Fire Pump Replacement, Our Second Opinion

A manufacturing risk with high piled rack storage had a fire pump to support their sprinkler system. The fire pump was tested and the insurance company reviewed the test results and determined that the pump did not reach the final test point. Since the pump “failed” its test, the insurance carrier recommended the pump be replaced. This would be a six-figure cost, and the carrier wanted an answer in thirty days. We received a copy of the recommendation letter and offered to review the situation.

What was the Issue?

The fire pump has three test points.

1. Churn when no water flows, and the pressure should be 120% of the rated pressure

2. Rated flow and pressure

3. 150% flow at 65% rated pressure

This pump failed to produce 150% flow and 65% pressure. The system ran out of water.

Potential causes would be a degraded water supply from the city. We had access to the original plans and calculations. We reached out to the water department, and they confirmed that the test flows and pressures from the original installation were consistent with current conditions. We placed a pressure recording meter on the system for a week to verify that there were no significant pressure fluctuations. No issue was found.

Another possibility was that the backflow preventer failed and was causing a restriction. The firm that tested the backflow devices was contacted and a second test was performed. The backflow device performed as designed.

Comparing water pressures at the test hydrant and the intake of the fire pump showed a significant loss of pressure. These was enough pressure loss to be equivalent to 700 feet of pipe. The distance was less than 100 feet. We asked the city to bring out a locating crew to trace the underground pipe from the fire pump to the street. The locating crew identified a valve that was not on the plans between the hydrant and the city connection for the sprinkler system. The water department used a hydra - vac truck to expose the valve sleeve and found the valve was partially closed. A crew member recalled that the valve was used for repairs on the street within the last year, The cover was not returned, and the valve was buried.

The fire pump test was repeated with the valve open, and the test was successful. Copies of the investigation and new pump test were provided to the insurance company who withdrew their recommendation.

The Driehaus Difference

Our agency has in-house expertise to help clients with complex risk control recommendations and issues. We publish articles for our clients on fire pumps to educate our clients on risk management topics. We want our clients to have the tools and information to make the right choices.

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