Quick answers
What is the difference between a main fire pump and a jockey pump?
The main fire pump boosts water flow and pressure when a hydrant, hose reel or sprinkler opens. The jockey pump only keeps the pipes at normal pressure and makes up for small leaks. It cannot do the main pump's job.
Why does the jockey pump keep starting again and again?
Frequent starts usually mean a leak, a faulty non-return valve, a wrong pressure setting or loss of trapped pressure. Find and fix the cause. Do not change the setting just to hide it.
Does starting the fire pump by hand prove it works?
No. A manual start does not test the automatic start, the controller or the remote alarm. A no-flow test also cannot show that the pump delivers its rated flow; only a full-flow test does.
What should be checked after a fire pump test?
Controllers back on Auto, all required valves open and secured, alarms normal, test drains shut, fuel and water topped up, and the system formally signed back into service by a second person.
In most Indian high-rises, malls, hospitals and factories, the hydrants, hose reels and sprinklers depend on a set of pumps in a room in the basement or next to the fire water tank. If those pumps do not start, or cannot push enough water, the whole system on the floors above is useless. Yet the pump room is often the most neglected room in the building. It is dark and damp, used as a store, and visited only when something goes wrong.
What the pumps do
- The main fire pump starts automatically when a hydrant or sprinkler opens and the pressure in the pipes drops. It delivers the flow and pressure the system was designed for. It may run on an electric motor or a diesel engine.
- The standby pump, often diesel, takes over if the main pump or its power supply fails. Its power or fuel, and its suction, must be as independent as the design requires.
- The jockey pump is a small pump that keeps the pipes at normal pressure and makes up for minor leaks, so the main pump does not start for nothing. It cannot do the main pump’s job.
If the jockey pump keeps starting every few minutes, something is wrong. It could be a leak, a faulty non-return valve or a wrong pressure setting. Find the cause. Do not just change the setting to make it stop.
Which rules apply in India
In India, installing and maintaining firefighting pumps is covered by BIS IS 15301:2003, along with the National Building Code, your local fire authority’s conditions, the approved design and the maker’s manual. Some sectors have their own rules, for example PNGRB regulations for petroleum installations and CPWD specifications for government works. The US standard NFPA 25 sets out weekly, monthly and yearly checks, but it applies here only where your authority, insurer or contract adopts it. Find out which schedule applies to your building.
Checks and tests, and what each one proves
Routine checks
Regular walk-round checks look for the things that quietly go wrong: valves not in their correct open position, gauge readings, fuel, oil and coolant levels on the diesel engine, batteries and charger, power supply and phase lights on the electric panel, ventilation, drainage and leaks. The controllers must be on Auto.
Start test (no-flow or churn test)
The pump is started by dropping the pressure, just as a real fire would, and run without water flowing out. This proves the pump starts on its own and runs. It does not prove that it can deliver the required flow. Starting the pump by hand with the button proves even less, because it does not test the automatic start or the alarms.
Full-flow performance test
Every so often, water is let out through a test connection while the technician records suction pressure, discharge pressure, flow, speed and the engine or motor readings. This is usually done at no flow, at rated flow and at the highest test flow the procedure asks for. The results are compared with the pump’s certified curve and with past tests. A pump that is slowly losing performance shows up here, long before it lets you down in a fire. Use calibrated gauges and flow-measuring equipment, and plan where the test water will go.
A diesel engine needs a long enough run to reach its normal temperature, so that any cooling, lubrication, exhaust or battery problems show up.
The last step is the most dangerous
A good test can still leave the building unprotected if, at the end, a valve is left closed, the controller is left on Manual, an alarm is left bypassed or the tank is not refilled. Make the restoration checklist part of the test, and have a second person sign it.
Whenever a pump is out of service for repair, treat it as a gap in fire protection. Tell the people who need to know, put temporary precautions in place, fix it fast and test it again before relying on it.
Keep the pump room fit for purpose
Keep it clean, lit, ventilated and drained. Do not store anything in it. Keep the door, the controller and the valves easy to reach. Put the pump schematic, the certified curve, the pressure settings and the operating instructions up on the wall.
If there is a fire
Raise the alarm, get out and call 101 or 112. Never stop a running fire pump during a fire because it sounds rough or is leaking. Only the incident commander, or the approved emergency procedure, decides that. Do not close any pump valves. Tell the fire brigade which pumps are running, which are out of order, the tank level and any hazards in the pump room.
This week, open the pump room door. Check that the controllers say Auto, the valves are open and the tank is full. Then ask for the last full-flow test report. If nobody can find one, book a test.
What needs attention
- IS 15301:2003 is the Indian code of practice for installing and maintaining firefighting pumps; check for the latest edition and how your authority applies it
- A single NFPA schedule does not fit every site, because diesel and electric pumps, building risks and Indian sector rules can need different intervals
- A no-flow or churn test shows only that the pump starts and runs; it cannot show that it delivers rated flow
- Starting a pump by hand does not prove the automatic pressure start, the controller logic or the remote alarm
- A jockey pump that starts often can point to leaks, non-return valve trouble, wrong pressure settings or loss of trapped pressure
- Low discharge pressure can come from the water source or suction pipe, the pump itself, the engine or motor, or an open test or relief line downstream
- Net pump pressure is worked out from discharge and suction readings; discharge pressure alone can hide a change in the water supply
- Diesel engines need a long enough run to reach a steady temperature and show cooling, lubrication, exhaust and battery problems
- Electric pumps need more than a motor that turns: phase condition, controller power, cables, alternate supply and voltage and current under load all matter
- Flooding, blocked ventilation, heat, rust, poor drainage and stored junk in the pump room can knock out equipment that is otherwise fine
- Yearly performance should be compared with the original certified curve and past results, not judged by whether water came out
- Test gauges and flow-measuring equipment must be suitable and calibrated; wrong instruments can give a false failure or false comfort
- Closing or throttling the wrong valve, running without enough suction, loose hoses and exposed rotating parts can injure testers and damage the system
- The final restoration check is a high-risk step, because a good test can still leave the building unprotected if a valve stays shut or a controller stays on Manual
Controls that reduce risk
- Fix the current pump schematic, certified curve, pressure settings and operating instructions on the pump-room wall
- Keep one record for each main, standby and jockey pump, engine or motor, controller and water source
- Confirm every required suction, discharge and bypass valve is open, secured and clearly labelled
- Keep a count of jockey-pump starts and look into anything unusual
- Write down the actual automatic-start pressures, not just pass or fail
- Log suction and discharge pressure, speed, vibration, temperature and diesel or electrical readings on every run
- Test local and remote alarms all the way to the point where they are received
- Book full-flow tests with calibrated instruments and a safe place for the water to go
- Compare each performance curve with the acceptance test and past results and look into any decline
- Look after diesel fuel quality, batteries, charger, cooling, lubrication, belts, hoses, exhaust and ventilation
- Look after the electric controller power, phase monitoring, connections, motor and alternate supply where provided
- Keep tanks full, refilling working, suction clear and pump rooms drained and easy to reach
- Use a formal impairment permit with notices, temporary precautions, urgent repair and a restoration sign-off
- After any repair, repeat the failed function and any performance tests affected
- Have someone independent check the final valve, controller, alarm, tank and fuel restoration steps
Common unsafe practices
- Treating a fire pump like a household booster pump
- Using one test interval everywhere without checking Indian, local, insurer, maker and sector rules
- Starting the pump by hand and recording it as an automatic-start test
- Calling a no-flow churn test a yearly performance test
- Reading only discharge pressure and ignoring suction, flow, speed and engine or motor readings
- Testing with an uncalibrated meter or damaged gauges
- Running a pump dry, against an unsafe closed valve or without the minimum circulation and cooling it needs
- Allowing loose hoses, uncontrolled test water or water hammer
- Ignoring frequent jockey-pump starts or changing settings to hide a leak
- Resetting overloads, engine alarms or controller faults again and again without finding the cause
- Leaving diesel fuel low, batteries weak, the charger dead or cooling-water strainers blocked
- Using the pump room as a store or blocking access to the controller, valves and equipment
- Servicing one pump without declaring and managing the gap in protection
- Testing without telling the alarm monitoring centre, causing a false response or leaving signals switched off
- Ending the test with a suction or discharge valve closed, the controller on manual, an alarm bypassed or the tank not refilled
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