The following article is a general description of an annual service test on rated fire pumps and is not intended to be an exact procedure.  It is primarily here to introduce you to the procedure and let you know what you are getting into.  If you need a more detailed description of exactly how to perform the test and make the calculations, NFPA Pamphlet 1911 or the IFSTA Pumping Apparatus Driver/Operator Handbook will give you all of the information you need. 

In a nutshell, an annual pump test is a documented procedure to prove your apparatus can perform at its rated capacity from draft.  The chassis drivetrain, pump, pump transmission and associated plumbing are run through a progressive series of tests that are designed to prove the system is in sound working order.

In order to obtain the maximum number of ISO points for pump testing (100 points out of a maximum of 654), your department should have documented tests for at least the last three years.  Besides performing and documenting this test on an annual basis it should also be performed on any apparatus that has been repaired or modified.  The test not only assures you that the pump and its associated plumbing can deliver its rated capacity, it also proves that the engine and drive train are up to the task.  In addition to ISO points, performing this test on a regular basis will give you peace of mind because you will know that your apparatus is ready to deliver if it needs to.

The annual test does not need to be performed by a third party or outside entity.  In fact, performing the test with your own personnel can be a great learning experience.  As long as you carefully document the exact layout and all readings, ISO will give your department credit where credit is due.  From start to finish the actual testing will only take about 45 minutes.  Setting up the equipment and tearing it down will probably take longer so it is a good idea to test all units on the same day.  If you have a good place to test your trucks you may want to invite the neighbors over to test theirs on the same day.  A basic list of equipment needed to properly perform an annual pump test is as follows:

•   Clipboard,
•   Pens & pencils,
•   Stop watch,
•   Discharge table for smooth bore tips,
•   Hand held mechanical RPM counter (for older trucks),
•   Test gauges, one for suction and one for discharge,
•   Annual Pump Service Checksheet (can be your own design),
•   Handheld pitot gauge (0-160 PSI would be best),
•   Smooth bore tips (Sizes will depend on pumps being tested, minimum 3 will be needed),
•   20' of correct size suction hose (1750 GPM and larger may require 40'),
•   Correct size suction hose strainer,
•   2-1/2" Fire hose (See suggested layouts),
•   Multi-inlet monitor (2 required for 1750 GPM pumps or higher), 

One way to make the job easier and much more accurate from year to year is to substitute a flow test kit for the pitot gauge and tip assortment.  The test kit will give a continuous reading to your personnel, keep them drier, and give much more accurate and repeatable results.  The test kit setup will place the pitot inlet in the exact right location and keep it there.

Before beginning any pump test it is a good idea to perform normal periodic maintenance on the rig to be tested.  If the unit is not close to requiring periodic maintenance, check and correct all fluid levels, primer oil level (if applicable,) and make sure the fuel tank is topped off.

The test sequence should ideally be performed at a 10' lift as measured from the surface of the water to the center of the main suction inlet.  If you cannot find a location where a 10' lift is achievable there is a formula in the reference materials that can be used to correct gauge readings to accommodate you.  Additionally, calculations will also be required to determine "the corrected net pump pressure."  What all this means is that you won't actually be reading 150 psi on the master gauge when running the 150 psi pump test.  You will be reading a pressure which is corrected to reflect the amount of vacuum in the suction and the actual lift.

An annual pump test is actually a series of timed tests as follows:

•  5 minute dry vacuum test,
•  Timed primer test,
•  20 minute test at rated capacity and 150 PSI,
•  5 minute "spurt" test at rated capacity and 165 psi, (Not required by ISO but recommended by NFPA)
•  10 minute test at 70 percent capacity and 200 psi,
•  10 minute test at 50 percent capacity and 250 psi. 

The individual tests are performed in that order and if the unit should fail any single test the entire series must be repeated after repairs.  This test is different from the certification test that is performed by a third party for apparatus manufacturers which is much longer and much more rigorous.

The most important part of the test is recording the results.  Here is an example (Microsoft Excel spreadsheet) of a form that can be used and/or modified to meet your needs. 

It is interesting to note that of the total 654 points ISO CAN award for an engine company, all are based on equipment carried except pump testing (100) and hose testing (50).  Those departments that think they can get by on equipment carried alone will automatically loose 150 points.  So, even if your budget is tight, once you have the equipment needed to perform a pump test you can ensure your department gets these big point items every time.  As a bonus, pump testing can be used as training too.

                           
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Last modified: 07/28/10