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BLADDER TANK PROPORTIONING SYSTEM

INSTALLATION, COMMISSIONING,
AND MAINTENANCE MANUAL

( REV 6 DT 21/01/2012)

HD FIRE PROTECT PVT. LTD.

K-98, MIDC, AJANTA ROAD
JALGAON - 425 003
 ED
1. INSTALLATION AND COMMISSIONING

1.1 TANK FOUNDATION

1.2. FIELD PIPING

1.3. FOAM CONCENTRATE FILLING PROCEDURE

1.4 SUBSEQUENT REFILLING OF FOAM CONCENTRATE

1.5 OPERATION CONCENTRATE CONTROL VALVE

2. INSPECTION AND MAINTENANCE

3. TROUBLESHOOTING

4. REFERENCE DRAWINGS AND DOCUMENTS

HD FIRE PROTECT PVT.LTD. REV 5 , DT 15/06/2010 Page 2 of 9

 Q
1. INSTALLATION AND COMMISSIONING

CAUTION :

• THE BLADDER TANK PROPORTIONING SYSTEM IS TO BE STORED /

INSTALLED UNDER A SHADE TO AVOID DIRECT SUNLIGHT ON THE
EQUIPMENT.

• DO NOT WELD ON THE TANK AS IT MAY DAMAGE BLADDER AND

TANK.

1.1 Tank Foundation

Tank is to be leveled and aligned on the concrete foundation and secured by

foundation bolts. keeping adequate distance for maintenance activities.

1.2. Field Piping

The water piping is to be connected to the inlet and outlet of the ratio controller
and supported firmly to prevent strain on the bladder tank proportioning system
piping network.

Note : refer Fig-1 & 2 for identifying the valve nomenclature on installed equipment.

1.3. Foam concentrate filling procedure

Required auxiliary equipment and accessories ( to be provided by user)

Ref drg no.: 7031 page 1 of 1

• Air supply with air filter regulator or nitrogen cylinder of 0 to 1.0 kg/sq.cm
secondary regulation.
• Foam concentrate filling centrifugal pump with max 2.0 kg/SQCM delivery
pressure.
• 10- 15 feet long clear PVC Hose pipes with connections
• Barrel.

1.3.1 .First time filling of the bladder tank with foam concentrate.

Reference drawing no. : 7032 OR 7033 — representative sketch of tank showing

valves.

STEP : 1 Water filling.

(ref drg no. 7032 OR 7033 page 1 of 3)

• Close all the valves V1 To V8 .

• Open tank vent valve V4 , tank drain valve V3 and bladder vent valve V5,V6.
• Connect the valve V4 to drain
• Connect the valve V3 to water supply
• Fill the tank with water ( do not exceed 1.5 KG/SQCM of water pressure ) till the
water starts coming out of valve V4. ( Do not close V4 with water pressure at V3)
• Close valve V3

HD FIRE PROTECT PVT.LTD. REV 5 , DT 15/06/2010 Page 3 of 9

 STEP : 2 Air filling
(ref drg no. 7032 OR 7033 page 2 of 3)

• Place the low range pressure gauge assembly having the range of 0-4
KG/SQCM on valve V5 as shown in the drawing. Open the pressure gauge
cock so that the pressure gauge is in service.
• Connect air source to air valve.
• Fill the bladder with air to 0.4 to 0.7 KG/SQCM.( 6 to 10 psi ), while displacing
the water through valve V4 , for vertical tank 10 to 15 % of the water (i.e. 10 to
15% of tank capacity ) is to be drained out and for horizontal tank 25 to 30 % of
water ( i.e. 25 to 30% of tank capacity. ( measure it by collecting in the drum of
known volume )
• Stop the compressor close V4 and air valve.
• Remove the air source pipe
• Note : A nitrogen cylinder with regulator can be used in place of air compressor.

STEP : 3. Foam concentrate filling.

(ref drg no. 7032 OR 7033 page 3 of 3)

• Connect concentrate pump fill connection to valve V6

• Open valve V4 ( leading to drain )
• Start pump and open the Valve V6
• Fill foam concentrate , maintain the air pressure of 0.4 to 0.7 KG/SQCM ( 6 to 10
PSI ) by controlling the opening/closing air valve connected to V5 .
• When approximately 90 % of foam concentrate is filled water will stop coming
out of valve V4 and tank air pressure will begun to exceed.
• Now slowly open the air valve and make the air pressure to zero. Carry out the
filling until the bladder is filled up with foam concentrate to the rated capacity of
the tank.
• Stop pump and close valve V6 and valve V4
• Remove foam concentrate pump fill connection and low range air pressure
assembly.
• Close valve V5
( note : Overfilling may damage the bladder)

STEP:4 Checking of the foam concentrate level

(ref drg no. 7032 OR 7033 page 1 of 3)

• Open valve V5 , V4.

• Open valve V3 completely drain the water from the tank.
• Open V7, the foam will rise in the sight glass.
• After the level is verified, MARK THE LEVEL. The marking of the level will help
in future for identifying and determining the quantity of the foam concentrate and
consumption. Close valve V7 and drain the foam concentrate from the sight
glass by opening the valve V8
• Close valve V8

STEP 5 : Placing bladder tank into service.

(ref drg no. 7032 OR 7033 page 1 of 3)

• Connect valve V3 to water line.

• Open valve V4

HD FIRE PROTECT PVT.LTD. REV 5 , DT 15/06/2010 Page 4 of 9

 • Allow the water to enter tank pressure not exceeding 1.5 KG/SQCM ( 25 PSI )
by opening the valve V3 till you get water flow from valve V4.
• Close valve V3 and then V4
• Now set the valve position as given in Table I and Table II

Table - I

VALVE NORMAL POSITION DESCRIPTION

MANUAL AUTOMATIC
OPERATION OPERATION

V1 CLOSE FOAM CONCENTRATE SHUT OFF VALVE

V1 # CLOSE AUTOMATIC FOAM CONCENTRATE VALVE

V2 OPEN OPEN WATER SHUT OFF VALVE

V3 CLOSE CLOSE TANK DRAIN VALVE

V4 CLOSE CLOSE TANK VENT VALVE

V5 CLOSE CLOSE BLADDER VENT VALVE

V6 CLOSE CLOSE BLADDER DRAIN VALVE

V7 CLOSE CLOSE SIGHT GLASS FILL VALVE

V8 CLOSE CLOSE SIGHT GLASS DRAIN VALVE

# Valve V1 is automatic valve (i.e Foam concentrate control valve — Model CV.),
as optional when automatic operation is required. Refer 1.5 &Table- II for
setting/operation of this valve .

1.3.2 Concentrate level checking procedure

(ref drg no. 7032 OR 7033 page 1 of 3)

• Close valve V1 and V2 to isolate the tank from the system.

• Open valve V4 and V5
• Open valve V3 completely drain the water from the tank.
• The foam will rise in the sight glass.
• Check the level .
- if only small quantity of the foam con. Is to be filled follow the procedure
1.4.1,
- if less than 50% of foam con . is to be filled follow the procedure 1.4.2.
if more than 50% of the tank is to be filled then follow procedure 1.4.3.
- if none of the above then proceed further.
• Close valve V7 and drain the foam concentrate from the level indicator by
opening the valve V8
• Close valve V8
• Close valve V5
• Carryout the shell water refill procedure. 1.3.3

HD FIRE PROTECT PVT.LTD. REV 5 , DT 15/06/2010 Page 5 of 9

.5.3.2 Shell water fill procedure
(ref drg no. 7032 OR 7033 page 1 of 3)

• Connect valve V3 to water line.

• Open valve V4
• Allow the water to enter tank , pressure not exceeding 1.5 KG/SQCM ( 25 PSI )
by opening the valve V3 till you get water flow from valve V4.
• Close valve V3 and V4
• Now set the vale position as given in Table I

1.4. Subsequent refilling of the bladder tank with foam concentrate.

1.4.1 Fill cup procedure.

This is to be followed when 5 %-10% of foam is discharged from tank.

(ref drg no. 7032 OR 7033 page 1 of 3)

• Attach a funnel to the valve V5

• Open valve V4
• Open valve V3 and drain water from tank.
• Open valve V7 and observe the level.
• Add foam concentrate via the funnel till the level is attained.
• Close valve V7 , drain the sight glass tube by opening the valve V8
• Carry out shell water fill procedure. 1.3.3
• Set the valve position as shown in the TABLE-I

1.4.2 Refilling if less than 50% of foam concentrate is discharged.

• Concentrate level is ascertained as per procedure 1.3.2

• Connect concentrate filling pump to valve V6.
• Continue to fill till the tank is full. I.e. the foam concentrate attains level mark
marked in the 1.3.1-STEP 4) on the indicator.
• Close valve V6
• Carry out shell water fill procedure. 1.3.3
• Set the valve position as shown in the TABLE-I

1.4.3. Refilling if more than 50 percent of foam concentrate is discharged.

• Concentrate level is ascertained as per procedure 1.3.2

• Carry out
- water filling as per 1.3.1. Step —1 , with the exception of valve V6 which is
to be kept closed to prevent draining of foam concentrate from tank.
- Air filling procedure as per 1.3.1. Step —2
- Concentrate filling procedure as per 1.3.1. Step — 3
Checking of foam concentrate level as per 1.3.1 Step — 4
- Placing the bladder tank in to service as pert 1.3.1 Step - 5

1.5 Operation of Foam concentrate control valve.( Model-CV)

( Refer Fig-2)
(it is not a standard component of system , it is supplied only against order)

HD FIRE PROTECT PVT.LTD. REV 5 , DT 15/06/2010 Page 6 of 9

 1.5.1 Automatic operation of valve

1.5.1.1 Opening of the Valve

The concentrate control valve operates on water pressure . The water pressure is
sensed through the valve BV-1 . When the water pressure reaches above
3 kg/sqcm the cylinder forces the ball valve to open automatically.

1.5.1.2 Closing of the Valve

Closing of the valve is manual. To close the valve manually, first close the valve BV-1.
, the trapped water which is under pressure in the cylinder is to be relived by opening
the valve BV-2. Now close the ball valve through the valve handle

( Caution — Do not stand in line of the ball valve BV-2 . The jet may cause injury)

1.5.2 Manual operation of the Valve.

Keep valve BV-1 closed so that the system pressure is isolated and keep valve BV-2
in open condition. Now the vale can be opened and closed manually through the
handle on the ball valve.

Table —II Valve positions on Concentrate Control Valve

Type of Position of valve Position of valve Position of valve

Operation V1 BV-1 BV-2
Automatic Close Open Close
Manual Close Close Open

HD FIRE PROTECT PVT.LTD. REV 5 , DT 15/06/2010 Page 7 of 9

 rn)
2. INSPECTION AND MAINTENANCE

2.1 General

A qualified and trained person must commission the system . After a few initial
successful test, an authorized person must be trained to perform the inspection and
testing of the system.

It is recommended to carry out physical inspection of the system at least once in a

week. The inspection should verify that all the valves are in the proper position as
per the system requirement and no damage has taken place to any component.

The system should be fully tested at least once a year or in accordance with
applicable NFPA code or in accordance to the guidelines of the organization having
local jurisdiction

Do not turn off the system or any other valve to repair or test the system without
placing a roving fire patrol in the area covered by the system. The patrol should
continue until the system is put back in service . Also inform the local security guard
and the control alarm station , so that a false alarm is not signaled.

2.2. CAUTION.

• Do no weld on the tank as it may damage the bladder and tank.

• Remove pressure before inspection and maintenance of the system

• Sight glass is not pressure tight so before checking foam concentrate level
reading tank pressure must be released.

• During hydrotesting of the system piping isolate the piping connection to the tank
to prevent the tank from being pressurised.

• The equipment is to be installed as per the manual provided by us and in

accordance to the guidelines of the local authority having jurisdiction. Site
handling and installation control is beyond our reach , hence we give no
guarantee for results and take no liability for damages, loss or penalties
whatsoever resulting from our suggestion, information, recommendation or
damage due to our product.

The foam bladder tank proportioning system are recommended to be kept

in fully charged with foam concentrate and operational condition.
Immediately after trials or use in actual fire condition , the bladder tank
system must be refilled or topped up so that it is ready to be used again
and foam supply is adequate for the desired duration for fighting fire as per
the calculated system data for which the system is designed.

HD FIRE PROTECT PVT.LTD. REV 5 , DT 15/06/2010 Page 8 of 9

 3. TROUBLE SHOOTING.

3.1 Inadequate quality of generated foam

• Check the Quality of foam

• Improper or no foam induction.

3.2. Improper or no foam induction

• Check the level of the foam concentrate.

• The foam concentrate supply valve may be partially closed.

• The water supply valve may be partially closed.

• Check the swing check valve for obstruction.

4. REFERENCE DRAWINGS AND DOCUMENTS.

DRG./ DOC.NO. DESCRIPTION

7032 ( 3 PAGES) Bladder filling Arrangement for Horizontal Tank

7033 ( 3 PAGES) Bladder filling Arrangement for Vertical Tank

7031 Accessories

Fig.1 ( 2 PAGES) P& ID diagram of bladder tank system

Fig.2 Foam Concentrate Control Valve Model — CV

Refer : Catalogue for Ratio controller, Bladder tank and concentrate control valve
are available on the website www.hdfire.com

NOTICE :
The equipment presented in this bulletin is to be installed in accordance with the latest publication standards
of NFPA or other similar organizations and also with the provision of government codes or ordinances or
authority having jurisdiction wherever applicable.
The information provided by us are to the best of our knowledge and belief, and are general guidelines only.
Site handling and installation control is beyond our reach. Hence we give no guarantee for result and take no
liability for damages, loss or penalties whatsoever, resulting from our suggestion, information,
recommendation or damages due to our product.
Product development is a continuous programme of HD FIRE PROTECT PVT. LTD. and hence the right to
modify any specification without prior notice is reserved with the company.

HD FIRE PROTECT PVT.LTD. REV 5 , DT 15/06/2010 Page 9 of 9
 V8
uu

DRAIN
0-4 KG/SQCM GAUGE
CAUTION: WATER PRESSURE SHOULD NOT EXCEED I .5KG/CM2

WATER INLET

V2
VI

WATER FILLING ARRANGEMENT

REV. -06
TITLE :- BLADDER TANK FILLING ARRANGEMENT
DT.28/08/08
DRG. NO.

HD FIRE PROTECT PVT. LTD. 7032

PAGE 1 OF 3
 0-4 KG/SQCM GAUGE 0-4 KG/SQCM GAUGE
CAUTION: AIR
PRESSURE
SHOULD NOT
EXCEED 10 PSI

1/4 " BSP (F)

V5

.■1

V3
V7 V8
7
V6

DRAIN

AIR FILLING ARRANGEMENT

REV. -06
TITLE :- BLADDER TANK FILLING ARRANGEMENT
DT.28/08/08
DRG. NO.

HD FIRE PROTECT PVT. LTD. 7032

PAGE 2 OF 3
 0-4 KG/SQCM GAUGE

V8

DRAIN
0-4 KG/SQCM GAUGE
CAUTION: PRESSURE SHOULD NOT EXCEED 1.5KG/CM2

L CF PUMP 0-30 PSI

FOAM
CONCENTRATE
INLET

FOAM CONCENTRATE FILLING ARRANGEMENT

REV. -06
TITLE :- BLADDER TANK FILLING ARRANGEMENT
DT.28/08/08
DRG. NO.

HD FIRE PROTECT PVT. LTD. 7032

PAGE 3 OF 3
 V5

V8
uU

DRAIN
0-4 KG/SQCM GAUGE
CAUTION: WATER PRESSURE SHOULD NOT EXCEED 1.5KG/CM2

[0:1 - 0-040---1{13 WATER INLET

V2
VI

WATER FILLING ARRANGEMENT

REV. -0
TITLE :- BLADDER TANK FILLING ARRANGEMENT
DT.15/06/10
DRG. NO.

HD FIRE PROTECT PVT. LTD. 7033

PAGE 1 OF 3

0-4 KG/SQCM GAUGE 0-4 KG/SQCM GAUGE
CAUTION: AIR
PRESSURE
SHOULD NOT
EXCEED 10 PSI

1/4 " BSP (F)

Inl

V5

V4

F
V3

V7 V8

V6

DRAIN

AIR FILLING ARRANGEMENT

REV. -0
TITLE :- BLADDER TANK FILLING ARRANGEMENT
DT.15/06/10
DRG. NO.

gz• HD FIRE PROTECT PVT. LTD. 7033

PAGE 2 OF 3
 0-4 KG/SQCM GAUGE

Inl

/ / / / / / / /
0-4 KG/SQCM GAUGE
CAUTION: PRESSURE SHOULD NOT EXCEED 1.5KG/CM2

CF PUMP 0-30 PSI

FOAM
CONCENTRATE
INLET

FOAM CONCENTRATE FILLING ARRANGEMENT

REV. -0
TITLE :- BLADDER TANK FILLING ARRANGEMENT
DT.15/06/10
DRG. NO.

HD FIRE PROTECT PVT. LTD. 7033

PAGE 3 OF 3


1" PVC TRANSPERENT HOSE

WITH 1" SWIVEL (F) CONNECTION 015.9-4 HOLES
1 ON BOTH ENDS 4 METER LONG EQUISPACED ON PCD 79.4
(1" FLANGE ANSI B16.5)
----E 01079
" Ig
tilfflr
# i" HEX NIPPLE Wrq K.,
(ATsO wSU47, LABELED)
a
(BSPT THREADS) II I LI ..-
ON BLADDER TANK)

WATER DRAIN PIPE ASSEMBLY REFERENCE DIMENSIONS FOR

1"THREADED ANSI B16.5 FLANGE

1" HEX NIPPLE 0-4 KG/SQCM GAUGE

(TO SUIT VALVE ( 0-60 PSI) 1/2" BOTTOM
LABELED AS "V3 ,V6" 1111 — CONNECTION.
ON BLADDER TANK) ■
_.,3_ 1/2" BALL VALVE
—1/2" X 1" REDUCING HEX NIPPLE 1" ELBOW
CI CENTRIFUGAL PUMP ,
Jo 013 INI —cfla— In1-43—gg— 43 0.5 HP , I" X 1" WITH SINGLE PHASE
I
1 11 11 ,I
„I I 230V AC 50 Hz TEFC MOTOR
43' ,S. 41, , , c4,v v4. 1 (SAFE AREA APPLICATION)
'1, ' .01 , 1 I c,"
$
CP.
-‘-‘‘
,s'i-' 1
0,4 4c,4-, 4.; 4
. s .., tA) 4\1v
4 (00•CC) e TRANSPERENT
,1,,,4 184,t■ , 4‘ .- \50 ..1.:%4 HOSE WITH I" SWIVEL (F)
■..,• . 1
ztjt"'" 1' 1,-‘' 4 10c0 .4.. . 8Zs- CONNECTION ON ONE END
, SSi < '' *) 44, .,,,,. c4, 1
;• N.., 2 METER LONG
1"
4N•,10'`"
,s.IY-N' os
g, /
1 ..,,,.0,i,z,
WATER FILLING UNIT ASSEMBLY Nsp1,0%
o+ 1" HEX NIPPLE
I f

FOAM CONCENTRATE FILLING UNIT ASSEMBLY

0-4 KG/SQCM GAUGE

0-4 KG/SQCM GAUGE ( 0-60 PSI) 1/2" BOTTO
( 0-60 PSI) 1/2" BOOM
TT Q— 1 CONNECTION.
CONNECTION.

1/2" BALL VALVE X4\

414 I,-\' 1/2" BALL VALVE
.4.4 , A ,V'1
1/2 " BSPT (F)
1/2" HEX NIPPLE 0" „'cr- .. — I /2" HEX NIPPLE
: \'0,
I
1/2" X1/2"X1/2" TEE (V— —It —_f AIR SUPPLY
TO BE ARRANGED
# 1-1/4"(BSPT) X 1/2" INCH /14,
, 1, BY INSTALLER
REUCING NIPPLE „ \
'1 '
40 10'
0 ) CO
4 V ,s$ 'C& 1
1,,lz -$.10' JN7' 0.4'
REMOVE THE FILL CUP ALOGWITH \s, 1Ci: e 4\4. ,c‘
REDUCING NIPPLE OF 1-1/4" X 1" „/"" ., '<'
. e4
(BSPT ) TO FIT THIS UNIT 4-v- t'1% V CP
1,1-coi
0 1 4:
>c,N-‘R Cf'
,, ot,., 4-
\1 r-Cr er
CP
AIR FILLING UNIT ASSEMBLY
NOTE : 1) WHEN ORDERED ALONG WITH BALLDER TANK ALL THE THREADINGS ARE BSPT
2) WHEN ARRENGED BY INSTALLER CARE TO BE TAKEN TO ENSURE THAT # MARKED
THREADING COMPATBILITY WITH THE BLADDER TANK FITTING IS MAINTAINED
TO AVOID MISMATCH
DCN NO. 155 227 R6 R7
DATE 27/01/05 30/05/07 28/08/08 02/10/10
MATE TITLE SCALE 2002 NAME DATE
BLADDER TANK COMMISIONING KIT. DRN AVAN I 5 / 11
REF. HD MAKE VERICAL AND HORIZONTAL PROJ. CHD
is am
BLADDER TANK mr, Nos APPD

gi) HD FIRE PROTECT PVT. LTD,

CODE DRG. NO. REV.
7031 7031 7
 III

5i9
V v 01-0•1'
FpA s
opl

'1
04
vigc'

NOMENCLATURE :-
NON-RETURN VALVE

FUNNEL • BALL VALVE

SAFTY VALVE
[:=2:3 REDUCER

D REDUCING BUSH RATIO CONTROLLER

TEE (SCREWED) PRESSURE GAUGE

O
FLANGE JOINT
▪ ELBOW

_L. TEE

P & I DIAGRAM - BLADER TANK PROPORTIONING SYSTEM

WITH SINGLE RATIO CONTROLLER

p HD FIRE PROTECT PVT. LTD.

Rev -0
16/02/10
FIG -1
PAGE 1 OF 2
 III

GI 055
5i9
V

014
,01,0 50"

NOMENCLATURE :-
NON-RETURN VALVE

FUNNEL NI BALL VALVE

SAFTY VALVE
:223 REDUCER

REDUCING BUSH 1{1 RATIO CONTROLLER

TEE (SCREWED) O PRESSURE GAUGE

FLANGE JOINT
ELBOW

TEE

P & I DIAGRAM - BLADER TANK PROPORTIONING SYSTEM

WITH MULTIPLE RATIO CONTROLLERS

Rev -0 FIG -1
ra) HD FIRE PROTECT PVT. LTD.
16/02/10 PAGE 2 OF 2
 FOAM CONCENTRATE
INLET

PAM
vost°4
) '"
4

CLOSE

vl
BV-1

FOAM CONCENTRATE
OUTLET
WATER PRESSURE
SUPPLY FROM
INLET SIDE OF
RATIO CONTROLLER

4 HOSE TEFLON HOSE WITH S,S, BRAIDED

3 VALVE STAINLESS STEEL 304

2 CYLENDER STAINLESS STEEL 304

1 BODY STAINLESS STEEL 304

SR.NO. DESCRIPTION MATL. SPECIFICATION

TITLE :- FOAM CONCENTRATE CONTROL VALVE MODEL - CV
REV-0 DT 16/02/10
RI HD FIRE PROTECT PVT. LTD. FIG - 2