D-23

Annual Pump Test - Policy

• All pumpers, including reserve pumpers, undergo annual testing starting the first Monday of March.

Responsibility - Training Division

• The Training Division conducts annual tests on all pumpers, including reserve pumpers
• These tests are performed during In-service Training, scheduled pump tests, or other opportunities
• Reports go to the Fire Commissioner, listing the company, battalion, number, manufacturer, and model of tested apparatus, along with the results.

Responsibility - Apparatus Officer

• The Apparatus Officer acts as a liaison between the manufacturer and Fleet Management.
• They also provide technical assistance to the Training Division.

Responsibility - Company Officer

• A pre-test check is conducted before any pump test
• The pre-test occurs either at the station or the test site, as directed by the Training Division.

Dry Prime Test Procedure

• Purpose is to check the priming capability of a pumper
• Take the apparatus outside the station, apply the parking brake, and chock the rear wheels.
• The tank-to-pump valve is closed and the pump is drained
• Intakes, discharge outlets, drain valves, and cooling by-pass valves are checked to ensure they are tightly closed.
• Check the priming oil tank; refill if low, and ensure the vent hole is clear of debris.
• Keep the gear selector in neutral and do not put the apparatus in pump, with the parking brake applied and rear wheels chocked.
• Engage priming pump.
• Look at the compound gauge for a negative reading
• A reading of at least 10 inches of mercury should be reached within 30 seconds.
• If not reached in 45 seconds, stop and check for leaks, and never engage the priming pump for more than 45 seconds
• Drafting can be accomplished with a reading of less than 10 inches of mercury, but pump testing requires at least 10 inches of mercury.
• Once 10 inches or more is reached on the compound gauge, disengage the priming pump and shut off the engine.
• The gauge should show a negative reading for at least 2 minutes; check the possible causes if it does not occur.

Testing Hard Suctions

• This test is performed only after a pump passes the dry prime test.
• Inspect and replace the large hard suction gaskets, if needed.
• Pre-connect the hard suctions and place the pump intake cap on the male end of the suction.
• Attach the suctions to the apparatus, ensuring tight connections
• Apparatus with 5” Storz adaptors must have them removed and NST connections used for this test.
• Repeat the dry prime operations; a successful result means the apparatus can perform the pump test at the draft site.
• An unsuccessful result indicates an air leak at the suction connection or in one of the suctions.
• Tighten the connections or test the suctions one at a time to find the defective suction
• Borrow a hard suction from another unit and retest the pump; if successful, the fault with the regular suction(s) will need to be corrected at the PFD warehouse.
• The test will be conducted with borrowed suctions for testing if needed.

Failure of pump to prime or pump loses prime

• A failure is indicated on the compound gauge; no vacuum on the gauge can be caused by one or more of the following:
• The compound gauge is turned off or broken
• No oil is in the priming tank
• Air leaks existing at the suction connections or in the suction hose
• A discharge gate is open
• The pump drain valve is open
• The cooling valve or the relief valve is open
• Air leaks caused by a loose packing gland
• The hose reel by-pass valve is open

Test for Failure

• Connect a 2-1/2” discharge outlet to a hydrant via a 2-1/2” high-pressure hoseline.
• Cap the other discharge outlets and the suction, then open the hydrant and the 2-1/2" discharge outlet to check for leaks.
• A packing leak of 10 to 12 drops a minute is normal (except for apparatus with ceramic pump packing) and will not impact drafting.
• An overflowing water tank indicates a leak in the tank-fill valve or the tank-to-pump valve, and will affect the dry prime, but not the pump's ability to draft.
• Always check the Apparatus Manual for the type of pump packing being used

Remedial action

• If leaks can't be fixed by company personnel or if there are other mechanical problems, the company officer will call Fleet Management for corrective action.
• If a pump fails the dry prime, it must still be brought to the Fire Academy for the scheduled pump test after checking all fluids (engine oil, transmission fluid, priming oil and coolant).

Pump Test Operating Procedures at Draft

• Place the pumper as close to the water source as possible
• Apply the parking brake and chock the rear wheels.
• Connect the suction on the officer’s side when possible for safety
• Use the side intakes, avoiding the front or rear intakes because the piping between the pump and the inlet can be more restrictive.
• Connect the hard suctions tightly.
• Attach the suction strainer and the rope to the male end of the suction.
• Attach the female end of the suction to the pump intake tightly after checking the pump intake strainer on the panel and removing Storz adaptors.
• Replace any deteriorated pump intake strainer with new ones, which are available at the Training Division
• Secure connections tightly on apparatus with recessed suction intakes.
• Submerge the suction strainer to a depth of at least 2 feet, avoiding mud
• Secure the free end of the rope to a stationary object to keep the strainer off the bottom after lifting it.
• Set the transfer valve to the VOLUME position and ensure that the relief valve is at its highest setting.
• Tighten all connections and keep valves and drain cocks closed.
• Engage the pump and place the gear selector in the proper range.
• Turn on all headlights, running lights, warning lights, and air conditioner(s), if equipped.
• Engage the priming pump and raise the motor to a fast idle, approximately 1000 to 1200 RPM
• Priming the pump does not require raising the engine speed above 1200 RPM and increasing the wear on the pump
• When the priming pump discharge flows continuously and contains no air, the pump is primed.
• Disengage the priming pump. The master pump pressure gauge should read approximately 50 psi.
• Record the time it takes to prime the pump, and never engage the priming pump for over 45 seconds.
• Open discharge gates slowly, one at a time, partially, until the hoselines are filled.
• Always secure master stream devices before opening the discharges.
• Adjust the throttle to the rpm listed on the Underwriters’ Plate on the pump panel.
• Gate down the discharge outlets slowly, while watching the master pressure gauge, until the desired pressure is reached.
• Lock the discharge outlets in that position; old apparatus may need increased rpm above the Underwriters’ Test, but not exceeding 80% of peak engine speed.
• Secure the hoselines at the discharges for safety, while earplugs or other sound reducing devices are used where required.
• Adjust the rpm and discharge opening to achieve the correct pump and nozzle pressures.
• Hoseline layouts should be free of sharp bends and kinks, which can affect Pitot readings.
• Proper rpm readings require removing the cap from the rotating spur on the pump panel and pressing the digital tachometer tip against it until a consistent reading is registered.
• This reading is the pump transmission gear's rpm.
• To find the engine rpm, multiply the transmission gear rpm by the gear ratio, found above the rotating dial
• American La France’s gear ratio is 1 to 2
• E-One’s gear ratio is 1 to 10
• Seagrave’s gear ratio is 1 to 2
• If prime is suddenly lost, take these immediate actions:
• Throttle down and close the discharge gate(s)
• Check all caps, gates, and valves for tightness
• Check for loose large hard suction connections
• Check for clogged suction strainer and that it is not positioned on the bottom of the water source or too close to the surface
• Return to 3.1.11 and resume the pump test procedure.

Hoseline Layouts – 2-1/2” High Pressure Hoseline (1000 GPM Pumps)

• TEST #1: Test for 20 minutes, with 3 Pitot readings taken: one at setup, one after 10 minutes, and one before shutdown.
• Use three 100' stretches of 2-1/2 high-pressure hoseline to a deluge or Stang Gun with a 2” tip
• A 150 psi net pump pressure provides 1000 gpm discharge.
• TEST #2: Test for 10 minutes, taking 2 Pitot readings: one at setup and one before shutdown.
• Use two 100' stretches of 2-1/2” high-pressure hoseline to a deluge or Stang Gun with a 1-3/4” tip.
• A 200 psi net pump pressure will provide 700 gpm discharge.
• TEST #3: Test for 10 minutes, with 2 Pitot readings taken: one at setup and one before shutdown.
• Set the transfer valve to the PRESSURE position.
• Use one 100' stretch of 2-1/2" high-pressure hoseline to a deluge or Stang Gun with a 1-1/2" tip.
• A 250 psi net pump pressure will provide 500 gpm discharge.
• Record all data, including Pitot readings, pressures, rpm readings, time intervals, oil pressure, water temperature, and transmission oil temperature, accurately on the Pump Test Form.

Hoseline Layouts – 2-1/2” High-Pressure Hoseline (1500 GPM Pumpers)

• TEST #1: Test for 20 minutes, taking 3 Pitot readings: one at setup, one after 10 minutes, and one before shutdown.
• Use three 100' stretches of 2-1/2" high-pressure hoseline and one 50' stretch of 2-1/2" high-pressure hoseline to a deluge or Stang Gun with a 2” tip and a 1-1/2” tip
• A 150 psi net pump pressure provides 1500 gpm discharge.
• TEST #2: Test for 10 minutes and take two Pitot readings, one immediately after set-up and one just prior to shut-down.
• Utilize three 100' stretcheds of 2-1/2” high-pressure hoseline to a deluge or Stang Gun with a 2" tip.
• A 200 psi net pump pressure will provide 1050 gpm discharge.
• TEST #3: Test for 10 minutes and note 2 pitot readings, one directly after set-up and another just before shutdown, place the transfer valve in the PRESSURE position, and use two 100' stretching of 2-1/2" high-pressure hoseline to a deluge or Stang Gun with a 1-3/4" tip
• A 250 psi net pump pressure provides 750 gpm discharge
• Record all data, including Pitot readings, pressures, rpm readings, time intervals, oil pressure, water temperature, and transmission oil temperature, accurately on the Pump Test Form.

Pump Test - Vertical Lift

• Conduct pump tests with a vertical lift of no more than 10 feet, with the vertical lift being the vertical distance from the water surface to the pump suction inlet center.

Net Pump Pressure (NPP)

• NPP is defined in NFPA 1911 as either the sum of discharge pressure (DP) and dynamic suction lift (DSL) in psi when pumping at draft, or the difference between discharge pressure and intake pressure (IP) when pumping from a hydrant.
• From draft: NPP= DP + DSL
• From a hydrant: NPP= DP-IP

Dynamic Suction Lift

• The difference between net pump pressure and discharge pressure is called “dynamic suction lift.”
• NFPA 1911 defines dynamic suction lift as the sum of the vertical lift and the friction/entrance loss, in feet, divided by 2.31 to get psi.
• The formula for 1000 gpm pumps with 20’ of 5” hard suction is:
  • Dynamic suction lift = (lift + 8 + 1.5) / 2.31

Dynamic Suction Lift Adjustment

• Reduce the computed dynamic suction lift for a capacity test by:
• 1 psi for the 200 psi test
• 2 psi for the 250 psi test.

Capacity Test (1000 gpm pump) - 150 psi

• Tip size: 2”
• Table provided includes lift in feet, flow GPM, discharge pressure, DSL, net pump pressure, and Pitot reading 2” tip.
• The discharge pressures listed in 3.4.6 and 3.4.7 will be for a 10’ lift; for other lifts, calculate the discharge pressure using the formula in 3.4.3
• 4 ft lift is 1164 GPM at 144 discharge pressure and 96 pitot reading

Capacity 200 psi test

• For a 1000 gpm pump with a 1-3/4” tip, discharge pressure is 193 psi
• Take 70% of the flow from the first test.

Pressure 250 psi test

• With a 1000 gpm pump with a 1-1/2" tip, the discharge pressure is 244 psi.
• Flow should be 50% of the first test.

Computing Dynamic Suction Lift

• Compute in 1500 gpm pumps with 20’ of 6” hard suction using the formula:
• Dynamic suction lift = (Lift + 9 + 1) / 2.31
  • Reduce the dynamic suction lift computed for the capacity test - 1 psi for the 200 psi test and 2 psi for the 250 psi test

Capacity 150 psi test (1500 gpm pump)

• Measurements provided chart based on tip sizes – 2” & 1-3/4”
• Lifts are shown from 4ft to 16ft in 2ft increments

Discharge Pressure

• Listed discharge pressures in 3.4.10 and 3.4.11 are for a 10’ lift; use the formula in 3.4.8 to calculate for other lifts.
• The 200 psi test for a 1500 gpm pump with a 2” tip has a discharge pressure of 192 psi - take 70% of the flow from the first test.
• The 250 psi test for a 1500 gpm pump with a 1-3/4” tip has a discharge pressure of 243 psi - take 50% of the flow from the first test.

Tachometer and Pressure Gauge Calibration

• Calibrate tachometers using a digital counter.
• Check portable pressure gauges against the master pressure gauge, so all adjustments are made to ensure data accuracy and any discrepancies noted on the Pump Test Form.

Relief Valve Testing

• The relief valve will be tested before disconnecting hoselines to ensure proper operation; this requires using two hoselines.
• Open and then close drains on apparatus with relief valve drains before activating the relief valve for testing.
• Charge the two hoselines.
• If the relief valve has an “on” and “off” switch, place the switch in the “on” position to activate.
• Set the relief valve by throttling up the engine until the master pressure gauge reads 150 psi
• Then, carefully observe the master pressure gauge while rotating the relief valve control COUNTER-CLOCKWISE until the master pressure gauge shows a slight drop in pressure.
• Afterwards, turn the relief valve control CLOCKWISE until the master pressure gauge returns to the original setting.
• Shut down one of the two hoselines to test the relief valve setting; the relief valve is operating properly if the master pressure gauge does not increase more than 30 psi.
• When relief valves with drains are used in hoseline service, the drain must be bled and then closed.
• Clean the strainers on certain apparatus relief valves after their use
• After 1991, pumpers that comply with NFPA standard 1901, are equipped with systems that provide discharge and suction protection against excess pressure

Tank to Pump Flow Test

• In accordance with NFPA 1901, the tank to pump valve must be checked for proper operation, and the piping and valve arrangement must be capable of delivering water to the pump at least 500 gpm, sustainable while pumping a minimum of 80% of the tanks capacity.

Tank to Pump Flow Test - Steps

• Step 1: Disconnect the large suction and put on the suction cap.
• Step 2: Connect a 2-1/2” high-pressure hoseline from a hydrant to the 2-1/2” auxiliary suction intake.
• Fill the tank until it overflows, then close the 2-1/2” suction intake.
• Step 3: Attach a 1-1/2" tip from the Pitot kit to the deluge or Stang Gun
• Step 4: Open the tank-to-pump valve and the deluge or Stang Gun’s appropriate 2-1/2” discharge
• Step 5: Pressurize one stretch of 2-1/2" high-pressure hoseline, and advance the throttle until the Pitot reading at the tip is 56 psi for 45 seconds, approximately 500 gpm
• Caution: A 500-gallon tank may run dry in 60 seconds at this discharge rate.

Flushing the Pump

• After drafting, the pump should be connected to a hydrant and flushed thoroughly with clean water to remove dirt and grit.

Flow Meter Test/Calibration

• Attach a discharge hoseline to the outlet equipped with a flow meter.
• Use the same deluge and Stang Gun and pitot test kit and open the outlet, take a pressure reading with the pitot test kit, convert the pressure to a GPM format using the charts with the kit, the pitot tubes reading converted to GPM after friction loss and the flow meter should be the same.
• Change the flow meter reading in the apparatus as necessary

Discrepancies

• Note any inability to calibrate on the Pump Test Form.

Suction Side Dump Valve Test

• Attach a 2-1/2” high-pressure hoseline from a low pressure hydrant to the 2-1/2” auxiliary suction intake of the apparatus.
• Pressurize the hydrant and open the 2-1/2” auxiliary suction gate.
• Record the static pressure reading from the compound gauge on the Pump Test Form.
• Adjust the dump valve to a setting lower than the static pressure so that it activates, expelling water due to the pressure difference.
• A different pumper must be used for water supply if the static pressure is lower than the lowest setting on the dump valve.

Forms Required

• Use Pump Test Form 76-98 and see the Forms Directive for preparation instructions.

Pump Test Form - Filing

• The training division will complete five copies of Pump Test Form (76-98)
• They will provide data on the pump and pass or fail the test
• Distribution:
• Send the original to the Apparatus Officer
• Send one copy to the company’s battalion chief for review and retention
• Send one copy to the Training Divisions file
• Send one copy to the company’s Apparatus File
• Send one copy to Fleet Management.

Equipment Needed

• Two master stream devices, either deluge or Stang Guns, with stream straighteners.
• Six 50' lengths of 2-1/2” high-pressure hoseline for 1000 gpm pumpers, or seven 50' lengths for 1500 gpm pumpers.
• 100' roof ropes to secure the master stream devices, along with 100' guide line to lower and secure suctions and strainer.
• Pitot gauges with 2”, 1-3/4", and 1-1/2" tips, with two kits at the P.F.A. (two gauges are used to test 1500 gpm pumps).
• A digital tachometer including portable pressure and vacuum gauges, along with two large hard suctions, coupled together, with a strainer attached.
• Flow meters with tubes, which are available at the P.F.A., can be used instead of Pitot gauges; all equipment is available at the Training Division.