Testing Firefighting Systems: Key Practices for Reliability in Maritime Operations

Testing Firefighting Systems: Key Practices for Reliability in Large-Scale and Maritime Operations

In high-risk environments such as offshore oil platforms, industrial facilities, and maritime vessels—including tugs, fireboats, and offshore support vessels (OSVs)—the reliability of firefighting systems is vital to prevent catastrophic failure. This is why FFS Fire Fighting Systems, (who supplies 70% of the world’s external firefighting systems), places a strong emphasis on rigorous testing and customization to meet the highest standards of safety and performance. ‍

But how are these critical systems tested to ensure they meet these demanding standards?

Understanding Key Elements for Reliable Performance

To ensure that firefighting systems meet real-world operational demands, various tests validate their performance, durability, and safety.

Here are some key elements that ensure reliability in diverse settings:

1. Capacity and Pressure Testing: Fi-Fi (Firefighting) systems classify a vessel’s firefighting capabilities, typically installed on tugboats, fireboats, and offshore support vessels to combat fires on other ships or offshore platforms. These systems must pump large volumes of water over long distances.

The three main FiFi classifications are:

• Fi-Fi1: 2,400 m³/h (10,500 GPM) with a minimum throw length of 120 meters.
• Fi-Fi2: 7,200 m³/h (31,700 GPM) with a throw length of minimum 150 meters. (Depending on Class Society)
• Fi-Fi3: Up to 9,600 m³/h (42,300 GPM) with a throw length of minimum 180 meters. (Depending on Class Society)

Fi-Fi1 requires at least two fire monitors, with water spray systems protecting the vessel from external fires. Some end users also include foam on Fi-Fi1 systems (although this is not a class rule). Higher classes like Fi-Fi3 involve more powerful systems, and this class notation requires dedicated foam monitors and high expansion foam generators for enhanced fire suppression. These classifications are based on industry standards, ensuring vessels equipped with FiFi systems have the necessary water delivery capacity and reach to effectively fight fires in marine and offshore environments. FiFi systems adhere to international standards set by organizations such as DNV GL, ABS, and Lloyd’s Register, who collaborate with global regulatory bodies to align their requirements with best practices.

2. Durability Testing: Marine environments expose firefighting systems to corrosive saltwater, extreme weather, and humidity. Materials like duplex stainless steel and Ni-Al-Bronze undergo rigorous testing to ensure they maintain durability under these harsh conditions.
3. Power and Pump Efficiency: Fi-Fi systems often rely on the vessel's engines or auxiliary power units. FFS Fire Fighting Systems, for example, tests these systems under maximum load to ensure they operate efficiently without disrupting other essential vessel functions.
4. System Redundancy and Safety: Firefighting systems on tugboats and fireboats are often the first line of defence in maritime fires. Testing ensures redundancy, such as dual-monitor setups and integrated foam systems, so systems continue to operate effectively even if a component fails.
5. Integration with Vessel Systems: A critical aspect of Fi-Fi systems is their integration with a vessel's propulsion and manoeuvring systems. High-powered water jets can affect vessel stability, and testing ensures that firefighting systems work in harmony with station-keeping functions. According to ABS rules, 20% of engine power must always be available for station-keeping and manoeuvring during firefighting operations. This is crucial for ensuring vessels remain stable and safe while firefighting, especially when operating near platforms or other vessels.
6. Self-Protection Systems: Fi-Fi1 vessels feature a self-protection deluge system that sprays water over the vessel to shield it from heat and flames.  These systems are tested to ensure they operate effectively alongside the main firefighting equipment without compromising water delivery.
7. Foam System Integration: Fi-Fi systems often include foam for enhanced fire suppression, particularly in oil fires. Foam is mixed with water to smother the fire, and rigorous testing ensures proper foam-to-water ratios and smooth switching between foam and water. According to class rules, Fi-Fi2 systems use high-expansion foam and mobile foam generators. Foam proportioning tests ensure the foam-to-water ratio meets required standards under Fi-Fi system classifications, ensuring reliable firefighting performance, especially in oil-based fire scenarios.

FFS’s Advanced Testing Facilities and Capabilities

FFS operates one of the most advanced testing facilities in Europe, allowing us to thoroughly evaluate every product, from pumps to high-capacity water monitors, under extreme conditions. This comprehensive process ensures that our firefighting systems perform reliably across diverse environments, from industrial sites and offshore rigs to the maritime sector.

• Stringent Component Testing: Our products, certified by 12 leading accreditation bodies, undergo thorough testing to ensure reliable operation under maximum load. Each material component is meticulously inspected—transmissions undergo spin-tests, while pumps and other parts are pressure-tested before assembly begins. This ensures quality control at every step.
• Comprehensive System Testing: Once custom-made pumps are designed to meet specific project requirements, they face comprehensive tests, including pressure and functional evaluations, alongside classification verification. After assembly, the units undergo full-scale load testing at our FFS pump test station, supervised by class surveyors. This final verification ensures that each pump adheres to both contract specifications and ISO standards.

Our test beds, powered by 2000 kW and 500 kW motors, are among the most advanced in Europe, enabling full-scale system testing. FFS is the only company in the world that conducts in-house testing of pumps directly coupled with transmissions and gearboxes at maximum power in our dedicated pump test station. Additionally, diesel engine packages are comprehensively tested in our dedicated hall, where calibrated sensors capture precise performance data. Just five minutes from our factory, we also have a real-world testing facility that allows for full-scale pump performance monitoring, in-depth customer demonstrations, and thorough Factory Acceptance Tests (FAT).

Customized Solutions and Class Certification

FFS customizes firefighting systems to meet specific customer needs, tailoring pump curves to ensure optimal flow rates, pressure, and coverage for various fire risks. As a single-source supplier, FFS oversees the seamless integration of all components from design in Norway to production in Sweden, ensuring long-term reliability.

1. Integrated Design and Manufacturing: FFS manages the entire product lifecycle—from design to testing—ensuring that all components work together smoothly, minimizing incompatibility risks and boosting efficiency.
2. Consistency, Flexibility, and Standardization: By controlling every stage of production internally, FFS maintains high-quality standards and adapts designs quickly to meet customer requirements, streamlining response times and improving performance.
3. Accountability and Stringent Testing: FFS takes full responsibility for the system’s quality, conducting strict testing on complete systems to ensure they operate reliably in critical environments such as oil platforms and industrial sites.

FFS is a global leader in marine firefighting systems. Our advanced testing processes ensure that every pump, monitor, and transmission is tested under maximum load conditions, guaranteeing optimal performance. By controlling design, manufacturing, and testing in-house, we ensure the reliability and efficiency of every system.

In high-risk environments, where failure is not an option, comprehensive testing provides peace of mind that FFS firefighting systems will perform flawlessly when needed most. This focus on engineering excellence and thorough testing has made FFS the most trusted name in external firefighting systems worldwide. By investing in rigorous testing, FFS safeguards lives, infrastructure, and the environment, reaffirming our commitment to global safety and reliability.