Fire System Testing Requirements Guideline: WMC Environment, Health & Safety Management System

WMC Environment, Health & Safety Management System
Fire System Testing Requirements

Guideline
WMC-EHS-GUI-006.1
Owner:
DocsOpen Ref:
Darren Batchler
157400
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Revision
0
Reviewed
Description of Changes
First Issue
Date
31/03/2004
Approved
M Webb
WMC Resources Ltd

WMC has developed this document for internal use, specific to circumstances and conditions within its operations. It is
intended to provide general information and its applicability to external parties may therefore be limited. WMC makes no
representations as to the applicability of the information for use by any party other than WMC and should not be relied
upon as such. WMC provides no representation or warranty as to safety or business outcomes arising from application
of this document and its requirements by third parties.
Guideline Fire System Testing Requirements
CONTENTS
1
PURPOSE ................................................................................................................................. 3
GENERAL.................................................................................................................................. 3
TESTING REQUIREMENTS ..................................................................................................... 4
WEEKLY TESTING ................................................................................................................... 4
MONTHLY TESTING................................................................................................................. 4
QUARTERLY TESTING ............................................................................................................ 5
ANNUAL TESTING.................................................................................................................... 5
TWO-YEARLY OR GREATER REQUIREMENTS .................................................................... 5

8.1
2-Yearly Requirements .......................................................................................................... 5
8.2
8.3
8.4
8.5
10-Yearly Requirements ........................................................................................................ 5
REFERENCES .......................................................................................................................... 5
10
APPENDICES ........................................................................................................................ 7
APPENDIX A - Tables ...................................................................................................................... 8
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Last Updated: 12/07/04
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PURPOSE
The Purpose of this Guideline is assist WMC operations in complying with the requirement for a
fire protection management plan as detailed in the WMC EHS Management System Standard,
Crisis and Emergency Preparedness (WMC-EHS-STD-006).
GENERAL
This Guideline provides a summarised description of the relevant testing, inspection and
maintenance requirements for fire protection systems. The requirements have been compiled from
relevant Australian Standards (AS) and National Fire Protection Association (NFPA) standards.
These standards include requirements for the following:
Fire pumps
Monitors and hydrants
Deluge systems
Foam systems; and
Fire ring mains.
The testing intervals described in the tables in the following sections are based on the
maintenance requirements of the various systems.
Requirements for small fire protection items such as fire blankets and fire extinguishers have not
been addressed in this guideline.
It should be noted that often standards specify prescriptive requirements to address a particular
item. These may not necessarily be practical in given circumstances or may be superseded by
advances in design. In cases such as these, the main focus is on meeting the performance
requirement or desired outcome of the standard.
The standards often provide guidance or suggest alternative testing or inspection methods for
different or unusual designs. In the event that a particular task cannot be completed due to design
or other external factors, then the referenced standard should be reviewed before contemplating a
solution.
The inspection, testing and maintenance routines have been sorted into different frequency
intervals. The following frequency intervals are used:
Weekly
Monthly
Quarterly
Annual; and
Two yearly or greater.
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The testing requirements are further split from the above headings into subsections.
subsections are divided into tables for the following systems:
These
Hydrants and Monitors

Fire Pumps
Foam Systems
Deluge Systems; and
Ring Mains.
TESTING REQUIREMENTS
Each operation should review the following tables and identify the requirements that are applicable
to their fire protection systems.
Certain requirements listed in the tables in this guideline may not be relevant to a particular sites
fire protection system. In this event they may be disregarded however a note made to substantiate
this decision.
Once requirements have been identified and agreed upon the specific testing and inspection
requirements should be entered into the WMC SAP maintenance module.
The record in SAP should contain the actual test required, the piece of equipment for which it is
intended, the level of performance required and the organisational position that has responsibility
for performing the test or inspection.
Completed inspections and tests should be entered into SAP together with any maintenance
performed on the fire protection equipment.
NOTE: A procedure or similar document, stipulating who needs to be contacted and what
additional precautions need to be taken prior to any inspection, testing, or maintaining of fire
protection equipment is performed should be available and communicated to responsible
personnel.
WEEKLY TESTING
Weekly tasks that are required for the pump and deluge systems are listed in Table 3.1 and Table
3.2 respectively.
MONTHLY TESTING
Monthly tasks that are required for the pump systems, deluge systems, foam systems and hydrant
and monitors systems are listed in Table 4.1, Table 4.2 and Table 4.3 respectively.
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6
QUARTERLY TESTING
Quarterly tasks that are required for the pump system, deluge system, hydrants and monitors,
foam system, and ring main are listed in Table 5.1, Table 5.2, Table 5.3 and Table 5.4. It is also
worth noting that certain subtasks listed at the end of the Pump System Table (Table 5.1) and the
Deluge System Table (Table 5.2) only need to be performed semi-annually.
ANNUAL TESTING
Annual tasks that are required for the pump system, deluge system, hydrants and monitors, foam
system and ring main are listed in Table 6.1, Table 6.2, Table 6.3, Table 6.4 and Table 6.5
respectively.
TWO-YEARLY OR GREATER REQUIREMENTS
8.1
2-Yearly Requirements
2-Yearly tasks that are required for the pump system are listed in Table 7.1.
8.2
3-Yearly tasks that are required for the pump system, deluge system and hydrants and monitors
systems are listed in Table 7.2, Table 7.3 and Table 7.4 respectively.
8.3
5-Yearly tasks that are required for the deluge system, foam systems and ring main systems are
listed in Table 7.5, Table 7.6 and Table 7.7 respectively.
8.4
6-Yearly tasks that are required for the hydrants and monitors systems are listed in Table 7.8.
8.5
10-Yearly tasks that are required for the foam systems are listed in Table 7.9.
REFERENCES
Fire System Testing Requirements, Moduspec Australia. Ref 350-57 release 01, March 2004
Australian Standard, AS 1851.3-1997, Maintenance of fire protection equipment Part 3:
Automatic fire sprinkler systems , Standards Australia, Third Edition, 1997.
Australian Standard, AS 1851.2-1995, Maintenance of fire protection equipment Part 2: Fire
hose reels, Standards Australia, Fourth Edition, 1995.
Australian Standard, AS 1851.4-1992, Maintenance of fire protection equipment Part 4: Fire
hydrant installation, Standards Australia, Third Edition, 1992.
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Automatic fire detection and alarm systems, Standards Australia, First Edition, 1987.
Pumpset systems, Standards Australia, First Edition, 1996.
NFPA 25. Standard for the Inspection, Testing, and Maintenance of Water-Based Fire
Protection Systems, National Fire Protection Association (NFPA), Quincy, Massachusetts,
2002.
NFPA 1962. Standard for the Care, Use, and Service Testing of Fire Hose Including Couplings
and Nozzles, National Fire Protection Association (NFPA), Quincy, Massachusetts, 1998.
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10
APPENDICES
Appendix A
Tables
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APPENDIX A - Tables
Table 3.1: Weekly Pump System Requirements
Action No.
Action Required
Reference
W-1
Check that all required pump spares are on hand.
AS 1851.4-1992
W-2
Ensure all valves located around the pump are correctly set and secured.
AS 1851.141996 (Table
7.1)
W-3
Complete a general visual inspection of the electrical system.
NFPA 25 (Section 8.5.3)
W-4
Check the pump controllers:

(a) Check enclosure for corrosion, the ingress of water, dust and insects; and
(b) Check operation of all visual indicators, switches and alarms.
AS 1851.141996 (Table
7.1)
W-5
Inspect pump house conditions:

(a) Ensure temperature is not less than 4.4C (21C for pump room with diesel
pumps without engine heaters); and
(b) Ensure ventilating louvers are free to operate.
NFPA 25 (Section 8.2.2(1))
W-6
Inspect fire pump system conditions:

(a) Ensure piping is free of leaks;
(b) Ensure pressure gauge readings are normal; and
(c) Ensure suction reservoir is full
(d) Clean wet pit suction screens and ensure that they are unobstructed.
NFPA 25 (Section 8.2.2(2))
W-7
Start each pump by using one of the installed starting devices:

(a) If more than one starting device is installed, then this test may be carried out
on a weekly rotating basis. However, each device must be tested within a
month; and
(b) The time between successive starts on an individual pump should be less
than 5 minutes.
Test the fire pump:
(a) A weekly test of the fire pump assemblies should be conducted without
water flowing out of the fire water system. (A valve installed to open as a
safety feature is permitted to discharge water);
(b) An electric pump should run for a minimum of 10 minutes. (Check phase
failure alarm);
(c) A diesel pump should be run for a minimum of 30 minutes. (Check that after
stopping, it returns to start position);
(d) AS recommend that the pump be run under load condition until normal
operating temperature is reached;
(e) Record the pressure at all water supply gauges before, during and after
testing; and
(f) Ensure that both the local and remote pump alarms operate.
(g) Check the pump gland performance and the supply of pump priming liquid.
Pump start is as per AS

1851.14 1996 (Table 7.1)
and
Pump test is as per NFPA
25 (Section 8.3.1), and
AS1851.4-1992
W-8
Check the cooling systems:

(a) Check that there is adequate cooling water to the heat exchanger;
(b) Check water pumps;
(c) Inspect and check flexible hoses and connections; and
(d) Check jacket water heater.
W-9
Check the exhaust systems:

(a) Check for exhaust system leakage; and
(b) Check the drains condensate trap.
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Action No.
Action Required
Reference
W-10
Check the Electric Motor Systems:

(a) Ensure that all safety guards are in place and secure;
(b) Ensure pump starts at the nominated start signal and where valid, check
starting pressure;
(c) Ensure pump operates at correct shut-off pressure;
(d) Ensure pump gland and drain or mechanical seal operate efficiently;
(e) Ensure excessive vibration or noise are not evident;
(f) Ensure both local and remote pump running alarms and lights operate;
(g) If alternative power supplies are provided, run the pump(s) continuously for
a minimum of 3 minutes off each alternative supply; and
(h) Ensure that the circulation relief valve operates and is water tight under
normal operating pressure when deluge systems are being tested.
AS 1851.141996 (Table
7.1)
W-11
Compression-Ignition System or Diesel Engine Checks:

(a) Ensure all safety guards are in place and secure;
(b) Ensure that the pump starts at the nominated start signal and where valid,
check the starting pressure;
(c) Check the water, oil and fuel levels;
(d) Inspect and test the fuel tank float switch;
(e) Ensure pump operates at the correct shut-off pressure;
(f) Ensure that an out-of-balance problem is not evident;
(g) Ensure running speed is correct;
(h) Ensure water, oil and fuel leaks are not evident and fittings on ancillary
equipment are secure;
(i) Check that the battery charging alternator/generator operates correctly;
(j) Ensure that the engine stop mechanism automatically returns to the start
position;
(k) Ensure that the pump casing air relief valve operates correctly;
(l) Ensure that the battery charger power failure alarm operates correctly;
(m) Ensure that the circulation relief valve operates;
(n) Inspect and test the solenoid valves operation;
(o) Ensure cooling water is discharging visibly (heat exchanger cooled engines
only);
(p) Inspect flexible hoses and connections; and
(q) Check the lube oil heater.
(a-n) AS 1851.141996
(Table 7.1)
and
(d and o-q) NFPA 25
(Section 8.5.3)
W-12
Check Batteries and Charger:

(a) Check that the battery complies with details on identification plate fitted to
the 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; and
(e) Check electrolyte level.
(a-d) AS 1851.14 1996

(Table 7.1) and
(e) NFPA 25 (Section
8.5.3)
W-13
After completion of maintenance procedures return all equipment to the

operational condition and record observations in a maintenance log.
AS 1851.14 1996 (Table

7.2)
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Table 3.2: Weekly Deluge System Requirements

Action No.
Action Required
Reference
W-14
Check control valves:

Ensure that they are unobstructed.
AS 1851.3-1997 (Table
4.1) and NFPA 25 (Section
12.3.2.1)
W-15
Inspect backflow prevention assembly:

Ensure that the system is in service and that all isolation valves are in the normal
open position and properly locked or electrically supervised.
W-16
Test deluge system alarms:

(a) Record readings from each pressure gauge;
(b) Operate alarm valve, check that local and remote alarms have operated
correctly and record results;
(c) Close test valves and ensure that the alarm valve has reseated;
(d) Restore installation pressure where necessary and record final pressure
gauge readings; and
(e) Reset and secure valves in the appropriate positions and ensure that the
system is operational.
AS 1851.3-1997 (Table 4.1

& Appendix C)
W-17
Test automatic fire detection alarms:

(a) Simulate a fire alarm and ensure correct operation;
(b) Check fire alarm battery conditions; and
(c) Record results.
AS 1851.8-1987.
W-18
Check the block plan, location plate, and emergency instructions:

Ensure that they are adequate for the system and that they are legible.
AS 1851.3-1997 (Table
4.1)
Table 4.1: Monthly Deluge System Requirements

Action No.
Action Required
Reference
M-1
Test the isolating switch and check the circuit breakers or fuses.

and AS1851.4-1992
M-2
Check the battery system:

(a) Remove the case exterior and clean and dry;
(b) Remove corrosion;
(c) Test specific gravity or state of charge;
(d) Inspect charger and charge rate; and
(e) Check the equalize charge.
M-3
Inspect the preaction or deluge valve:

(a) Ensure that the valve is free from physical damage;
(b) Ensure that all trim valves are in the appropriate open or closed position;
(c) Ensure that the valve seat is not leaking; and
(d) Ensure that electrical components are in service.
NFPA 25 (Section
12.4.3.1.6)
M-4
Inspect and maintain water spray nozzles:

(a) Ensure that they are in place and continue to be aimed or pointed in the
direction intended in the system design;
(b) Ensure they are free from external loading and corrosion; and
(c) Confirm that any caps or plugs are in place and free to operate as intended.
NFPA 25 (Section
10.2.1.1, 10.2.1.2,
10.2.1.6, 10.2.5.1, &
10.2.5.2)
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Action No.
M-5
Action Required
Reference
Test each automatic fire detection alarm zone:

(a) Check all visual and aural indicators;
(b) Check all control and indicating equipment is clean and in good operating
condition; and
(c) Record results.
AS1851.8-1987.
Table 4.2: Monthly Hydrant and Monitor Requirements

Action No.
Action Required
Reference
M-6
Check hydrant and monitor valves:

(a) Ensure that they are in the correct operating position and that they are
secure and accessible; and
(b) Visually inspect all valves for leaks.
AS1851.4-1992
M-7
Inspect the condition of fire hoses, including fittings. Ensure they are properly
stowed
AS1851.4-1992
M-8
Check that the hydrants have the correct fittings and that they are secure.
AS1851.4-1992
M-9
Check the accessibility of all hydrant cabinets.
AS1851.4-1992
M-10
Check water levels and automatic filling facilities of all water supply tanks.
AS1851.4-1992
Table 4.3: Monthly Foam System Requirements

Action No.
Action Required
Reference
M-11
Perform maintenance on the foam concentrate pump:

Operate the pump and circulate the foam concentrate back to the tank.
NFPA 25 (Sections
11.4.6(a) & 11.4.7(a))
M-12
Inspect and maintain the foam-water discharge devices:

(a) Ensure that they are free from external loading and corrosion;
(b) Ensure that any caps or plugs are in place and free to operate as intended;
(c) Misaligned discharge devices should be adjusted (aimed) by visual means,
and the discharge patterns should be checked at the next scheduled flow
test; and
(d) Verify that the discharge device is approved for the particular foam
concentrates being used.
Table 5.1: Quarterly Pump System Requirements

Action No.
Action Required
Reference
Q-1
Check the operation of all pump isolation valves and non-return valves, including
monitoring valves if fitted.
AS 1851.141996 (Table
7.1)
Q-2
Check that the pressure switch setting is correct.
AS 1851.141996 (Table
7.2)
Q-3
Clean the fuel strainer and the fuel crank case breather.
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Action No.
Action Required
Reference
Q-4
Compression-Ignition or Diesel Engine Checks:

(a) Check the fuel filter;
(b) Run the driver for a minimum period of 30 minutes (This test should be
carried out at a minimum of 60% operating load);
(c) Record the engine operating temperature, oil pressure and tachometer
reading;
(d) Stop the driver and restart using manual start mechanisms; and
(e) Check that exhaust guard is in place.
AS 1851.141996 (Table
8.5.3)
Q-51
Electric motor requirements:

Test the manual starting mechanism.
Q-6
For a hydro-pneumatic accumulator, check that the pressure is the same as

shown on the plate.
AS 1851.141996 (Table
7.2)
Q-7
Battery System Checks:

(a) Clean and tighten the battery terminals;
(b) Inspect wire chafing if battery movement is applicable; and
(c) Semi-annually test and check safety devices and alarms. Semi-annually
clean boxes, panels and cabinets.
(d) Clean and tighten the battery terminals;
(e) Inspect wire chafing if battery movement is applicable; and
(f) Semi-annually test and check safety devices and alarms. Semi-annually
clean boxes, panels and cabinets.
Q-8
Clean the water strainer in the cooling system. Semi-annually test the antifreeze
protection levels.
Q-9
Check the exhaust systems insulation for fire hazards. Semi-annually inspect
the flexible exhaust section.
Table 5.2: Quarterly Deluge System Requirements

Action No.
Action Required
Reference
Q-10
Test each water flow alarm switch and indicators at the panel. Operate the flow
switch test valve and ensure correct operation at indicator panel.
AS 1851.3-1997 (Table
4.1) and
Q-11
Operate and check all system and water supply valves.
AS 1851.3-1997 (Table
4.1)
Q-12
Check that all water supply non-return valves are correctly seated.
AS 1851.3-1997 (Table
4.1)
Q-13
Supervised preaction systems:

The priming water level in supervised preaction systems shall be tested for
compliance with the manufacturers instructions.
NFPA 25 (Section
12.4.3.2.1)
Q-14
Test low air pressure alarms.
NFPA 25 (Section
12.4.3.2.10)
The different available starting sequences for fire pumps should be used on a rotating basis during regular
tests, meaning that each are tested within the required timeframe.
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Action No.
Action Required
Reference
Q-15
Clean the mainline strainer and inspect and clean nozzle strainers:
(a) Mainline strainers (basket or screen) shall be flushed until clear after each
operation or flow test;
(b) Individual water spray nozzle strainers shall be removed, cleaned, and
inspected after each operation or flow test; and
(c) Oil the external alarm water motor.
(d) Mainline strainers (basket or screen) shall be flushed until clear after each
operation or flow test;
(e) Individual water spray nozzle strainers shall be removed, cleaned, and
inspected after each operation or flow test; and
(f) Oil the external alarm water motor.
AS 1851.3-1997 (Table
4.1) and
NFPA 25 (Sections 10.2.7,
10.2.1.7, 10.2.1.8 & 10.2.7)
Q-16
Continuous monitoring of isolation valves:

Where such facilities are installed, ensure that they are operating correctly.
AS 1851.3-1997 (Table
4.1)
Q-17
Operate all pressure-reducing valves:

(a) Check for correct operation under flow conditions; and
(b) Check pressure readings on the low-pressure side of the valves for a
deviation from the original test readings.
AS 1851.3-1997 (Table
4.1)
Q-18
Inspect the drainage for the deluge systems:

Ensure that drainage facilities are not blocked and that retention embankments
or bunds are in good repair.
Q-19
For systems where the sole water supply is through a backflow preventer and/or
pressure reducing valve, perform a drain test:
For such systems, the main drain test of at least one system downstream of the
device should be conducted quarterly (main drain test requirements for other
systems are detailed in the annual tasks (Table 6.2)).
NFPA 25 (Section 12.2.6 &

12.2.6.1)
Q-20
Inspect and maintain system piping, fittings, hangers and supports:

(a) Check for mechanical damage (e.g., broken piping or cracked fittings);
(b) Check for external conditions such as missing or damaged paint, rust and
corrosion;
(c) Check for misaligned or trapped sections;
(d) Check low point drains (automatic or manual);
(e) Check the location of rubber-gasket fittings; and
(f) Water supply piping should be maintained to prevent internal obstructions.
(g) Check for mechanical damage (e.g., broken piping or cracked fittings);
(h) Check for external conditions such as missing or damaged paint, rust and
corrosion;
(i) Check for misaligned or trapped sections;
(j) Check low point drains (automatic or manual);
(k) Check the location of rubber-gasket fittings; and
(l) Water supply piping should be maintained to prevent internal obstructions.
NFPA 25 (Section 10.2.4,

10.2.4.1, 10.2.4.2, 10.2.6.1
& 10.2.6.2)
Q-21
Inspect fire department connections:

(a) Ensure that the fire department connections are visible and accessible;
(b) Ensure that the couplings or swivels are not damaged and rotate smoothly;
(c) Check, clean and lubricate the caps and plugs;
(d) Check that the gaskets are in place and that they are in good condition;
(e) Ensure identification signs are in place;
(f) Ensure that the check valve is not leaking;
(g) Check that the automatic drain valve is in place and operating properly; and
(h) Check that the fire department connection clapper(s) is in place and
operating properly.

and AS 1851.3-1997
(Table 4.1)
Q-22
Test any quick opening devices.
NFPA 25 (Section
12.4.4.2.4)
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Action No.
Action Required
Reference
Q-23
Check the operation of the alarm. Ensure that it is directly linked to the fire
authority.
AS1851.4-1992
Q-24
Test all water flow alarms or valve monitoring system switches.
AS1851.4-1992
Q-25
Check the pressure readings on the low pressure side of the pressure reducing
and pressure limiting valves:
Compare with design operating pressure.
AS1851.4-1992.
Q-26
Semi-annually inspect fire hose reels:

(a) Ensure presence of legible instructions;
(b) Check for leakage;
(c) Check hose runs freely through the guide; and
(d) Check for corrosion or damage.
AS1851.2-1995.
Table 5.3: Quarterly Foam System Requirements

Action No.
Action Required
Reference
Q-27
Inspect and maintain the foam concentrate strainers.
NFPA 25 (Section
11.2.7.2)
Q-28
Ensure that the blow-down valve is closed and plugged.
NFPA 25 (Section
11.2.7.2)
Q-29
Ensure that drainage facilities, such as trap sumps and drainage trenches, are
not blocked and retention embankments or bunds are in good repair.
Table 5.4: Quarterly Ring Main Requirements

Action No.
Action Required
Reference
Q-30
Inspect hose houses:

(a) Repair or replace equipment as necessary;
(b) Ensure the area is accessible.
NFPA 25 (Section 7.2.2.4)
Q-31
Inspect monitor nozzles semi-annually:

(a) Repair any leakage;
(b) Repair and replace any physical damage; and
(c) Clean, replace and lubricate as necessary.
Table 6.1: Annual Pump System Requirements

Action No.
Action Required
Reference
A-1
Check all wiring and connectors to ensure correct functioning:

Tighten connections as required.
AS 1851.141996 (Table
7.1 & 7.2), AS1851.4-1992
and NFPA 25 (Section
8.5.3)
A-2
Overhaul engine cooling system pressure reducing valves.
AS 1851.141996 (Table
7.1)
A-3
Inspect piping for corrosion.
AS 1851.141996 (Table
7.1)
A-4
Check air-release valves.
AS 1851.141996 (Table
7.1)
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Action No.
Action Required
Reference
A-5
Check alignment of pump couplings.
AS 1851.141996 (Table
8.5.3)
A-6
Change the lubricant to the pump bearings, the mechanical transmission

couplings and the right angle gear drive.
A-7
Lubricate mechanical moving parts (excluding starters and relays).
A-8
Check the pump shaft end play.
A-9
Check accuracy of pressure gauges and sensors.

Change or recalibrate when 5% out of calibration.
A-10
Test the trip circuit breaker.
A-11
Calibrate pressure switch settings.
A-12
Change the grease for the motor bearings.
A-13
Clean water and foreign material from the fuel tank.
A-14
Check tank vents and ensure overflow piping is unobstructed.
A-15
Inspect ducting, clean louvers.

Replace if necessary
A-16
Exhaust System Checks:

(a) Test the system for excessive back pressure; and
(b) Visually inspect the exhaust system hangers and supports.
Pump Driver Checks:

(a) Ensure that the circuit-breakers/fuses are of the correct type and rating for
the pump start and operating conditions; and
AS 1851.141996 (Table
7.2)
A-17
(b) With power isolated, check all components for wear.

A-18
Conduct tests on each pump assembly. Tests should be conducted under

minimum, rated, and peak flows of the fire pump. Either of the three following
tests can be used:
(a) Determine the total pump output by measuring the pump suction and
discharge pressures and the flowrate of the water out of a number of hoses;
(b) Determine the total pump output by measuring the pump suction and
discharge pressures and the flowrate of water out through a bypass
flowmeter; or
(c) Determine the total pump output by measuring the pump suction and
discharge pressures and the flowrate of water flowing through a bypass
flowmeter to the pump suction (closed-loop metering).
If the test is normally conducted using test method 3, then every 3 years a test
needs to be conducted using method 1 or 2 instead.
A-19
Conduct preventative maintenance on all components of the pump assembly:

Hydraulics, mechanical transmission, electrical system, controllers, pump motors
and diesel engines should all be maintained in accordance with manufacturer
recommendations.
NFPA 25 (Section 8.5)
A-20
Service electric motor driven pumps as follows;

(a) Ensure that the starting sequence is completed within 30 seconds;
(b) Run the pump for a minimum of 30 minutes. During this period operate the
pump at 0 and 100% of flow characteristics designated for the installation;
(c) Check and record the pressure and the load current for each phase; and
(d) Check that the phase failure alarm is operating correctly.
AS 1851.141996 (Table
7.1)
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Action No.
Action Required
Reference
A-21
Service compression-ignition or diesel engine pumps as follows:

(a) Check and clean or replace engine fuel sludge, sediment trap, fuel filter, oil
filter and the air filter elements;
(b) Remove, inspect and clean the heat exchanger strainer;
(c) Replace the engine oil;
(d) Run the pump for a minimum period of 30 minutes. During this period
operate the pump at 0 and 100% of flow characteristics designated for the
installation; and
(e) Flush engine cooling system and refill using corrosion inhibitor.
(f) Change the oil and the oil filter every 50 hours of operation or annually.
(g) Change the antifreeze and clean the heat exchanger.
(a-e) AS 1851.141996
(Table 7.1) and (f & g)
A-22
Compression-ignition or diesel engine room checks:

(a) Check that the installed heating for maintaining the engine room
temperature above 10C is operating correctly; and
(b) Check the ventilation. (The room temperature should be less than 10C
above ambient temperature).
AS 1851.141996 (Table
7.1)
Table 6.2: Annual Deluge System Requirements

Action No.
Action Required
Reference
A-23
Check that all open discharge devices are clear and operational.
AS 1851.3-1997 (Appendix
C)
A-24
Check the system operating mechanism by activating the automatic and manual
releases.
C)
A-25
Test the water supply to verify that the system pressure/flow requirements are
satisfied.
AS 1851.3-1997 (Table
4.1)
A-26
Operate the alarm valves(s) by opening the remote test valve.

Check that the response time is less than 6 minutes.
AS 1851.3-1997 (Table
4.1)
A-27
Check the condition of the wiring with the brigade/monitoring station.
AS 1851.3-1997 (Table
4.1)
A-28
Physically check all pressure sensors:

Ensure that all components are free of corrosion, securely mounted, correctly
labelled and in working order.
AS 1851.3-1997 (Table
4.1)
A-29
Check auxiliary fire trip and alarm switches:

Ensure that an electric signal is generated at the output of the switch.
AS 1851.3-1997 (Table
4.1)
A-30
Check pump priming tanks:

(a) Check correct operation of automatic filling and starting variants; and
(b) Inspect internally and externally for structural integrity problems, corrosion
and foreign matter.
AS 1851.3-1997 (Table
4.1)
A-31
Alarm valve maintenance:

(a) Fit new alarm valve seating or port seating;
(b) Check and clean valve annulus groove and outlet ports;
(c) Polish and lubricate seating spindle/shaft and check operation of
compensatory valve if fitted; and
(d) Fit a new alarm valve faceplate gasket.
AS 1851.3-1997 (Table
4.1)
WMC Resources Ltd
Page 16 of 21
Action No.
Action Required
Reference
A-32
Test the deluge system:

(a) During the test ensure that all affected personnel, any supervisory service,
the owners representative, the authority having jurisdiction and the fire
department or fire brigade are notified;
(b) Ensure that the water spray fixed systems respond as designed, both
automatically and manually;
(c) Ensure that the heat detection system, operates within 40 seconds (record
times);
(d) Ensure that the flammable gas detection system, operates within 20
seconds (record times);
(e) Record times between operation of detection systems and water delivery;
(f) Check the water discharge patterns from all of the nozzles. Ensure that
they are correctly positioned (In the event of obstructions, retest);
(g) Pressure readings shall be recorded at the hydraulically most remote nozzle
to ensure the water flow has not been impeded;
(h) Record pressure reading at the deluge valve to ensure the water supply is
adequate;
(i) Compare readings to the hydraulic design pressures;
(j) After the full flow test, the water spray system shall be maintained and
returned to service; and
(k) In the case of multiple systems, the maximum number of systems expected
to operate should be tested simultaneously.
NFPA 25 (Section 10.2.1.3,

10.2.1.6 & 10.3)
A-33
Deluge or preaction valve trip test and inspection:

(a) Test at full flow in warm weather;
(b) During the annual trip test clean, replace or repair the interior of the
preaction or deluge valves as necessary; and
(c) During the trip test inspect the detection devices and the interior of the
preaction or deluge valves.
NFPA 25 (Section
12.4.3.2.2, 12.4.3.3.2,
12.4.4.2.2, 12.4.4.3.2
12.4.4.1.5 &
12.4.3.1.7)
A-35
All backflow preventers installed in fire protection system piping shall be tested.
This is normally completed by performing a full flow test.
A-36
Conduct a full operational test of any ultra-high-speed water spray systems:

Ensure that the response time is measured and that it is in accordance with the
requirements of the system.
A-37
Main drain test:

(a) Conduct a main drain test at each water-based fire protection system riser
to determine whether there has been a change in the condition of the water
supply piping and control valves;
(b) Record static and residual water pressures before, during and after the
operation of the fully opened drain valve;
(c) Compare readings with the original and previous tests to determine whether
there has been any deterioration of the water supply; and
(d) Prevent freezing and corrosion by opening ring all low point drains in
aboveground piping or inspect weep holes to ensure they are clear and
unobstructed.
NFPA 25 (Section 12.2.6,

12.2.6.1 & 12.3.3.4)
A-38
Inspect the automatic detectors in the fire system:

(a) Visually inspect all detectors for deterioration;
(b) Remove one detector from each alarm zone and confirm correct fault signal
is registered;
(c) Check the operation of 20% of the heat detectors (all should be checked
within 5 years) and 50% of the flame detectors (all should be checked within
2 years.)
(d) Check the operation of ancillary control facilities;
(e) Check operation of manual call points;
(f) Check power supply supervision alarm; and
(g) Ensure availability of replacement manual call point glasses and tools.
AS 1851.8-1987
WMC Resources Ltd
Page 17 of 21
Table 6.3: Annual Hydrant and Monitor Requirements

Action No.
Action Required
Reference
A-39
Check that every hydrant valve is open in the system and prove the presence of
water at each point.
AS1851.4-1992
A-40
Examine all pipework located in a corrosive atmosphere:

Clean, repaint or replace as required.
AS1851.4-1992 and
AS1851.14-1996
A-41
Check to ensure that all water supply non-return valves are correctly seated.
AS1851.4-1992
AS 2845.1-1998 (where
potable water is used for
hydrant supply)
A-42
Externally check all water storage tanks and take off connections:
Ensure they are in a good condition.
AS1851.4-1992
A-43
Check and lubricate all hydrant stems, caps, plugs and threads.
A-44
Check and lubricate all monitor nozzles.
A-45
Ensure that the monitors and nozzles are clear of obstructions and are
undamaged.
NFPA 1962 (Section 1.2 &

1.3)
A-46
Ensure the proper operation of the monitor shutoff valves (if supplied).

1.3)
A-47
Ensure that all parts associated with the monitor are intact.

1.3)
A-48
Inspect fire hose reels:

(a) Ensure hose can be easily withdrawn in intended direction;
(b) Ensure flow is greater than 0.33 L/s when using the nozzle in jet mode.
AS1851.2-1995.
A-49
Inspect the thread gasket in couplings and nozzles:

Ensure that they are present, tightly fitted and have not deteriorated.
A-50
All monitor nozzles shall be oscillated and moved throughout their full range to
ensure proper operability.
NFPA 25 (Section 7.3.3.2

& 7.3.3)
Table 6.4: Annual Foam System Requirements

Action No.
Action Required
Reference
A-51
Operational test on the complete foam-water system:

(a) Ensure that the foam-water system(s) responds as designed (test both
automatic and manual modes); and
(b) Simulate anticipated emergency events so the response of the foam-water
system(s) can be evaluated.
(c) Ensure that the foam-water system(s) responds as designed (test both
automatic and manual modes); and
(d) Simulate anticipated emergency events so the response of the foam-water
system(s) can be evaluated
A-52
Testing of the foam-water solution (concentration testing):

During the full flow foam test, a foam sample should be checked to verify the
concentration of the solution (Required to be within 10 percent).
NFPA 25 (Section 11.3.6 &

11.2.10)
WMC Resources Ltd
Page 18 of 21
Table 6.5: Annual Ring Main Requirements

Action No.
Action Required
Reference
A-53
Inspect hydrants (wet barrel, dry barrel and wall)

(a) Inspect annually and after each operation;
(b) If a dry barrel hydrant contains water or ice the hydrant must be repaired
and drained;
(c) Repair or replace gaskets, packing, or parts as necessary;
(d) Repair or replace cracks in the hydrant barrel;
(e) Lubricate and tighten outlets if necessary;
(f) Repair or replace worn nozzle threads;
(g) Repair or replace worn hydrant operating nut; and
(h) Ensure operating wrench is available.
NFPA 25 (Section 7.2.2.4

& 7.2.2.5)
A-54
Inspect exposed piping:

(a) Repair any leaks in pipes;
(b) Repair and replace any physical damage;
(c) Coat with corrosion protection if corrosion occurs; and
(d) Repair or replace any restraint methods.
A-55
Test hydrants:
(a) Each hydrant should be opened fully and left open until all foreign material
has cleared;
(b) Flow shall be maintained for not less than 1 minute;
(c) After operation, dry barrel and wall hydrants shall be observed for proper
drainage from the barrel; and
(d) Full drainage shall take no longer than 60 minutes.
A-56
Maintain hose houses:

Ensure that all fire hoses and required components are in a usable condition.
Table 7.1: Pump Systems 2-Yearly Requirements.

Action No.
2yr-1
Action Required
Reference
Biennially change the circuit breakers or fuses.
Table 7.2: Pump Systems 3-Yearly Requirements.

Action No.
Action Required
Reference
3yr-1
Overhaul pressure relief/flow control valves (if fitted).
AS 1851.141996 (Table
7.1)
3yr-2
Compression-ignition or diesel engine checks:

(a) Carry out service procedures in accordance with the manufacturers
instructions; and
(b) Ensure all safety guards are in place and secure.
AS 1851.141996 (Table
7.1)
WMC Resources Ltd
Page 19 of 21
Table 7.3: Deluge Systems 3-Yearly Requirements.

Action No.
Action Required
Reference
3yr-3
Where fitted, renew the main diaphragm in the deluge valve.
C)
3yr-4
Fit new drain and test valve washers and examine seating.
AS 1851.3-1997 (Table
4.1)
3yr-5
Remove the alarm cock barrels, clean, lap in, grease and reinstall.
AS 1851.3-1997 (Table
4.1)
3yr-6
Fit the new pump path cock washers and inspect seatings.
AS 1851.3-1997 (Table
4.1)
3yr-7
Maintain jacking pump path cocks:

Fit the new gland packing for the path cocks, drain and test the cocks, main the
stop valve and hand pump.
AS 1851.3-1997 (Table
4.1)
3yr-8
Maintain direct brigade alarm transmitter:

(a) Clean out well of direct brigade alarm;
(b) Clear the water jet, renew the gasket and flush the drain pipe;
(c) Remove the gear train and check the operation of the main spindle; and
(d) Remove the excess grease and lubricate.
AS 1851.3-1997 (Table
4.1)
3yr-9
Maintain the local water motor alarm:

(a) Clean the strainer on the local alarms;
(b) Clear the water jet, flush the drain and renew the gasket;
(c) Check the operation of the main spindle and striker; and
(d) Remove excess grease and lubricate.
AS 1851.3-1997 (Table
4.1)
3yr-10
Renew the water supply non-return valve seatings and gaskets, check the
seating and spindle.
AS 1851.3-1997 (Table
4.1)
3yr-11
Check the operation of the retard chamber and drain pipe.
AS 1851.3-1997 (Table
4.1)
3yr-12
Check all pressure gauges against a calibrated gauge.
AS 1851.3-1997 (Table
4.1)
3yr-13
Overhaul valves:
Overhaul all pressure-reducing valves, deluge valves and any other special
valves that may be installed in accordance with suppliers specifications.
AS 1851.3-1997 (Table
4.1)
3yr-14
Inspect water storage tanks and associated equipment:

Inspect, internally and externally, for structural integrity, freedom from corrosion
and internal accumulation of foreign matter.
AS 1851.3-1997 (Table
4.1)
3yr-15
Remove, inspect and clean the mainline strainer.
NFPA 25 (Section 10.2.1.8,

& 10.2.7)
Table 7.4: Hydrants and Monitors Systems 3-Yearly Requirements.

Action No.
3yr-16
Action Required
Reference
Water flow and booster tests;

(a) Carry out water flow commissioning and booster tests at all pumps using the
most hydraulically disadvantaged hydrant; and
(b) Operate and test all stop valves and overhaul as necessary.
WMC Resources Ltd
AS1851.4-1992.
Page 20 of 21
Table 7.5: Deluge Systems 5-Yearly Requirements.

Action No.
Action Required
Reference
5yr-1
Internally inspect check valves:

Verify that all components operate correctly, move freely and are in good
condition.
NFPA 25 (Section
12.4.2.1)
5yr-2
Internally inspect the strainers, filters, restricted orifices, and diaphragm

chambers.
NFPA 25 (Section
12.4.3.1.8)
Table 7.6: Foam Systems 5-Yearly Requirements.

Action No.
5yr-3
Action Required
Reference
Maintain and service the foam pumps, drive train, and drivers:
Frequency should be as per manufacturers instructions but not at intervals of
more than 5 years.
NFPA 25 (Section 11.4.6

(b) & 11.4.7 (a and b))
Table 7.7: Ring Main Systems 5-Yearly Requirements.

Action No.
5yr-4
Action Required
Reference
Conduct a flow test on exposed and underground piping:

(a) Determine the internal condition of the piping; and
(b) Conduct the test with flows that are representative of those expected during
a fire.
Table 7.8: Hydrants and Monitors Systems 6-Yearly Requirements.

Action No.
6yr-1
Action Required
Reference
Conduct a hydrostatic test on the system.
AS1851.4-1992.
Table 7.9: Foam Systems 10-Yearly Requirements.

Action No.
10yr-1
Action Required
Reference
Foam concentrate tank maintenance:

(a) The foam tanks should be drained of liquid and flushed (foam liquid may be
reused);
(b) The foam tanks should be inspected for internal and external corrosion and
hydrostatically tested to the specified working pressure; and
(c) Pickup pipes inside the tank should be inspected for corrosion, separation,
or plugging.
WMC Resources Ltd
NFPA 25 (Section 11.4.3

(b & c), 11.4.4 (b), 11.4.5
(a & b) &
11.4.6 (d))
Page 21 of 21

Fire System Testing Requirements Guideline: WMC Environment, Health & Safety Management System

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Fire System Testing Requirements

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WMC Resources Ltd

Guideline Fire System Testing Requirements

TESTING REQUIREMENTS ..................................................................................................... 4

WEEKLY TESTING ................................................................................................................... 4

QUARTERLY TESTING ............................................................................................................ 5

TWO-YEARLY OR GREATER REQUIREMENTS .................................................................... 5

2-Yearly Requirements .......................................................................................................... 5

3-Yearly Requirements .......................................................................................................... 5

5-Yearly Requirements .......................................................................................................... 5

6-Yearly Requirements .......................................................................................................... 5

10-Yearly Requirements ........................................................................................................ 5

APPENDIX A - Tables ...................................................................................................................... 8

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Guideline Fire System Testing Requirements

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WMC Resources Ltd

Guideline Fire System Testing Requirements

Hydrants and Monitors

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WMC Resources Ltd

Guideline Fire System Testing Requirements

TWO-YEARLY OR GREATER REQUIREMENTS

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WMC Resources Ltd

Guideline Fire System Testing Requirements

Australian Standard, AS 1851.8-1987, Maintenance of fire protection equipment Part 8:

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WMC Resources Ltd

Guideline Fire System Testing Requirements

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WMC Resources Ltd

Guideline Fire System Testing Requirements

Check that all required pump spares are on hand.

Complete a general visual inspection of the electrical system.

NFPA 25 (Section 8.5.3)

Check the pump controllers:

Inspect pump house conditions:

NFPA 25 (Section 8.2.2(1))

Inspect fire pump system conditions:

NFPA 25 (Section 8.2.2(2))

Start each pump by using one of the installed starting devices:

Pump start is as per AS

Check the cooling systems:

NFPA 25 (Section 8.5.3)

Check the exhaust systems:

NFPA 25 (Section 8.5.3)

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WMC Resources Ltd

Guideline Fire System Testing Requirements

Check the Electric Motor Systems:

Compression-Ignition System or Diesel Engine Checks:

Check Batteries and Charger: