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WMC Resources Ltd WMC has developed this document for internal use, specific to circumstances and conditions within its operations. It is intended to provide general information and its applicability to external parties may therefore be limited. WMC makes no representations as to the applicability of the information for use by any party other than WMC and should not be relied upon as such. WMC provides no representation or warranty as to safety or business outcomes arising from application of this document and its requirements by third parties.
CONTENTS
1 2 3 4 5 6 7 8 PURPOSE ................................................................................................................................. 3 GENERAL.................................................................................................................................. 3 TESTING REQUIREMENTS ..................................................................................................... 4 WEEKLY TESTING ................................................................................................................... 4 MONTHLY TESTING................................................................................................................. 4 QUARTERLY TESTING ............................................................................................................ 5 ANNUAL TESTING.................................................................................................................... 5 TWO-YEARLY OR GREATER REQUIREMENTS .................................................................... 5
8.1 8.2 8.3 8.4 8.5 2-Yearly Requirements .......................................................................................................... 5 3-Yearly Requirements .......................................................................................................... 5 5-Yearly Requirements .......................................................................................................... 5 6-Yearly Requirements .......................................................................................................... 5 10-Yearly Requirements ........................................................................................................ 5
9 10
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PURPOSE
The Purpose of this Guideline is assist WMC operations in complying with the requirement for a fire protection management plan as detailed in the WMC EHS Management System Standard, Crisis and Emergency Preparedness (WMC-EHS-STD-006).
GENERAL
This Guideline provides a summarised description of the relevant testing, inspection and maintenance requirements for fire protection systems. The requirements have been compiled from relevant Australian Standards (AS) and National Fire Protection Association (NFPA) standards. These standards include requirements for the following: Fire pumps Monitors and hydrants Deluge systems Foam systems; and Fire ring mains. The testing intervals described in the tables in the following sections are based on the maintenance requirements of the various systems. Requirements for small fire protection items such as fire blankets and fire extinguishers have not been addressed in this guideline. It should be noted that often standards specify prescriptive requirements to address a particular item. These may not necessarily be practical in given circumstances or may be superseded by advances in design. In cases such as these, the main focus is on meeting the performance requirement or desired outcome of the standard. The standards often provide guidance or suggest alternative testing or inspection methods for different or unusual designs. In the event that a particular task cannot be completed due to design or other external factors, then the referenced standard should be reviewed before contemplating a solution. The inspection, testing and maintenance routines have been sorted into different frequency intervals. The following frequency intervals are used: Weekly Monthly Quarterly Annual; and Two yearly or greater.
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The testing requirements are further split from the above headings into subsections. subsections are divided into tables for the following systems: Hydrants and Monitors Fire Pumps Foam Systems Deluge Systems; and Ring Mains.
These
TESTING REQUIREMENTS
Each operation should review the following tables and identify the requirements that are applicable to their fire protection systems. Certain requirements listed in the tables in this guideline may not be relevant to a particular sites fire protection system. In this event they may be disregarded however a note made to substantiate this decision. Once requirements have been identified and agreed upon the specific testing and inspection requirements should be entered into the WMC SAP maintenance module. The record in SAP should contain the actual test required, the piece of equipment for which it is intended, the level of performance required and the organisational position that has responsibility for performing the test or inspection. Completed inspections and tests should be entered into SAP together with any maintenance performed on the fire protection equipment. NOTE: A procedure or similar document, stipulating who needs to be contacted and what additional precautions need to be taken prior to any inspection, testing, or maintaining of fire protection equipment is performed should be available and communicated to responsible personnel.
WEEKLY TESTING
Weekly tasks that are required for the pump and deluge systems are listed in Table 3.1 and Table 3.2 respectively.
MONTHLY TESTING
Monthly tasks that are required for the pump systems, deluge systems, foam systems and hydrant and monitors systems are listed in Table 4.1, Table 4.2 and Table 4.3 respectively.
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Quarterly tasks that are required for the pump system, deluge system, hydrants and monitors, foam system, and ring main are listed in Table 5.1, Table 5.2, Table 5.3 and Table 5.4. It is also worth noting that certain subtasks listed at the end of the Pump System Table (Table 5.1) and the Deluge System Table (Table 5.2) only need to be performed semi-annually.
ANNUAL TESTING
Annual tasks that are required for the pump system, deluge system, hydrants and monitors, foam system and ring main are listed in Table 6.1, Table 6.2, Table 6.3, Table 6.4 and Table 6.5 respectively.
8
8.1
2-Yearly tasks that are required for the pump system are listed in Table 7.1.
8.2 3-Yearly Requirements
3-Yearly tasks that are required for the pump system, deluge system and hydrants and monitors systems are listed in Table 7.2, Table 7.3 and Table 7.4 respectively.
8.3 5-Yearly Requirements
5-Yearly tasks that are required for the deluge system, foam systems and ring main systems are listed in Table 7.5, Table 7.6 and Table 7.7 respectively.
8.4 6-Yearly Requirements
6-Yearly tasks that are required for the hydrants and monitors systems are listed in Table 7.8.
8.5 10-Yearly Requirements
10-Yearly tasks that are required for the foam systems are listed in Table 7.9.
REFERENCES
Fire System Testing Requirements, Moduspec Australia. Ref 350-57 release 01, March 2004 Australian Standard, AS 1851.3-1997, Maintenance of fire protection equipment Part 3: Automatic fire sprinkler systems , Standards Australia, Third Edition, 1997. Australian Standard, AS 1851.2-1995, Maintenance of fire protection equipment Part 2: Fire hose reels, Standards Australia, Fourth Edition, 1995. Australian Standard, AS 1851.4-1992, Maintenance of fire protection equipment Part 4: Fire hydrant installation, Standards Australia, Third Edition, 1992.
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Australian Standard, AS 1851.8-1987, Maintenance of fire protection equipment Part 8: Automatic fire detection and alarm systems, Standards Australia, First Edition, 1987. Australian Standard, AS 1851.14-1996, Maintenance of fire protection equipment Part 14: Pumpset systems, Standards Australia, First Edition, 1996. NFPA 25. Standard for the Inspection, Testing, and Maintenance of Water-Based Fire Protection Systems, National Fire Protection Association (NFPA), Quincy, Massachusetts, 2002. NFPA 1962. Standard for the Care, Use, and Service Testing of Fire Hose Including Couplings and Nozzles, National Fire Protection Association (NFPA), Quincy, Massachusetts, 1998.
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10
APPENDICES
Tables
Appendix A
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W-5
W-6
W-7
Pump start is as per AS 1851.14 1996 (Table 7.1) and Pump test is as per NFPA 25 (Section 8.3.1), and AS1851.4-1992
W-8
W-9
Page 8 of 21
Action Required Check the Electric Motor Systems: (a) Ensure that all safety guards are in place and secure; (b) Ensure pump starts at the nominated start signal and where valid, check starting pressure; (c) Ensure pump operates at correct shut-off pressure; (d) Ensure pump gland and drain or mechanical seal operate efficiently; (e) Ensure excessive vibration or noise are not evident; (f) Ensure both local and remote pump running alarms and lights operate; (g) If alternative power supplies are provided, run the pump(s) continuously for a minimum of 3 minutes off each alternative supply; and (h) Ensure that the circulation relief valve operates and is water tight under normal operating pressure when deluge systems are being tested. Compression-Ignition System or Diesel Engine Checks: (a) Ensure all safety guards are in place and secure; (b) Ensure that the pump starts at the nominated start signal and where valid, check the starting pressure; (c) Check the water, oil and fuel levels; (d) Inspect and test the fuel tank float switch; (e) Ensure pump operates at the correct shut-off pressure; (f) Ensure that an out-of-balance problem is not evident; (g) Ensure running speed is correct; (h) Ensure water, oil and fuel leaks are not evident and fittings on ancillary equipment are secure; (i) Check that the battery charging alternator/generator operates correctly; (j) Ensure that the engine stop mechanism automatically returns to the start position; (k) Ensure that the pump casing air relief valve operates correctly; (l) Ensure that the battery charger power failure alarm operates correctly; (m) Ensure that the circulation relief valve operates; (n) Inspect and test the solenoid valves operation; (o) Ensure cooling water is discharging visibly (heat exchanger cooled engines only); (p) Inspect flexible hoses and connections; and (q) Check the lube oil heater. Check Batteries and Charger: (a) Check that the battery complies with details on identification plate fitted to the enclosure; (b) Check battery for corrosion, physical damage, and security; (c) Check battery enclosure for corrosion, and the ingress of water, dust and insects; (d) Check float voltage of the battery and record; and (e) Check electrolyte level. After completion of maintenance procedures return all equipment to the operational condition and record observations in a maintenance log.
W-11
(a-n) AS 1851.141996 (Table 7.1) and (d and o-q) NFPA 25 (Section 8.5.3)
W-12
(a-d) AS 1851.14 1996 (Table 7.1) and (e) NFPA 25 (Section 8.5.3)
W-13
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W-14
W-15
W-16
W-17
AS 1851.8-1987.
W-18
M-3
M-4
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Action Required Test each automatic fire detection alarm zone: (a) Check all visual and aural indicators; (b) Check all control and indicating equipment is clean and in good operating condition; and (c) Record results.
Reference AS1851.8-1987.
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Action Required Compression-Ignition or Diesel Engine Checks: (a) Check the fuel filter; (b) Run the driver for a minimum period of 30 minutes (This test should be carried out at a minimum of 60% operating load); (c) Record the engine operating temperature, oil pressure and tachometer reading; (d) Stop the driver and restart using manual start mechanisms; and (e) Check that exhaust guard is in place. Electric motor requirements: Test the manual starting mechanism. For a hydro-pneumatic accumulator, check that the pressure is the same as shown on the plate. Battery System Checks: (a) Clean and tighten the battery terminals; (b) Inspect wire chafing if battery movement is applicable; and (c) Semi-annually test and check safety devices and alarms. Semi-annually clean boxes, panels and cabinets. (d) Clean and tighten the battery terminals; (e) Inspect wire chafing if battery movement is applicable; and (f) Semi-annually test and check safety devices and alarms. Semi-annually clean boxes, panels and cabinets. Clean the water strainer in the cooling system. Semi-annually test the antifreeze protection levels. Check the exhaust systems insulation for fire hazards. Semi-annually inspect the flexible exhaust section.
Q-8 Q-9
Q-14
The different available starting sequences for fire pumps should be used on a rotating basis during regular tests, meaning that each are tested within the required timeframe.
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Action Required Clean the mainline strainer and inspect and clean nozzle strainers: (a) Mainline strainers (basket or screen) shall be flushed until clear after each operation or flow test; (b) Individual water spray nozzle strainers shall be removed, cleaned, and inspected after each operation or flow test; and (c) Oil the external alarm water motor. (d) Mainline strainers (basket or screen) shall be flushed until clear after each operation or flow test; (e) Individual water spray nozzle strainers shall be removed, cleaned, and inspected after each operation or flow test; and (f) Oil the external alarm water motor. Continuous monitoring of isolation valves: Where such facilities are installed, ensure that they are operating correctly. Operate all pressure-reducing valves: (a) Check for correct operation under flow conditions; and (b) Check pressure readings on the low-pressure side of the valves for a deviation from the original test readings. Inspect the drainage for the deluge systems: Ensure that drainage facilities are not blocked and that retention embankments or bunds are in good repair. For systems where the sole water supply is through a backflow preventer and/or pressure reducing valve, perform a drain test: For such systems, the main drain test of at least one system downstream of the device should be conducted quarterly (main drain test requirements for other systems are detailed in the annual tasks (Table 6.2)). Inspect and maintain system piping, fittings, hangers and supports: (a) Check for mechanical damage (e.g., broken piping or cracked fittings); (b) Check for external conditions such as missing or damaged paint, rust and corrosion; (c) Check for misaligned or trapped sections; (d) Check low point drains (automatic or manual); (e) Check the location of rubber-gasket fittings; and (f) Water supply piping should be maintained to prevent internal obstructions. (g) Check for mechanical damage (e.g., broken piping or cracked fittings); (h) Check for external conditions such as missing or damaged paint, rust and corrosion; (i) Check for misaligned or trapped sections; (j) Check low point drains (automatic or manual); (k) Check the location of rubber-gasket fittings; and (l) Water supply piping should be maintained to prevent internal obstructions. Inspect fire department connections: (a) Ensure that the fire department connections are visible and accessible; (b) Ensure that the couplings or swivels are not damaged and rotate smoothly; (c) Check, clean and lubricate the caps and plugs; (d) Check that the gaskets are in place and that they are in good condition; (e) Ensure identification signs are in place; (f) Ensure that the check valve is not leaking; (g) Check that the automatic drain valve is in place and operating properly; and (h) Check that the fire department connection clapper(s) is in place and operating properly. Test any quick opening devices.
Reference AS 1851.3-1997 (Table 4.1) and NFPA 25 (Sections 10.2.7, 10.2.1.7, 10.2.1.8 & 10.2.7)
Q-16 Q-17
Q-18
Q-19
Q-20
Q-21
Q-22
Page 13 of 21
Action Required Check the operation of the alarm. Ensure that it is directly linked to the fire authority. Test all water flow alarms or valve monitoring system switches. Check the pressure readings on the low pressure side of the pressure reducing and pressure limiting valves: Compare with design operating pressure. Semi-annually inspect fire hose reels: (a) Ensure presence of legible instructions; (b) Check for leakage; (c) Check hose runs freely through the guide; and (d) Check for corrosion or damage.
Q-26
AS1851.2-1995.
Q-31
Overhaul engine cooling system pressure reducing valves. Inspect piping for corrosion. Check air-release valves.
Page 14 of 21
Reference AS 1851.141996 (Table 7.2) and NFPA 25 (Section 8.5.3) NFPA 25 (Section 8.5.3) NFPA 25 (Section 8.5.3) NFPA 25 (Section 8.5.3) NFPA 25 (Section 8.5.3) NFPA 25 (Section 8.5.3) NFPA 25 (Section 8.5.3) NFPA 25 (Section 8.5.3) NFPA 25 (Section 8.5.3) NFPA 25 (Section 8.5.3) NFPA 25 (Section 8.5.3) NFPA 25 (Section 8.5.3)
A-6 A-7 A-8 A-9 A-10 A-11 A-12 A-13 A-14 A-15 A-16
Change the lubricant to the pump bearings, the mechanical transmission couplings and the right angle gear drive. Lubricate mechanical moving parts (excluding starters and relays). Check the pump shaft end play. Check accuracy of pressure gauges and sensors. Change or recalibrate when 5% out of calibration. Test the trip circuit breaker. Calibrate pressure switch settings. Change the grease for the motor bearings. Clean water and foreign material from the fuel tank. Check tank vents and ensure overflow piping is unobstructed. Inspect ducting, clean louvers. Replace if necessary Exhaust System Checks: (a) Test the system for excessive back pressure; and (b) Visually inspect the exhaust system hangers and supports. Pump Driver Checks: (a) Ensure that the circuit-breakers/fuses are of the correct type and rating for the pump start and operating conditions; and
A-17
A-19
A-20
Page 15 of 21
Action Required Service compression-ignition or diesel engine pumps as follows: (a) Check and clean or replace engine fuel sludge, sediment trap, fuel filter, oil filter and the air filter elements; (b) Remove, inspect and clean the heat exchanger strainer; (c) Replace the engine oil; (d) Run the pump for a minimum period of 30 minutes. During this period operate the pump at 0 and 100% of flow characteristics designated for the installation; and (e) Flush engine cooling system and refill using corrosion inhibitor. (f) Change the oil and the oil filter every 50 hours of operation or annually. (g) Change the antifreeze and clean the heat exchanger. Compression-ignition or diesel engine room checks: (a) Check that the installed heating for maintaining the engine room temperature above 10C is operating correctly; and (b) Check the ventilation. (The room temperature should be less than 10C above ambient temperature).
Reference (a-e) AS 1851.141996 (Table 7.1) and (f & g) NFPA 25 (Section 8.5.3)
A-22
A-29 A-30
A-31
Page 16 of 21
Action Required Test the deluge system: (a) During the test ensure that all affected personnel, any supervisory service, the owners representative, the authority having jurisdiction and the fire department or fire brigade are notified; (b) Ensure that the water spray fixed systems respond as designed, both automatically and manually; (c) Ensure that the heat detection system, operates within 40 seconds (record times); (d) Ensure that the flammable gas detection system, operates within 20 seconds (record times); (e) Record times between operation of detection systems and water delivery; (f) Check the water discharge patterns from all of the nozzles. Ensure that they are correctly positioned (In the event of obstructions, retest); (g) Pressure readings shall be recorded at the hydraulically most remote nozzle to ensure the water flow has not been impeded; (h) Record pressure reading at the deluge valve to ensure the water supply is adequate; (i) Compare readings to the hydraulic design pressures; (j) After the full flow test, the water spray system shall be maintained and returned to service; and (k) In the case of multiple systems, the maximum number of systems expected to operate should be tested simultaneously. Deluge or preaction valve trip test and inspection: (a) Test at full flow in warm weather; (b) During the annual trip test clean, replace or repair the interior of the preaction or deluge valves as necessary; and (c) During the trip test inspect the detection devices and the interior of the preaction or deluge valves. All backflow preventers installed in fire protection system piping shall be tested. This is normally completed by performing a full flow test. Conduct a full operational test of any ultra-high-speed water spray systems: Ensure that the response time is measured and that it is in accordance with the requirements of the system. Main drain test: (a) Conduct a main drain test at each water-based fire protection system riser to determine whether there has been a change in the condition of the water supply piping and control valves; (b) Record static and residual water pressures before, during and after the operation of the fully opened drain valve; (c) Compare readings with the original and previous tests to determine whether there has been any deterioration of the water supply; and (d) Prevent freezing and corrosion by opening ring all low point drains in aboveground piping or inspect weep holes to ensure they are clear and unobstructed. Inspect the automatic detectors in the fire system: (a) Visually inspect all detectors for deterioration; (b) Remove one detector from each alarm zone and confirm correct fault signal is registered; (c) Check the operation of 20% of the heat detectors (all should be checked within 5 years) and 50% of the flame detectors (all should be checked within 2 years.) (d) Check the operation of ancillary control facilities; (e) Check operation of manual call points; (f) Check power supply supervision alarm; and (g) Ensure availability of replacement manual call point glasses and tools.
A-33
NFPA 25 (Section 12.4.3.2.2, 12.4.3.3.2, 12.4.4.2.2, 12.4.4.3.2 12.4.4.1.5 & 12.4.3.1.7) NFPA 25 (Section 12.6.2) NFPA 25 (Section 10.4)
A-35 A-36
A-37
A-38
AS 1851.8-1987
Page 17 of 21
Externally check all water storage tanks and take off connections: Ensure they are in a good condition. Check and lubricate all hydrant stems, caps, plugs and threads. Check and lubricate all monitor nozzles. Ensure that the monitors and nozzles are clear of obstructions and are undamaged. Ensure the proper operation of the monitor shutoff valves (if supplied). Ensure that all parts associated with the monitor are intact. Inspect fire hose reels: (a) Ensure hose can be easily withdrawn in intended direction; (b) Ensure flow is greater than 0.33 L/s when using the nozzle in jet mode. Inspect the thread gasket in couplings and nozzles: Ensure that they are present, tightly fitted and have not deteriorated. All monitor nozzles shall be oscillated and moved throughout their full range to ensure proper operability.
A-49 A-50
A-52
Page 18 of 21
A-54
A-55
A-56
Page 19 of 21
3yr-8
3yr-9
AS 1851.3-1997 (Table 4.1) AS 1851.3-1997 (Table 4.1) AS 1851.3-1997 (Table 4.1) AS 1851.3-1997 (Table 4.1) AS 1851.3-1997 (Table 4.1) NFPA 25 (Section 10.2.1.8, & 10.2.7)
3yr-14
3yr-15
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5yr-2
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