Electric vs. Diesel Fire Pumps: Where Does the Jockey Pump Fit?

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n engineers compare electric vs. diesel fire pumps, the discussion usually centers on the driver: Is the building better protected with a reliable electric motor, or does the application justify a diesel engine that can operate independently of normal utility power?

But there is another pump in the room that plays a completely different role.

The jockey fire pump does not compete with the electric or diesel fire pump. It supports the entire fire protection system by maintaining pressure during normal conditions and handling small pressure losses before they become a reason for the main fire pump to start.

This distinction is becoming increasingly important as fire protection systems become more connected, closely monitored, and engineered around reliability rather than simply equipment selection. The 2025 edition of NFPA 20 continues to recognize the jockey pump as the standard term for pressure-maintenance and make-up pumps, while also refining requirements around automated testing, remote testing, controllers, power arrangements, and monitoring.

So, where exactly does the jockey pump fit when choosing between electric and diesel fire pumps?

The short answer is: it belongs upstream in the pressure-maintenance strategy, not in the electric-vs-diesel decision itself.

Electric and Diesel Fire Pumps Have Different Jobs

A fire pump is selected to provide the water flow and pressure required by the fire protection system when there is an actual demand.

That demand may come from:

• Automatic sprinkler activation
• Standpipe or hose valve operation
• Hydrant demand
• Deluge or water spray systems
• Other engineered fire protection applications

The driver determines how the main fire pump receives the energy required to deliver that water.

Electric fire pumps

An electric fire pump uses an electric motor as its driver. Its biggest advantage is straightforward operation when a reliable power supply is available.

Electric systems generally have:

• No diesel fuel storage
• No engine oil or fuel filters
• Fewer engine-related maintenance requirements
• Compact equipment arrangements
• No combustion exhaust system
• Straightforward starting and monitoring

However, the reliability of the electrical supply becomes a critical design consideration.

An electric fire pump is only as dependable as the power arrangement supporting it. NFPA 20 contains specific requirements addressing electric fire pump power supplies and controllers, and the authority having jurisdiction (AHJ) ultimately plays an important role in determining whether the available power arrangement is acceptable.

Diesel fire pumps

A diesel fire pump uses an engine rather than an electric motor.

That makes it particularly useful where maintaining fire pump operation independently of normal utility power is an important part of the system's reliability strategy.

Diesel installations introduce additional considerations, including:

• Fuel storage
• Batteries and battery charging
• Engine cooling
• Ventilation
• Exhaust
• Fuel maintenance
• Engine testing
• Additional mechanical components

The 2025 edition of NFPA 20 includes specific provisions addressing diesel engine-driven pumps, controllers, automatic testing, monitoring, and fuel-related arrangements.

Neither driver is universally "better."

The right selection depends on the building, available power, fire protection demand, environmental conditions, applicable codes, AHJ requirements, and the overall reliability strategy.

And this is where the jockey pump enters the picture.

What Is a Jockey Pump?

A jockey pump is a small pressure-maintenance pump designed to keep the fire protection system pressurized during normal conditions.

Think of the main fire pump as the equipment designed for a significant event.

The jockey pump handles the much smaller events that happen routinely.

Fire protection piping does not remain perfectly static forever. Small pressure losses can occur because of:

• Minor leakage
• Temperature-related pressure changes
• Small valve-seat leakage
• Maintenance activities
• Pressure fluctuations
• Other normal system conditions

Without a pressure-maintenance strategy, these relatively small losses could cause the main fire pump to start.

That is not what the main fire pump is intended to do.

The jockey pump compensates for these minor losses and restores system pressure without unnecessarily operating the primary fire pump.

NFPA 20's 2025 edition specifies that a pressure-actuated fire pump system is to have a means of maintaining pressure, with a jockey pump being one recognized method. It also establishes requirements for jockey pump discharge pressure, piping, controls, and related components.

The Jockey Pump Is Not a Backup Fire Pump

This is one of the most important distinctions engineers, facility managers, and building owners need to understand.

A jockey pump is not a smaller version of the main fire pump.

It is not intended to replace the electric fire pump.

It is not intended to replace the diesel fire pump.

And it should not be treated as an emergency fire pump.

Its primary function is pressure maintenance.

The main fire pump is selected around the hydraulic demand of the fire protection system. The jockey pump, by contrast, is selected around maintaining system pressure and preventing unnecessary operation of the main fire pump.

NFPA 20 specifically states that the primary or standby fire pump should not be used as a jockey pump, except under specific provisions in the standard.

That separation of duties is fundamental to proper system design.

How the Three Pumps Work Together

Consider a typical fire protection system containing:

1. An electric-driven fire pump
2. A diesel-driven fire pump
3. A jockey pump

The three pumps are not simply three different sizes of the same equipment.

They represent three different functions.

1. Jockey pump: Maintain pressure

During normal conditions, the jockey pump keeps the system pressure within the desired range.

A small pressure drop occurs.

The jockey pump starts.

It restores pressure.

Once the pressure reaches its designated stop point, the jockey pump stops.

2. Electric fire pump: Respond to significant demand

If system pressure continues to fall beyond the jockey pump's ability to compensate, the electric fire pump may start according to the system's pressure settings and control logic.

This is associated with a substantially greater water demand.

3. Diesel fire pump: Provide another driver option

If the system is designed with both electric and diesel-driven fire pumps, the diesel unit provides an additional source of pumping capability based on the system's design and sequencing.

The exact arrangement depends on the project and applicable requirements.

The key idea is simple:

The jockey pump manages pressure. The main fire pumps manage fire demand.

Why Does the Jockey Pump Matter With an Electric Fire Pump?

At first glance, the jockey pump might seem less important when the main fire pump is electric.

After all, electric motors can start quickly and are relatively straightforward to operate.

But frequent unnecessary starts are still undesirable.

Every time the main fire pump starts, the system is asking a much larger piece of equipment to respond to what may be a very small pressure loss.

The jockey pump provides a controlled first response.

This helps separate normal pressure maintenance from genuine system demand.

For example, imagine a sprinkler system experiencing a small pressure reduction because of minor leakage.

Without a suitable pressure-maintenance arrangement, the pressure may eventually reach the main pump's start setting.

The electric fire pump starts.

Water moves.

The pump runs according to its control strategy.

Then the system pressure recovers.

This is a disproportionate response to a minor condition.

A correctly designed jockey pump can handle that smaller pressure loss instead.

What About Diesel Fire Pumps?

The same principle applies when the main fire pump is diesel-driven.

The jockey pump does not become unnecessary simply because the primary driver is an engine.

In fact, separating pressure maintenance from emergency pumping becomes particularly useful because diesel equipment has additional mechanical systems that operators must maintain.

A diesel fire pump involves more components than an electric motor-driven pump, including batteries, engine systems, fuel systems, cooling arrangements, and exhaust provisions.

There is little reason to start that equipment for every minor pressure fluctuation if a properly selected pressure-maintenance pump can handle the condition.

This is also consistent with the broader direction of modern fire pump design: reduce unnecessary equipment operation while making testing, monitoring, and system performance more verifiable.

NFPA 20's 2025 edition has expanded and refined provisions for automatic and remote automatic testing for both electric- and diesel-driven fire pumps, along with monitoring requirements.

Does the Jockey Pump Need to Be Electric or Diesel?

This is where the terminology can become confusing.

A jockey pump is normally a small electrically driven pump, but the important design question is not whether it is "electric vs. diesel" in the same sense as the main fire pump.

The jockey pump has a different duty.

NFPA 20's 2025 requirements state that a jockey pump is not required to have alternate or standby power.

That is an important distinction.

The main fire pump's driver is selected around the ability to provide the required fire protection water supply under emergency conditions.

The jockey pump's job is pressure maintenance under normal system conditions.

Therefore, engineers should avoid applying the same selection logic to both.

Pressure Settings Are Where the Jockey Pump Really Fits

The relationship between the jockey pump and the main fire pump is heavily influenced by pressure settings.

The system needs a deliberate sequence.

A simplified arrangement looks like this:

Normal system pressure

↓

Small pressure loss

↓

Jockey pump starts

↓

Pressure restored

↓

Jockey pump stops

↓

Larger pressure loss

↓

Main fire pump starts

The exact pressure settings must be established based on the system design, equipment characteristics, available pressure, and applicable requirements.

NFPA technical material describes the jockey pump stop point in relation to the fire pump's churn pressure and minimum static supply pressure, with staged pressure settings separating jockey pump and fire pump activation.

This sequencing matters because poorly coordinated pressure settings can create operational problems.

If the jockey pump start and stop points are too close, it may cycle excessively.

If the jockey pump is set too aggressively, it may mask a developing problem.

If the main fire pump starts too easily, minor pressure losses can cause unnecessary activation.

If settings are poorly coordinated, the system may not behave as the design team intended.

Oversizing the Jockey Pump Can Be a Problem

A common misconception is that a larger jockey pump provides better protection.

It does not necessarily.

The jockey pump needs enough capacity to maintain pressure under expected minor losses, but making it unnecessarily large can interfere with the intended separation between pressure maintenance and fire demand.

An oversized jockey pump may restore pressure too aggressively or make it capable of handling flows that should instead trigger the main fire pump.

The result can be a system that appears stable during normal operation but behaves differently during an actual demand condition.

Jockey pump selection should therefore be based on the system's pressure-maintenance requirements rather than simply selecting the largest convenient pump.

The Jockey Pump and Modern Fire Pump Monitoring

Fire pump design is moving beyond basic mechanical equipment selection.

Modern systems increasingly incorporate:

• Remote monitoring
• Automated testing
• Controller event logs
• Digital alarms
• Equipment status monitoring
• Connectivity
• Condition-based maintenance strategies

The 2025 edition of NFPA 20 includes expanded and refined requirements for automatic and remote automatic testing, particularly for electric- and diesel-driven fire pumps. It also includes an annex addressing fire pump room connectivity.

That makes the jockey pump more than just a small pump sitting beside the main equipment.

Its starts and stops can provide useful operational information.

If a jockey pump that normally operates infrequently begins starting repeatedly, that may indicate:

• Leakage
• A pressure-control problem
• A faulty check valve
• A valve issue
• Pressure fluctuations
• A developing system condition

In other words, jockey pump cycling can become an operational signal.

Modern fire protection teams should pay attention to those patterns instead of treating every jockey pump start as routine.

A New Development: Can Technology Replace the Jockey Pump?

This is one of the more interesting developments in current fire pump engineering.

A 2025 NFPA public input proposed recognizing a listed electric fire pump controller with integrated pressure-maintenance capabilities as an alternative to a conventional jockey pump arrangement.

The proposed technology was designed to distinguish minor pressure losses from actual system demand and temporarily operate the main pump in a controlled "system recharge" mode for small losses.

This is important because it shows where the industry is heading.

The question is no longer simply:

"Which pump should we buy?"

It is increasingly:

"How should the entire fire pump system detect, manage, test, and respond to pressure changes?"

However, engineers should distinguish between a proposal or emerging technology and an adopted code requirement. A project still needs to comply with the edition of NFPA 20 adopted by the AHJ and any applicable local requirements.

Electric vs. Diesel: A Practical Comparison

Factor	Electric Fire Pump	Diesel Fire Pump
Driver	Electric motor	Diesel engine
Main dependency	Reliable electrical supply	Fuel and engine systems
Fuel storage	Not required	Required
Exhaust system	Not required	Required
Engine maintenance	Lower	Higher
Battery maintenance	Not applicable to driver	Required
Typical space requirements	More compact	More equipment/ventilation needs
Pressure maintenance	Jockey pump can be used	Jockey pump can be used
Emergency role	Main fire protection pumping	Main fire protection pumping
Jockey pump role	Pressure maintenance	Pressure maintenance

The key takeaway is that the jockey pump's fundamental role does not change simply because the main fire pump driver changes.

When Is an Electric Fire Pump a Strong Choice?

An electric-driven fire pump can be attractive when the project has a dependable power arrangement and the applicable requirements permit its use.

Potential advantages include:

• Lower mechanical complexity
• Easier routine maintenance
• No diesel fuel management
• Smaller equipment footprint
• No combustion exhaust
• Straightforward integration with building electrical infrastructure

But engineers should never select an electric driver solely because it is cheaper or easier to maintain.

The power supply must be evaluated as part of the complete fire protection design.

A reliable-looking electrical source is not automatically a compliant fire pump power source.

When Does Diesel Make More Sense?

Diesel becomes attractive when electrical reliability is a major concern or when the project's risk profile and code requirements favor an independent driver.

The diesel engine brings its own energy source and avoids direct dependence on normal utility power.

But that independence comes with responsibilities.

Fuel must remain usable.

Batteries must remain capable of starting the engine.

Ventilation and exhaust arrangements must work.

Cooling systems must be maintained.

Testing must be performed correctly.

The engine cannot simply be installed and forgotten.

In modern fire protection design, driver independence is valuable only when the complete diesel system is maintained as a reliable system.

Common Jockey Pump Mistakes Engineers Should Watch For

1. Treating the jockey pump as a backup fire pump

It is not.

Its purpose is pressure maintenance, not primary fire suppression.

2. Oversizing the jockey pump

A jockey pump that is unnecessarily large can interfere with the intended operating sequence.

3. Poor pressure coordination

Start and stop points need to be deliberately coordinated with the main fire pump.

4. Ignoring repeated cycling

Frequent jockey pump starts can indicate leakage or another system problem.

5. Assuming electric means automatically reliable

The electric pump's reliability depends heavily on its power supply arrangement.

6. Assuming diesel means maintenance-free independence

Diesel eliminates dependence on normal utility power, but introduces fuel, battery, cooling, exhaust, and engine maintenance requirements.

7. Treating technology as a substitute for code compliance

New controller and pressure-maintenance technologies are evolving quickly, but the installed system still has to satisfy the requirements adopted for the project.

What Engineers Should Evaluate During Pump Selection

Before selecting an electric or diesel fire pump arrangement, the engineering team should evaluate the entire system rather than focusing on the pump nameplate.

Key questions include:

What is the hydraulic demand?

The pump must be capable of meeting the required flow and pressure across the relevant operating range.

How reliable is the electrical supply?

For an electric-driven pump, the power arrangement is a fundamental part of the reliability assessment.

What happens if utility power is unavailable?

If continued pumping capability is required independent of normal utility power, a diesel arrangement or another compliant power strategy may need to be considered.

What pressure must the jockey pump maintain?

The jockey pump should be selected to perform its pressure-maintenance duty without taking over the role of the main fire pump.

How will the pumps be sequenced?

Pressure switches, controllers, pressure-sensing lines, and pump settings need to work together.

How will the system be monitored?

Modern projects should consider how pump status, alarms, testing, and unusual operating patterns will be identified.

What does the AHJ require?

Code compliance cannot be separated from local adoption, project-specific requirements, and AHJ interpretation.

The Bigger Picture: Think in Terms of a Pumping Strategy

The electric-versus-diesel debate can become too narrow when it focuses only on the driver.

A properly engineered fire pump system is a coordinated network.

The water supply provides the available source.

The main fire pump delivers the required fire flow.

The driver provides the energy.

The controller manages starting and operation.

The jockey pump maintains pressure during normal conditions.

The monitoring system provides visibility into equipment status and abnormal behavior.

Each component has a specific job.

The goal is not simply to select the strongest pump.

It is to make sure the right pump responds to the right condition.

Final Takeaway

So, where does the jockey pump fit in the electric vs. diesel fire pump discussion?

It fits beside the main fire pump as a pressure-maintenance component, not as an alternative driver.

Whether the primary fire pump uses an electric motor or diesel engine, the jockey pump can help maintain system pressure and prevent minor pressure losses from unnecessarily starting the main fire pump.

The electric-versus-diesel decision should focus on the reliability and suitability of the main pump's driver. The jockey pump decision should focus on pressure maintenance, system behavior, pump sequencing, and the conditions under which the main fire pump should respond.

And as fire pump technology moves toward greater automation, remote testing, connectivity, and smarter pressure management, engineers will increasingly need to evaluate the entire pumping system rather than individual pumps in isolation. The latest NFPA 20 developments reinforce this broader approach by addressing automated testing, remote monitoring, connectivity, controller arrangements, and pressure-maintenance terminology

Inside Callaghan Pump’s High Capacity Fire Protection Solution at JFK Airport

 

When fire protection serves an airport, the margin for error is exceptionally small.

John F. Kennedy International Airport is a complex transportation hub with aircraft operations, terminals, hangars, gates, support facilities, fuel related infrastructure, utilities, and extensive service areas. Protecting such a large environment requires more than individual fire pumps placed where needed. It requires a coordinated water supply strategy capable of supporting demanding fire protection requirements across a large network.

That challenge is exactly what made Callaghan Pump JFK Airport project significant.

Callaghan Pump supplied a 10 pump packaged fire protection system for JFK Airport. The system replaced an older arrangement that relied on diesel engines originally designed for commercial marine applications. The replacement solution included six diesel driven fire pumps and four electric driven fire pumps, creating a high capacity combination designed around the airport’s extensive fire pump loop.

According to Callaghan Pump, the JFK installation became the company’s largest packaged fire pump project and is described by the company as the world’s largest packaged fire pump system.

The project offers an important look at how high capacity fire protection systems can be approached when reliability, redundancy, hydraulic performance, equipment selection, and long term serviceability all matter.

Why JFK Airport Needed a Different Approach to Fire Protection

Large airports create a unique fire protection challenge because the protected area is not concentrated in one conventional building.

At JFK, the fire protection infrastructure includes a loop surrounding the airport that serves multiple hangars and gates. This means the pumping system has to support a distributed network rather than a single compact sprinkler installation.

A system of this scale introduces several engineering considerations.

Water must be delivered at the required pressure.

The pumps must provide sufficient flow.

The equipment needs to remain dependable under demanding operating conditions.

The system must accommodate multiple pumps and drivers.

The overall arrangement needs to support continuity of fire protection service.

And the equipment must be compatible with applicable fire protection requirements and the authority having jurisdiction.

This is where pump selection becomes much more than a product purchase.

A fire pump is one component within a larger fire protection system. Its capacity, driver, controller, suction arrangement, discharge piping, testing provisions, and interaction with the water supply all influence system performance.

NFPA 20, the Standard for the Installation of Stationary Pumps for Fire Protection, provides requirements covering fire pump installation, including pump equipment, pump rooms, piping, testing, and related system considerations.

For New York City projects, local requirements also interact with NFPA 20. NYC fire code provisions require fire pumps to be installed in accordance with the applicable construction codes and NFPA 20.

Replacing an Outdated Pumping Arrangement

One of the most interesting aspects of the JFK project was the equipment that existed before the upgrade.

Callaghan Pump reports that the airport’s previous fire pump engines were diesel engines originally intended for commercial marine applications. These engines operated at approximately 600 RPM, significantly below the rotational speeds commonly associated with many conventional fire pump arrangements.

So how could those engines drive fire protection pumps effectively?

The original arrangement used gear increasers to increase engine speed from approximately 600 RPM to the pump speed required for fire protection service. Callaghan Pump explains that the gear increasers converted the engine speed to approximately 1,750 RPM.

This arrangement demonstrates an important principle in industrial pump engineering: equipment can sometimes be made to perform outside what would now be considered the most straightforward configuration, but changing technology, equipment availability, maintenance requirements, and system expectations can eventually make replacement a better long term strategy.

For JFK, the Port Authority of New York and New Jersey sought recommendations for replacing the existing system.

Callaghan Pump recommended a completely new packaged configuration rather than simply continuing with the legacy approach.

The 10 Pump Configuration

The replacement system consisted of 10 horizontal split case fire pumps.

The configuration included:

• Six Clarke diesel fire pump engines

• Four Aurora electric driven fire pumps

• Four 500 HP Aurora electric driven units operating at 4,160 volts

• Packaged pump systems arranged for the airport’s high capacity fire protection requirements

Callaghan Pump's project information identifies the system as a combination of six diesel and four electric pumps.

This combination is particularly important when discussing resilience.

A large fire protection system should not be viewed only in terms of maximum theoretical output. Reliability also depends on how the system responds when individual components are unavailable, when maintenance is required, or when the facility experiences conditions that affect one source of power.

Using both diesel and electric driven pumps creates diversity in the driving equipment. It does not mean every pump operates simultaneously during normal conditions. Instead, the arrangement provides a substantial pool of fire pumping capacity designed around the system's overall demand and operating requirements.

That distinction matters.

The goal of a fire pump system is not simply to install the biggest possible equipment. It is to provide the required hydraulic performance within a properly engineered and code compliant system.

High Flow Capacity for a Large Airport Network

Callaghan Pump has also reported that each pump in the JFK packaged system was capable of approximately 3,500 gallons per minute at 150 PSI, giving the 10 pump system a combined nominal capacity of approximately 35,000 gallons per minute when considering all ten pumps together.

That number puts the scale of the installation into perspective.

A conventional commercial building may require a fire pump to support a comparatively localized sprinkler and standpipe demand. JFK's system had to support an airport wide fire protection loop serving multiple facilities.

The difference is enormous.

At this scale, hydraulic planning becomes critical. Engineers have to consider the available water supply, friction losses, elevation changes, piping configuration, required pressure, system demand, pump characteristics, and the operating relationship between multiple pumping units.

A pump's rated flow alone does not tell the complete story.

The pump must deliver the required flow at the pressure demanded by the fire protection system. Its performance must also be evaluated across the applicable operating range.

That is why pump curves, system calculations, equipment listings, control logic, and acceptance testing remain central to professional fire pump engineering.

Why Horizontal Split Case Pumps Made Sense

The JFK project used horizontal split case fire pumps.

This pump configuration is widely used in larger fire protection applications because it is well suited to high flow requirements and allows convenient access to major internal components during maintenance.

For a large installation, serviceability matters.

Fire protection equipment can remain installed for many years. That means the original equipment selection has implications far beyond the initial installation.

A pump room team may eventually need to inspect bearings, couplings, seals, impellers, shafts, or other components. A configuration that provides practical access can make future maintenance more manageable.

That is one reason lifecycle thinking should be part of fire pump selection.

The lowest initial equipment cost is not necessarily the lowest total cost of ownership.

For major facilities, decision makers should consider:

Capacity: Can the pump meet the hydraulic demand?

Reliability: Is the equipment suitable for critical fire protection service?

Redundancy: How does the overall system respond when equipment is unavailable?

Serviceability: Can technicians inspect and maintain the equipment efficiently?

Compliance: Does the equipment and installation satisfy applicable requirements?

Testing: Can the system be properly tested and documented?

Future support: Are replacement parts, technical expertise, and service resources available?

The JFK project illustrates why these questions become increasingly important as system scale increases.

Diesel and Electric Drivers Add System Resilience

Another defining characteristic of the JFK installation is its combination of diesel and electric drivers.

The project used six diesel driven pumps and four electric driven pumps.

For critical fire protection systems, driver selection is an important part of reliability planning.

Electric driven fire pumps can provide substantial pumping capacity where an appropriate electrical power source is available. Diesel driven pumps can provide an alternative source of mechanical power when electrical power availability becomes a concern.

NFPA 20 includes requirements addressing alternate power considerations for electric motor driven fire pumps.

However, the exact arrangement for any project must be determined from the project's engineering design, water supply, building conditions, electrical infrastructure, fire protection demand, applicable codes, and AHJ requirements.

The key takeaway is that driver diversity can be an important part of a broader resilience strategy.

For an airport operating around the clock, that resilience has particular significance.

Packaged Fire Pump Systems Simplify Complex Installations

Another notable aspect of the JFK project is that the pumps were supplied as packaged systems.

Packaging can provide advantages when a project involves multiple large fire pump assemblies.

Rather than treating every pump, driver, controller, and associated component as an isolated procurement item, a packaged approach can help coordinate equipment into an engineered assembly.

For large projects, this can improve consistency and simplify coordination between equipment suppliers, engineers, contractors, and facility representatives.

It can also help address space, installation, testing, and equipment interface considerations earlier in the project.

That does not eliminate the need for proper field installation.

Callaghan Pump identifies John P. Picone Inc. as the contractor responsible for installation of the JFK system.

This distinction is important because supplying the equipment and installing the complete fire protection system are separate responsibilities that must work together.

Successful fire protection projects depend on coordination throughout the process.

From Pump Selection to System Performance

One of the biggest lessons from the JFK project is that fire protection engineering should begin with the system requirement rather than a pump model.

Start with the question:

What does the fire protection system need to accomplish?

From there, engineers can determine the required flow and pressure, evaluate the available water supply, calculate system losses, establish pump requirements, select suitable equipment, and develop the appropriate control and testing arrangement.

This systems first approach becomes even more important for large facilities.

For example, increasing pump horsepower does not automatically solve a water supply problem.

Likewise, selecting a pump with a high flow rating does not guarantee that the required pressure will be available at the most hydraulically demanding point in the system.

The complete hydraulic picture matters.

This is also why fire pump sizing should not be based on assumptions or generic commercial building requirements. Every facility has different characteristics.

Testing Is Part of the Engineering Story

A fire pump system is only useful if it performs when required.

Testing therefore plays a critical role in fire protection.

Callaghan Pump states that its fire pumps undergo the required 50%, 100%, and 150% testing at the Aurora pump factory, with test results provided with each fire pump.

Field acceptance testing is another important part of the process. NFPA 20 includes provisions for field acceptance testing of pump units after installation.

For a major airport installation, testing becomes particularly important because the system is not merely an isolated piece of mechanical equipment. It is part of a critical safety infrastructure network.

Testing helps verify that the installed equipment performs in accordance with the intended design and provides an opportunity to identify installation or performance issues before the system is placed into service.

What Modern Fire Pump Engineering Can Learn From JFK

The JFK project remains relevant because today's fire protection challenges increasingly emphasize resilience, maintainability, and lifecycle performance.

Modern facility owners are also paying closer attention to equipment monitoring, preventive maintenance, documentation, energy considerations, and operational continuity.

That does not mean every older fire pump system needs to be replaced with the latest technology.

Instead, facility managers should evaluate whether existing equipment continues to satisfy current operational requirements and applicable regulations.

A system assessment can examine:

• Pump performance

• Driver condition

• Controller condition

• Water supply adequacy

• Piping condition

• Pressure performance

• Test results

• Maintenance history

• Equipment availability

• Code and AHJ requirements

• Future facility expansion

This approach can reveal whether maintenance, rehabilitation, controls upgrades, equipment replacement, or a larger system redesign is appropriate.

The lesson from JFK is not simply that bigger pumps are better.

The real lesson is that critical infrastructure needs an engineered system designed around its actual risk and operating environment.

Why Airport Fire Protection Requires Specialized Pump Expertise

Airports are not ordinary commercial facilities.

They operate continuously.

They contain large open spaces, specialized structures, aircraft related facilities, passenger areas, mechanical systems, utility infrastructure, and extensive external networks.

Fire protection systems therefore need to be designed with the facility's complete operating environment in mind.

A pump supplier or engineer working on such projects must understand more than pump specifications. They need to understand hydraulics, drivers, controls, installation requirements, testing, applicable standards, and project coordination.

Callaghan Pump's portfolio includes other major New York area projects, including LaGuardia Airport, the Lincoln Tunnel, the World Trade Center, and major commercial and industrial facilities.

The company also reports that it supplied five packaged pump systems for LaGuardia Airport before receiving the JFK project.

That project history demonstrates how experience with one complex facility can contribute to understanding the challenges of another.

The Bigger Picture: Designing for the Moment That Matters Most

Fire pumps may sit idle for long periods.

That does not make them unimportant.

Quite the opposite.

Their value is measured by their ability to perform immediately when a fire protection system demands water.

For an airport, that expectation becomes even more critical.

The JFK installation demonstrates what happens when fire protection requirements are approached at infrastructure scale. Ten large packaged fire pump systems were brought together to serve a distributed airport fire protection loop. The configuration combined diesel and electric drivers and replaced a legacy arrangement that relied on specialized low speed marine engines and gear increasers.

It was not simply an equipment upgrade.

It was a strategic modernization of critical water pumping infrastructure.

Final Takeaway

Callaghan Pump's JFK Airport project demonstrates the engineering principles behind high capacity fire protection: understand the facility, evaluate the water demand, select equipment around the hydraulic requirement, build in appropriate resilience, and plan for long term service.

The project included 10 horizontal split case fire pumps, six diesel driven and four electric driven, with Callaghan Pump reporting approximately 3,500 GPM at 150 PSI per pump.

For a facility as complex as JFK Airport, that scale is not about achieving an impressive specification.

It is about creating dependable fire protection infrastructure capable of supporting a vast network when it is needed most.

And that is the real measure of a high capacity fire protection solution.

A successful fire pump system does not simply move water.

It delivers confidence that critical infrastructure has the pumping capacity, redundancy, and engineering behind it to respond when every second matters.

Connecticut Fire Pump Systems for Commercial Facilities

 

For a commercial facility, a fire protection system cannot afford to depend on inconsistent water pressure. When sprinklers, standpipes, or other fire suppression equipment demand immediate water flow, the fire pump must deliver the required pressure and volume when it matters most.

In Connecticut, commercial fire pump installations must align with applicable state codes, local requirements, and NFPA 20. The right system also needs to match the building’s water supply, occupancy, hydraulic demand, and operating conditions.

Why Do Commercial Facilities Need Fire Pump Systems?

Municipal water supplies do not always provide sufficient pressure or flow for a building’s fire protection demands. This can become a major concern in large commercial properties, high rise buildings, warehouses, manufacturing facilities, and buildings with extensive sprinkler networks.

A fire pump increases water pressure and moves the required volume through the fire protection system. It helps ensure that sprinklers and standpipes receive adequate water during an emergency.

The pump is only one part of the system. The overall installation can include:

• Fire pump

• Electric or diesel driver

• Fire pump controller

• Suction and discharge piping

• Pressure sensing equipment

• Test header or flow test arrangement

• Fire department connection

• Valves and gauges

• Backup power provisions where required

Each component needs to work together as part of a properly engineered fire protection system.

What Does Connecticut Code Require?

Connecticut requirements are based on the state's adopted building and fire safety codes. Where fire pumps are provided, Connecticut Fire Pump code provisions reference NFPA 20 for their installation.

The Connecticut State Fire Safety Code also gives fire code officials authority to require construction documents and calculations for fire protection systems before installation. Contractors may also need to provide documentation confirming that the system was installed and tested according to approved plans and applicable standards.

This makes proper engineering and documentation an important part of any commercial fire pump project.

How Is the Right Fire Pump Selected?

There is no universal fire pump size for every commercial facility.

Pump selection begins with understanding the building's hydraulic requirements and available water supply. Engineers evaluate factors such as required flow, pressure demand, building height, sprinkler requirements, standpipe demand, available suction pressure, and system configuration.

Common fire pump configurations can include horizontal split case, vertical turbine, and end suction pumps. The appropriate design depends on the specific project rather than simply choosing the largest available pump.

Oversizing can create unnecessary costs and operational concerns, while undersizing can prevent the fire protection system from achieving its required performance.

Electric vs. Diesel Fire Pumps

Commercial facilities may use electric or diesel driven fire pumps depending on project requirements.

Electric fire pumps can provide a practical solution where a suitable electrical supply is available. Their installation must account for the reliability and protection of the power supply.

Diesel fire pumps can provide an alternative where electrical reliability is a concern or where project requirements call for an independent driver.

Connecticut provisions also address protection of circuits serving required fire pumps. For example, the 2022 Connecticut State Fire Safety Code includes requirements concerning survivability of critical circuits and specific provisions for electric fire pumps in buildings with standby electrical power.

The final selection should be based on the facility's engineering requirements, code requirements, and approved design.

Why Does Fire Pump Room Design Matter?

A fire pump cannot perform reliably if its environment compromises operation.

Connecticut code provisions require fire pumps to be protected against conditions that could interrupt service. These can include fire, flooding, freezing, vandalism, and other hazards identified by NFPA 20.

Fire pump room design should therefore consider:

• Required fire separation

• Adequate access

• Temperature control

• Ventilation

• Drainage

• Equipment clearances

• Electrical protection

• Maintenance access

The 2022 Connecticut State Fire Safety Code specifically references separation requirements for rooms containing fire pumps.

A well planned pump room makes inspection, testing, servicing, and emergency operation easier.

Testing and Maintenance Are Not Optional

Installing a compliant fire pump is only the beginning. Commercial facilities need ongoing inspection, testing, and maintenance to keep the system ready.

NFPA 25 provides requirements for inspection, testing, and maintenance of water based fire protection systems. Connecticut's fire safety provisions also reference NFPA 25 for periodic inspection, testing, and maintenance of fire department connections.

Facility managers should maintain accurate records and address issues such as:

• Abnormal pressure readings

• Valve problems

• Controller alarms

• Engine or motor issues

• Leaks

• Corrosion

• Battery problems

• Unusual pump performance

Routine testing can identify developing problems before they become emergency failures.

Why Work With an Experienced Fire Pump Provider?

Commercial fire pump projects involve more than supplying a pump. The system needs to be properly selected, configured, installed, tested, and documented.

An experienced provider can help coordinate pump selection with hydraulic requirements, controllers, drivers, piping, testing arrangements, and applicable code requirements. This can reduce design conflicts and make the approval process smoother.

For Connecticut commercial facilities, the project should also account for requirements from the authority having jurisdiction, or AHJ. Connecticut's fire code framework allows officials to review construction documents and require appropriate permits and approvals for fire protection system work.

Build a Fire Protection System Ready for the Moment It Matters

A commercial fire pump system should never be treated as just another mechanical installation. It is a critical part of the building's fire protection infrastructure.

From hydraulic calculations and pump selection to installation, testing, and maintenance, every stage affects system reliability.

For Connecticut commercial facilities, choosing the right fire pump system means combining engineering, code compliance, dependable equipment, and professional support. A properly designed system helps ensure that the building's fire protection network has the pressure and flow it needs when an emergency demands it.

How Do Jockey Pump Controllers Differ From Fire Pump Controllers?

 

A fire protection system relies on more than just pumps and sprinkler heads. Behind the scenes, controllers determine when pumps start, how they operate, and how the system responds to changing pressure conditions.

Two controllers often found in the same fire pump room are the jockey pump controller and the fire pump controller. Although both respond to pressure changes, they serve very different purposes.

A jockey pump controller maintains normal system pressure and handles minor pressure losses. A fire pump controller starts and controls the main fire pump when the system experiences a significant pressure drop that indicates actual water demand.

Understanding the difference is important when designing, installing, servicing, or upgrading a fire protection system.

What Is a Jockey Pump Controller?

A jockey pump controller is designed to operate a jockey pump, also called a pressure maintenance pump. Its primary job is to maintain the pressure within a fire protection system when there is no significant water flow.

Fire sprinkler piping can experience small pressure losses for several reasons. Minor leakage, temperature changes, maintenance activities, or gradual pressure variations can cause the system pressure to fall.

Instead of allowing every small pressure drop to start the main fire pump, the jockey pump restores the pressure.

The controller monitors system pressure and starts the jockey pump when pressure reaches its predetermined cut-in point. Once pressure is restored, it stops the pump at the configured cut-out point.

NFPA 20 describes the jockey pump as a pressure maintenance or make-up pump intended to maintain system pressure when the system is not flowing water.

In simple terms, the jockey pump controller handles pressure maintenance.

What Is a Fire Pump Controller?

A fire pump controller is responsible for controlling the main fire pump that supplies water during a fire event or another significant demand condition.

When water begins flowing through sprinkler heads, standpipes, hose stations, or other fire protection equipment, system pressure can drop substantially. If the pressure falls to the fire pump controller's start setting, the controller automatically starts the main fire pump.

Fire pump controllers are specifically designed for fire protection applications and are built around requirements established by NFPA 20. Depending on the system, they can control electric motor driven or diesel engine driven fire pumps. Listed fire pump controllers are available with features such as automatic starting, monitoring, alarms, event logging, and power transfer equipment where applicable.

The main objective is not simply to maintain pressure.

It is to make sure the fire pump is ready to deliver the required water supply when the system needs it.

Jockey Pump Controller vs Fire Pump Controller

The easiest way to understand the difference is to look at what each controller is designed to accomplish.

Feature	Jockey Pump Controller	Fire Pump Controller
Controls	Jockey pump	Main fire pump
Primary purpose	Maintain system pressure	Provide required fire flow
Typical trigger	Minor pressure drop	Significant pressure drop
Pump size	Usually smaller	Typically much larger
Main function	Pressure maintenance	Fire protection water delivery
Controller requirements	Appropriate industrial/controller requirements	Fire pump specific requirements
Typical operation	Frequent short cycles	Starts during actual demand or testing
System role	Prevents unnecessary fire pump starts	Delivers water during fire demand

The two controllers therefore work together rather than compete with each other.

How Do the Controllers Work Together?

Think of the fire protection system as having two layers of response.

The jockey pump handles the small pressure changes.

The fire pump handles the serious ones.

For example, suppose a sprinkler system normally operates at a stable pressure. A small pressure loss occurs because of a minor leak.

The pressure drops to the jockey pump controller's start setting.

The jockey pump starts.

It restores system pressure and shuts down once the pressure reaches its stop setting.

Now imagine a sprinkler activates during a fire.

The water demand is much greater than the jockey pump can handle. System pressure continues to fall despite the jockey pump operating.

When the pressure reaches the fire pump controller's start setting, the main fire pump starts.

This staged response helps prevent the main fire pump from starting every time the system experiences a small pressure fluctuation.

NFPA technical material discusses the use of different pressure settings between jockey and fire pump controllers to help prevent unintended fire pump starts and nuisance conditions.

Why Are Jockey Pump Controllers Important?

Without an appropriately designed jockey pump arrangement, minor pressure losses could repeatedly trigger the main fire pump.

That is undesirable for several reasons.

First, unnecessary fire pump starts can increase mechanical and electrical wear. Second, repeated operation can make system maintenance more demanding. Third, frequent starts can create confusion when operators are trying to determine whether the system is responding to an actual fire protection demand.

A jockey pump provides a smaller, controlled method of restoring pressure.

Modern jockey pump controllers can include features such as adjustable cut-in and cut-out pressure settings, manual and automatic operation, pressure monitoring, motor overload indication, pump start counters, elapsed time meters, and timers.

The exact configuration should always be based on the fire protection system design, applicable codes, equipment listings, and the requirements of the authority having jurisdiction.

Why Is a Fire Pump Controller Different?

A fire pump controller has a much more critical responsibility.

During a fire, the controller must initiate fire pump operation when the system requires it and provide the appropriate control and monitoring functions for the fire pump installation.

Because the consequences of failure can be severe, fire pump controllers are subject to fire protection specific requirements and listings.

For example, listed electric fire pump controllers are manufactured for fire pump service and can incorporate different motor starting methods, monitoring functions, and automatic transfer switch configurations depending on the application.

Diesel engine fire pump controllers have their own specialized control requirements because the prime mover, starting system, batteries, fuel system, and monitoring requirements differ from those of an electric motor driven pump.

This is one of the biggest differences between the two controller types.

A jockey pump controller primarily manages a relatively small pressure maintenance pump. A fire pump controller manages equipment that forms a critical part of the building's fire suppression water supply.

Are Jockey Pump Controllers and Fire Pump Controllers Interchangeable?

No.

Although both controllers monitor pressure and can automatically start their associated pumps, they are not interchangeable components.

A jockey pump controller is selected for the jockey pump's motor, electrical characteristics, operating requirements, and pressure maintenance function.

A fire pump controller must be specifically suitable for the fire pump application and comply with the applicable requirements, listings, approvals, and installation conditions.

Using the wrong controller can affect system performance, compliance, reliability, and inspection acceptance.

It is also important not to assume that a standard industrial motor controller can simply replace a listed fire pump controller. Fire protection equipment has application specific requirements that must be considered during system design and installation.

What Should You Consider When Selecting a Controller?

Choosing the right controller requires more than matching voltage and horsepower.

Consider:

Pump type: Determine whether the controller operates a jockey pump, electric fire pump, or diesel driven fire pump.

Motor requirements: Voltage, phase, horsepower, starting method, and other electrical characteristics must match the application.

Pressure settings: Jockey pump and fire pump start and stop settings must be coordinated correctly.

System design: The controller should support the operating requirements of the complete fire protection system.

Listings and approvals: Verify that the equipment has the required listing or approval for its intended application.

Environmental conditions: Enclosure type, temperature, moisture, and installation location can affect controller selection.

AHJ requirements: Local authorities and project specifications may impose additional requirements beyond the basic equipment selection.

Working with an experienced fire pump professional can help ensure that the controller, pump, piping, power supply, and system controls operate as one properly coordinated system.

The Bottom Line

A jockey pump controller and a fire pump controller may sit next to each other in the same pump room, but they have completely different jobs.

The jockey pump controller maintains pressure during normal conditions and responds to minor pressure losses.

The fire pump controller starts and controls the main fire pump when significant pressure loss indicates a genuine demand for fire protection water.

Together, they create a coordinated response. The jockey pump handles routine pressure maintenance, while the main fire pump remains available for the high-demand conditions it was designed to handle.

For any fire pump installation, controller selection should be based on the complete system design, applicable NFPA requirements, equipment listings, manufacturer specifications, and local AHJ requirements.

Need Help With Your Fire Pump System?

Choosing the right controller is only one part of designing a dependable fire protection system. The pump, controller, pressure settings, power supply, piping, and monitoring equipment all need to work together.

Callaghan Pump & Controls can help you evaluate your fire pump and jockey pump requirements and identify the right control solution for your application.

Which Factors Should You Consider Before Installing a Variable Speed Booster Pump?

 

Water pressure problems rarely announce themselves. They appear as weak showers, inconsistent water flow, inefficient operations, and frustrated building occupants. Whether you manage a commercial facility, residential complex, industrial plant, or municipal system, maintaining consistent water pressure is essential.

This is where a variable speed booster pump becomes a smart solution. Unlike traditional constant speed pumps that operate at one fixed speed, variable speed systems automatically adjust motor speed according to real-time water demand. This helps improve efficiency, reduce energy consumption, and maintain stable pressure throughout the system.

However, choosing and installing the right system requires careful planning. Several factors influence the performance, reliability, and long-term value of a variable speed booster pump.

Let’s explore the key considerations before installation.

What Is a Variable Speed Booster Pump?

A variable speed booster pump is an advanced pumping system designed to regulate water pressure by automatically adjusting pump speed based on demand.

Traditional pumps operate at full capacity whenever they run, even when water requirements are low. This can lead to unnecessary energy usage and mechanical stress.

A variable speed booster pump uses sensors, controllers, and variable frequency drives (VFDs) to monitor pressure changes and adjust performance accordingly.

For example:

• Low water demand → Pump slows down
• Increased demand → Pump speed increases
• Stable pressure requirement → System maintains optimized operation

This intelligent approach improves efficiency while extending equipment life.

Why Is Proper Planning Important Before Installation?

Installing a booster pump is not just about selecting a powerful motor and connecting pipes. A poorly designed system can result in:

• Pressure fluctuations
• Higher energy costs
• Frequent maintenance issues
• Reduced pump lifespan
• Improper water distribution

A detailed evaluation ensures the selected pump matches your building’s requirements and delivers reliable performance.

1. Understand Your Water Demand Requirements

The first step before installing a variable speed booster pump is understanding your actual water demand.

Every facility has different requirements based on:

• Number of occupants
• Building size
• Number of fixtures
• Peak usage hours
• Industrial processes
• Water consumption patterns

A residential building may experience high demand during mornings and evenings, while a commercial facility may require consistent pressure throughout operating hours.

Accurate demand calculations help determine the correct pump capacity, flow rate, and operating range.

Choosing an oversized pump can increase costs and waste energy. An undersized system may struggle to maintain pressure during peak demand.

2. Evaluate Required Flow Rate and Pressure

Flow rate and pressure are two of the most important factors when selecting a variable speed booster pump.

Flow Rate

Flow rate refers to the amount of water the pump must deliver within a specific time. It is usually measured in gallons per minute (GPM).

The required flow depends on:

• Fixture count
• Building usage
• Water consumption patterns

Pressure Requirements

The pump must also provide sufficient pressure to overcome:

• Building height
• Pipe friction losses
• Equipment requirements
• Distance between pump and usage points

A professional pump assessment helps determine the ideal pressure range without overworking the system.

3. Check Existing Plumbing System Conditions

Before installation, inspect the current plumbing infrastructure.

Important factors include:

Pipe Size

Incorrect pipe sizing can restrict water flow and reduce pump efficiency.

Pipe Condition

Old, damaged, or corroded pipes may create additional pressure losses.

Water Source

The pump must be compatible with the available water supply, whether connected to:

• Municipal water lines
• Storage tanks
• Wells
• Industrial water systems

A variable speed booster pump performs best when integrated with a properly designed piping system.

4. Consider Energy Efficiency Benefits

One of the biggest advantages of variable speed technology is energy savings.

Traditional pumps frequently operate at maximum speed regardless of demand. Variable speed systems reduce unnecessary operation by matching output with actual requirements.

Energy efficiency benefits include:

• Lower electricity consumption
• Reduced operating costs
• Less mechanical stress
• Improved system performance

The savings can be significant, especially in large commercial or industrial facilities where pumps operate for long hours.

5. Select the Right Pump Size and Configuration

Choosing the correct pump size is critical for long-term reliability.

Factors to consider include:

• Required flow capacity
• Pressure range
• Number of pumps needed
• Duty and standby requirements
• Future expansion plans

Many commercial systems use multiple pump configurations to improve reliability. For example, a duplex or triplex booster system can maintain water supply even if one pump requires service.

The right configuration depends on your facility’s operational needs.

6. Evaluate the Quality of Sensors and Controls

Sensors are the intelligence behind variable speed booster pumps.

Pressure sensors continuously monitor system conditions and send information to the controller, which adjusts pump speed accordingly.

A reliable system should include:

• Accurate pressure sensors
• Advanced control panels
• Variable frequency drives
• Automatic monitoring capabilities

High-quality controls help maintain consistent pressure and prevent unnecessary cycling.

7. Check Installation Space and Location

The installation environment plays an important role in pump performance.

Before installation, consider:

• Available equipment space
• Ventilation requirements
• Accessibility for maintenance
• Protection from extreme temperatures
• Noise considerations

A well-planned installation location makes future inspections, repairs, and upgrades easier.

8. Consider Maintenance and Service Requirements

Even the most advanced booster pump requires regular maintenance.

Before installation, review:

• Availability of replacement parts
• Service support
• Inspection requirements
• Preventive maintenance schedules

Regular maintenance helps identify issues early and prevents unexpected downtime.

Working with an experienced pump service provider ensures your system remains efficient and dependable.

9. Verify Electrical Requirements

Variable speed booster pumps rely on advanced electrical components, including VFDs and control panels.

Before installation, confirm:

• Available voltage supply
• Electrical capacity
• Control system compatibility
• Safety requirements

Incorrect electrical planning can affect pump performance and create operational problems.

10. Choose a Reliable Pump Manufacturer and Installer

The performance of your booster pump depends heavily on equipment quality and installation expertise.

A trusted pump specialist can help with:

• System evaluation
• Pump selection
• Installation
• Testing
• Maintenance support

Experienced professionals understand hydraulic requirements and ensure the system meets industry standards.

How Does a Variable Speed Booster Pump Improve System Performance?

A properly installed variable speed booster pump provides several benefits:

Consistent Water Pressure

The system automatically adjusts to maintain stable pressure throughout changing demand conditions.

Reduced Energy Consumption

The motor operates only at the speed required, improving efficiency.

Longer Equipment Life

Smooth speed adjustments reduce mechanical wear and unnecessary cycling.

Improved User Experience

Buildings receive reliable water pressure during both low and peak demand periods.

Common Mistakes to Avoid During Installation

Avoid these mistakes when planning your booster pump system:

❌ Selecting a pump based only on horsepower
❌ Ignoring peak water demand
❌ Choosing incorrect pressure settings
❌ Installing without proper system evaluation
❌ Neglecting future expansion needs
❌ Skipping regular maintenance planning

A properly designed system delivers better performance and greater return on investment.

Final Thoughts

A variable speed booster pump is more than just a water pressure solution. It is an intelligent system designed to improve efficiency, reliability, and long-term performance.

Before installation, factors like water demand, pressure requirements, plumbing conditions, energy goals, electrical compatibility, and maintenance needs must be carefully evaluated.

When selected and installed correctly, a variable speed booster pump provides consistent water pressure while reducing operational costs and improving system efficiency.

Partnering with an experienced pump professional ensures your investment delivers reliable performance for years to come.