Preventive Maintenance in Pharmaceutical Firefighting Systems

My housing society conducts fire drills regularly. It’s a responsible and necessary exercise, but the poor turnout says otherwise. Participation dropped so low that a special meeting was held to address residents who never showed up. They were reminded of how critical fire safety is, not just in homes, but across industries. As a life engineer, working in pharmaceutical engineering, I spoke up to share how seriously fire prevention is taken in our field.

Preventive maintenance in firefighting systems plays a key role in ensuring optimal fire risk management in pharma facilities, along with protection from operational disruptions and contamination risks.

Key aspects of preventive maintenance in pharmaceutical fire safety:

1. Fire Detection and Alarm Systems

Regular checks of fire alarm and detection systems are essential to verify that smoke detectors, heat sensors, visual and audible alarms, and control panels are fully functional, are free from dust or obstruction, and are capable of alerting personnel without delay. Fire alarms must undergo monthly functional tests, while control panels and backup batteries should be inspected and serviced on an annual basis by certified professionals.

2. Sprinkler Systems

These systems play a vital role in automated fire suppression, especially in areas that may not always be staffed. Routine visual inspections help identify any leaks, corrosion, or misaligned sprinkler heads. Flow testing is typically carried out quarterly to verify that the system is delivering the required water pressure and that the distribution meets the required standards. In sterile or cleanroom environments, it’s important to ensure that these systems adhere to GMP-compliant fire systems to avoid contamination.

Read More: All about Good Manufacturing Practices (GMP) guidelines for pharmaceuticals Ensuring Quality in Manufacturing

3. Hydrant Systems and Hose Reels

They require periodic checks, typically twice a year, to ensure that hoses are intact, nozzles function properly, and pressure levels are within the required range. Hoses must be free of cracks, mildew, or kinks, and should be neatly rewound after testing to prevent long-term damage.

4. Portable Fire Extinguishers

They are often the first line of defence in small-scale incidents, and must be checked monthly for pressure status, damages, accessibility, and intact seals. They must be easily accessible and appropriate for the type of fire risk in the area—for example, CO₂ extinguishers near electrical panels or foam extinguishers near solvent storage. Expired or used extinguishers must be serviced or replaced promptly, with all checks properly documented and tagged. 

5. Fire Pump (including jockey pumps and diesel-powered backups)

They are essential for maintaining water flow during emergencies. These systems require weekly test runs to check for proper automatic and manual operation. Maintenance checks must include the condition of electrical wiring, alignment of pump shafts, and lubrication levels. In diesel systems, fuel levels, oil quality, and battery health are crucial to reliability. All tests should be logged digitally in the facility’s computerised maintenance management system (CMMS) during audits.

6. Clean Agent Suppression Systems

For areas where water-based suppression is not suitable, such as server rooms or certain sterile manufacturing zones, clean agent systems like FM-200 or Novec 1230 are used. These systems must be inspected regularly to ensure that cylinder pressure is within limits, pipes are leak-free, and discharge nozzles are properly aligned. Annual room integrity tests, such as door fan tests, help confirm that the agent will remain in the room long enough to suppress a fire effectively.

7. Emergency lighting and Fire Safety Signage

They are also integral to preventive maintenance. Exit signs, directional arrows, and backup lighting must be tested routinely to ensure they remain visible during power outages. Damaged or faded signs must be replaced immediately, especially in complex facility layouts where quick evacuation is crucial.

8. Fire Doors

Fire doors are a critical line of defence in containing fire and smoke, especially in high-risk areas like solvent storage, production lines, and corridors connecting cleanrooms. These doors must be routinely inspected for proper closure, seal integrity, and unobstructed access. Automatic fire doors linked to alarm systems should be tested for functional response during simulations. Fire-rated doors connected to alarm systems should be tested to ensure they close automatically during simulations or drills.

9. Electrical Systems

Electrical systems, if not properly maintained, can become another source of fire. Electrical panels, distribution boards, and cable trays should be inspected for overheating, loose wiring, or corrosion. Thermographic scanning can help detect hot spots early, especially in high-load zones like HVAC systems or production machinery. Proper earthing, load balancing, and periodic testing of emergency shutdown systems must be part of the facility’s preventive maintenance routine. In cleanroom areas where vapours or fine particles may be present, all equipment must meet flame-retardant or explosion-proof standards.

10. Storage of Flammables

Flammable substances like solvents, alcohols, and other combustible chemicals must be stored in fire-rated cabinets or explosion-proof rooms, with clear labelling and separated based on compatibility. Quantities should be limited to operational needs, and bulk storage should be located away from production or clean areas. Ventilation systems in these storage zones must be regularly inspected to prevent vapour accumulation. Spill kits must be available, and spill response protocols must be well understood by all staff.

11. Training and Awareness

All employees, from engineering and maintenance teams to production operators and housekeeping staff, must be trained in fire prevention in the pharmaceutical industry, use of firefighting equipment, evacuation protocols, and emergency response. Fire drills should be conducted regularly across all shifts, and the results reviewed to identify gaps or delays. Specialised training must also be provided to personnel working in high-risk zones, such as solvent handling rooms, battery charging areas, or HVAC control rooms. Signage, floor markings, and access to fire safety manuals further reinforce awareness and preparedness across the facility. 

12. Documentation and Compliance

All maintenance activities must be thoroughly documented, with a preventive maintenance calendar and SOPs tailored to the needs of specific zones, such as production, warehouse, cleanroom, or solvent handling areas. Maintenance tasks should ideally be coordinated with production downtimes to avoid disruptions. Where possible, fire safety systems in pharma should be integrated with the facility’s Building Management System (BMS), allowing alerts to be tracked and acted on in real time.

By implementing a comprehensive preventive maintenance program, pharmaceutical companies can significantly enhance the reliability and effectiveness of their firefighting systems, creating a safer and more secure environment for their operations. 

In pharmaceutical engineering fire safety, preventive maintenance is about going beyond routine inspection and supporting long-term operational reliability, protecting life and property, and upholding the industry’s commitment to safety, compliance, and product integrity.

In our industry, where the cost of failure can be high, the goal is not only to extinguish fire risks but to design them out before they ever ignite.

Fabtech’s Perspective: Safety by Design 

As experts in turnkey engineering for pharmaceutical and high-tech facilities, we, at Fabtech, understand how critical fire prevention is for the overall operational safety, compliance, and business continuity. Our holistic project approach ensures that every aspect, from HVAC and cleanroom safety to utilities and infrastructure, is designed with safety, precision, and industry standards in mind.

We believe that sharing knowledge strengthens the entire ecosystem.

Stay connected with us for more insights that support safe, compliant, and future-ready facilities.