001330

FOAM CONCENTRATES AND

FOAM PRE-MIX SOLUTIONS
Field Inspection Manual

INTRODUCTION

RELATED INFORMATION

This manual is designed to serve as a guide to inspection

procedures for ANSUL Foam Concentrates and Pre-mix
Solutions.

The following is a list of Technical Bulletins that can be

found in the Appendix of your Foam Systems Design
Manual or at A N S U Ls internet home page
www.ansul.com.

As ANSUL manufactures many types of foam concentrates,

locate the product data sheet for the specific concentrate to
be tested. Product Data Sheets can be accessed at
www.ansul.com.
The designated inspector should be a responsible, experienced person with sound, basic knowledge of fire equipment hardware and extinguishing agents. A t h o r o u g h
briefing on the procedures to be followed should include the
need for precise execution of each analysis step.
Form No. F-8822 is included in this manual for use in
recording proportioning results.
Form Part No. 428680, Foam Analysis Request, is for use
in recording the information required when sending in
samples to the ANSUL Agents Laboratory. This form also
outlines the correct procedure for submitting samples.
Review and complete the form as thoroughly as possible.
This form is included in the Foam Agent Test Kit, Part No.
428679. It is also available on www.ansul.com under Foam
Products. (N o t e : There is a charge for this testing service.)
FREQUENCY AND ACCURACY OF TESTS
ANSUL recommends that proportioning tests be done at
system commissioning and every three (3) years minimum
thereafter.

Technical Bulletin Number 52

(Environmental Impact of ANSULITE AFFF Products)
Technical Bulletin Number 54
(Shelf Life of ANSULITE AFFF Concentrates and Their
Pre-mixed Solutions)
Technical Bulletin Number 55
(Aspirated Versus Nonaspirated AFFF)
Technical Bulletin Number 59
(Acceptable Materials of Construction For Use Wi t h
ANSUL Foam Concentrates)
Technical Bulletin Number 60
(Foam and The Environment)
Technical Bulletin Number 64
(Compatibility of AFFF/Alcohol-Resistant AFFF
Concentrates)
REFRACTIVE INDEX VS. CONDUCTIVITY
ANSUL recommends refractive index testing instead of
conductivity testing in the field because there is less chance
of results being skewed by water quality or temperature.
Also, continuous stirring is required during conductivity
testing to obtain stable results.

ANSUL recommends that Standard Quality Analysis Testing

be done annually by the ANSUL Agents Laboratory which
not only tests the chemical properties of the sample, but
also does lab scale fire testing to assure the products
performance. Packages of two (2) sample containers with
labels can be purchased under Part No. 428679.
STORAGE CONDITIONS
ANSUL recommends that its concentrates be stored at the
temperatures indicated on the specific product data sheet.
Accelerated aging studies have been conducted with the
concentrate and pre-mix solutions stored at 150 F
(65.5 C) with no adverse effect. However, Underwriters
Laboratory Standard No. 162 requires that the maximum
storage temperature be listed at 120 F (48.9 C).
Storage of concentrates below the minimum temperature
listed on the product data sheets could result in freezing. If
the agent freezes, it should be thawed at or near room
temperature and agitated or stirred to ensure a homogenous mixture. If previous freezing is suspect, agitation will
again ensure a homogenous mixture.
To maximize life of concentrates stored in atmospheric
storage tanks, ANSUL recommends that a 1/4 in. (0.6 cm)
layer of mineral oil be added to the air-exposed surface of
the concentrate. This is critical for Alcohol Resistant
Concentrates.

3-15-07

FOAM SOLUTION CONCENTRATION DETERMINATION

REFRACTIVE INDEX OR CONDUCTIVITY
This test is used to determine the percent concentrate of a
foam concentrate in the water being used to generate foam.
It is typically used as a means to determine the accuracy of
the systems proportioning equipment.
This method is based upon comparing foam solution test
sample to pre-measured solutions (Calibration Standard)
that are plotted on a baseline graph of percent concentration versus instrument reading.
A hand-held refractometer is used to measure the refractive
index of the foam solution sample. Scales on refractometers vary, but what is actually being used to determine
concentration is a change in reading from one premeasured solution to another (Calibration Standards
Curve vs. Discharge Samples). The philosophy applies
when using a conductivity meter which is measuring the
changes in the solutions conductivity. (Refer to Te s t
Instruments Data Sheet for more detailed information about
the specific meters.)
A base curve is prepared by using the following apparatus:
1. Four 100 ml or larger plastic bottles with leak-resistant
screw caps
2. One 10 ml (10 cc) measuring syringe
3. One 100 ml graduated cylinder
4. Four or more eye droppers
5. One Test Meter Model PA 202, 10419, 1500-32
6. Graph paper
7. Ruler or straight edge
Using water and foam concentrate from the system to be
tested, make up three 100 ml calibration standard solutions.
For a 6% concentrate, typically a 4%, 6% and 8% samples,
for a 3% concentrate, typically a 2%, 3% and 4% samples,
and for a 1% concentrate, typically a 0.5%, 1% and 1.5%
samples are made.
Label bottles with percent sample calibration solution that
will be utilized, i.e. 2%, 3% and 4% for a 3% concentrate.
As an example, for the 2% calibration solution sample,
measure 98 ml of system water in the graduate cylinder,
then pour into the bottle labeleled 2%. Then with the
measuring syringe, transfer 2 ml (2 cc) of the concentrate
into the labeled bottle. Secure the cap on the bottle and
shake to thoroughly mix the solution. Repeat for the 3%
calibration sample (97 ml water and 3 ml concentrate) and
for the 4% calibration sample (96 ml water and 4 ml
concentrate). Increasing sample sizes will increase
accuracy relative to the measurement instrument. After
thoroughly mixing the foam sample, a meter reading is
taken of each percentage foam solution sample. It is important that temperatures between discharges samples and
calibration standards have normalized with temperatures
above 50 F working best. Each instrument has specific
instructions for its correct operation.

3-15-07

Using the graph paper, plot the meter reading on the X axis
and the percent concentrate reading on the Y axis. This
plotted curve will serve as the known baseline for the
proportioning test. Meters may have different scales and
the plotted resolution should be as large as possible with
the complete range of the calibration solutions known. The
scale you set must be linear.
Collect foam solution sample from the proportioning
system, using care to ensure that the sample is taken at an
adequate distance downstream from the proportioner being
tested. (Usually any place downstream of the first change in
direction is adequate if samples are taken in the riser
room.) Stabilize a water flow through your discharge device
within the known acceptable range for the proportioner and
open the concentrate control valve. Take the sample about
30 to 60 seconds after foam appears from the test connection. Take meter readings of the samples and compare
them to the plotted curve to determine the percentage of
the samples.
Per NFPA 11, Standard for Low-, Medium-, and HighExpansion Foam, acceptable ranges of proportioning
systems are not less than the rated concentration and not
more than 30% above the rated concentration or one
percentage point above the rated concentration, whichever
is less. For example, the acceptable range for a 3%
concentrate is from 3 to 3.9%.
Note: There is some variability dependant on the accuracyy
of the meter, the accuracy to which the calibration samples
were made, and if temperatures between calibration standards and discharge samples have not normalized.
Conductivity is especially susceptible to reading fluctuation,
thus the sample should be continuously stirred until a stabilized reading can be estimated. Care should be taken to
not bump the sides or bottom of the sample container or
contaminate the sample with salts or solids, i.e. dirty fingers
while stirring. The conductivity of water stored in or for
systems can vary throughout a discharge which may affect
results. Conductivity should not be used for sea, salt, or
brackish water supplies. Although conductivity can be the
most accurate means of measuring foam solution in clean
water supplies under ideal conditions, with the stated
reasons A N S U L recommends that the refractive index
method is best for most real world testing.
If discharge samples are sent to ANSULs Lab for testing,
they should be packaged per the instructions with the Test
Kit and sent in for immediate processing. Largely dependent on water quality and the type of concentrate used,
foam solutions may start to biodegrade in a short period of
time which can affect results (possibly as little as three to
five days with nutrient-rich water and detergent-based foam
concentrates).
The following graphs are examples of typical refractive
index values for various concentrate pre-mixes. Results
may vary depending on the concentrate pre-mix type, site
water supply, and actual concentrate lot number. Therefore,
it is important that a new calibration curve be developed on
each date a proportioning test is required.

TYPICAL RESULTS WHEN USING PART NO. 405713 HANDHELD REFRACTOMETER

006876

NOTES:

006912

3-15-07

007596

3-15-07

SUGGESTED FOAM SYSTEM TESTING (BLADDER TANK

WITH TEST HEADER)
1. If bladder tanks are not filled, fill per ANSUL Bladder Tank
Manual or ANSUL representatives instruction.
2. Prepare required refractive index standards, and generate
refractive index curve for testing foam discharge samples
3. Prior to testing, make sure all valves on bladder tanks are
in the correct position. All 1 in. (2.5 cm) vent, fill and drain
valves should be closed. The hydraulic actuated concentrate valve should be closed (1/4 in. (0.6 cm) connection
not used should be left open to vent air). The concentrate
isolation valve should be closed. Slowly open the water
inlet valve to pressurize tank.
4. Connect hoses to test header. With only water flowing,
adjust hose valve to establish the desired system test
flow. (N o t e : Recommended system test flow for closed
head system is typically at the low end listed flow rate for
the size proportioner being tested.) Shut down system
valve without closing the adjusted hose valve, and reset
system valve for test actuation. If using a containment
truck for the foam solution, attach discharge hoses to
truck. A test sample valve (1/4 in. (0.6 cm) minimum) is
required in the discharge piping somewhere between the
proportioner and the containment truck. Note: Spraying or
pretreating the truck tank with a defoaming agent is
recommended to prevent nuisance foaming in the truck
tank during testing.
5. Once the bladder tank has been filled and hose valves
have been adjusted, one zone is selected for foam
discharge. Personnel are required to be stationed at the
test sample valve to take samples of foam discharge and
at the bladder tank to shut off the foam concentrate once
the foam sample is taken. Communication between these
two persons is important to minimize concentrate used.
6. Once everyone is in their positions, trip selected zone.
Thirty to forty-five seconds after foam appears from the
test valve, take a sample of the solution discharge. Shut
concentrate isolation valve as soon as the samples are
taken. Check refractive index against the standard curve
that was made in step #2. If sample is low, retest. When
sample tests OK, shut down test valve, and change over
to other risers that need to be tested repeating procedure.

BLADDER INTEGRITY VERIFICATION PROCEDURE

1. Isolate the bladder tank from the system by closing both
the Water Inlet and Concentrate Isolation Valves. Drain
water from the tank shell by opening shell drain and shell
vent valves.
2. Transfer remaining foam concentrate in bladder to 55
gallon drums or some other container.
3. When tank is completely drained, the valves on the
bladder tank should be in the following positions:
Water Inlet Valve . . . . . . . . . . . . . . . . . Closed
Concentrate Isolation Valve . . . . . . . . . . . . Closed
Tank Shell Drain Valve . . . . . . . . . . . . . . Closed
Tank Shell Vent Valve . . . . . . . . . . . . . . . Closed
Bladder Vent Valve . . . . . . . . . . . . . . . . . Open
Bladder Drain Valve . . . . . . . . . . . . . . . . Open
4. Using a Wet/Dry shop vacuum of 2 HP minimum, attach
the vacuum hose to the tank shell vent valve. This may be
accomplished by using pipe fitting and securing with duct
tape.
5. Connect vacuum hose to shop vacuum and start vacuum.
Note the high pitched sound from the vacuum before
opening the valve. This is the same sound that should be
heard in step #7.
6. Open Tank Shell Vent Valve to pull the air out between the
bladder and the tank shell, which will pull the bladder out
to the tank shell wall.
7. When the change in pitch from the vacuum is heard, this
indicates that bladder is now completely pulled out to the
tank shell wall.
8. If no change in pitch is noted after about 15 minutes, the
bladder is damaged and needs to be replaced.
9. If there is a change in pitch, the bladder is not damaged.
Close the Tank Shell Vent Valve and turn off the vacuum.
The bladder tank can now be refilled as per the ANSUL
Bladder Fill Manual (Part No. 74177), using the vacuum
method.

7. After system tests are completed, refill bladder tank if

required; and return valves to their normal operation positions. On the main tank, the hydraulic valves need to be
closed (this has to be done manually). The water inlet
valve and the concentrate isolation valves are to be in the
open position. On the reserve tank, all tanks are to be in
the closed position as this is a reserve supply to put the
system back in service quickly after a discharge.
Note: Containment and disposal of the foam solution
is the responsibility of others.

BLADDER REMOVAL & REPLACEMENT PROCEDURES

1. Remove all water from tank shell by opening both the tank
shell vent valve and the tank shell drain valve. A hose
should be connected to the drain valve to direct the flow of
water to an approved disposal area.
2. Remove all foam concentrate from the bladder by opening
the bladder vent valve and the bladder fill/drain valve. A
hose should be connected to the bladder drain valve to
direct the concentrate using a transfer pump to an
approved disposal containment tank/drums.
3. Remove top and bottom flange from the tank.

The hydraulic actuated ball valve requires pressure to open.

There are two 1/8 in. (0.3 cm) ports on each actuator, one is
labeled in and the other is unlabeled. Most valve sizes use a
single actuator, but some larger valves use a twin actuator
assembly.
With the ball valve in the closed position, the actuation piping is
piped to the in port(s), the vent port(s) is left open to allow air
pressure to be relieved as the internal piston is pushed over by
the water pressure.

4. Slowly remove the vertical center tube out through the top
flange opening. This tube must be removed on all horizontal tanks. (If the center tube cannot be completely
removed on the vertical tanks, drop the tube through the
lower flange opening and remove bladder out through the
top flange opening sliding the bladder past the center
tube.)

The actuator has to be manually reset by relieving the

actuation water pressure and with a wrench manually
turning the indicator stub back to the closed position.

5. Remove end flanges on horizontal tanks and slowly

remove the horizontal center tube so as not to damage
the bladder.

Remember the vent port(s) must be left open to atmosphere and not plugged, otherwise the valve will not open.

6. Attach cords on the flange bolt holes on all ends of the

bladder with the exception of the end that the bladder will
be pulled out of. This is to help guide the flange ends of
the new bladder into place. Slowly pull the bladder out of
the end that does not have the cord attached.
7. Prior to reinstalling the replacement bladder, mark the
bladder flanges to ensure proper alignment once it has
been reinstalled. Re-attach the cords on the flange ends
to help guide them back into place. Use of duct tape to
compress bladder flanges is helpful in re-installing the
bladder.
8. Re-install the bladder and check to ensure that the
bladder is properly aligned. Before re-inserting the center
tubes, close the tank shell drain valve and attach a
vacuum cleaner hose to the tank shell vent valve. With
this valve open, start the vacuum. This will pull the bladder
out toward the tank shell wall. Once the bladder has been
sucked out toward the shell wall, look through the flange
end to ensue that the bladder is not twisted (if twisted
make the adjustment to correct this). Once the bottom
flange opening is visible, close the tank shell vent valve
and then shut vacuum off .
9. Re-insert the center tubes taking care not to damage the
bladder.
10 . Re-install the flanges following the procedure for bolting
instruction per ASME flange torquing procedures. This is
tightening the bolts to 162 ft. lbs. each in 1/5 increments
using 0-180, 90-270, 45-225, 135-315 degree sequence.
Note: Torque specification above is a maximum. If during
torquing of bolts bladder flange appears to become
deformed, stop torquing at this point. Only torque bolts
further if a leak is present while inspecting during tank
pressurization.

HYDRAULIC ACTUATED BALL VALVE INSTALLATION /

OPERATION

3-15-07

If the in label has been removed, with the valve in the closed
position, put a finger over both ports and manually open the
valve with a wrench. The port(s) that is pulling a suction is the
port(s) to pipe the actuation piping to.

CUSTOMER/LOCATION: ____________________________________________________________ FILE NO.: ____________

DATE: __________________________________________ TESTED BY: __________________________________________
FOAM CONCENTRATE TYPE / LOT NO.:______________________________________________________________________
METER TYPE:________ CONDUCTIVITY:________ REFRACTOMETER; MODEL: __________________________________
CALIBRATION STANDARDS

METER READING

FOAM CONCENTRATE
WATER
PRE-MIX #1
PRE-MIX #2
PRE-MIX #3
CALIBRATION CURVE

METER READING

SYSTEM DISCHARGE SAMPLE

ANSUL is a trademark of Ansul Incorporated or its affiliates.

ANSUL INCORPORATED, MARINETTE, WI 54143-2542

METER READING

715-735-7411

PERCENT FOAM SOLUTION

3-15-07

ANSUL INCORPORATED
MARINETTE, WI 54143-2542