5 Yearly Hydrant Service & Testing Fire Brigade Booster Flow Testing and Hydrostatic Pressure Testing

View Our Hydrant Booster 5 Yearly Flow Testing Explanatory Video on YouTube

Fire Brigade “Fire Fighting” Operations The Fire Brigade relies on hydrant systems more than any other equipment when fire fighting. “Fire Brigade Boosters” provide a point of attachment for the fire brigade to supply additional water flow/pressure into the hydrant system. Purpose of 5 Yearly Hydrant Service & Testing This test proves the Fire Brigade Booster Assembly and associated on-site pump bypass, valving and piping can sustain firefighting operations. It verifies there are no obstructions or impediments within the system that may restrict water flow/pressure available to the hydrants. Water is pumped through the Fire Brigade Booster to the most hydraulically remote hydrant. This test is critical because over time, pipework and valves will corrode/ deteriorate internally and can subsequently seize or become blocked. As a result, failure of the hydrant booster system may occur.

Figure 1 - 3: A 10-year-old, defective check valve removed from a fire hydrant system

AS1851-2012 (Table 4.4.4) nominates two tests: Item 3: FIRE BRIGADE BOOSTER FLOW TESTING – Simulates Fire Brigade operations when fire fighting, utilising the building’s designed water flows & pressures. This test verifies there are no obstructions or impediments between the booster assembly, the fire pump bypass and the most remote hydrant. This test is often NOT performed but is arguably the most critical. The flows/pressures required through the Fire Brigade Boosters can be substantial – flows that only a fire appliance (or similar) can deliver. Item 4: HYDROSTATIC PRESSURE SERVICE & TESTING – The 5 Yearly service includes replacing all valve seatings, gaskets and washers within the hydrant system. The purpose of the hydrostatic pressure test is to prove the replaced parts and the piping system can sustain the elevated water pressures applied during fire fighting operations. This is a static test and is performed under zero flow conditions and does NOT alone prove the condition of the hydrant system. Difference between Annual Water Supply Proving & the 5 Yearly Booster Flow Test Annual water supply proving verifies each water supply (town’s main, fire pumps, tanks etc) provide the required flow and pressure at the most hydraulically remote hydrant. This test does not encompass the fire brigade booster and the pump bypass – the 5 yearly booster flow tests does. See Figure 4 below depicts the difference between the Annual Water Supply Proving Test & 5 Yearly Booster Flow Testing. Figure 4: AS1851-2012 (Table 4.4.4) Five-Yearly Service Schedule Fire Hydrant Systems

Figure 5: Difference between the Annual Water Supply Proving Test & 5 Yearly Booster Flow Testing.

Why are these tests important? Failure of the hydrant system during a fire emergency could be catastrophic. Over time the hydrant system will deteriorate internally & restrictions do result. We have found many systems with badly corroded/obstructed piping and valving. Water damage caused by a hydrant system piping failure can be substantial. What Is required for issuing an AFSS to Council?

[The system] Was found to be capable of performing to a standard no less than that to which the

measure was originally designed & implemented. After a fire or a system failure, if it is found the system has not been serviced & tested to the recognised standard, then insurance issues and other litigation may result. The same principal is applied to the 5 yearly scheduled servicing of extinguishers & sprinkler alarm valves etc. The test is required by AS1851-2012 and should be conducted within the scheduled year. Why we offer this service? Prior to 2013 no such service was in Sydney/NSW and therefore the fire brigade booster flow test was not done. There was the need for a competent & accountable service which addresses the 5 Yearly Testing of Hydrant Systems. We now have two ex-Fire Brigade appliances and drawing on the expertise of our staff we offer a comprehensive package for this service.

Many fire companies cannot offer this service - we happily offer the use of our “Flow Test Unit” to other fire companies.

SERVICES AFT PROVIDES: • Hydrant Booster Flow Testing • 5-Yearly • Installation Commissioning • Hydrostatic Pressure Testing for existing hydrant systems • Annual Water Supply Proving • To AS1851, AS2419, AS2118.1 & 6 • NSW – Statewide • Offered to other fire companies STUDY 2

Case Study 1 – 5 Yearly Hydrant Testing Medium Rise Residential Building in Sydney, March 2014 AFT Fire performed the 5 yearly “Fire Brigade Hydrant Test” within a medium rise residential building in Sydney’s eastern suburbs.

Details of System and Testing- In accordance with AS1851 (2012), Table 4.4.4, items 4.2 & 4.3

Hydrant System Design: • Block plan not provided • Installation standard • Given the age of the building and system configuration

we assumed: o Ordinance 70 Spec. 10 o Required flow: 22 l/s @ 275kPa

Hydrant System Configuration: • Hydrant Boosters – Tank model booster, 0 x feed

hydrants – town’s main supply • 11 x internal attack hydrants • 1 x electric booster pump at ground level • Most hydraulically remote hydrant – Level 9 Roof Results from the Hydrostatic Pressure Test

Hydrostatic Pressure Test – FAILED

We attempted to pressurise the system to the required 1.5 times the working pressure – 975kPa. The test was aborted at a maximum of 650kPa. At this pressure the check valve on the booster assembly failed – water was then being pumped back into the town’s main. The stop valve on the booster assembly also failed to close.

Results from the Booster Flow Testing Booster Flow Test – PASSED

The system was flow tested via the booster assembly. The system achieved the required pressure and flow rates (same as the annual test) at the most hydraulically remote hydrant.

Resulting Remedial Works Undertaken

• Drafted and affixed • Hydrant System Block Plan • Pressure Gauge Schedule • Water Supply Valve List • System “Working, Test and Boost Pressure” signage • Replaced the failed check valve, stop valve and hydrant booster

Figure 6: Booster System Failing at the Inlet Valve

Case Study 2 – 5 Yearly Hydrant Testing High Rise Commercial Building, Sydney CBD, March 2016 AFT Fire performed the 5 yearly “Fire Brigade Hydrant Test” within a high-rise commercial building in the Sydney CBD. AFT were engaged by a mainstream fire protection services company. The highest hydrant valve is at 81m above ground level and the hydrant system has two pressure zones which are serviced by a Fire Brigade relay pump.

Details of System and Testing- In accordance with AS1851 (2012), Table 4.4.4, items 4.2 & 4.3 Hydrant System Design:

• AS2419.1 (2005) o The system designed working pressures/flows are

provided on the block plan o 20l/s @ 700kpaat the most remote hydrant valve

Hydrant System Configuration: • Fire Brigade Boosters –adjacent the driveway • 2 x feed hydrant – Town’s main supply • Water storage tank supply – 25,000 litres on L19 • 48 x internal attack hydrants • 1 x diesel fire pump at L19 1 x electric fire pump at L19 • Fire Brigade Relay Pump and PRV station – L6 • Most hydraulically remote hydrant –Level 19 and L6

Results from the Hydrostatic Pressure Test

The 2 x zones were pressurised to 1.5 times the working pressure – 1050kpa.

1) Lower Pressure Zones: PASSED 2) Upper Pressure Zone: PASSED

Results from the Booster Flow Testing

The 1st booster flow was conducted as per standard procedures and FAILED. The system was flowed via the boosters the feed the relay pump on level 6 too achieve the required flow and pressure at the most hydraulically remote hydrant. This was producing excessively high and unsafe pressure and the test was aborted. It appeared that pipe configuration caused the pump to boost in a loop and over pressurised the system. The 2nd test was conducted as follows and PASSED. The system was flowed via the boosters to feed the relay pump on level 6 to achieve the required flow and pressure at the most hydraulically remote hydrant. To prevent the relay pump from over pressurising the system the stop valves above the pressure relief valves were closed. This ensured the pump did not feed itself and relied solely on water fed from the boosters in the driveway. The measured system working pressure was 700kPa at the boosters to achieve the required pressure at the inlet of the Fire Brigade relay pump on L6. The relay pump provided the most hydraulically remote hydrants (L19) with 20l/s @ 700kpa. The L6 hydrant valve (fed off the tank and PRV station) was flow tested and achieved the required flow/pressure.

Conclusion of Findings

The System Failed the Test The system had been generally installed to the requirements of AS2419.1 (2005). The original installation could not have been commissioned to the requirements of AS2419.1 (utilising the boosters) – the deficiencies encountered during our testing would have been identified at that time. The Fire Brigade could not effectively operate the relay booster system, in its current state, without manipulating certain isolation valves in a specific sequence. Recommendations 1) Seek Fire Brigade approval to post instructions at the boosters and in fire control centre detailing the

required boosting procedure and the sequence of valve closers required to operate the boosting system via the relay pump.

OR 2) Install additional piping and reconfigure the water supply pipework servicing the relay booster pump.

This would avoid the need for complicated valve manipulation during boosting by the Fire Brigade. Additionally: Installation of a pressure gauge above the pressure relief valve (relay pump) to show the true system pressure when boosting as per AS 2419.1-2005. Provide a working pressure sign that states “working pressure of 700kPa -when boosting with the onsite relay pump running”

CASE STUDY 1