Fire pumps are the heart of any fire protection system, particularly in high-risk environments like oil and gas facilities. These industries handle flammable materials under high pressure and temperature, meaning even a small fire can quickly escalate into a catastrophic event. Ensuring your fire pumps operate reliably is not just a matter of compliance — it’s a matter of safety, reputation, and operational continuity.
This article explores the key steps, standards, and best practices for maintaining fire pumps in oil and gas facilities, including preventive maintenance routines, testing methods, and performance verification.
Fire pumps ensure consistent water pressure throughout a fire protection system. In oil and gas facilities, they serve as the primary force behind hydrants, sprinklers, and deluge systems. Because these environments often involve remote or offshore installations, the reliability of the fire pump system is non-negotiable.
Typical setups include:
Diesel engine fire pumps – essential for areas without a guaranteed power supply.
Electric fire pumps – used where stable electricity is available.
Jockey pumps – maintain system pressure and prevent unnecessary operation of the main pump.
A single malfunction in these systems could delay firefighting response time — a risk that no refinery or offshore platform can afford.
Oil and gas facilities often require robust fire pump configurations due to harsh operating conditions. These setups typically include:
Vertical turbine fire pumps: Ideal for drawing water from underground tanks or seawater sources, commonly used in offshore and desert environments.
End suction and split case fire pumps: Preferred for onshore plants due to ease of maintenance and accessibility.
Diesel engine-driven units: Provide emergency operation during electrical failures, ensuring continuous protection.
Each configuration requires tailored maintenance procedures to ensure long-term reliability under demanding conditions.
Maintenance procedures must comply with established standards to ensure both safety and certification integrity. The most relevant fire pump maintenance standards for oil and gas facilities include:
NFPA 20: Standard for the Installation of Stationary Fire Pumps for Fire Protection.
NFPA 25: Standard for the Inspection, Testing, and Maintenance of Water-Based Fire Protection Systems.
API 610: Centrifugal Pumps for Petroleum, Petrochemical, and Natural Gas Industries.
Following these standards ensures that your fire pump systems meet both performance and safety requirements demanded by insurers, auditors, and local authorities.
A well-structured maintenance plan should combine daily, weekly, monthly, and annual inspection routines.
Check for leaks, abnormal noise, or vibration.
Confirm pump room temperature and cleanliness.
Verify that suction and discharge valves are open.
Inspect gauges and indicators for correct readings.
Conduct a no-flow (churn) test to confirm the automatic start function.
For diesel pumps, check fuel, oil, and coolant levels.
Record suction and discharge pressures to track performance trends.
Inspect the pump coupling alignment and foundation bolts.
Test automatic transfer switches and control panels.
Verify operation of jockey pumps and relief valves.
Perform a flow test at 100%, 150%, and churn points to verify pump curve performance.
Inspect impeller, casing, bearings, and shaft for wear or corrosion.
Clean strainers and suction lines.
Review all test data to identify early signs of performance degradation.
Regular inspection and testing not only ensure compliance but also detect issues before they evolve into costly failures.
Oil and gas sites often pose extreme challenges for equipment maintenance. Fire pump maintenance in such environments must address the following:
For offshore and coastal facilities, corrosion protection is crucial. Pumps should have marine-grade coatings, stainless steel shafts, and corrosion-resistant fasteners. Periodic visual inspection and repainting help prevent surface deterioration.
Onshore refineries in desert climates often experience dust ingress and high ambient temperatures. Air filters, cooling systems, and motor ventilation passages should be cleaned frequently to prevent overheating or mechanical wear.
For remote installations, implementing automated monitoring systems is essential. Parameters such as pressure, temperature, vibration, and flow can be tracked via SCADA systems for early fault detection.
All electrical connections, sensors, and control panels in hazardous zones should be explosion-proof and certified according to IECEx or ATEX standards. Regular inspection of seals and enclosures ensures continued compliance.
Diesel-driven fire pumps are widely used in oil and gas facilities because they operate independently of the electrical grid. However, their maintenance requires careful attention to several systems:
Fuel System: Ensure clean, water-free fuel. Drain and refill tanks periodically to prevent microbial growth.
Cooling System: Check radiator cleanliness, coolant concentration, and belt tension.
Lubrication: Change oil and filters according to manufacturer recommendations or after a set number of operating hours.
Battery Maintenance: Test battery voltage, electrolyte levels, and charging systems weekly.
Exhaust System: Inspect for leaks or blockages to avoid backpressure.
A well-maintained diesel fire pump ensures instant response during power outages — a vital factor for uninterrupted fire protection.
Electric motor-driven pumps are simpler to maintain but require regular electrical inspections to prevent faults:
Insulation Resistance Test: Perform annually to detect winding deterioration.
Motor Bearings: Grease according to manufacturer’s schedule to prevent overheating.
Control Panel Check: Ensure the integrity of contactors, relays, and alarm circuits.
Voltage and Current Monitoring: Verify readings against nameplate values to detect unbalanced loads.
Proper record-keeping of test data can reveal early signs of wear, saving both time and repair costs.
Every inspection, test, and maintenance activity should be documented in detail. These records serve multiple purposes:
Verify compliance with NFPA 25 and insurance requirements.
Support root cause analysis in the event of failure.
Track performance trends to anticipate maintenance needs.
Provide data for third-party audits or authority inspections.
Modern digital maintenance software or cloud-based platforms can simplify scheduling, reporting, and historical tracking.
Operators should always remain alert to early warning signs of system malfunction, such as:
Sudden drop in discharge pressure or flow.
Excessive vibration or unusual noise.
Overheating of bearings or motor.
Frequent automatic starts of the main pump.
Visible leaks or oil contamination.
Addressing these issues promptly can prevent unplanned downtime or pump failure during a fire emergency.
Beyond technical procedures, the effectiveness of fire pump maintenance depends on human factors — training, awareness, and culture.
Regular training ensures operators understand how to run tests correctly and interpret results.
Cross-department collaboration between operations, maintenance, and safety teams enhances accountability.
Management commitment to preventive maintenance reduces reactive repairs and strengthens compliance with NFPA and API standards.
When maintenance becomes a proactive routine rather than an afterthought, fire protection reliability significantly improves.
Maintaining fire pumps in oil and gas facilities demands strict discipline, technical expertise, and adherence to international standards. Regular inspections, full-flow tests, and environmental considerations ensure that the system operates flawlessly when needed most.
By following structured maintenance schedules and implementing continuous monitoring, operators can safeguard both personnel and assets, while ensuring full compliance with NFPA 20, NFPA 25, and API 610 requirements.
Fire pumps are the last line of defense in a high-risk environment — and their reliability depends entirely on how well they’re maintained.
