Reasons for a Failed Fire Pump Test & Next Steps
Each year, fire suppression systems must undergo a fire pump flow test to ensure compliance with industry standards. This test evaluates the flow rate of the fire line being tested. A low flow rate increases the likelihood of a failed test, which can compromise building safety and code compliance.
Several factors can contribute to a fire line’s low flow, including the type of fire line system, the pipeline material, and the substances transported. Most fire line systems are constructed from metallic pipes, with cast iron being the most common material. The primary cause of low flow in these pipes is tuberculation, a buildup inside the pipe that restricts water movement.
Keep reading to learn more about fire line tuberculation, how to detect it, and how American Pipeline Solutions can restore and maintain optimal fire line performance.
What Causes Tuberculation in Fire Lines?
Tuberculation occurs primarily in metallic pipelines, including cast iron and ductile iron pipes. It is caused by chemical reactions between bacteria in the fire line water and the iron in the pipe’s interior. Over time, this reaction creates a buildup, known as pipe scale or tuberculation, which narrows the pipeline and disrupts flow.
Left untreated, tuberculation can significantly reduce the efficiency of your fire suppression system and increase the risk of a failed fire pump test.
How to Detect Tuberculation?
The most common indicator of tuberculation in a fire line is low flow during a fire pump test. Additional signs may include uneven pressure readings or water discoloration.
At American Pipeline Solutions, we begin by performing a visual inspection of the fire line to determine the severity and location of the buildup. This inspection allows our team to assess the thickness of the tuberculation and plan the most effective cleaning approach.
Determining the Best Cleaning Approach
While replacing your fire line can remove tuberculation, it is often not cost-effective. Moreover, without proper prevention measures, new pipes can develop the same issue over time.
APS offers targeted solutions to clean and restore your existing fire lines. Our approach includes reviewing as-builts and fire line drawings, conducting a site visit, and creating a comprehensive proposal that outlines the recommended fire line descaling method.
Fire Line Descaling Methods
APS addresses tuberculation using a combination of:
Pigging
Rotary head technology
Picote mechanical equipment
The method chosen depends on the characteristics of the fire line.
Pigging is not typically the first choice for heavy-scale buildup, as foam pigs can break apart instead of removing the scale. Instead, APS often relies on Picote mechanical equipment, which applies stronger force to remove pipe scale efficiently. This method uses less water than pigging or rotary head technology while effectively cleaning the fire line.
Preventing Future Scale Build-Up and Low Flow
After cleaning, your fire line’s flow rate will return to optimal levels. To maintain this performance, fire lines should be cleaned approximately every five years. Without routine maintenance, tuberculation will reoccur, potentially leading to another failed flow test.
Epoxy coating offers a long-term solution to prevent future tuberculation. Unlike repiping, which can take several weeks and disrupt system operation, epoxy coating is a cost-effective, trenchless solution. Coating your cleaned pipelines can prevent tuberculation for up to 50 years, extending the life of your fire line while minimizing downtime.
Why Choose APS for Fire Line Cleaning and Prevention?
With extensive experience in fire line descaling and epoxy coating, APS provides reliable, industry-standard solutions that restore flow, improve efficiency, and ensure fire line compliance. Our team specializes in:
Fire line cleaning and tuberculation removal
Pipe descaling for metallic pipelines
Long-term prevention with epoxy pipe coating
Maintaining optimal flow rates for fire suppression systems
Take the Next Step
If your fire line has low flow or has failed a fire pump test, don’t wait for issues to worsen. Contact American Pipeline Solutions today to schedule a fire line inspection and learn more about our tuberculation cleaning and prevention services.
FAQs:
What are the most common reasons a fire pump test fails?
A fire pump test usually fails because the fire line can’t deliver the required flow rate. In metallic fire lines, the most common cause is tuberculation—internal scale buildup that narrows the pipe and restricts water flow. Other contributors include aging infrastructure, poor maintenance history, or partial blockages that reduce effective internal diameter.
What is tuberculation in fire lines?
Tuberculation is a form of internal scale buildup that occurs in metallic pipes such as cast iron and ductile iron. It’s caused by chemical reactions between iron in the pipe wall and bacteria in the water. Over time, these reactions create mounds of corrosion products that narrow the pipe and reduce the flow needed for a passing fire pump test.
How can I tell if tuberculation is affecting my fire line?
The most common sign of tuberculation is low flow during a fire pump test. You may also see uneven pressure readings or discolored water during testing or flushing. To confirm, American Pipeline Solutions performs a visual inspection of accessible segments and reviews drawings to pinpoint where scale is thickest and which sections need targeted cleaning.
Do I have to replace my fire line if it fails a fire pump test?
Not necessarily. Full replacement is expensive, disruptive, and doesn’t always address the underlying causes of tuberculation. In many cases, APS can restore performance by mechanically descaling the existing fire line and then applying epoxy coating. This approach is often more cost-effective, faster to complete, and can extend the life of the existing pipeline significantly.
How does APS clean and descale a tuberculated fire line?
APS starts by reviewing as-builts and fire line drawings, then conducts a site visit to confirm layout and condition. Based on that assessment, we develop a proposal using methods such as pigging, rotary head technology, or Picote mechanical equipment. For heavy scale, Picote tools are often preferred because they apply strong mechanical force while using less water than traditional pigging.
Why isn’t pigging always the best option for heavy scale in fire lines?
Pigging can be effective in some fire lines, but foam pigs may break apart when pushed through severe tuberculation instead of removing the scale. In heavily tuberculated systems, APS often chooses Picote mechanical descaling or rotary tools because they can cut and remove thick deposits more reliably, especially in older cast iron fire mains with significant buildup.
How often should fire lines be cleaned to prevent low flow?
In many buildings, cleaning the fire line approximately every five years is a good starting point to maintain acceptable flow for fire pump tests. The ideal interval depends on water quality, pipe age, and system design. APS helps building owners and facility managers set a cleaning and inspection schedule that supports both performance and code compliance over time.
How does epoxy coating help prevent future tuberculation?
Once the fire line is cleaned and dried, APS can apply an internal epoxy coating to seal the pipe’s interior surface. This barrier reduces direct contact between water and iron, which helps prevent new tuberculation from forming. Compared to repiping, epoxy coating is trenchless, less disruptive, and can protect the line for decades while keeping flow rates closer to design values.
Is epoxy coating better than replacing the fire line?
It depends on the condition of your existing system, but epoxy coating is often more cost-effective and less disruptive than full replacement. Instead of excavating or opening ceilings and walls, APS uses a trenchless approach to coat the cleaned pipe interior. This can deliver long-term protection, extended service life, and restored flow without weeks of downtime or major structural work.
Why should I choose American Pipeline Solutions for fire line issues?
American Pipeline Solutions has extensive experience diagnosing and treating fire line tuberculation, restoring flow after failed fire pump tests, and protecting systems with epoxy coating. We combine targeted mechanical descaling methods, careful inspection, and long-term prevention strategies to help building owners improve fire suppression performance, maintain code compliance, and avoid unnecessary repiping projects.
Looking to improve the low flow of your fire line?
Contact American Pipeline Solutions today to learn about our fire line tuberculation cleaning and prevention solutions.
