Pumping Apparatus Driver/Operator —
Lesson 16
Pumping Apparatus Driver/Operator
Handbook, 2nd Edition
Chapter 16 — Apparatus Testing
Learning Objectives
1. Select facts about various preservice tests.
2. List the minimum pumper service tests
required by NPFA 1911.
3. Select facts about the site considerations for
pumper service tests.
(Continued)
Pumping Apparatus Driver/Operator
16–1
Learning Objectives
4. State the equation for determining the
correct pump discharge pressure for pump
service tests.
5. Calculate corrected net pump discharge
pressure.
6. List equipment needed to perform pumper
(Continued)
service tests.
Pumping Apparatus Driver/Operator
16–2
Learning Objectives
7. List equipment recommended, but not
required, to perform pumper service tests.
8. State the safety precautions to be followed
when performing fire pump service testing.
9. Perform an engine speed service test.
(Continued)
Pumping Apparatus Driver/Operator
16–3
Learning Objectives
10. Perform a vacuum service test.
11. Perform a hard intake hose service test.
12. Prepare the pumper and perform a pumper
service test.
(Continued)
Pumping Apparatus Driver/Operator
16–4
Learning Objectives
13. Perform a pressure control service test.
14. Perform discharge gauge and flowmeter
operational service tests.
15. Perform a tank-to-pump flow service test.
(Continued)
Pumping Apparatus Driver/Operator
16–5
Learning Objectives
16. Select facts about reviewing test results.
17. List causes of problems that may occur
during service testing.
18. Perform foam proportioning equipment
service tests.
Pumping Apparatus Driver/Operator
16–6
Manufacturer’s Tests
• If the requirements of NFPA 1901 are included
in the apparatus bid specifications, the
manufacturer is required to perform two
specific tests in addition to the pump
certification tests discussed later. These two
tests are the road test and the hydrostatic
test.
Pumping Apparatus Driver/Operator
16–7
Road Tests
• Road tests must be conducted on the fire
apparatus after its construction is complete.
• The apparatus should be fully loaded in the
same manner as it would be once in service.
(Continued)
Pumping Apparatus Driver/Operator
16–8
Road Tests
• Road tests should be conducted in a location
and manner that will not violate any
applicable traffic laws or motor vehicle codes.
• The test surface should be a flat, dry, paved
road surface that is in good condition.
(Continued)
Pumping Apparatus Driver/Operator
16–9
Road Tests
• At a minimum:
– The apparatus must accelerate to 35 mph (56
km/h) from a standing start within 25 seconds.
This test must consist of two runs, in opposite
directions, over the same surface.
– The apparatus must achieve a minimum top speed
of 50 mph (80 km/h). This requirement may be
dropped for specialized wildland apparatus not
designed to operate on public roadways.
(Continued)
Pumping Apparatus Driver/Operator
16–10
Road Tests
• At a minimum:
– The apparatus must come to a full stop from 20 mph
(32 km/h) within 35 feet (10.7 m).
– The apparatus parking brake must conform to the
specifications listed by the braking system
manufacturer.
• Beyond minimums, road tests are specific to
the department taking delivery.
Pumping Apparatus Driver/Operator
16–11
Hydrostatic Tests
• The hydrostatic tests determine whether the
pump and pump piping can withstand
pressures normally encountered during fire
fighting operations.
• Pumps are tested hydrostatically at 250 psi
(1 725 kPa) for three minutes.
(Continued)
Pumping Apparatus Driver/Operator
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Hydrostatic Tests
• The tank fill line, tank-to-pump line, and bypass line valves should be closed during this
test.
• Discharged valves should be opened and
capped.
(Continued)
Pumping Apparatus Driver/Operator
16–13
Hydrostatic Tests
• Intake valves should be closed and/or capped.
• The test pressure should be maintained on the
system for a minimum of three minutes
without the failure of any component of the
system.
Pumping Apparatus Driver/Operator
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Pump Certification Tests
• Pump certification tests are performed to
make sure that the fire pump system operates
in the manner for which it was designed after
the pump and components are installed on
the apparatus chassis.
• These tests must be conducted by an
independent testing organization, such as
(Continued)
Underwriters Laboratories.
Pumping Apparatus Driver/Operator
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Pump Certification Tests
• These tests are conducted either at the
manufacturer’s plant or at the fire department
after delivery.
• These tests assure both the fire department
and the insurance companies that the
apparatus will perform as expected after being
placed into service.
(Continued)
Pumping Apparatus Driver/Operator
16–16
Pump Certification Tests
• The results of these tests are required to be
stamped into a plate that is affixed to the
pump panel of the apparatus.
• These tests must be required in the apparatus
bid specifications, either by referencing NFPA
1901 or by specific wording.
(Continued)
Pumping Apparatus Driver/Operator
16–17
Pump Certification Tests
• NFPA 1901 requires the following pump
certification tests for apparatus that are
equipped with a 750 gpm (3 000 L/min) or
larger fire pump:
– Pumping test
– Pumping engine overload test
– Pressure control system test
– Priming device test
(Continued)
Pumping Apparatus Driver/Operator
16–18
Pump Certification Tests
• NFPA 1901 requires the following pump
certification tests for apparatus that are
equipped with a 750 gpm (3 000 L/min) or
larger fire pump (continued):
– Vacuum test
– Water tank-to-pump flow test
– Internal intake pressure relief valve test (if so
equipped)
(Continued)
Pumping Apparatus Driver/Operator
16–19
Pump Certification Tests
• Apparatus equipped with a fire pump that has
a rated capacity of less than 750 gpm (3 000
L/min) are required to undergo the same
certification tests, with the exception of the
pumping engine overload test.
Pumping Apparatus Driver/Operator
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Acceptance Testing
• These tests are conducted to assure the
purchaser that the apparatus meets bid
specifications at the time of delivery.
• A representative of the manufacturer is
present during testing.
(Continued)
Pumping Apparatus Driver/Operator
16–21
Acceptance Testing
• The types of tests and test criteria vary widely
with local jurisdiction preference and
conditions.
• These tests should include another pump test,
even if a certification test was performed at
the factory.
(Continued)
Pumping Apparatus Driver/Operator
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Acceptance Testing
• If the apparatus fails to perform according to
the requirements detailed in the bid
specifications, it should be rejected.
Pumping Apparatus Driver/Operator
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Minimum Pump Service Tests
Required by NFPA 1911
• Engine speed check
• Priming device tests
• Vacuum test
• Pumping test
• Overload test
(Continued)
Pumping Apparatus Driver/Operator
16–24
Minimum Pump Service Tests
Required by NFPA 1911
• Pressure control test
• Gauge and flowmeter test
• Tank-to-pump flow rate test
• Internal intake pressure relief valve test (if so
equipped)
Pumping Apparatus Driver/Operator
16–25
Site Considerations for
Pumper Service Tests
• NFPA 1911 says that pumper service tests may
be conducted using either a fire hydrant or
static body of water as a supply source. Most
jurisdictions prefer to draft from a static
source during testing because this is a true
test of the pump’s capability.
(Continued)
Pumping Apparatus Driver/Operator
16–26
Site Considerations for
Pumper Service Tests
• When using a static water supply source, the
water must be at least 4 feet (1.2 m) deep.
The strainer must be submerged at least 2 feet
(0.6 m) below the surface of the water. The
surface of the water may be no more than 10
feet (3 m) below the centerline of the pump
intake, and 20 feet (6 m) of hard intake hose
should be used for drafting during testing.
(Continued)
Pumping Apparatus Driver/Operator
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Site Considerations for
Pumper Service Tests
(Continued)
Pumping Apparatus Driver/Operator
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Site Considerations for
Pumper Service Tests
• The atmospheric air temperature during
testing should be between 0ºF and 100ºF
(-18ºC and 38ºC).
• The water being used for testing should be
between 35ºF and 90ºF (2ºC and 32ºC)
because hotter water has less surface tension
and could affect test results.
(Continued)
Pumping Apparatus Driver/Operator
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Site Considerations for
Pumper Service Tests
• The barometric pressure should be at least
29 in.Hg (98.2 kPa), corrected to sea level.
(Continued)
Pumping Apparatus Driver/Operator
16–30
Site Considerations for
Pumper Service Tests
• Table 16.1 on page 487 shows the minimum
hard intake hose arrangements that are
necessary to perform tests on pumps of
varying capabilities. These figures are good for
tests that are performed at altitudes of up to
2,000 feet (610 m) above sea level.
(Continued)
Pumping Apparatus Driver/Operator
16–31
Site Considerations for
Pumper Service Tests
• Beyond that figure, it may be necessary to
increase intake hose diameter or the number
of intake hoses used to pump the rated
capacity. Altitude affects pump performance:
lifting ability drops about 1 foot (0.3 m) per
1,000 feet (300 m) increase in altitude;
gasoline engines have 3.5 percent less
efficiency per 1,000 feet (300 m) increase in
(Continued)
altitude.
Pumping Apparatus Driver/Operator
16–32
Site Considerations for
Pumper Service Tests
• It is also necessary to lay out a sufficient
number of discharge hoses and nozzles to
pump the rated capacity of the fire pump;
2½-inch (65 mm) hose is the minimum size
hose that may be used for this application.
Larger hoses may be used if available.
(Continued)
Pumping Apparatus Driver/Operator
16–33
Site Considerations for
Pumper Service Tests
• Scribe a mark where
the hose and
couplings meet. While
the pump testing is
proceeding, regularly
check the couplings to
make sure that the
hose is not starting to
pull loose of the
coupling.
Pumping Apparatus Driver/Operator
(Continued)
16–34
Site Considerations for
Pumper Service Tests
• If the scribe mark
moves more than
3/8-inch (9.5 mm)
away from the
coupling, stop the
test and replace
the hose.
Pumping Apparatus Driver/Operator
(Continued)
16–35
Site Considerations for
Pumper Service Tests
• Tables 16.2 a and b on page 488 show the
minimum hose and nozzle arrangements
needed to discharge sufficient water for
various size pumps being tested.
Pumping Apparatus Driver/Operator
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Determining Correct Pump Discharge Pressure
for Pump Service Tests
• Customary
Pressure correction =
Lift (ft.) + intake hose friction loss
2.3
(Continued)
Pumping Apparatus Driver/Operator
16–37
Determining Correct Pump Discharge Pressure
for Pump Service Tests
• Metric
Pressure correction =
Lift (m) + intake hose friction loss
0.1
Pumping Apparatus Driver/Operator
16–38
Equipment Needed to Perform
Pumper Service Tests
• A gauge to check the pump intake pressure
– This gauge should have a range of 30 in.Hg (100
kPa) to zero for a vacuum gauge, or 30 in.Hg
vacuum to 150 psi (1 050 kPa) for compound
gauges.
• A gauge to check the pump discharge
– This gauge should be capable of a range from at
(Continued)
least 0 to 400 psi (0 kPa to 2 800 kPa).
Pumping Apparatus Driver/Operator
16–39
Equipment Needed to Perform
Pumper Service Tests
• Pitot tube with knife edge and air chamber
rated at least from 0 psi (kPa) to 160 psi
(1 110 kPa).
– This is not needed if a flowmeter is used.
• Straight stream nozzles of correct sizes to
match the volumes pumped for the different
tests.
– If a flowmeter is used, fog nozzles may be used
(Continued)
provided they are rated for the necessary flows.
Pumping Apparatus Driver/Operator
16–40
Equipment Needed to Perform
Pumper Service Tests
• Rope, chain, or test stand for securing test
nozzle(s)
• Revolution counter or hand tachometer
• Fire department or insurance agency forms
Pumping Apparatus Driver/Operator
16–41
Equipment Recommended to
Perform Pumper Service Tests
• Two 6-foot (2 m) lengths of ¼-inch (7 mm),
300 psi (2 100 kPa) hose with screw fittings
– These are used to connect the test gauges to the
test gauge fittings at the pump operator’s panel.
• Clamp to hold pitot tube to test nozzle
(Continued)
Pumping Apparatus Driver/Operator
16–42
Equipment Recommended to
Perform Pumper Service Tests
• Test stand for gauges
• Thermometer
• Stopwatch or watch with sweep second hand
Pumping Apparatus Driver/Operator
16–43
Safety Precautions to be Followed When
Performing Fire Pump Service Testing
• All personnel should wear protective headgear
and hearing protection (if exposed to noise in
excess of 90 dB).
• Prevent water hammer: Open and close all
valves and nozzles slowly.
(Continued)
Pumping Apparatus Driver/Operator
16–44
Safety Precautions to be Followed When
Performing Fire Pump Service Testing
• Do not stand over or straddle hose.
• Manipulate the engine throttle slowly. Prevent
sudden pressure changes, which can damage
equipment and injure personnel.
• Tie down test nozzles and devices securely.
(Continued)
Pumping Apparatus Driver/Operator
16–45
Safety Precautions to be Followed When
Performing Fire Pump Service Testing
• Cover all open manholes at the test pit.
• Be aware of the location of all personnel in
the test area in relation to hoselines.
Pumping Apparatus Driver/Operator
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Reviewing Test Results
• At no time during the tests should the
pumping system or pumping engine show
signs of overheating, power loss, or any other
mechanical problems.
• All fluid levels should again be checked and
any losses noted.
(Continued)
Pumping Apparatus Driver/Operator
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Reviewing Test Results
• All calculations and figures determined during
the tests should be recorded so that they may
be filed according to departmental recordkeeping procedures.
(Continued)
Pumping Apparatus Driver/Operator
16–48
Reviewing Test Results
• If the fire pump tests to less than 90 percent
of its capabilities when it was new and
underwent certification testing, two options
are available:
– Take the pump out of service and restore it to its
designed capabilities (preferred option).
– Give the pump a lower rating based on the test
results of its actual performance.
Pumping Apparatus Driver/Operator
16–49
Causes of Problems that May
Occur During Service Testing
• Transmission in wrong gear
• High gear lockup not functioning (automatic
transmission)
• Clutch slipping
• Engine overheating
Pumping Apparatus Driver/Operator
(Continued)
16–50
Causes of Problems that May
Occur During Service Testing
• Muffler clogged
• Tachometer inaccurate
• Engine governor malfunctioning
• Intake hose too small
(Continued)
Pumping Apparatus Driver/Operator
16–51
Causes of Problems that May
Occur During Service Testing
• Intake strainer submerged incorrectly
• Intake screens clogged
• Wrong strainer is being used for that type of
hose
• Lift is higher than 10 feet (3 m)
Pumping Apparatus Driver/Operator
(Continued)
16–52
Causes of Problems that May
Occur During Service Testing
• Intake hose clogged or inner lining collapsed
• Excessive air leaks at intake side of pump
• Pump impellers are clogged
• Pump or intake hose not fully primed
(Continued)
Pumping Apparatus Driver/Operator
16–53
Causes of Problems that May
Occur During Service Testing
• Relief valve or pressure governor
malfunctioning
• Transfer valve in wrong position
• Inaccurate gauges
(Continued)
Pumping Apparatus Driver/Operator
16–54
Causes of Problems that May
Occur During Service Testing
• Pitot tube partially clogged
• Nozzle too large
• Seized turbocharger
• Excessive wear on impeller clearance rings
Pumping Apparatus Driver/Operator
16–55
Summary
• Preservice tests are conducted prior to the
apparatus being delivered, and usually do not
involve fire department personnel.
• Once delivered, fire department pumpers are
tested again before being placed into service,
and driver/operators may or may not be
involved in this testing.
(Continued)
Pumping Apparatus Driver/Operator
16–56
Summary
• Once in service, pumping apparatus are tested
at least annually to ensure continued
acceptable performance. Fire department
driver/operators are often directly involved in
these annual service tests.
(Continued)
Pumping Apparatus Driver/Operator
16–57
Summary
• Fire department driver/operators must be
familiar with the preservice testing
procedures, and be capable of conducting or
assisting with annual service tests.
(Continued)
Pumping Apparatus Driver/Operator
16–58
Summary
• To perform these duties adequately,
driver/operators must be familiar with
correcting net pump discharge pressure for
tests, the sequence of tests, equipment
needed, safety precautions, and possible
causes of trouble during the tests.
Pumping Apparatus Driver/Operator
16–59