Section 3 — Process Safety & Loss Prevention
Testing of Fire Pumps Both Fixed and Mobile
IPE Engineering Practice IPE-EP-3-5-5
Document number: IPE-EP-3-5-5 · Section: 3 — Process Safety & Loss Prevention
SCOPE
- The acceptance test and service test(s) of fixed and mobile fire pumps are a very important part of a loss prevention program. This Engineering Practice establishes the plant’s minimum requirement for proper testing. Testing requirements of federal and local jurisdictions shall also apply. In case of conflicts, the more stringent requirement shall apply.
- Any deviation from this Practice must be approved by the procedure described in EP 1–1–3.
- Documentation required in accordance with this Practice is given in Table 2.
2.0 REFERENCES
The latest edition of the following publications are referred to herein.
STANDARDS AND PUBLICATIONS
| IPE Engineering Practices |
|---|
| EP 1–1–3 Deviations to IPE Engineering Practices |
| NFPA |
| 20 Installation of Centrifugal Fire Pumps 1901 Pumper Fire Apparatus 1911 Service Tests of Pumps on Fire Department Apparatus |
| Other Publications |
| FM 20 Star Tech Fire Protection Water & Foam Systems Data Handbook FM Handbook of Industrial Loss Prevention, Chapter 20, Fire Pumps |
DEFINITIONS
- Acceptance Test – Test made at the time the apparatus is delivered and before it is placed in service at the Plant.
- Discharge Pressure – The pressure at the point of gauge attachment on the fire pump discharge.
- Dynamic Suction Lift – The sum of the vertical lift and friction and entrance loss due to the flow through the suction strainer and hose.
- Manufacturer – The recipient of a direct or indirect purchase order for materials and/or equipment. In this context, a direct order is one issued to a Manufacturer by a Contractor or the Owner. An indirect order is one issued to a Manufacturer by a vendor (recipient of a direct order) for materials, fabricated components, or subassemblies.
- Net Pump Pressure – (A) The sum of the discharge pressure and the dynamic suction life when testing at draft. (B) The difference between the discharge pressure and the suction pressure when testing from a hydrant or other sources of water under positive pressure.
- Service Tests – Tests made on at least an annual basis, after the pump has been put in service, to determine if performance is still acceptable.
MOBILE APPARATUS ACCEPTANCE TEST
A three–hour certification test shall be performed to meet the following conditions. Results of the tests shall be recorded and submitted to the Owner’s Engineer.
- All acceptance tests will be run by drafting water at approximately 10 ft.
- Pumping the rated capacity of the pump at 150 psi for a period of two hours.
- Pumping 70% of the rated capacity at 200 psi for a period of one–half hour.
- Pumping 50% of the rated capacity at 250 psi for a period of one–half hour.
- The engine will demonstrate its ability to deliver rated capacity at 165 psi net pump pressure for a period of 10 minutes.
- For pumpers rated less than 1,500 gpm capacity, tests shall be made with 20 ft. of hard suction hose in a single line.
- A vacuum test shall be performed and shall consist of subjecting the interior of the pump with a capped suction and uncapped discharge outlets to a vacuum of 22 in. Hg in 10 minutes.
- The vacuum shall not drop more than 10 inch Hg in 10 minutes.
- Once the test has been started, the prime is not permitted to be used.
- All related pumping equipment shall be tested at this time.
HOSE AND NOZZLE LAYOUT FOR TEST
- A pump rated at 500 gpm or less shall be tested with an NPS 2–1/2 inch line into an NPS 1–3/8 or NPS 1–1/2 inch nozzle.
- A pump rated at 2,000 gpm minimum shall be tested with an NPS 4–1/2 inch line into a Siamese which is connected to a master stream appliance with an NPS 2 inch nozzle.
- All discharge hose lines shall be securely fastened to the apparatus at the pump outlets. This is to prevent injury to personnel if the coupling should fail. Additonally:
- All hoses used during the pumping test shall be double jacketed hose.
- Hose shall be in good condition and hydrostatically tested to 250 psi within three months prior to the apparatus test.
ACCEPTANCE OR SERVICE TEST RESULTS
- Records shall be maintained for the life of the vehicle.
- The test results shall be recorded on a form similar to the one in Table 1. If this form is not used, then the minimum amount of information contained on the form must be on the substitute form.
SERVICE TEST
- Service tests are conducted to assure the plant management that the pump is capable of the required performance.
- A service test shall be conducted on a yearly basis and after each major overhaul.
- The pump shall be subject to a pumping test of at least forty minutes duration as follows:
- Pumping the rated capacity of the pump at 150 psi for a period of 20 minutes.
- Pumping 70% of the rated capacity at 200 psi for a period of 10 minutes.
- Pumping 50% of the rated capacity at 250 psi for a period of 10 minutes.
- The pump shall not be stopped except when discharges are closed to permit changing hose or nozzle.
- All requirements for hose and nozzle layout shall be the same as in Section 5.0 of this Practice.
8.0 FOAM
The foam pump and all proportionals shall be tested during the acceptance and annual test in accordance with NFPA and the Manufacturer’s recommended method.
FIXED FIRE WATER PUMPS TEST
- All fire water pumps shall be tested before putting them in service and on a yearly basis after the initial test. All test results shall be maintained for the life of the pump. All test results shall be put on a pump curve and compared to the Manufacturer’s test.
- The pump test shall be in accordance with the following:
- All pump testing shall be in accordance with NFPA 20.
- The pump shall start automatically on pressure drop, if it is so equipped.
- After the driver reaches its rated rpm, the static (shutoff) pressure shall be recorded. The rated rpm shall be maintained throughout the test. This information can be found on the pump’s nameplate.
- After the procedures in paragraph 9.2.3 have been completed, proceed to the flow test area. A sufficient number of appropriately sized orifices shall be opened to obtain a flow with a pump discharge pressure between the static pressure and the 100% rated pressure of the pump. A test header with appropriate instrumentation is also acceptable. Test headers shall be installed when the firewater system is upgraded. See Figure 1.
- Additional nozzles may be opened as necessary to obtain a pump discharge pressure approximately 100% of the rated pressure.
- Additional nozzles may be opened as necessary to obtain a pump discharge pressure which should give a flow rate of approximately 150% rated capacity.
FIRE PUMP OPERATION
- The fire pump shall be maintained in a ready state.
- The fire pump house shall not be used for a storage area.
- All pumps shall be operated on a weekly basis and at least one start shall be by reducing the water pressure. Pump operations shall be performed by a qualified person.
- A record of all fire pump tests shall be maintained. Items that are to be included are: suction pressure, discharge pressure, condition of suction supply, fuel tank level.
FIRE PUMP MAINTENANCE
- A preventive maintenance program shall be established in accordance with the pump Manufacturer’s recommendations.
- Records shall be maintained on all work performed on pump, driver and controller.
AUDIT OF FIRE PUMPS QUESTIONS
An annual audit of fire pumps shall be performed. The audit shall update the answers to the following questions:
- Have all fire pumps been given an acceptance test? Are records available?
- When was the last test date of the service test for all mobile apparatus?
- Are records available?
- Do the records indicate the amount of time for tests?
- Were the discharge hoses hydrostatically tested prior to the test?
- Are the fixed fire pumps tested on an annual basis?
- Are the performance curves compared to the Manufacturers’?
- Are weekly tests made of all fire pumps? Are records available?
13.0 TABLES
TABLE 1 SERVICE TEST RESULTS
| PUMPER NO: | PUMPER NO: | PUMPER NO: | PUMPER NO: | PUMPER NO: | PUMPER NO: | PUMPER NO: | PUMPER NO: | PUMPER NO: | PUMPER NO: | PUMPER NO: | PUMPER NO: | PUMPER NO: | PUMPER NO: | PUMPER NO: | PUMPER NO: | PUMPER NO: | PUMPER NO: | PUMPER NO: | PUMPER NO: | PUMPER NO: | PUMPER NO: | PUMPER NO: |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| MANUFACTURER: | MANUFACTURER: | MANUFACTURER: | MANUFACTURER: | MANUFACTURER: | MANUFACTURER: | MANUFACTURER: | MANUFACTURER: | MANUFACTURER: | MANUFACTURER: | MANUFACTURER: | YEAR BUILT: | YEAR BUILT: | YEAR BUILT: | YEAR BUILT: | YEAR BUILT: | YEAR BUILT: | YEAR BUILT: | YEAR BUILT: | YEAR BUILT: | YEAR BUILT: | YEAR BUILT: | YEAR BUILT: |
| MANUFACTURER’S MODEL: | MANUFACTURER’S MODEL: | MANUFACTURER’S MODEL: | MANUFACTURER’S MODEL: | MANUFACTURER’S MODEL: | MANUFACTURER’S MODEL: | MANUFACTURER’S MODEL: | MANUFACTURER’S MODEL: | MANUFACTURER’S MODEL: | MANUFACTURER’S MODEL: | MANUFACTURER’S MODEL: | MANUFACTURER’S SERIAL NO: | MANUFACTURER’S SERIAL NO: | MANUFACTURER’S SERIAL NO: | MANUFACTURER’S SERIAL NO: | MANUFACTURER’S SERIAL NO: | MANUFACTURER’S SERIAL NO: | MANUFACTURER’S SERIAL NO: | MANUFACTURER’S SERIAL NO: | MANUFACTURER’S SERIAL NO: | MANUFACTURER’S SERIAL NO: | MANUFACTURER’S SERIAL NO: | MANUFACTURER’S SERIAL NO: |
| ENGINE: MAKE AND MODEL: | ENGINE: MAKE AND MODEL: | ENGINE: MAKE AND MODEL: | ENGINE: MAKE AND MODEL: | ENGINE: MAKE AND MODEL: | ENGINE: MAKE AND MODEL: | ENGINE: MAKE AND MODEL: | ENGINE: MAKE AND MODEL: | ENGINE: MAKE AND MODEL: | ENGINE: MAKE AND MODEL: | ENGINE: MAKE AND MODEL: | ||||||||||||
| PUMP: MAKE AND MODEL : | PUMP: MAKE AND MODEL : | PUMP: MAKE AND MODEL : | PUMP: MAKE AND MODEL : | PUMP: MAKE AND MODEL : | PUMP: MAKE AND MODEL : | PUMP: MAKE AND MODEL : | PUMP: MAKE AND MODEL : | RATED CAPACITY: | RATED CAPACITY: | RATED CAPACITY: | RATED CAPACITY: | RATED CAPACITY: | RATED CAPACITY: | RATED CAPACITY: | GPM AT PSI | GPM AT PSI | GPM AT PSI | GPM AT PSI | GPM AT PSI | GPM AT PSI | ||
| GEAR RATIO: ENGINE TO PUMP:CAPACITY: | GEAR RATIO: ENGINE TO PUMP:CAPACITY: | GEAR RATIO: ENGINE TO PUMP:CAPACITY: | GEAR RATIO: ENGINE TO PUMP:CAPACITY: | GEAR RATIO: ENGINE TO PUMP:CAPACITY: | GEAR RATIO: ENGINE TO PUMP:CAPACITY: | GEAR RATIO: ENGINE TO PUMP:CAPACITY: | GEAR RATIO: ENGINE TO PUMP:CAPACITY: | GEAR RATIO: ENGINE TO PUMP:CAPACITY: | GEAR RATIO: ENGINE TO PUMP:CAPACITY: | GEAR RATIO: ENGINE TO PUMP:CAPACITY: | GEAR RATIO: ENGINE TO PUMP:CAPACITY: | GEAR RATIO: ENGINE TO PUMP:CAPACITY: | 200 PSI | 200 PSI | 200 PSI | 200 PSI | 200 PSI | 200 PSI | 250 PSI I | 250 PSI I | 250 PSI I | 250 PSI I |
| TRANSMISSION GEAR USED: CAPACITY: | TRANSMISSION GEAR USED: CAPACITY: | TRANSMISSION GEAR USED: CAPACITY: | TRANSMISSION GEAR USED: CAPACITY: | TRANSMISSION GEAR USED: CAPACITY: | TRANSMISSION GEAR USED: CAPACITY: | TRANSMISSION GEAR USED: CAPACITY: | TRANSMISSION GEAR USED: CAPACITY: | TRANSMISSION GEAR USED: CAPACITY: | TRANSMISSION GEAR USED: CAPACITY: | TRANSMISSION GEAR USED: CAPACITY: | TRANSMISSION GEAR USED: CAPACITY: | TRANSMISSION GEAR USED: CAPACITY: | 200 PSI | 200 PSI | 200 PSI | 200 PSI | 200 PSI | 200 PSI | 250 PSI I | 250 PSI I | 250 PSI I | 250 PSI I |
| SUCTION SIZE: | SUCTION SIZE: | SUCTION SIZE: | SUCTION SIZE: | SUCTION SIZE: | SUCTION SIZE: | LENGTH: | LENGTH: | LENGTH: | LENGTH: | LENGTH: | LENGTH: | LENGTH: | LENGTH: | LENGTH: | LIFT: | LIFT: | LIFT: | LIFT: | LIFT: | LIFT: | LIFT: | LIFT: |
| HAND COUNTER SOUND CHECK READINGS TAKEN FROM: | HAND COUNTER SOUND CHECK READINGS TAKEN FROM: | HAND COUNTER SOUND CHECK READINGS TAKEN FROM: | HAND COUNTER SOUND CHECK READINGS TAKEN FROM: | HAND COUNTER SOUND CHECK READINGS TAKEN FROM: | HAND COUNTER SOUND CHECK READINGS TAKEN FROM: | HAND COUNTER SOUND CHECK READINGS TAKEN FROM: | HAND COUNTER SOUND CHECK READINGS TAKEN FROM: | HAND COUNTER SOUND CHECK READINGS TAKEN FROM: | HAND COUNTER SOUND CHECK READINGS TAKEN FROM: | HAND COUNTER SOUND CHECK READINGS TAKEN FROM: | HAND COUNTER SOUND CHECK READINGS TAKEN FROM: | HAND COUNTER SOUND CHECK READINGS TAKEN FROM: | HAND COUNTER SOUND CHECK READINGS TAKEN FROM: | HAND COUNTER SOUND CHECK READINGS TAKEN FROM: | ||||||||
| RATIO TO ENGINE: | RATIO TO ENGINE: | RATIO TO ENGINE: | RATIO TO ENGINE: | RATIO TO ENGINE: | RATIO TO ENGINE: | 1 TO | 1 TO | 1 TO | 1 TO | 1 TO | 1 TO | 1 TO | 1 TO | 1 TO | 1 TO | 1 TO | 1 TO | 1 TO | 1 TO | 1 TO | 1 TO | 1 TO |
| CAPACITY TEST: | CAPACITY TEST: | CAPACITY TEST: | CAPACITY TEST: | CAPACITY TEST: | CAPACITY TEST: | CAPACITY TEST: | CAPACITY TEST: | CAPACITY TEST: | CAPACITY TEST: | CAPACITY TEST: | CAPACITY TEST: | 250 PSI TEST: | 250 PSI TEST: | 250 PSI TEST: | 250 PSI TEST: | 250 PSI TEST: | 250 PSI TEST: | 250 PSI TEST: | 250 PSI TEST: | 250 PSI TEST: | 250 PSI TEST: | 250 PSI TEST: |
| LAYOUT | LAYOUT | LAYOUT | NOZZLE SIZE | NOZZLE SIZE | NOZZLE SIZE | NOZZLE SIZE | NOZZLE SIZE | NOZZLE SIZE | NOZZLE SIZE | NOZZLE SIZE | NOZZLE SIZE | LAYOUT | LAYOUT | LAYOUT | LAYOUT | LAYOUT | NOZZLE SIZE | NOZZLE SIZE | NOZZLE SIZE | NOZZLE SIZE | NOZZLE SIZE | NOZZLE SIZE |
| TIME | COUNT ER | RPM | RPM | TACH. | TACH. | PUMP PRESSURE | PUMP PRESSURE | PUMP PRESSURE | PITOT TIME | PITOT TIME | PITOT TIME | COUNT ER | COUNT ER | RPM | RPM | TACH. | TACH. | PUMP PRESSURE | PUMP PRESSURE | PUMP PRESSURE | PUMP PRESSURE | PITOT |
| 200 PSI TEST: | 200 PSI TEST: | 200 PSI TEST: | 200 PSI TEST: | 200 PSI TEST: | 200 PSI TEST: | 200 PSI TEST: | 200 PSI TEST: | 200 PSI TEST: | 200 PSI TEST: | 200 PSI TEST: | 200 PSI TEST: | FINAL RESULTS: | FINAL RESULTS: | FINAL RESULTS: | FINAL RESULTS: | FINAL RESULTS: | FINAL RESULTS: | FINAL RESULTS: | FINAL RESULTS: | FINAL RESULTS: | FINAL RESULTS: | FINAL RESULTS: |
| LAYOUT | LAYOUT | LAYOUT | NOZZLE SIZE | NOZZLE SIZE | NOZZLE SIZE | NOZZLE SIZE | NOZZLE SIZE | NOZZLE SIZE | NOZZLE SIZE | NOZZLE SIZE | NOZZLE SIZE | CAPACITY | CAPACITY | CAPACITY | CAPACITY | 200 PSI | 200 PSI | 250 PSI | ||||
| TIME | COUNTER | COUNTER | RPM | RPM | TACH. | TACH. | PUMP PRESSURE | PUMP PRESSURE | PUMP PRESSURE | PITOT | PITOT | DURATION | DURATION | DURATION | DURATION | |||||||
| AVE. NOZ. PRESSURE | AVE. NOZ. PRESSURE | AVE. NOZ. PRESSURE | AVE. NOZ. PRESSURE | |||||||||||||||||||
| CORRECTION | CORRECTION | CORRECTION | CORRECTION | |||||||||||||||||||
| CORRECTED PRESS | CORRECTED PRESS | CORRECTED PRESS | CORRECTED PRESS | |||||||||||||||||||
| GALLONS PER MIN. | GALLONS PER MIN. | GALLONS PER MIN. | GALLONS PER MIN. | |||||||||||||||||||
| DISPLACEMENT | DISPLACEMENT | DISPLACEMENT | DISPLACEMENT | |||||||||||||||||||
| DISPLACMENT NOMINAL | DISPLACMENT NOMINAL | DISPLACMENT NOMINAL | DISPLACMENT NOMINAL | |||||||||||||||||||
| SLIP PER CENT | SLIP PER CENT | SLIP PER CENT | SLIP PER CENT | |||||||||||||||||||
| PUMP STG (SER PAR) | PUMP STG (SER PAR) | PUMP STG (SER PAR) | PUMP STG (SER PAR) | |||||||||||||||||||
| AVE. PUMP PRESS | AVE. PUMP PRESS | AVE. PUMP PRESS | AVE. PUMP PRESS | |||||||||||||||||||
| RPM ENGINE | RPM ENGINE | RPM ENGINE | RPM ENGINE | |||||||||||||||||||
| RPM PUMP | RPM PUMP | RPM PUMP | RPM PUMP | |||||||||||||||||||
| *TEST GAGE READING REMARKS: | *TEST GAGE READING REMARKS: | *TEST GAGE READING REMARKS: | *TEST GAGE READING REMARKS: | *TEST GAGE READING REMARKS: | *TEST GAGE READING REMARKS: | *TEST GAGE READING REMARKS: | *TEST GAGE READING REMARKS: | *TEST GAGE READING REMARKS: | *TEST GAGE READING REMARKS: | *TEST GAGE READING REMARKS: | *TEST GAGE READING REMARKS: | |||||||||||
| TESTED AT | TESTED AT | TESTED AT | TESTED AT | TESTED AT | TESTED AT | WITNESSED BY | WITNESSED BY | WITNESSED BY | WITNESSED BY | WITNESSED BY | WITNESSED BY | WITNESSED BY | WITNESSED BY | WITNESSED BY | DATE | DATE | DATE | DATE | DATE | DATE | DATE | DATE |
TABLE 2
DOCUMENTATION REQUIREMENTS FOR FIRE PROTECTION FROM EP 3–5–5
| Item | Description | Format | As–Built |
|---|---|---|---|
| 1 | Documentation of testing of mobile apparatus | See EP 2–5–2 | N/A |
| 2 | Documentation of testing of fixed fire water pumps | See EP 2–5–2 | N/A |
| 3 | Record of fire pump tests | See EP 2–5–2 | N/A |
| 4 | Records of fire pump maintenance | See EP 2–5–2 | N/A |
| 5 | Updated audit records for fire pump testing | See EP 2–5–2 | N/A |
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