Foam System Testing And Calibration Today’s Program Foam System Testing And Calibration

Your Presenters Are… Jim Johannessen Bill Ballantyne Fire Equipment Services Group of Underwriters Laboratories Inc. for the past 26 years Member of the NFPA 1901 (Automotive Apparatus) and 1500 (Fire Department Occupational Safety and Health) Committees Bill Ballantyne Vice President – FoamPro (16 years) President Fire Apparatus Manufacturers Association (2004) NFPA 1901 Committee Principal Member (FAMA) Chairman – Foam Technical Committee

Disclaimer… This is not an official NFPA presentation No committee member can speak for the NFPA Members can only give their opinion

NFPA Standards Compliance with standards is Voluntary They are Minimum standards They are Consensus standards Committee work is voluntary – No Pay

NFPA Standards… Editions are reviewed and updated every 5 years Editions can be “short-cycled” to address significant developments or changes A TIA (Temporary Interim Amendment) can be implemented to address issues that may arise Over 250 standards in the NFPA system

NFPA Standards… Main body is mandatory…SHALL Annex material is recommended… SHOULD

NFPA Apparatus Committee NFPA 1901 Committee is responsible for: 1901: FD Apparatus 1906: Wildland Apparatus 1911: In-Service Testing, Maintenance and Replacement 1912: Refurbishment

NFPA Apparatus Committee… Committee balance is mandatory 1/3 Fire Service (10) 1/3 Manufacturers (10) 1/3 Experts, Specialists, Testing (10)

NFPA Apparatus Committee… Almost all current members have been in the fire service Chairman is always a fire service officer Chief Don Frazeur, LAFD

One Last Word About The Standard Everything in 1901 is there for a reason! Usually something undesirable has happened: A firefighter has been injured or worse, killed Pay attention – they could save your life!

NFPA 1901 2009 Edition Now available. Order at: 800-344-3555 www.nfpa.org Applies to all orders signed after January 1, 2009

Proportioning Rates Ratio of concentrate to water Expressed as a percentage 1.0% = 1 unit of concentrate to 99 units of water 3.0% = 3 units of concentrate to 97 units of water 0.5% = 0.5 unit of concentrate to 99.5 units of water

Common Proportioning Rates Class A 0.1% - 1.0% Class B 1%, 3%, 6% (1% x 3%), (3% x 6%), (3% x 3%) (Hydrocarbons x Polar Solvent fuels) Emulsifiers / Gels Varies by manufacturer / usage

NFPA 1901 and 1906 Now Require… For proportioning rates equal or greater than 1%: - 0% to + 30% or 1 percentage point, whichever is less (20.10.3) For proportioning rates less than 1%: - 0% to + 40% (20.10.2) 6% 30% 20% 10% 3% 1% - + 40% Lean Rich Allowable Range: 6%: 6.0 – 7.0% 3%: 3.0 - 3.9% 1%: 1.0 – 1.3% 0.5%: 0.5 – 0.70% 0.2%: 0.2 – 0.28%

Why Is Accuracy So Important? Performance Ability to make wet, fluid or dry foam (Class A foam) Ability to richen for heavy rain (Class B foam) Ability to seal (Class B foam) Logistics Cost Environmental Concerns (Class B)

Manufacturer’s Responsibilities – What to Expect Chapter Four of NFPA 1901 requires: If the apparatus has a foam proportioning system, the foam proportioning system manufacturer’s certification of accuracy (see 20.10.4.2) and the final installer’s certification the foam proportioning system meets this standard(see 20.11.2)

Labels and Instruction Plates An instruction plate shall be provided for the foam proportioning system that includes, at a minimum, a piping schematic of the system and basic operating instructions.

Labels and Instruction Plates Foam classification type Maximum and minimum proportioning rates (percent) Maximum and minimum waterflow [gpm (L/min)] Maximum and minimum operating pressures The statement “Use only concentrates that are compatible with this foam proportioning system. Refer to the foam proportioning system manufacturer’s operating manual.”

Foam Proportioning System Accuracy. The foam proportioning system shall be type tested and certified by the foam proportioning system manufacturer to be accurate throughout the foam proportioning system’s declared range of waterflow, water pressure, foam percentage (or foam proportioning system capacity), and concentrate viscosity.

The methods of testing a foam proportioning system for calibration accuracy. Substituting water for foam concentrate Measuring foam concentrate pump output directly Determining foam percentage by use of a refractometer Determining foam percentage by use of a conductivity meter

How Accurate Are These Test Methods? Volumetric is most accurate (and least expensive) Measuring equipment must be calibrated correctly Foam viscosities may effect your results if you are substituting water for foam Conditions may not lend themselves to using refractometer or conductivity

Substituting water for foam concentrate The proportioning system is operated at the waterflow rates at which the system is to be tested. Using water as a foam substitute draw from a separate calibrated tank rather than the foam concentrate tank. The volume of water drawn from the calibrated tank divided by the volume of water pumped over the same time period multiplied by 100 represents the percentage of foam the proportioning system is producing.

Measuring foam concentrate pump output directly With the foam proportioning system operating at a given waterflow rate and either foam concentrate or water used as a substitute for foam concentrate, the output of the foam concentrate pump is measured by diverting that output into a calibrated container for direct measurement over a given period of time. An alternative is to measure the foam concentrate flow or water substitute with a calibrated meter.

Determining Foam Percentage by Use of a Refractometer. This test determines the accuracy of a foam system’s proportioning equipment by measuring the percentage concentration of a foam concentrate in the foam solution.

Determining Foam Percentage by Use of a Refractometer. The amount of foam concentrate in the solution is measured with a refractometer. A base calibration curve is first drawn using the samples of foam concentrate and water taken from the foam system. Samples of the actual foam solution produced by the system are then tested and plotted on the graph. The results must fall within the parameters set by NFPA

Determining Foam Percentage by Use of a Conductivity Meter. The conductivity test method is based on changes in electrical conductivity as foam concentrate is added to water. The accuracy of this type of testing will deteriorate as the conductivity of the water and concentrate approach each other.

Measuring Foam Output Using The Volumetric Method

Instrumentation The instruments on the right of the ruler are conductivity meters and the instrument on the left is a refractometer

NFPA 1911 Standard for the Inspection, Maintenance, Testing, and Retirement of In-Service Automotive Fire Apparatus 2007 Edition

Performance Testing Of Foam Proportioning Systems (1911) 20.1 Test to determine if capable of delivering foam for the agents used 20.1.1 Tested at least annually 20.1.2 Inspect all components 20.2 Operated at % specified by AHJ at flows and pressures for the agent(s) used 20.2.1 Measure calibration accuracy 20.2.2 Use same test points for every test 20.3 Acceptable Testing Methods 20.4 Test all concentrates carried 20.5 Meet accuracy level in effect during install

NFPA 11 Inspection and Test Forms

NFPA 1901 Purchaser Requirements 20.3.2 The purchaser shall specify the following: Range of waterflows and pressures Proportioning rates Types of concentrate(s) (Class A, Class B, etc) Brand and viscosity of concentrate

20.10 Foam Proportioning System Accuracy (1901 and 1906) 20.10.1 The foam proportioning system shall be type tested and certified by the foam proportioning system manufacturer to be accurate throughout the foam proportioning system’s declared range of water flow, water pressure, foam percentage (or foam proportioning system capacity), and concentrate viscosity.

Foam Percentage or Foam Proportioning System Capacity 20.10.1.1 Test Points for (Manufacturer’s) Certification of Foam Proportioning System Performance (1901 and 1906) Waterflow Water Pressure Foam Percentage or Foam Proportioning System Capacity Minimum Maximum Midrange

3-D Description Of Terms Water Flow Water Pressure Foam Output Maximum / Maximum / Maximum Midrange Minimum / Minimum / Minimum

20.11 Testing and Documentation 20.11.1 The final installer shall test and certify the following: The foam proportioning system, as installed, complies with the foam manufacturer’s installation recommendations. The foam proportioning system has been calibrated and tested to meet the foam equipment manufacturer’s and the purchaser’s specifications. At a minimum, the foam proportioning system has been tested at the points defined in Table 20.11.1 for each foam system injection point.

Foam Percentage or Foam Proportioning System Capacity 20.11.1 Test Points for Installation Testing of Foam Proportioning System Performance (1901 and 1906) Waterflow Water Pressure Foam Percentage or Foam Proportioning System Capacity Midrange Minimum Maximum

Performance Testing A FoamPro Most accurate test method is volumetric. Measure water by either flow or volume Flow using a pitot gauge Volume using a calibrated container Measure foam by volume or flow Flow using a calibrated flow meter

Tools Required Pitot gauge for measuring water flow Calibrated container for collecting foam (water) Pressure gauge with load valve to set “back pressure” Stop watch

Measuring Water Flow – Pitot Gauge

Pressure Gauge / Load Valve Assembly To Simulate Back Pressure In Foam Line Plumb to calibrate side of Cal / Inject Valve Use Load Valve to adjust Back Pressure

Installer Testing A FoamPro Model 2001 And 2-1/2” Flowmeter Cross reference the proportioner model and the flowmeter size on the testing matrix chart Water Flow: Use Simulated Flow Rate: Foam Percentage: Water Pressure Set At: Foam System Output Should Be: 250 GPM 100 0.8% 400 PSI 0.8 Gallons 750 GPM 2.6% 150 PSI 2.6 Gallons 20 GPM 20 0.1% 0.02 Gallons

Download this presentation at: Questions / Comments Jim Johannessen james.johannessen@us.ul.com 717-459-3391 Bill Ballantyne bill.ballantyne@hypropumps.com 651-766-6308 Download this presentation at: www.foampro.com

And Finally, Remember To Always: Buckle Up! Use Foam! Be Safe! Thank You!