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2 LEVELS OF INSPECTION, TESTING AND MAINTENANCE

2 LEVELS OF INSPECTION, TESTING AND MAINTENANCE

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11

S E C T I O N 6
M AI N T E N AN C E O F
P U MP S E T S Y S T E M S

AS 1851.14 — 1996

F I R E

6.1 MAINTENANCE LEVEL 1 Maintenance Level 1 procedure shall be carried out
weekly, as follows:
(a)

Inspect and maintain batteries and battery chargers in accordance with the
requirements of AS 2676.1 and AS 2676.2.

(b)

Inspect and maintain battery cabinets such that they are free from corrosion and the
ingress of water, dust and insects.

(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 ignition
pumpsets 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.

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6.2 MAINTENANCE LEVEL 2 Maintenance Level 2 procedure shall be carried out
quarterly, as follows:
(a)

Carry out Level 1 procedure (see Clause 6.1).

(b)

Run pumps under load to ensure correct operation.

6.3 MAINTENANCE LEVEL 3 Maintenance Level 3 procedure shall be carried out
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.

6.4 MAINTENANCE LEVEL 4
3-yearly intervals, as follows:

Maintenance Level 4 procedure shall be carried out at

(a)

Carry out Level 3 procedure (see Clause 6.3).

(b)

Service pumps, electric drivers and compression-ignition drivers in accordance with
the manufacturer’s instructions.

NOTES:
1

The maintenance procedures of Clauses 6.1 to 6.4 are provided in Table 7.1 for sprinkler
and hydrant pumpsets, Table 7.2 for pressure maintenance pumps and Table 7.3 for hosereel
pumps.

2

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

6.5 RECORDING All tests and maintenance of fire pumpset systems shall be recorded
in the appropriate records.

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AS 1851.14— 1996

12

S E C T I O N 7
I N S P E C TI O N , T E S T A N D
M A I N T E N A N C E S C HE D U L E S
The maintenance and testing of pumpset systems shall be carried out in accordance with
the following Tables:
(a)

Table 7.1 — provides inspection, test and maintenance schedules for pumpsets
installed to serve—
(i)

sprinklers complying with the requirements of AS 2118.1, AS 2118.2,
AS 2118.4 and AS 2118.6;

(ii)

hydrants complying with the requirements of AS 2419.1 and AS 2419.2; and

(iii)

waterspray systems.

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

(b)

Table 7.2 — provides inspection,
maintenance pumpsets.

test and maintenance schedules for pressure

(c)

Table 7.3 — provides inspection test and maintenance schedules for pumpsets
installed to serve—
(i)

hosereels complying with the requirements of AS 2441; and

(ii)

domestic sprinklers complying with the requirements of AS 2118.5.

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TABLE

AS 1851.14—1996

7.1

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INSPECTION, TEST AND MAINTENANCE SCHEDULES FOR AS 2941 PUMPSETS
Frequency
Item

Component or function

Action required

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
(h) the circulation relief valve operates.

Compression-ignition
engine

Where compression-ignition engine driven pumpsets are installed,
check water, oil, fuel levels and belt drives prior to running.

7

Weekly
(Level 1)

Quarterly
(Level 2)

Yearly
(Level 3)

3 Yearly
(Level 4)

(continued )

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AS 1851.14—1996

14

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TABLE

7.1

(continued )
Frequency

Item

Component or function

Action required

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. Compressionignition 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;
(h) water, oil and fuel leaks are not evident and fittings on ancillary
equipment are secure;
(i) battery charging alternator/generator operates correctly;
(j) engine stop mechanism automatically returns to the start
position;
(k) cooling water is discharging visibly (heat exchanger cooled
engines only);
(l) pump casing air relief valve operates correctly;
(m) battery charger power failure alarm operates correctly;
(n) water, oil and fuel levels are fully topped up;
(o) the circulation relief valve operates; and
(p) exhaust system does not leak.

* It is recommended that the pump be run under load condition and until normal operating temperature is reached.

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Weekly
(Level 1)

Quarterly
(Level 2)

Yearly
(Level 3)

3 Yearly
(Level 4)

(continued )

15

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TABLE

7.1

AS 1851.14—1996

(continued )
Frequency

Item

Component or function

Action required

Weekly
(Level 1)

10

Valves

Check the operation of all pumpset isolation, non-return valves
including monitoring if fitted.



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.



Quarterly
(Level 2)

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
immediately 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.
(e) Check that phase failure alarm is operating correctly.





Yearly
(Level 3)

3 Yearly
(Level 4)

(continued

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AS 1851.14—1996

16

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TABLE

7.1

(continued )
Frequency

Item

14

15

16

Component or function

Action required

Weekly
(Level 1)

Quarterly
(Level 2)

Service compression-ignition driven pumpsets as follows:
(a) Carry out maintenance and inspection in accordance with
AS 2676.1 or 2676.2 as appropriate.
(b) Check and clean or replace as required, engine fuel sludge and
sediment trap, and fuel, oil and air filter elements.
(c) Remove, inspect and clean heat exchanger strainer.
(d) Replace engine oil with oil that meets the engine manufacturer’s
specification. More frequent oil changes shall be carried out if
recommended by the engine manufacturer.
(e) Run the pumpset for a minimum period of 30 min. During this
period operate the pumpset at 0, and 100% of flow
characteristics designated for the installation.
(f) Flush engine cooling system and refill using manufacturer’s
approved corrosion inhibitor.





Compression-ignition
engine room
(where applicable)

Check that—
(a) the installed heating for maintaining engine room temperature
above 10°C is operating correctly; and
(b) the ventilation for engine aspiration and for limiting room
temperature rise to less than 10°C above ambient temperature is
satisfactory.





Valves and pipework

(a)

Overhaul engine cooling system pressure reducing valves (if
fitted).
(b) Test all non-return valves and ensure proper seating.
(c) Clean piping, inspect for corrosion, neutralize corrosion where
necessary and repaint (external only).
(d) Check air-release valve

















Compression-ignition
driven pumpsets

17

Valves

Overhaul pressure relief/flow control valves (if fitted)

18

Compression-ignition
driver

(a)

19

Recommission

After completion of maintenance procedures return all equipment to
the operational condition.

20

Recording

Record maintenance in log.

Carry out service procedures in accordance with the
manufacturer’s instructions.
(b) Ensure all safety guards are in place and secure.

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Yearly
(Level 3)

3 Yearly
(Level 4)

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17

TABLE

AS 1851.14—1996

7.2

INSPECTION, TEST AND MAINTENANCE SCHEDULES FOR PRESSURE MAINTENANCE PUMPS
Frequency
Item

Component or function

Action required

Weekly
(Level 1)

Quarterly
(Level 2)

1

Valves

Check and ensure all valves are correctly set and secured.

2

Pump

(a)
(b)

3

Pressure switch

Check pressure switch setting is correct.



4

Hydro-pneumatic accumulator

Check that pressure is correct (as shown on plate).



5

Valves

Check operation of all pumpset isolating, non-return and pressure
relief valves, and monitoring if fitted.



6

Pump coupling

Check alignment and adjust as required.





7

Wiring

Check all wiring and connectors.





8

Pump driver

(a)





(b)

Check operation (manual and automatic).
Check that setpoint is achieved.

Check circuit-breakers/fuses protecting pump driver circuits
to ensure that this equipment is of the correct type and rating
for the pump start and operating conditions.
With power isolated, check all components for wear. Replace
as required.

9

Recommission

After completion of maintenance procedures return all equipment
to the operational condition.

10

Recording

Record maintenance in log.

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Yearly
(Level 3)

3 Yearly
(Level 4)

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AS 1851.14—1996

18

TABLE

7.3

INSPECTION, TEST AND MAINTENANCE SCHEDULES FOR HOSEREEL PUMPS*
Frequency
Item

Component or function

Action required

Weekly
(Level 1)

Quarterly
(Level 2)

1

Valves

Check that all valves are correctly set and secured.

2

Lockable isolating switch

Check that switch is in the correct position.

3

Pump

Check that pump operates when hosereel is operated.



4

Pump

Check that pump functions correctly in conjunction with hosereel
test (see AS 1851.2)





5

Valves and pipework

(a)
(b)





Test all non-return valves and ensure proper seating.
Clean piping, inspect for corrosion, neutralize corrosion where
necessary and repaint (external only).

6

Recommission

After completion of maintenance procedures return all equipment to
operational condition.

7

Recording

Record maintenance in log.

Yearly
(Level 3)

3 Yearly
(Level 4)

* It is recommended that domestic sprinkler system pumps be exercised monthly to ensure operation. Table 7.3 may be used as a guide where more comprehensive
maintenance is required.

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AS 1851.14— 1996

APPENDIX A

SUMMARY OF INSPECTION, TEST AND MAINTENANCE SCHEDULES
(Informative)

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Item

Component

Table 7.1
Reference

Function

1

Water supply

Tank level

1

2

Valves

Set and secured

2
10



Monitoring

10



Overhaul pressure reducing
valve (PRV ) (if fitted)

16(a)





Test non-return valves

16(b)





Check air release valves

16(d)





Overhaul pressure
releasing/flow control valves
(if fitted)

17





Pump
controller

Check cabinet for corrosion
and ingress of dust, water
and insects

3

4

Batteries,
chargers, and
cabinets

Maintain batteries in
accordance with the
appropriate part of AS 2676

4

Electric motor
driven
pumpsets

Quarterly

Operation

3

5

Weekly

Check battery is of correct
type

5(a)

Check battery for corrosion,
damage and security

5(b)

Check battery cabinet for
corrosion and ingress of
water, dust and insects

5(c)

Check battery float voltage

5(d)

Check safety guards

6(a)

Check pump start signal and
devices

6(b)

Check pump operates at
correct shut-off pressure

6(c)

Check gland/seal and drain

6(d)

Check vibration and noise

6(e)

Check pump running alarms
and lights

6(f)

Check pump under load

6(g)

Check operation of
circulation relief valve

6(h)

Check circuit-breakers/
fuses

13(a)





Check motor starter
condition

13(b)





Check starter sequence

13(c)





Run pump and check
characteristics

13(d)





Check phase fail alarm

13(e)





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Yearly



3 Yearly

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AS 1851.14— 1996

Item

Component

6

Compressionignition engine

20

Table 7.1
Reference

Function
Check water, oil and fuel
levels, and drive belts
Check safety guards

9(a)

Check pumpstart signal and
devices

9(b)

Check pump operates at
correct shut-off pressure

9(c)

Check gland/seal and drain

9(d)

Check pump running alarm
and lights

9(e)

Check for noise and
vibration

9(f)

Check running speed

9(g)

Check water, oil and fuel
leaks

9(h)

Check alternator/generator
operation

9(i)

Check engine stop
mechanism

9(j)

Check cooling water
discharge

9(k)

Check pump casing air relief
valve

9(l)

Yearly

Check charger fail alarm

9(m)

Check water, oil and fuel
levels

9(n)

Check operation of pressure
relief/flow control valve

9(o)

Check exhaust system for
leaks

9(p)

Check condensate drains

11(a)



Run motor for 30 min

11(b)



Check exhaust system for
leaks

11(c)



Carry out manufacturer’s
service procedures

18(a)







Ensure all safety guards are
fitted

18(b)







12





16(c)





Wiring

Check alarm wiring

8

Pipework

Clean, inspect and repaint

9

Recommission

Recording

Quarterly

7

7

10

Weekly

19

Return to operating
condition
Record maintenance/service
in log

20

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3 Yearly

21

AS 1851.14— 1996

APPENDIX B

TYPICAL LOGBOOK REPORTS
(Informative)
This Appendix sets out examples of typical logbook reports, as follows:
(a)

Figure B1

... .. .. .. .. ... .....

(b)

Figure B2

. . . . . . . . . . . . . . . . . . quarterly inspection, testing and maintenance.

(c)

Figure B3

. . . . . . . . . . . . . . . . . . . . yearly inspection, testing and maintenance.

(d)

Figure B4

. . . . . . . . . . . . . . . . three-yearly inspection, testing and maintenance.

Pumpsets record

weekly inspection, testing and maintenance.

(Weekly inspection, testing and maintenance)

Premises . . . . . . . . . . . . . . . . . .

Maintenance
organization . . . . . . . . . . . . . . . . . . . . . .

Address . . . . . . . . . . . . . . . . . . .

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Telephone . . . . . . . . . . . . . . . . . . . . . . .
Place in box where item is satisfactory
Place × in box where item is unsatisfactory
Write N/A where not applicable
NO TE: Give details of all unsatisfactory items in Report section.

Week
Weekly checks

1

2

3

Storage tank water level
Isolation valves
Pump controller cabinet condition
Battery correct type
Battery corrosion, damage and security
Battery cabinet condition
Battery float voltage
Electric motor driven pumpset
Pump start and pressure devices
Vibration and noise
Pump running alarms and lights
Pump under load
Pressure relief/flow control valve

FIGURE B1 (in part) TYPICAL LOGBOOK REPORT—
WEEKLY INSPECTION, TESTING AND MAINTENANCE

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