Testing & Commissioning Of Fire Pumps

Fire Pump Testing and Commissioning Procedure

The purpose of this procedure is to define the step by step method to implement the correct practices for the pre-commissioning & commissioning of “Fire Pumps” through the guidelines contained herein so as to ensure that the job execution complies with the project requirements and serves the intended function to satisfactory level.

The scope of this Method Statement is to define the method of Testing and Commissioning of Fire Pumps installed within the project in accordance with the a part of commissioning checks at site. All necessary tools and equipment shall be arranged before T&C works.

In general, it shall be ensured by site engineer that product manufacturer’s recommendations are followed.

Firefighting engineer shall further oversee the Pre-commissioning and commissioning activity as per the approved method statement for Start-up and Commissioning of Fire Pumps.

The Fire Pump shall be tested and commissioned under direct supervision of manufacturer / local dealer’s representatives.

Mechanical Pre – Commissioning Procedure for Fire Pump

1. Check and inspect the installation of Fire Pump is complete; verify the installation is as per approved drawings.
2. Verify compliance to the manufacturer’s installation instructions.
3. Obtain installation certification from manufacturer or their authorized local representative.
4. Check and ensure adequate clearance available for service and maintenance of pumps and motors.
5. Check the installation is coordinated with other services.
6. Ensure the shipping bolts / clamps are removed.
7. Check all nuts, bolts, screws, fasteners etc., are fixed and tightened as required.
8. Ensure the piping is pressure tested.  Verify test certificates.
9. Check all piping connections are complete at pumps, flow meter and pressure relief line
10. Check and ensure the piping is flushed and cleaned.
11. Check the alignment is completed as per manufacturer’s instructions.
12. Check and verify the water level in the water tank is full.
13. Check and ensure the safety guards are in place and secure.
14. Adjust desired cut-in and cut off pressure as per requirements.
15. Ensure the pumps are cleaned prior to start-up and all identification labels and tags are in place.

Electrical Pre-Commissioning Method of Fire Pump

1. Check all power cabling and control wiring is completed and dressed neatly.
2. Check the power isolator is fixed close to the pump motor for emergency stop and power isolation, as per approved drawings / details.
3. Check all terminations are completed and tightened as required.
4. Check the grounding connections are completed and tightened as required.
5. Ensure the overload protections are set correctly as per the pump motor load current.
6. Ensure all identification tags and labeling works are complete.

Starting Up Method For Electric Fire Pump

1. Open suction valves
2. Check that pump is full of water and that all air contained in the pump been escaped through the air release valve.
3. Compress the packing evenly with gland ( i.e. hand tight)
4. Lower setting of pressure switch to prevent pump from starting
5. Check incoming voltage for all phases
6. Place isolator and breaker in “ON” position and check “Power On” light is illuminated
7. Press start then stop to check the direction of rotation and adjust
8. Bleed the system to create pressure drop
9. When the pump starts check if full load current value is within the electric motor name plate rating
10. Check packing adjustment to obtain slight leak
11. Stop the pump and allow jockey pump to pressurize the system again

Start up Method for Diesel Fire Pump

1. Open suction valves
2. Check that pump is full of water and that all air contained in the pump been escape through the air release valve
3. Compress packing evenly with gland (hand tight)
4. Close the pressure relief valve using maximum spring pressure
5. Lower setting of starting pressure
6. Start engine manually on either battery
7. adjust relief valve to open at tested pressure of the system
8. stop engine and open system valve
9. bleed the system to create pressure drop
10. when the pump starts check Engine speed, Oil pressure, Fuel pressure, Abnormal noise or vibration and Cooling water drain.
11. Check packing adjustment to obtain slight leak.
12. Stop the pump by putting selector switch to “Off” Position and allow jockey pump to pressurize the system again

Flow Test for Electric Fire Pump

1. Close system valve
2. Open gate valve for flow meter discharge valve and keep butterfly valve after flow meter fully close
3. Press start button to start the pump
4. Adjust flow by butterfly valve after the flow meter
5. Take suction and discharge pressure and ampere readings at shut off, rated,150% of rated flow and another intermediate flow
6. Plot the pump curve and match it with the factory test curve

Flow Test for Diesel Pump

1. Close system valve
2. Open gate valve for flow meter discharge valve and keep butterfly valve after flow meter fully close
3. Press start button to start the pump
4. Adjust flow by butterfly valve after the flow meter
5. Take sectional discharge pressure and RPM of the engine at shut off, rated, 150% of the rated flow and another intermediate flow
6. Plot the pump curve and match it with the factory test curve

Testing of Automatic Operation of Fire Pump

Open system valve and turn all isolating valves to the fully open position

Set pressure switches to the following setting valves:

• All fire pump stop pressure = fire pump shut off pressure + minimum suction pressure
• Jockey pump start pressure = stop pressure – 10 PSI
• Electric pump start pressure = jockey start pressure – 5 PSI
• Diesel pump start pressure = electric pump start pressure – 10 PSI

Use 10 PSI for each additional pump

The final pressures should not exceed the pressure rating of the system

Place all switches for all control panels to the auto mode

Check Applicable three modes

Automatic Mode:

In case of any pressure drop in line due to hose reel, fire hose, sprinkler opening or any small leak in the lines, if the pressure reaches to the cut-in pressure point for the jockey pump it will start automatically and stop automatically at cut-off pressure.

If the jockey pump couldn’t maintain the pressure in the system and pressure drop to the cut-in pressure of the duty pump it will start automatically and stop manually or automatically after 10 minutes if the pressure reaches to the cutoff point.

Incase of electric supply failure or mechanical failure of the electric pump, then the diesel engine pump will start automatically when the pressure in the system will reach to cut in pressure of the standby pump and it should stop manually from the control panel after assuring there is no requirement of fire pump to keep running or automatically after 30 minutes if the pressure reaches to the cutoff point.

Manual Mode Operation

In case of emergency, the pumps can run in manual mode function for jockey pump by placing selector switch in “hand mode”, electric pump by depressing the “start” push button and diesel pump it can start either from control panel or engine itself by putting selector switch in “Manual” mode and depressing “crank push button” for a few second (i.e. for 3-4 seconds only just to reach firing condition of the engine) or from the engine instrument panel.

All pumps should stop manually if run in manual mode by returning switch to OFF position or depress stop push button.

Emergency Start

In case of any problem in the control circuit of Electric and Diesel Controller, Fire Pumps can run through emergency start handle to mechanically close the contactor.

HSE Requirements

• All safety precautions shall be followed as per the established Project Safety Plan.
• Only experienced and skilled technicians shall be engaged for carrying out Start-up and Commissioning of Fire Pumps.
• Safety Guards shall be in place and secured prior to start-up.
• Cable test reports shall be verified prior to energization.
• Appropriate Warning signs and tapes shall be placed during start-up and commissioning as required.
• All PPE shall be worn as appropriate according to the nature of the job.
• Work area shall be maintained neat and clean all the times.