Fire Pump Inspection Checklist: NFPA 20 and NFPA 25 for Saudi Arabia

Pump types in a typical installation

• Electric duty pump — the primary fire pump, driven by an AC motor through a controller with automatic transfer from utility to a backup source where required.
• Diesel backup pump — required where reliable utility power cannot be guaranteed, with its own fuel tank, batteries, and engine controller.
• Jockey (pressure maintenance) pump — a small pump that maintains system pressure and prevents the duty pump from cycling on minor leaks.

Weekly inspections

NFPA 25 requires a weekly visual and functional check that includes both a no-flow (churn) test for diesel pumps and a visual review of the room.

Pump room walk-through

• Verify pump room temperature is maintained (NFPA 20 minimum 4 °C / 40 °F to prevent freezing).
• Confirm ventilation louvres and exhaust paths are clear.
• Inspect for water leaks at packing glands, flanges, and gauges.
• Verify all valves on the suction and discharge sides are in their normal operating position (open or closed as designed) and chained where required.
• Read suction and discharge gauges and record values.

Diesel pump weekly churn test

• Start the pump from the controller and let it run for at least 30 minutes.
• Verify oil pressure, water temperature, and engine speed are within the manufacturer values.
• Check the fuel tank level — NFPA 20 requires a minimum of 1 US gallon per HP plus 5%, kept topped up.
• Verify the battery charger is operating and battery voltage is stable.
• Record any unusual noise, vibration, or exhaust colour.

Electric pump weekly check

NFPA 25 permits a no-flow test on electric pumps every month rather than every week, but a weekly visual inspection of the controller and pump unit is still required.

Monthly inspections

• Run the electric pump in churn for at least 10 minutes and record suction and discharge pressures.
• Verify controller signal lamps, alarms, and remote indication work as designed.
• Check all auxiliary devices: low suction pressure switch, high water level alarm, jockey pump operation.
• Inspect the jockey pump cycle count — frequent cycling indicates a leak or failed check valve.
• Verify diesel battery specific gravity and electrolyte level for flooded cells; lithium and AGM batteries follow manufacturer instructions.

Annual flow test

The annual flow test is the most important single event in a fire pump’s year. It is also the one that fails most often when prior maintenance has been weak. The procedure verifies that the pump can deliver its rated capacity at rated pressure and 150% of rated capacity at not less than 65% of rated pressure — its performance curve.

1. Coordinate the test with the building owner and notify any monitoring station to prevent a false alarm response.
2. Connect calibrated flow meters or use the test header with hose monitors and pitot gauges.
3. Operate the pump at three points: churn, 100% rated flow, and 150% rated flow.
4. Record suction pressure, discharge pressure, flow rate, RPM, voltage and current (electric) or RPM and oil/water temperatures (diesel) at each point.
5. Compare the measured curve against the original factory test curve. A significant drop indicates wear, an obstructed suction, or a degraded driver.
6. Restore valves to normal position, reset the controller, and document the test in the AMC file uploaded to Salamah.

Common reasons fire pumps fail inspection

• Closed isolation valves on the suction or discharge side. A single closed valve will defeat the entire pump, and it is one of the most frequent findings.
• Air-locked suction caused by a leaking suction line or empty suction reservoir.
• Diesel battery weakness — the engine cranks but does not start within the required time.
• Stale fuel. Diesel that has been sitting for more than a year should be tested or replaced.
• Worn pump impeller or wear rings causing a flatter performance curve.
• Controller faults that prevent automatic start.
• Missing or out-of-date weekly and monthly test records.

Lifecycle and major maintenance

• Replace diesel batteries every 2 to 3 years regardless of apparent condition.
• Service the diesel engine per the engine manufacturer schedule, typically annually for oil and filters.
• Inspect packing glands every 6 months and adjust to limit drip rate to NFPA 25 values.
• Replace mechanical seals as needed when leakage exceeds the allowable rate.
• Plan a full pump overhaul on a 10-year cycle for installations approaching that age.