India's Independent Engineering Audit Authority | Since 2010
Fire Pump Performance Testing at a Petrochemical Facility in Panipat – Case Study
Elion Technologies & Consulting Pvt. Ltd. carried out fire pump performance testing at Indian Synthetic Rubber Private Limited, Panipat, Haryana.
The facility is a large E-SBR manufacturing plant located near the Panipat refinery and naphtha cracker complex. The report identifies it as India’s first world-scale E-SBR facility. The fire pump testing covered multiple electric, diesel-driven and jockey pumps, with performance assessed under 0%, 100% and maximum/high-flow operating conditions.
The assignment was carried out during March and April 2026.
Client Info
- Indian Synthetic Rubber Private Limited
- Panipat, Haryana
- Petrochemical / Synthetic Rubber Manufacturing
- Fire Pump Performance Testing
🔥 Quick Answer: Annual Fire Pump Testing
Annual fire pump testing runs each pump at churn (no flow), rated flow and maximum flow, recording flow, discharge pressure, current and run time. NFPA 25 calls for it yearly, with readings compared against the pump curve. At a Noida electronics plant, four pumps reached 112–122% of rated flow in 10-minute runs.
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Scope
Scope of Testing
The assignment included performance evaluation of:
Main electric fire pump
Diesel engine-driven fire pump
Jockey pump
Pump operational condition
Fire-water flow
Hydrant-system performance
Noise and vibration
Pump running duration
Testing Methodology
Actual water flow was measured using an ultrasonic flow meter. Testing was performed using a recirculation arrangement, with the quantity of water controlled through the discharge valve. This enabled Elion to determine the actual flow being delivered by each tested pump rather than relying solely on pump nameplate data. The applicable technical references included:
- NFPA 20
- IS 15301
- NFPA 14
- National Building Code of India 2016, Part 4 – Fire & Life Safety
The report also references NFPA 25 requirements in relation to annual pump flow testing.
Main Electric Fire Pump Testing
The main electric fire pump had the following nameplate characteristics:
Parameter | Value |
Rated Discharge | 279 m³/hr |
Total Head | 80 m |
Motor Rating | 110 kW |
RPM | 2975 |
Motor Current Rating | 180 A |
The pump was tested using the ultrasonic flow measurement method. At full-capacity testing, the actual recorded flow was:
266.14 m³/hr the pump operated continuously for 10 minutes without disruption and was recorded as having passed the annual test.
Diesel Fire Pump Testing
The diesel-driven fire pump had:
Parameter | Value |
Rated Discharge | 273 m³/hr |
Total Head | 88 m |
Pump RPM | 2900 |
Engine RPM | 2300 |
Actual flow was measured using an ultrasonic flow meter through the recirculation testing arrangement.
The maximum flow recorded during testing was:
299.87 m³/hr the pump operated continuously for 10 minutes and passed the annual fire-pump performance test. That means the actual measured flow exceeded the stated rated discharge of 273 m³/hr.
Jockey Pump Testing
The jockey pump was also evaluated. Its recorded characteristics included:
Parameter | Value |
Total Head | 88 m |
Motor Rating | 11 kW |
RPM | 2900 |
Motor Current | 19 A |
The actual measured flow reached:
60.234 m³/hr and the pump operated continuously for 10 minutes. The report recorded the jockey pump as having passed the annual test.
Summary of Fire Pump Test Results
Pump | Rated Flow | Maximum Recorded Flow | Outcome |
Main Electric Fire Pump | 279 m³/hr | 266.14 m³/hr | Passed |
Diesel Fire Pump | 273 m³/hr | 299.87 m³/hr | Passed |
Jockey Pump | Not stated in report | 60.234 m³/hr | Passed |
All tested pumps were able to run continuously for the required test duration. The overall report concluded that the pumps were operating within the required performance parameters and that no significant issues were identified during testing.
Key Outcome
The testing demonstrated successful operation of the main electric, diesel and jockey pumps. The diesel pump delivered 299.87 m³/hr against its stated rated discharge of 273 m³/hr, while the main electric pump delivered 266.14 m³/hr during the evaluated full-capacity test.
All tested pumps successfully completed the prescribed operating duration and were recorded as passing the annual test.
Why Fire Pump Performance Testing Matters in Manufacturing Facilities
Elion used an ultrasonic flow meter to measure the actual water flow through the fire-pump system. The tests were performed using the recirculation method, with the flow controlled through the discharge arrangement. Where applicable, the following parameters were recorded:
Manufacturing plants rely on fire-water systems to protect production machinery, electrical installations, stores, utility areas and occupied buildings.
A fire pump starting successfully does not necessarily confirm that it can deliver the required water flow under operating conditions.
Performance testing helps verify:
- Actual flow delivery
- Pump running capability
- Hydrant-system readiness
- Diesel pump performance
- Electric pump performance
- Mechanical condition
- Abnormal vibration or noise
- Hydraulic performance under load
Periodic performance testing therefore provides facility management with measured evidence of the actual condition of the fire-pump system.
About Us
About Elion Technologies & Consulting
Elion Technologies & Consulting Pvt. Ltd. provides independent fire-pump performance testing for manufacturing plants, power plants, commercial facilities, warehouses, hotels and other industrial facilities across India.
Testing services include:
Annual fire pump testing
Fire pump performance testing
Fire pump flow testing
Hydrant pump testing
Sprinkler pump testing
Diesel fire pump testing
Electric fire pump testing
Jockey pump testing
Fire-water network assessment
Fire safety audit
Need Fire Pump Testing in Madhya Pradesh?
Elion undertakes third-party fire pump testing in Dewas, Indore, Bhopal and other industrial locations across Madhya Pradesh and India. Testing can include actual flow measurement using suitable flow measurement instruments, pump operating-condition assessment and detailed technical reporting.
Contact Elion Technologies & Consulting Pvt. Ltd. for fire pump performance testing requirements.
FAQ
What equipment is used for fire pump flow testing?
For this assignment, Elion used an ultrasonic flow meter for measuring actual water flow through the fire-water system.
Can diesel and electric fire pumps both be performance tested?
Yes. This assignment included testing of a main electric fire pump, diesel-driven fire pump and jockey pump.
How long should a fire pump run during performance testing?
The tested pumps in this assignment were operated continuously for 10 minutes, with the results documented in the technical report.
Does Elion provide fire pump testing in Madhya Pradesh?
Yes. Elion undertakes third-party fire-pump performance testing for industrial and commercial facilities across India, including Madhya Pradesh.