing. The sprinklers are then tagged and numbered and
pressure testing is conducted on the sprinklers per Central Sprinkler's
test protocol.
Test results are forwarded to the contact in the Return Authorization
file. This may be the building owner, the management company of a given
property, or the fire protection contractor who removed the sprinklers
for test. The time frame required to conduct pressure testing and
receive test results is approximately two (2) weeks, although this can
vary depending on the amount of diagnostic work the Engineering
Department has to complete. If outside independent testing is required,
the time to complete the test reports may be longer than the stated
two-week time frame.
Question: What is the universe of potentially affected Omega sprinklers
with EPDM O-rings?
Answer: Central Sprinkler has reviewed its sales history files and
reports that more than 8 million have been installed, with 2.5 to 3.5
million estimated to have been installed in steel piping systems. Of
these, Central Sprinkler has identified 850,000 units and has either
remedied or in the process of remedying those sprinkler systems
requiring corrective action. Central Sprinkler is continuing its search
for sprinklers installed in steel piping systems and continues to
increase the size of the population of sprinklers which have been
tested.
Question: What has been Central's experience with tested locations and
stop-leak contamination?
Answer: Central Sprinkler reports a reduced level of instances of
stop-leak contamination with installed Omega sprinklers in steel piping
systems as its universe of tested building increases. The level of
stop-leak contamination found within a specific type of building and
specific owner has proven to be higher than the percentage/level of
contamination found in the rest of the tested population. It is now
believed by Central that the use of stop-leak in steel piping systems is
a limited practice which, once identified, requires replacement of the
installed sprinklers given potential impairment. Central will not bear
the cost of such replacement, but will make sprinklers available at a
preferred price and may assist in arranging for field services crews if
requested by an owner.
Question: Is there a problem with brand new sprinklers as demonstrated
by testing of spare sprinklers?
Answer: No. Underwriters Laboratories reports that they have tested
unused Omega sprinklers from at least 20 different sources, and all have
operated at 5 psi inlet pressure. Some early test reports from an
independent laboratory indicated "spare" sprinklers requiring higher
pressures, but at least one such sample was reported as containing
residue, raising a question as to whether the sprinklers had been in
prior service.
Question: With respect to the EPDM O-ring installed in Omega sprinklers,
does EPDM continue to "get worse" over time given excessive hydrocarbon
contamination?
Answer: Central Sprinkler reports that it has worked with its O-ring
supplier and industry experts regarding effect on hydrocarbons on EPDM
rubber compounds. From the information that the company has gathered,
EPDM swells rapidly (within a few hours) when exposed to high
concentrations of hydrocarbons. Detection of this type of contamination
is readily possible since increased activation pressures are measured.
Once the O-ring/EPDM material is contaminated, the O-ring remains in a
swelled state. If the O-ring has not become contaminated by
hydrocarbons, the EPDM O-ring will not swell, and increased activation
pressures will not be created.
According to Central, the history of field returns and test results from
Omega sprinklers installed in steel piping systems does not indicate
that hydrocarbon contamination is time sensitive. Essentially, there are
two conditions: the EPDM O-ring is contaminated with hydrocarbons and
significant swell is noted or the EPDM O-ring is not contaminated with
hydrocarbons and the O-ring contains minimal swell or no swell at all.
EPDM rubber minimally swells in the presence of water (less than 5
percent). As such, all Omega EPDM O-ringed sprinklers will have some
measurable O-ring swell. The amount of O-ring swell created from the
absorption of water and small amounts of hydrocarbons reportedly does
not affect the performance of the sprinkler and does not create
increased activation pressures.
Factory Mutual has indicated that more information is needed in this
area before progressive deterioration can be ruled out.
Question: UL is recommending that all Omega sprinklers manufactured
prior to May 1996 be tested, including those in copper and plastic
piping systems. What test information is available on Omega sprinklers
installed in CPVC systems?
Answer: Central Sprinkler has received encouraging reports from
independent contractors in the State of Maryland (where CPVC systems are
prevalent due to residential codes) who tested sprinklers installed in
CPVC systems. Several of these tests were conducted by independent
laboratories without the knowledge of Central Sprinkler. For example,
Rothfus Engineering Company completed a study of Omega sprinklers
installed in five CPVC systems in Prince George's County in 1993 and
1994. All sprinklers removed operated at zero (0) psi. There have been a
few CPVC systems, however, in which dezincification apparently resulted
in higher minimum operating pressures. Such systems included those in
Sheraton hotels in Arizona and Hawaii.
Question: What is dezincification, and how commonly does it occur in
CPVC systems?
Answer: Dezincification is a corrosion process which requires copper
piping or other aggressive metals to come in contact with brass
components which contain certain levels of zinc. When copper piping is
installed with site specific system characteristics such as mineralized
water (which creates an acidic Ph in the piping system), chlorides from
the flux agents found in typical brazing compounds, and stagnated water
sources, a galvanic cell can be created which causes the breakdown of
the brass. Dezincification creates a porous copper base metal from the
brass since the zinc is leached from the alloy. This porous surface
usually creates leakage of the installed sprinkler. In advanced stages,
corrosion on the exterior of the sprinkler is typically white or
green-blue in color with a powdery appearance.
Dezincification is not found in CPVC products, but can occur in
combination copper and CPVC sprinkler systems. Dezincification in
combination CPVC and copper systems usually occurs in those brass
components closest to the copper underground or riser assemblies which
are installed with copper piping. CPVC is not conducive to
dezincification as it acts as a dielectric union in reducing the
conductivity of the water source. Dezincification has been found mainly
in pre-1990 Omega sprinklers, which had a high zinc content. Omega
sprinklers produced since 1990 are made of dezincification-resistant
brass alloys. Dezincification is a rare occurrence, since specific
characteristics must be present, including some copper alloy to initiate
the corrosion.
Question: Have any CPVC systems installed since 1990 experienced high
required operating pressures?
Answer: In one test series involving Omega sprinklers taken from a 1993
CPVC system, 23 sprinklers operated at 7 psi and one required 50 psi.
The tests were conducted by Hughes Associates for a Virginia copsi. The
tests were conducted by Hughes Associates for a Virginia contractor. It
sh
Question: What is the spring retrofit kit and for what situations is it
proposed as a solution?
Answer: The "Auxiliary Ejection Spring Retrofit Kit" consists of a
pre-compressed metal spring and housing and is intended to be installed
on-site only by personnel trained by Central. It has been listed by UL
for this purpose. The kit adds a mechanical advantage to the opening
process, but the advantage is not specifically quantified. If the
initial sample test results appear to be in the range where the retrofit
kit might provide a satisfactory remedy, additional samples are removed
from the system. These new samples are then fitted with the spring
mechanism and submitted for testing.
Question: What are NFPA 25 requirements regarding testing and
replacement of sprinklers?
Answer: Section 2-3.1.3 of the 1995 edition of NFPA 25 states: "Where
one sprinkler within a representative sample fails to meet the test
requirement, all sprinklers represented by that sample shall be
replaced." NFPA 25 does not, however, specify the "test requirement",
leaving that to the test laboratories instead.
Central Sprinkler has proposed that sprinklers should be considered
acceptable if their required operating pressure is less than the
available system pressure. Critics respond that the NFPA 25 sampling
mechanism may not identify the worst case sprinklers, and that property
owners could be receiving a false sense of security if Omega sprinklers
exhibiting any problems at all are permitted to remain in service.
The NFPA 25 Committee is currently preparing the 1998 edition of the
standard, and is struggling to deal with some of the issues raised as a
result of the Omega sprinkler problem. These issues include special
requirements for testing, the statistical validity of sampling methods,
pass/fail criteria, and consideration of conditions under which
sprinklers can be continued in use. More information on the NFPA 25
Committee decisions will be passed along to NFSA members as it becomes
available.
Question: Are efforts underway to further address these issues?
Answer: Central Sprinkler reports that it has retained statistical
experts to analyze the data resulting from sample testing. Our NFSA
Committee has asked Central to include the statistical validity of
sample testing among the issues to be addressed.
NFSA is also encouraging the NFPA 25 Committee to address some of the
specific issues regarding sample testing, even if it requires a
Tentative Interim Amendment (TIA) to the standard.
Question: How should contractors approach building owners to notify them
about the Omega sprinkler problem?
Answer: The NFSA Committee has recommended the following form letter:
Date
Name
Address
City, State, Zip
Dear ___________:
Central Sprinkler Company (the manufacturer of fire sprinklers) and
Underwriters Laboratories (the sprinkler approval agency) are
recommending a random representative sampling of Omega sprinklers. These
are specific models of automatic fire sprinklers, manufactured between
1983 and 1996.
We feel that it is incumbent on us, as your fire sprinkler
inspection/installing contractor, to make you aware of this
communication.
The manufacturer has recommended that a sample from each facility
protected by Omega model sprinklers be removed and tested by an approved
testing facility in accordance with recommendations of NFPA 25 (the
National Fire Protection Association's standard for the inspection,
testing, and maintenance of water-based fire protection systems). A
representative sample per NFPA 25 consists of a minimum of two
sprinklers per floor or riser, but no less than four or one percent of
the total, whichever is greater. Central is recommending at least a two
percent sample.
Please feel free to contact ______________________________of our company
for assistance or to answer questions you may have regarding this issue.
We stand ready to assist you in the removal of a representative sampling
of sprinklers for testing or in locating a qualified independent testing
agency.
Should you desire to speak directly with the manufacturer of the Omega
sprinkler, please feel free to call Central's customer service telephone
line at 800-523-6512. Underwriters Laboratories has also established a
toll-free number at 800-758-1794.
Central Sprinkler and UL Urging Omega Sprinkler Sample Testing
Central Sprinkler Corporation and Underwriters Laboratories are
publicizing the need to sample test "Omega" type sprinklers that were
manufactured prior to June of 1996 and installed in sprinkler systems.
Four incidents of non-activation of the sprinklers have been reported,
in which the sprinklers fused but did not operate due to sticking of the
o-ring assembly seal within the shaft of the device. In all four cases
adjacent sprinklers have operated, and the fires have not resulted in
any injuries.
The problems of possible non-activations of the Omega sprinklers at low
pressures have been attributed by Central to either reaction with
residual hydrocarbons in the water from cutting oils or from improper
use of stop leak products. For this reason, Central has been
recommending sample testing of all Omega sprinklers installed in steel
pipe systems. In June of 1996, the o-ring material was changed from EPDM
to silicone, reportedly eliminating the hydrocarbon reaction problem.
In both copper systems and CPVC systems with copper risers or feed
mains, there have also been isolated reports of higher required
operating pressures blamed on dezincification, where, in areas with
caustic water supplies, zinc may have leeched out of the high-zinc brass
sprinkler body. Although this phenomenon would normally make itself
evident by leaks in the sprinkler body, it might also have permitted the
formation of deposits potentially impairing sprinkler operation. Central
reports that it changed its alloy in 1990, eliminating the potential for
dezincification.
Underwriters Laboratories is recommending that samples be taken from all
existing sprinkler systems with Omega sprinklers manufactured prior to
June of 1996, and is providing sample testing free of charge.
The Omega sprinkler models are generally identified by their 3 circular
heat collection fins, although other manufacturers make similar-looking
models. Omega series models include the following: C-1, C-1A, C1A PRO,
C1A PRO ID, EC-20, EC-20A, EC-20 AID, HEC-12, HEC-12 ID, HEC-12 PRO,
HEC-12A PRO, HEC-12 RES, HEC-20, HEC-20 ID, R-1, R-1A, R-1M, AC, M, and
Flow Control.
Central is recommending that they be contacted for proper removal and
packaging procedures through Mr. Andy Post (215-362-0700 or
800-523-6512). Operational testing can then be completed if the samples
are shipped to Mr. Kerry Bell, Underwriters Laboratories, 333 Pfingsten
Road, Northbrook, IL 60062, USA.