AS 1851 14 1996 maintenance of fire protection equipment p

testing and maintenance shall be conducted at four levels, as follows: a Level 1 routines, consisting of testing and recording.. b Level 2 routines, consisting of Level 1 routines plus a

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AS 1851.14-1996 Maintenance of fire protection equipment - Pumpset systems

Licensed to LUU MINH LUAN on 25 Feb 2002

The following interests are represented on Committee FP/8:

The Association of Consulting Engineers AustraliaAssociation of Hydraulic Services Consultants AustraliaAustralian Chamber of Commerce and Industry

Australian Fire Authorities CouncilAustralian Institute of PetroleumAustralian Pump Manufacturers AssociationConfederation of Australian IndustryFire Protection Industry Association of AustraliaInsurance Council of Australia

Railways of Australia Committee

Review of Australian Standards To keep abreast of progress in industry, Australian Standards are

subject to periodic review and are kept up to date by the issue of amendments or new editions as

This Standard was prepared by the Standards Australia Committee FP/8 on Fire ServicePumps and defines the concept of levels of inspection and servicing These levels are on atime-elapsed basis and range from weekly inspection (Level 1) to three-yearly inspection(Level 4)

The Standard incorporates the necessary routine maintenance for fixed fire pumpsetsystems (referred to throughout as fire pumpsets) meeting the requirements of AS 2941,

Fixed fire protection installations —Pumpset systems, and also details the precautions to

be taken when systems are rendered inoperative

Where standby generator sets are used to power electric motor driven fire pumpsets it issuggested that the standby generator drivers be maintained in accordance with thisStandard

The term ‘informative’ has been used in this Standard to define the application of theappendix to which it applies An ‘informative’ appendix is only for information andguidance

Page

FOREWORD 4

SECTION 1 SCOPE AND GENERAL 1.1 SCOPE 5

1.2 APPLICATION 5

1.3 REFERENCED DOCUMENTS 5

1.4 DEFINITIONS 6

SECTION 2 PRECAUTIONS TO BE TAKEN WHEN A SYSTEM IS RENDERED INOPERATIVE 2.1 MANDATORY PRECAUTIONS 7

2.2 ADDITIONAL PRECAUTIONS 7

SECTION 3 MAINTENANCE PROGRAM 3.1 GENERAL 8

3.2 FOLLOW-U P ACTION 8

SECTION 4 MAINTENANCE DOCUMENTATION 4.1 GENERAL 9

4.2 MAINTENANCE SCHEDULE 9

4.3 LOG 9

4.4 PLANT REGISTER 9

4.5 PUMPSET PERFORMANCE LOG 9

SECTION 5 INSPECTION, TESTING AND MAINTENANCE 5.1 GENERAL 10

5.2 LEVELS OF INSPECTION, TESTING AND MAINTENANCE 10

5.3 FREQUENCY 10

SECTION 6 MAINTENANCE OF FIRE PUMPSET SYSTEMS 6.1 MAINTENANCE LEVEL 1 11

6.2 MAINTENANCE LEVEL 2 11

6.3 MAINTENANCE LEVEL 3 11

6.4 MAINTENANCE LEVEL 4 11

6.5 RECORDING 11

SECTION 7 INSPECTION, TEST AND MAINTENANCE SCHEDULES 12 APPENDICES

A SUMMARY OF INSPECTION, TEST AND MAINTENANCE

Maximum protection from fire demands the utmost in reliability and performance fromfire pumpsets, which are a critical component of a fire protection system To achieve thisreliability it is essential that regular testing and maintenance of the fire pumpsets becarried out

The generic procedures set out in this Standard have been prepared for general use andshould be used to prepare and review the on-site requirements, in conjunction with otherstatutory requirements, to ensure that the intent of the Standard is being followed

It is necessary for fire pumpsets to operate when called upon and to this end it is expectedthat the pumps and pumproom/pumphouse will be kept clean and free from rubbish anddebris

STANDARDS AUSTRALIA

Australian Standard Maintenance of fire protection equipment

Part 14: Pumpset systems

S E C T I O N 1 S C O P E A N D G E N E R A L

procedures which should identify items requiring correction or maintenance (seeSection 5) It also sets out the precautions to be taken when a system is renderedinoperative

NOTE: Although it is not classified as routine maintenance, a check on a regular basis isnecessary to ensure that the installed system characteristics as shown on the block plan areadequate to protect the current occupancy

meeting the requirements of AS 2941

Although petrol-engine-driven pumpsets are not currently recognized, some may still be inoperation and the maintenance requirements for pumpsets in this Standard may be used as

a guideline

The procedures set out in this Standard should be carried out, or be directly supervised,

by personnel competent in this class of work

Standard:

AS

1674 Safety in welding and allied processes

1674.1 Part 1: Fire precautions

1674.2 Part 2: Electrical

1851 Maintenance of fire protection equipment

1851.2 Part 2: Fire hose reels

2118 Automatic fire sprinkler systems

2118.1 Part 1: Standard

2118.2 Part 2: Wall wetting sprinklers (Drenchers)

2118.4 Part 4: Residential

2118.5 Part 5: Domestic

2118.6 Part 6: Combined sprinkler and hydrant

2419 Fire hydrant installations

2419.1 Part 1: System design, installation and commissioning

2419.2 Part 2: Fire hydrant valves

2441 Installation of fire hose reels

2676 Guide to the installation, maintenance, testing and replacement of secondary

batteries in buildings2676.1 Part 1: Vented cells

2676.2 Part 2: Sealed cells

2941 Fixed fire protection installations — Pumpset systems

AS 2484.2 and those below apply

or villa unit

a common mounting together with an integral or separate fire pump controller

and not exceeding four storeys in height

S E C T I O N 2 P R E C A U T I O N S T O B E T A K E N

W H E N A S Y S T E M I S R E N D E R E D

I N O P E R A T I V E

system required by statute is rendered partially or fully inoperative:

(a) The building or facility management shall be notified

(b) The fire station to which the system is connected, or the nearest fire station if there

is no brigade connection, shall be notified before work commences and after work iscompleted

NOTE: It is recommended that this practice be followed for all pumpset systems

far as is practicable:

(a) Under all circumstances as much of the system as is practicable should be keptoperational Should the work extend over a day, the system is to be reinstated as far

as practicable at the end of each day

(b) Where the system is to be left disconnected outside working hours thebuilding/facility management should be notified Consideration should be give to theemployment of a watchman at the premises for the period of disconnection

Where possible, the electrics should be isolated in areas where the fire protectionhas been limited or withdrawn, especially outside working hours

A warning and advice should be provided at the fire indicator panel (FIP) (whereprovided) or the fire pumpset The warning should include details of equipmentoutage, and contact name and phone number

(c) Whenever practicable, system disconnection should be undertaken when productionmachinery is inoperative

(d) Smoking in the vicinity of the affected areas should be prohibited for the period ofdisconnection

(e) Those senior department/tenancy representatives affected should be notified so thatfire extinguishing equipment can be held in special readiness for immediate use with

a sufficient number of trained personnel available to use them if required

(f) The insurer or insurance broker for the property should be notified

(g) All needed equipment and materials should be on hand and all work possible should

be done prior to isolation of the fire protection equipment

(h) Hot cutting and welding should not be performed on a fire pumpset in situ or in anarea where the fire protection equipment is impaired If such work is unavoidable itshould be carried out in accordance with AS 1674.1 and AS 1674.2

(i) Simultaneous undertaking of other work that may further reduce the integrity of fireprotection, or increase the fire risk, should be avoided

(j) All sources of ignition should be avoided

S E C T I O N 3 M A I N T E N A N C E P R O G R A M

detailed procedures and a recording system

and repairs are performed

malfunction of any sort, appropriate action at Level 2, Level 3 or Level 4 shall beimmediately carried out regardless of the timing for the selected action in the maintenanceschedule

replaced it shall be re-installed and function checked before returning the pumpset to the

‘ready to start’ condition

S E C T I O N 4 M A I N T E N A N C E

D O C U M E N T A T I O N

(see Section 3) shall include a maintenance schedule, a log, a plant register, a planthistory sheet and diagram(s) of the installation The information shall be current andreadily available

NOTE: The log may be an electronic form of record keeping

The following documents should be available at the pumpset for immediate use:

(a) Diagrams of the pumpset installation

(b) Informative operational procedures

plant and equipment and operational features to be subjected to the maintenance routinesdescribed in this Standard It shall include the frequencies at which the relevant levels ofroutines are to be carried out (see Section 6)

NOTE: Appendix A shows a summary of typical maintenance schedules

4.3 LOG The log shall contain records of operational and maintenance test procedureresults, and shall be dated and include verifier’s identification

NOTE: Appendix B gives typical logbook reports

inspection and maintenance, and shall describe their locations

Each pumpset and equipment in the plant register shall be allocated a reference number.The reference number allocated shall be unique within the facility and shall be indicated

on the diagram(s) and the plant

NOTE: A typical example of the listing in a plant register is illustrated in Figure C1 ofAppendix C

to record details of the pumpset performance at commissioning and any subsequent tests

or recommissioning

All subsequent inspection and test results shall be recorded and compared with the resultsachieved at commissioning or any subsequent recommissioning Any repairs andmodifications effected shall be recorded in the pumpset performance log

NOTE: Typical pumpset performance log sheets are illustrated in Figures C2 and C3 ofAppendix C

S E C T I O N 5 I N S P E C T I O N , T E S T I N G A N D

M A I N T E N A N C E

periodic intervals specified in this Section

During any inspection, testing and maintenance, any deficiency shall be reportedimmediately Deficiencies that would affect the performance of the system shall berectified with minimum delay (see Section 2)

Prior to testing, any recipient of a remote signal shall be advised that a test is to beconducted On completion of the test, the recipient shall be contacted to check that thecall was received and to advise that the installation has been reset and left in an operativecondition

Where facilities are protected by multiple pumpsets, it is essential that each individualpumpset system be fully checked and recommissioned before work is started on the nextpumpset system

testing and maintenance shall be conducted at four levels, as follows:

(a) Level 1 routines, consisting of testing and recording

(b) Level 2 routines, consisting of Level 1 routines plus additional tests and adjustmentswhich do not necessitate taking the pumpset out of service

(c) Level 3 routines, consisting of Level 2 routines plus additional testing andinspection procedures with consequential adjustments, as necessary, to ensurecorrect function These routines may require the pumpset to be taken temporarilyout of service, but shall enable rapid reinstatement to full operational status

(d) Level 4 routines, consisting of Level 3 routines plus overhaul and test procedureswhich may necessitate the pumpsets being out of service for short periods

be as follows:

(a) Level 1 routines weekly.(b) Level 2 routines quarterly.(c) Level 3 routines annually.(d) Level 4 routines three-yearly

(c) Inspect and ensure that batteries are firmly secured with their cabinets.

(d) Check the water, oil, fuel levels and any drive belts for all compression ignitionpumpsets prior to operation

(e) Check the operation of all pump starting devices and pump status indications

(f) Check pumpsets for physical condition and correct operation

quarterly, as follows:

(a) Carry out Level 1 procedure (see Clause 6.1)

(b) Run pumps under load to ensure correct operation

annually, as follows:

(a) Carry out Level 2 procedure (see Clause 6.2)

(b) Check full operation of pumpsets and service compression -ignition driver

(c) Carry out water supply flow test

(d) Check environment of compression-ignition pumpset pump room

3-yearly intervals, as follows:

(a) Carry out Level 3 procedure (see Clause 6.3)

(b) Service pumps, electric drivers and compression-ignition drivers in accordance withthe manufacturer’s instructions

NOTES:

1 The maintenance procedures of Clauses 6.1 to 6.4 are provided in Table 7.1 for sprinklerand hydrant pumpsets, Table 7.2 for pressure maintenance pumps and Table 7.3 for hosereelpumps

2 Aids to assist in analysing pump problems are contained in Appendix D

in the appropriate records

NOTE: Table 7.1 is to be used in conjunction with the log reports (see Appendix B).

(b) Table 7.2 — provides inspection, test and maintenance schedules for pressuremaintenance pumpsets

(c) Table 7.3 — provides inspection test and maintenance schedules for pumpsetsinstalled to serve—

(i) hosereels complying with the requirements of AS 2441; and(ii) domestic sprinklers complying with the requirements of AS 2118.5

INSPECTION, TEST AND MAINTENANCE SCHEDULES FOR AS 2941 PUMPSETS

Frequency Weekly

(Level 1)

Quarterly (Level 2)

Yearly (Level 3)

3 Yearly (Level 4)

1 Storage tank water level Check water level in storage tank.

2 Valves Check to ensure that all valves are correctly set and secured.

3 Pump controller (a) Check enclosure for corrosion, and the ingress of water, dust and

insects.

(b) Check operation of all visual indicators, switches and sounders.

4 Batteries and chargers All batteries and chargers shall be maintained in accordance with

AS 2676.1 or AS 2676.2.

5 Battery and enclosure (a) Check battery complies with details on identification plate fitted

to enclosure.

(b) Check battery for corrosion, physical damage, and security.

(c) Check battery enclosure for corrosion, and the ingress of water, dust and insects.

(d) Check float voltage of the battery and record.

6 Electric motor driven

pumpsets

Check that—

(a) all safety guards are in place and secure;

(b) pump starts at the nominated start signal and, where valid, check starting pressure;

(c) pump operates at correct shut-off pressure;

(d) pump gland and drain or mechanical seal operate efficiently;

(e) excessive vibration or noise are not evident;

(f) both local and remote ‘pump running’ alarms and lights operate;

(g) the pump runs continuously under load for not less than 3 min;

where alternative power supplies are provided, run the pump(s) continuously for not less than 3 min off each supply; and

Item Component or function Action required

Frequency Weekly

(Level 1)

Quarterly (Level 2)

Yearly (Level 3)

3 Yearly (Level 4)

8 Starting devices Start each pumpset by means of one of the installed starting devices.

Where more than one starting device is installed for each pumpset, this test may be carried out on a weekly rotating basis for each pump, but in no case shall the period between the exercising of each starting device exceed one month A period of not less than 5 min shall elapse between successive starts on an individual pump Compression- ignition engine driven pumpsets shall be driven continuously for at least 10 min at the duty point and electric motor driven pumpsets for

at least 3 min continuously.*

9 Compression-ignition

pumpsets

Check that—

(a) all safety guards are in place and secure;

(b) pump starts at nominated start signal and, where valid, check starting pressure;

(c) pump operates at correct shut-off pressure;

(d) pump gland or mechanical seals do not leak and drain operates efficiently;

(e) both local and remote ‘pump running’ alarms operate;

(f) out-of-balance condition is not evident;

(g) running speed is correct;

Item Component or function Action required

Frequency Weekly

(Level 1)

Quarterly (Level 2)

Yearly (Level 3)

3 Yearly (Level 4)

10 Valves Check the operation of all pumpset isolation, non-return valves

11 Compression-ignition

driver

(a) Check condensate drains at exhaust pipe and fuel filter.

(b) Run the driver for a period of not less than 30 min and then record the engine operating temperature, oil pressure and tachometer readings After stopping, restart using manual start mechanisms (This test should be carried out at not less than 60% operating load.)

(c) Check exhaust system for leaks and that exhaust guard is in place.

—

12 Wiring Check all alarm wiring and connectors to ensure correct functioning — —

13 Electric motor-driven

pumpsets

Service electric motor driven pumpsets as follows:

(a) Check circuit-breakers and/or fuses protecting pump driver circuits to ensure that this equipment is of the correct type and rating is as required for the motor starting and operating conditions.

(b) With electrical equipment isolated from all power supplies check the condition of all exposed heavy current carrying contacts Any item showing signs of wear or corrosion shall be imm ediately repaired or replaced.

(c) Check electric pumpset starter operation to ensure that the starting sequence is completed and the pumpset is fully operational within 30 s.

(d) Run the pumpset for a minimum of 30 min During this period operate the pumpset at 0, and 100% of flow characteristics designated for the installation, and check and record pressure, and load current for each phase.