Foam Solutions, LLC 2251 Performance Parkway, Columbus, Ohio 43207 Ph 614-586-1326; Fax 614-586-1278 Foam Proportioner Test Manual Aqua Foam Test Method U.S. Patent 7,080,694/7,513,315. Other patents pending Jan. 10, 2010
CONTENTS Page 1.0 INTRODUCTION... 1 1.1 Foam Fire Protection... 1 1.2 Requirements for Foam System Testing... 1 1.3 Foam System Inspection and Testing... 2 2.0 AQUA FOAM TEST METHOD... 3 2.1 General Description of the Method... 3 2.2 Attributes of the Method... 4 2.3 A Complete Foam System Inspection and Testing Program... 4 3.0 DESCRIPTION OF THE HARDWARE AND FORMS FOR AQUA FOAM TESTING... ERROR! BOOKMARK NOT DEFINED. 3.1 Components for an Aqua Foam Test...Error! Bookmark not defined. 3.2 Test Form...Error! Bookmark not defined. 3.3 Care and Maintenance of the Equipment...Error! Bookmark not defined. 4.0 INSTRUCTIONS FOR CONDUCTING AN AQUA FOAM TEST...ERROR! BOOKMARK NOT DEFINED. 4.1 Bladder Tank Systems... 9 4.2 ILBP System...Error! Bookmark not defined. 5.0 EXAMPLE OF AQUA FOAM TESTING... ERROR! BOOKMARK NOT DEFINED. 6.0 EQUIPMENT REQUIRED.. 19 6.1 Bladder Tank Systems... 19 6.2 ILBP Systems 19
1.0 INTRODUCTION 1.1 Foam Fire Protection FOAM PROPORTIONER TEST MANUAL AQUA FOAM TEST METHOD Foam fire protection systems are installed in many high hazard/high value locations. These systems are intended to suppress or extinguish very challenging Class B (flammable liquid) fires. Flammable liquid fires can grow extremely rapidly with tremendous heat output and must be rapidly controlled before building systems, contents and structures are destroyed. Foam fire protection systems discharge a foam solution (a mixture of foam concentrate at 1-6 percent concentration in water). The foam solution also is mixed with air at the discharge device or picks up air as the foam solution stream is applied. This water/concentrate/air mixture generates a mass of stable bubbles that form a foam blanket on the surface of a flammable liquid. The foam blanket extinguishes the fire primarily by sealing off and halting the vaporizing flammable liquid. The foam blanket also cools the fuel and fire exposed structure or contents. The foam blanket must be applied to and/or be able to flow over the entire flammable liquid surface to extinguish it. Flammable liquid firefighting relies on the foam blanket, which can only be generated when the proper ratio of foam concentrate is added to the water stream. It is imperative for the proper operation of a foam system, and the ability to provide flammable liquid fire protection, that the foam proportioning system is functioning properly. 1.2 Requirements for Foam System Testing The annual foam test is a crucial part of plant maintenance, these systems in most cases protect the most hazardous and flammable part of the facility. There are many cases where the systems are not flushed after the original acceptance testing. These systems tend to have blockages and corrosion in concentrate supply and proportioning equipment. NFPA 11 requires annual inspection and testing. The goal of this inspection and testing is to ensure that the system is in full operating condition and that it remains in that condition until the next inspection (section 11.1.4). NFPA 409 (section 11.1.1) requires an operational test with actual foam discharge on the foam proportioning device every 5 years. NFPA 16 also requires annual testing. In addition, most states have made testing part of their revised codes. 1
1.3 Foam System Inspection and Testing A. Background of foam system test difficulties: 1. The cost of concentrate is in the range of $20 to $40 per gallon. 2. A test on a 1000 Gallon Bladder Tank could use from 50 to 200 Gallons of foam concentrate for a foam only cost of $1500 to $6,000 3. The disposal of the foam consists of three parts. Capturing the foam Transportation / Clean up Disposal 4. Capturing the foam / Trucks, Tankers, Drivers ($800 per day) 5. Disposal of foam / Waste water treatment Plant/ Incineration/ Recycling (.20 to 2.00 per gallon) 6. Clean up and spillage / Vacuum tanks and Trucks, Labor ($500 - $5000) 7. The ongoing testing has several obstacles The Facility management and the A.H.J having proper knowledge and training of the system. Coordinating a test that can involve: Plant, Environmental department, Safety, Maintenance, Production. Outside, AHJ, Underwriter, Fire Protection Contractor, Foam Manufacturer, Transport Company, Offsite disposal facility. The overall cost. 2
2.0 AQUA FOAM TEST METHOD 2.1 General Description of the Method In this document, the word system is used to refer to the actual installed foam system. An Aqua Foam test is a single run of the system with water used in place of foam concentrate. The word method is used to refer to the overall process of testing a foam system; including the initial foam system discharge test, the first Aqua Foam test, the Aqua Foam test apparatus and the follow on Aqua Foam tests. The method relies on an initial foam system discharge test to establish that the system is working properly and to determine the concentration the proportioner is developing. This test is conducted in the same fashion as any other foam proportioning system acceptance test. This test is immediately followed by an Aqua Foam test (AFT) at the exact same conditions as the initial foam discharge test. This is a patented method, U.S. Patent 7,080,694/7,513,315 and other patents pending. An Aqua Foam test essentially replaces the foam concentrate supply to the proportioner with water, see Figure 1 and Figure 2. The flow rate of the system and the flow rate of the water used in place of the concentrate are both measured with precision flow meters, and an AFT proportioning rate is established. The proportioning system can then be tested in the future by repeating an AFT and comparing the results to the initial AFT. Flow of foam concentrate is not necessary. As long as the water proportioning rate from the original AFT and the new AFT are within +/- 5 percent, or a limit established by the Authority Having Jurisdiction, the system is considered to be proportioning within the bounds of the original foam concentrate acceptance test. For a complete test of the operation of the foam system, the following would also typically be performed; a concentrate test (sample sent to the manufacturer or other test lab), a concentrate delivery test (the foam pump would be run and tested for pressure and flowrate at the proportioner the concentrate being returned to the tank), and a valve operation test (ensure all valves are operating properly), etc 3
2.2 Attributes of the Method After the initial foam system acceptance test, this method of foam proportioning system testing has several positive attributes over continuing tests with foam concentrate. These include: A. Cost savings of the foam concentrate. B. Water only testing which has no environmental or clean up concerns. C. Ability to allow the system to operate for longer period of time while only flowing water. D. Ability to vary the system operating parameters over a wide range of flow rates. E. Simple set-up of equipment and ease of conducting the tests. F. Meeting manufactures requirements for flushing the system with water. Currently, discharge testing of foam systems (outside of system acceptance testing) is rarely performed because of the cost, clean up, and complications. The advantages of this method could lead to a significant increase in the frequency of system testing and also to more thorough and complete testing. An increase in system reliability would be expected. For a new foam system installation (or possibly even for some existing systems), the required piping and/or instrumentation for Aqua Foam testing could be permanently included as part of the system. This would result in very efficient and inexpensive testing of the system, along the lines of a sprinkler system flow test. A cost comparison is shown in Table 1. 2.3 A Complete Foam System Inspection and Testing Program A. Describe as part of a complete test program for a foam system. 1. The foam concentrate sample must be sent to certified lab for testing 2. The foam pump flow rate and pressure which must meet manufactures specifications 3. All controllers and activation equipment must be tested 4. The system total water flow must be tested and verified 5. The level of the foam concentrate tank must be verified 6. All foam makers and nozzles must be inspected 7. The foam proportioning system must be tested 4
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