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KWR 100/50
KWR 150/50
KWR 200/80
KWR 250/80
WIDE RANGE RATIO CONTROLLER
MODEL KWR
INSTALLATION, OPERATION AND
MAINTENANCE MANUAL
K.C.Antincendi s.r.l. - Via Pavia 76 – Bressana Bottarone - tel. +39 0383 886511/+39 0383 898412 Fax +39 0383 898353
E-mail [email protected]. Website: www.kcantincendi.com
KWR-ENG-AA Rev. 3 - October 2010
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KWR 100/50
KWR 150/50
KWR 200/80
KWR 250/80
NOTICE TO THE USER
TTH
HIISS D
DO
OC
CU
UM
ME
EN
NTT PPR
RO
OV
VIID
DE
ESS IIM
MPPO
OR
RTTA
AN
NTT
SSA
AF
FE
ETTYY IIN
NSSTTR
RU
UC
CTTIIO
ON
NSS
The user is strongly recommended to read and to follow carefully the instruction
contained in this manual to prevent damages to people and objects.
This document must be placed in a safe place together with all the technical
documentation relevant to the materials purchased (certificates, test report, etc...)
All the information contained in this manual are relevant to the description and
to the operation of the whole equipment. For more details regarding the system this
equipment is designated to be installed in, please make reference to the relevant
documentation.
DISCLAIMER
KCA declines any responsibility due to non-observance of these instructions,
improper use of the equipment or use outside its design limit.
The compliance, partial of full, with the prescriptions and the information
contained in this manual does not relieve anyone who is in charge to install, to operate
or to maintain in full efficiency the supplied equipment from the responsibility due to
improper actions or inexpertness.
KCA is not responsible for the damages and any other consequences caused by a
lack of skill of the personnel involved with the with the equipment operation.
It is the sole purpose of this document to provide operating personnel with a
basic understanding of the equipment and of its components. In order to maintain the
equipment and its accessories at a high level of efficiency, all the operators and the
maintenance crew are urged to carefully read this instruction manual and keep it
handy for ready reference.
This manual does not provide instructions on the procedures for installation,
operation and maintenance that are specifically applicable or mandatory at the
installation site. Moreover this manual does not provide instructions on the procedures
K.C.Antincendi s.r.l. - Via Pavia 76 – Bressana Bottarone - tel. +39 0383 886511/+39 0383 898412 Fax +39 0383 898353
E-mail [email protected]. Website: www.kcantincendi.com
KWR-ENG-AA Rev. 3 - October 2010
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KWR 100/50
KWR 150/50
KWR 200/80
KWR 250/80
for installation, operation and maintenance of the fire protection system the KWR
ratio controller is a part of. The user must get informed on the local existing
regulations and laws and shall get in contact with the local authority to obtain all the
permissions and approvals for operation at the installation plant.
In case any of the instructions provided in this manual is not completely
understood by anybody involved in installing, operating and maintaining the KWR
ratio controllers manufactured by KCA, this must be immediately reported to KCA
before making any further actions using the contact references indicated in this
document
K.C.Antincendi s.r.l. - Via Pavia 76 – Bressana Bottarone - tel. +39 0383 886511/+39 0383 898412 Fax +39 0383 898353
E-mail [email protected]. Website: www.kcantincendi.com
KWR-ENG-AA Rev. 3 - October 2010
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WIDE RANGE RATIO CONTROLLER
KWR 100/50
KWR 150/50
KWR 200/80
KWR 250/80
GENERAL INDEX
SECTION 1 – SAFETY PRECAUTIONS ................................................................................................................................5
1.1 Safety Notes.............................................................................................................................................................5
1.2 General notes for people safety..............................................................................................................................5
1.3 Safety during maintenance......................................................................................................................................6
SECTION 2 – SCOPE OF THE MANUAL..............................................................................................................................7
2.1 Purpose of the manual ............................................................................................................................................7
2.2 Precautions to extend the equipment lifetime .......................................................................................................7
2.3 Environment ............................................................................................................................................................7
SECTION 3 – EQUIPMENT DESCRIPTION.........................................................................................................................8
3.1 KWR description and principle of operation.........................................................................................................8
3.2 KWR design data.....................................................................................................................................................9
3.3 KWR dimensions ....................................................................................................................................................10
SECTION 4 – MATERIAL RECEPTION AND STORAGE.................................................................................................11
4.1 Checks on the KWR at the reception .....................................................................................................................11
4.2 Storage recommendation before installation.........................................................................................................11
SECTION 5 – BEFORE THE INSTALLATION.....................................................................................................................12
5.1 Installation place requirements...............................................................................................................................12
SECTION 6 – INSTALLATION REQUIREMENTS ..............................................................................................................13
6.1 General prescriptions ..............................................................................................................................................13
6.2 Technical requirements...........................................................................................................................................13
SECTION 7 – KWR CALIBRATION .......................................................................................................................................15
7.1 Before the calibration .............................................................................................................................................15
7.2 Calibration procedure .............................................................................................................................................16
SECTION 8 – PERIODIC MAINTENANCE ...........................................................................................................................20
8.1 Periodic maintenance frequency.............................................................................................................................20
8.2 General requirements..............................................................................................................................................20
8.3 Maintenance schedule .............................................................................................................................................20
K.C.Antincendi s.r.l. - Via Pavia 76 – Bressana Bottarone - tel. +39 0383 886511/+39 0383 898412 Fax +39 0383 898353
E-mail [email protected]. Website: www.kcantincendi.com
KWR-ENG-AA Rev. 3 - October 2010
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WIDE RANGE RATIO CONTROLLER
KWR 100/50
KWR 150/50
KWR 200/80
KWR 250/80
SECTION 1 – SAFETY PRECAUTIONS
1.1 Safety Notes
Throughout this publication, DANGER, WARNINGS and CAUTION signs may be used to alert
the installer/user to special instructions concerning a particular service or operation that may be hazardous
if performed incorrectly or carelessly. OBSERVE THEM CAREFULLY.
These "Safety Alerts" cannot eliminate by themselves the hazards that they signal. Strict
compliance to these special instructions plus "common sense" operations are major accident prevention
measures.
DANGER!
Immediate hazards which will result in severe personal injury or death
WARNING!
Hazards or unsafe practices which could result in severe personal injury or death.
CAUTION!
Hazards or unsafe practices which could result in minor personal injury or product or property damage
IMPORTANT!
Indicates information or instruction that are necessary for proper operation and/or maintenance.
1.2 General notes for people safety
CAUTION!
The wide range ratio controllers KWR manufactured by KCA are designed to work under pressure
and to handle fire fighting foam concentrates. Both these two conditions represent a potential risk for
people and properties. For the appropriate operations when the system the KWR is installed is under
pressure please refer to the applicable system’s instruction. For safe foam concentrate handling and first
aid measures, please refer to the applicable parts of the concentrate's MSDS.
K.C.Antincendi s.r.l. - Via Pavia 76 – Bressana Bottarone - tel. +39 0383 886511/+39 0383 898412 Fax +39 0383 898353
E-mail [email protected]. Website: www.kcantincendi.com
KWR-ENG-AA Rev. 3 - October 2010
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WIDE RANGE RATIO CONTROLLER
KWR 100/50
KWR 150/50
KWR 200/80
KWR 250/80
1.3 Safety during maintenance
WARNING !
The maintenance staff MUST carry out a risk analysis prior to perform any activity on the KWR.
Particular care must be paid to those actions where lowering or removal, even temporary, of safety
measures and measures may be required.
The personnel in charge for the maintenance must be equipped with all the individual protection
equipments to act safely and in accordance with all the applicable laws and rules. In particular:
1. Safety clothes must be worn
2. The work tools must be according to the applicable local law and in good conditions
K.C.Antincendi s.r.l. - Via Pavia 76 – Bressana Bottarone - tel. +39 0383 886511/+39 0383 898412 Fax +39 0383 898353
E-mail [email protected]. Website: www.kcantincendi.com
KWR-ENG-AA Rev. 3 - October 2010
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KWR 100/50
KWR 150/50
KWR 200/80
KWR 250/80
SECTION 2 – SCOPE OF THE MANUAL
2.1 Purpose of the manual
The scope of this manual is to provide adequate information and instructions to the KWR wide
range ratio controller users, to the maintenance staff and to any other qualified person who is involved and
authorized to operate and to maintain the unit. The attention is focused on the potential risk for damages,
injuries or death that may come from the lack of compliance with the prescriptions shown in this
document.
The manual informs on calibration and start-up operation of the KWR and on the main
maintenance activities.
2.2 Precautions to extend the equipment lifetime
IMPORTANT!
All the installation, commissioning, operation and maintenance operations must be carried out by
personnel who is qualified and authorized by the system’s owner or manager. The personnel in charge for
these activities must operate only after having read this manual and having fully understood its contents.
As the KWR ratio controllers manufactured by KCA have been designed, tested and approved
under the scrutiny if third organizations, taking in considerations the durability and performance of the
original accessories installed, only original spare parts must be used when replacements are needed.
The use of non-original spare parts may determine an unsafe or poor performance of the KWR and
decrease its overall lifetime. Use of non-original spare parts automatically determines the expiry of the
warranty clause of the supplied equipments.
2.3 Environment
CAUTION!
The KWR user is responsible for appropriate disposal of all the parts that have to be replaced,
during the ordinary and special maintenance, according to the local applicable laws and rules.
Care must be taken when flow and mixing tests are carried out at the installation site in to avoid
any hazard to the environment. Please always refer to the foam concentrate's MSDS indications
concerning the environmental issues prior to handle foam concentrate and water-foam solution.
K.C.Antincendi s.r.l. - Via Pavia 76 – Bressana Bottarone - tel. +39 0383 886511/+39 0383 898412 Fax +39 0383 898353
E-mail [email protected]. Website: www.kcantincendi.com
KWR-ENG-AA Rev. 3 - October 2010
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KWR 100/50
KWR 150/50
KWR 200/80
KWR 250/80
SECTION 3 – EQUIPMENT DESCRIPTION
3.1 KWR description and principle of operation
The KWR wide range ratio controller is a proportioning device designed to be used with balanced
pressure type of proportioning systems. In the balanced pressure systems the water pressure and the
foam concentrate pressure, both at the ratio controller inlet, are equalized under any operating condition of
flow and fire network water pressure. Typical balanced pressure systems are those using bladder tanks
(pressure equalization achieved in the tank by means of a separation bladder) or foam pumps (in this case
the pressure equalization is obtained through a balancing valve, for BP systems, or by a pressure
regulating valve, for ILBP systems). Please refer to the applicable proportioning system manual, to NFPA
11 and/or to EN13565-2 for more details.
The function of KWR ratio controllers is to admix foam concentrate and water at an appropriate,
stable, mixing ratio over a particularly wide range of flowrate. This is accomplished by means of a
variable geometry concept, where the foam concentrate inlet net cross section varies as a function of the
water flowrate. Reference is made to figure 3.1.1. Where water passes through the main waterway the
throttle no. (10) is displaced to increase progressively the net cross section as the flowrate increases.
Figure 3.1.1: KWR cross section (drawing not to scale)
K.C.Antincendi s.r.l. - Via Pavia 76 – Bressana Bottarone - tel. +39 0383 886511/+39 0383 898412 Fax +39 0383 898353
E-mail [email protected]. Website: www.kcantincendi.com
KWR-ENG-AA Rev. 3 - October 2010
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KWR 100/50
KWR 150/50
KWR 200/80
KWR 250/80
The water throttle (10) is connected, trough a leverage system, to the foam throtthle (9). The latter
regulates the foam cross section at the top of the KWR.
At very large water flowrates the water throttle and the foam throttle are fully open. The pressure
drop caused by the water flow through the KWR body, which has a reduced section compared to the inlet
pipe, provides the necessary energy for foam concentrate to be injected into the main water stream.
As the water flowrate decreases, the pressuredrop though the KWR reduces too. This
circumstance would lead to a point where the energy of the foam concentrate is no longer sufficient,
determining the lower mixing range limit. To avoid this the throttle (10) tends to restore its rest position,
minimizing the water cross section and therefore maintaining at a higher value the pressure drop. To keep
proportionality of the water and foam flows, the foam throttle is displaced by the leverages to choke the
foam flow at an appropriate rate. The overall result is a stable proportioning ratio over a range notably
wider than that of fixed-geometry ratio controllers.
The KWR ratio controllers can work with different foam concentrate and at different nominal
mixing ratios: a micrometric screw (6) permits to tune the foam admixture percentage from 0% to 6%.
3.2 KWR design data
The following design data applies to KWR ratio controllers manufactured by KCA:
ALL MODELS
Design pressure Ps
Hydraulic test pressure
Minimum/maximum metal design temperature Ts
Nominal mixing ratio
16,0 barg
24,0 barg
-10 °C, +50 °C
0%-6%
KWR 100/50
75 l/min
2500 l/min
1.5 bar
FM APPROVED(**)
80 l/min
2789 l/min
1.9 bar
STANDARD
100 l/min
5600 l/min
2.3 bar
FM APPROVED(**)
103 l/min
5609 l/min
2.3 bar
STANDARD
Minimum recommended flowrate
Maximum recommended flowrate(*)
Pressure drop at max recommended flowrate(***)
KWR 150/50
Minimum recommended flowrate
Maximum recommended flowrate(*)
Pressure drop at max recommended flowrate(***)
KWR 200/80
Minimum recommended flowrate
Maximum recommended flowrate(*)
Pressure drop at max recommended flowrate(***)
STANDARD
125 l/min
10600 l/min
2.6 bar
FM APPROVED(**)
127 l/min
10944 l/min
2.7 bar
KWR 250/80
Minimum recommended flowrate
Maximum recommended flowrate(*)
Pressure drop at max recommended flowrate(***)
STANDARD
150 l/min
16100 l/min
2.7 bar
FM APPROVED(**)
N/A
N/A
N/A
K.C.Antincendi s.r.l. - Via Pavia 76 – Bressana Bottarone - tel. +39 0383 886511/+39 0383 898412 Fax +39 0383 898353
E-mail [email protected]. Website: www.kcantincendi.com
KWR-ENG-AA Rev. 3 - October 2010
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(*)
(**)
KWR 100/50
KWR 150/50
KWR 200/80
KWR 250/80
The maximum flowrate is defined is a recommended value to avoid excessive pressure drop.
However KWR can work beyond this range if the available pressure in the system is enough
FM approved versions may have slightly different flow range depending on the specific foam
concentrate considered. Please refer to the individual FM approval details to link the range and
pressure drop to the specific type of foam concentrate.
(***)
The pressure drop curve may change depending on the viscosity/density characteristic of the
employed foam, as a consequence of the calibration adjustment (see section 7.).
3.3 KWR dimension
The main dimension of the KWR ratio controller is shown in figure 3.3.1
Entrata schiumogeno
Foam concentrate inlet
ØD
Alimentaz. acqua
Water supply
ØB
A
Regolatore percentuale schiuma
Mixing ratio regulator
Uscita soluzione schiumogena
Foam solution outlet
Montato a wafer
Wafer mounted
C
Figure 3.3.1: KWR overall dimension
A
B
C
D
WEIGHT
mm
Ø
mm
Ø
Kg
KWR-100/50
209
4”
70
2”
14
KWR-150/50
241
6”
70
2”
22
KWR-200/80
291
8”
82
3”
38
KWR-250/80
323
10”
82
3”
46
MODEL
K.C.Antincendi s.r.l. - Via Pavia 76 – Bressana Bottarone - tel. +39 0383 886511/+39 0383 898412 Fax +39 0383 898353
E-mail [email protected]. Website: www.kcantincendi.com
KWR-ENG-AA Rev. 3 - October 2010
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KWR 100/50
KWR 150/50
KWR 200/80
KWR 250/80
SECTION 4 – MATERIAL RECEPTION AND STORAGE
4.1 Checks on the KWR at the reception
IMPORTANT!
The KWR ratio controllers manufactured by KCA can be provided loose or pre-installed to bladder tanks.
In both cases the KWR are accurately packed to avoid damages during the transportation. When received,
the KWR must be checked for absence of any damage that may have occurred during the unloading
operations. Eventual defects may result in liquid leaks, liquid spray jets and structural failures. These
damages have to be reported immediately to KCA for a risk assessment.
Any other damage that, based on the judgment of the installer/end user, is supposed to potentially
result in a failure or that may affect the performance of KWR must be promptly highlighted to KCA
and rectified before the start-up according to the manufacturer's indications.
All KWR are calibrated in factory to obtain the best performance accuracy based on the
information received on foam density and viscosity. However a “fine tuning” calibration is normally
required at jobsite to take into account of foam type different than that specified at Order or of
different/variable temperature conditions compared to the affecting the foam viscosity and density.
KCA recommends the user to perform this calibration at the system start-up, as described in
section 7. After the factory calibration, seals are put by KCA on the percentage tuning screw (6) and on
the plug protecting the spring pre-load screw (11). In case these seals are impaired, please report it
immediately to KCA,
KCA is not responsible for damages due to equipment’s mishandling during the unloading and
displacement stage and during the transportation (KCA is hold responsible only when in charge for the
transportation). KWR must be handled by skilled and authorized staff only.
4.2 Storage recommendations before installation
IMPORTANT!
The KWR rario controllers made by KCA are fabricated using high quality materials like bronze
and AISI316 stainless steel. Nonetheless it is recommended to store them before the installation in a
sheltered or in an indoor area. The storage temperature should not be outside the range (-10 °C; +50 °C)
for a prolonged period of time.
K.C.Antincendi s.r.l. - Via Pavia 76 – Bressana Bottarone - tel. +39 0383 886511/+39 0383 898412 Fax +39 0383 898353
E-mail [email protected]. Website: www.kcantincendi.com
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WIDE RANGE RATIO CONTROLLER
KWR 100/50
KWR 150/50
KWR 200/80
KWR 250/80
SECTION 5 – BEFORE THE INSTALLATION
5.1 Installation place requirements
WARNING!
The KWR shall not be installed in areas:
1.
2.
3.
4.
5.
6.
7.
8.
9.
too close to other equipments/objects that may prevent a safe access for equipment’s operation
and periodic inspections;
where it is subject to heat sources that may affect the safety, the performance or the durability;
close to flammable materials or chemicals that can generate a fire concern to the KWR;
not protected against collision or tampering;
where vibrations can generate loads on the foam connection flange (in case of vibration, suitable
damping method shall be put in place);
where wind loads exceeds the calculated limits of the connected piping;
where seismic loads exceeds the calculated limits of the connected piping;
where the corrosion due to the atmosphere is not compatible with the construction materials;
where the temperature is outside the range (-10 °C; +50 °C);
.
K.C.Antincendi s.r.l. - Via Pavia 76 – Bressana Bottarone - tel. +39 0383 886511/+39 0383 898412 Fax +39 0383 898353
E-mail [email protected]. Website: www.kcantincendi.com
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WIDE RANGE RATIO CONTROLLER
KWR 100/50
KWR 150/50
KWR 200/80
KWR 250/80
SECTION 6 – INSTALLATION REQUIREMENTS
6.1 General prescriptions
WARNING!
The installer and the user of the equipments supplied by KCA have the responsibility to
ensure that the following points are fulfilled.
1.
The installation must be carried out by qualified and authorized personnel according to the
applicable local regulations and laws;
2.
Any safety measure to prevent accidents must be taken according to the applicable legislation;
3.
The KWR has to be connected to the piping system in such a way the foam connection flange is
not subject to stresses above the design limit;
4.
The KWR must be installed in systems where the maximum working pressure does not exceed the
equipment design pressure;
5.
The installation works must be accomplished avoiding damages to the equipments supplied by
KCA. In case damages occur, a thorough investigation must be made in order to assess the
potential consequences for the safety and the fire protection operation. KCA must be contacted;
6.
Do not remove or tamper the original seals installed by KCA on the KWR;
7.
Once the installation is completed, a final inspection must be carried out to ensure that the
installation drawings have been properly fulfilled and that the quality of works is satisfactory. Nonconformities must be recorded and rectified prior to step further to the commissioning/start-up
stage;
6.2 Technical requirements
IMPORTANT!
a.
The KWR can be installed wafer between EN1092-1 PN16 flanges and ASME B 16.5 150# flanges.
Other flange standards may be suitable for installation;
b.
The KWR installation can be either horizontal or vertical;
K.C.Antincendi s.r.l. - Via Pavia 76 – Bressana Bottarone - tel. +39 0383 886511/+39 0383 898412 Fax +39 0383 898353
E-mail [email protected]. Website: www.kcantincendi.com
KWR-ENG-AA Rev. 3 - October 2010
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KWR 100/50
KWR 150/50
KWR 200/80
KWR 250/80
c.
The foam connection must be made using EN1092-1 PN16 flanges;
d.
The KWR installation must respect the flow direction indicated by the engraved arrow on the
KWR’s body;
e.
For mixing performance accuracy and stability, it is recommended to install the KWR within a
straight pipe section 7 diameters long upstream, 5 diameters long downstream;
f.
To avoid water flow back to the foam reservoir, a suitable check valve must be installed in the pipe
section from the bladder tank or foam pump to the KWR;
g.
For mixing performance accuracy the pressure difference between the foam in the bladder tank (or
after the balancing valve) and the water at the KWR inlet should be limited to +0.1 bar at the
minimum flowrate and to +0,3 barg at the maximum flowrate. Care must be taken to position the
KWR not too far from the bladder tank (or from the foam balancing valve) and at a level not too
above the minimum expected foam level. Attention must be paid to properly select the foam line
diameter.
K.C.Antincendi s.r.l. - Via Pavia 76 – Bressana Bottarone - tel. +39 0383 886511/+39 0383 898412 Fax +39 0383 898353
E-mail [email protected]. Website: www.kcantincendi.com
KWR-ENG-AA Rev. 3 - October 2010
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WIDE RANGE RATIO CONTROLLER
KWR 100/50
KWR 150/50
KWR 200/80
KWR 250/80
SECTION 7 – KWR CALIBRATION
IMPORTANT!
The KWR ratio controllers are designed to adjust automatically the internal geometry to variable
water flow conditions. Moreover the KWR must be suitable to work with different viscosity concentrates.
To make sure that these two targets are achieved, KWR the must be calibrated before its use.
KCA performs a factory calibration according to the foam concentrate information received by the
Customer. It’s very important that KCA is informed at the Order stage on which concentrate will be used.
However a “fine tuning” calibration is normally required at jobsite to take into account of foam type
different than that specified at Order or of different/variable temperature conditions compared to
the affecting the foam viscosity and density. KCA recommends the user to perform this calibration
at the system start-up, as described in this section.
It is highly recommended that the installer/user contacts KCA in case of doubts on the
instructions shown hereinafter. KCA does not respond for damages or improper operation of the
equipment caused by lack of implementation of the right calibration procedure..
7.1 Before the calibration
The calibration should be made after the final system installation. Before the calibration operations
can take place the installer/end user has to make sure that:
1.
The installation of the foam system incorporating the KWR have been accomplished according to
the design documents, applicable standards and good engineering practice;
2.
All the threads, flanges and grooved fittings are tightened to the recommended values;
3.
The safety devices have been properly selected and installed to preserve bladder tanks or foam
pumps from overpressure;
4.
The Concentrate Control Valve (if present) and relevant trim is properly connected. Please make
reference to the CCV manual for the connection of the trim to the system;
5.
All the connecting piping have been thoroughly flushed to avoid debris in the bladder tank/pump
system, in the KWR and in the CCV trim (if present);
6.
The bladder tank/pump and piping systems are securely fixed to the ground or structural members
of the site ;
K.C.Antincendi s.r.l. - Via Pavia 76 – Bressana Bottarone - tel. +39 0383 886511/+39 0383 898412 Fax +39 0383 898353
E-mail [email protected]. Website: www.kcantincendi.com
KWR-ENG-AA Rev. 3 - October 2010
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7.
WIDE RANGE RATIO CONTROLLER
KWR 100/50
KWR 150/50
KWR 200/80
KWR 250/80
Any other prescription to be implemented before system’s operation is made according the the
relevant Owner’s manual(s);
IMPORTANT!
The KWR calibration relies on a full scale discharge procedure which requires the use of
some SPECIAL TOOLS. The following devices MUST BE procured by the installer/user before the
filling operation:
a)
b)
c)
Allen key size 4;
Flow meter on the water-foam solution line (discharge side of the KWR)
Flow meter on the foam concentrate line
As an alternative, yet not recommended by KCA as not practicable, the calibration procedure can be
based on measuring the mixing ratio with a:
d)
Conductivity meter and calibration kit to measure the foam solution mixing ratio;
In alternative to d) other methods and equipments can be employed to measure the mixing ratio (e.g.:
refactometer, where applicable to the foam type and concentration)
If direct foam solution mixing ratio measurements are made by conductivity method or
refractivity method, always make sure that the solution sample is taken at least 20 nominal diameter
downstream the KWR. Use the same water it is available in the system to prepare the calibration
curve, as stated in the Appendix of NFPA 11.
CAUTION!
The KWR calibration relies on a full scale discharge. Care must be taken when flow and mixing
tests are carried out at the installation site in to avoid any hazard to the environment. Please always refer to
the foam concentrate's MSDS indications concerning the environmental issues prior to handle foam
concentrate and water-foam solution.
7.2 Calibration procedure
Please make reference to figure 7.2.1.
K.C.Antincendi s.r.l. - Via Pavia 76 – Bressana Bottarone - tel. +39 0383 886511/+39 0383 898412 Fax +39 0383 898353
E-mail [email protected]. Website: www.kcantincendi.com
KWR-ENG-AA Rev. 3 - October 2010
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WIDE RANGE RATIO CONTROLLER
KWR 100/50
KWR 150/50
KWR 200/80
KWR 250/80
1.
Check that the mixing ratio regulating screw (6) is set at the proper nominal percentage. If not,
rotate it until the nominal mixing ratio is achieved on the visual indicator (13);
2.
Perform the minimum flowrate discharge test. Measure the obtained solution mixing ratio. Using
a flow meter in the water-foam solution side of the KWR and a flow meter in the foam concentrate
line of the KWR, the mixing ratio can be obtained in real time as the ratio between the latter and
the former readings, multiplied by 100. If the mixing ratio lays in the range [R;MIN(1.3 x
R;R+1)], where R is the foam nominal mixing ratio expressed in percentage and MIN(1.3 x
R;R+1) is the minimum between the nominal mixing ratio R increased by its 30% and the nominal
mixing ratio R increased by one absolute point percentage, jump to step 4. Otherwise go to step 3.
3.
The mixing ratio is not appropriate, it must be rectified. To do it remove the plug (11) and operate
on screw (12) from the bottom, using the Allen key. In case the obtained mixing ratio is below R
(mixture too lean), rotate the screw counterclockwise as seen from the bottom of the screw. This
will decrease the spring preload and will make the water throttle displaceable easier. If, oppositely,
Figure 7.2.1: KWR cross sectional view (not to scale)
K.C.Antincendi s.r.l. - Via Pavia 76 – Bressana Bottarone - tel. +39 0383 886511/+39 0383 898412 Fax +39 0383 898353
E-mail [email protected]. Website: www.kcantincendi.com
KWR-ENG-AA Rev. 3 - October 2010
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PART
NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
WIDE RANGE RATIO CONTROLLER
DESCRIPTION
MATERIAL
FOAM INLET FLANGE
MIXING RATIO INDICATOR
MAIN BODY
GASKET
GASKET
MIXING RATIO ADJUSTMENT SCREW
GASKET
GASKET
FOAM THROTTLE
WATER THROTTLE
PLUG
SPRING PRELOAD SCREW
MIXING RATIO INDICATOR
BRONZE
AISI 316
BRONZE
NBR SHORE 70
NBR SHORE 70
BRASS/AISI316
NBR SHORE 70
NBR SHORE 70
AISI 316
AISI 316
AISI316
AISI 316
AISI 316
KWR 100/50
KWR 150/50
KWR 200/80
KWR 250/80
RECOMMENDED
SPARE PART
YES OR 2-143
YES OR 2-239
YES OR 5-615
YES OR 2-237
YES 1/2”NPT M
-
the mixture is “too rich”, rotate the screw clockwise as seen from the bottom of the screw. This
will increase the spring preload and progressively make the water throttle harder to move. Make
one 360° screw rotation at a time, at the beginning, to decrease to 180° turn when a finer tuning is
needed. After the adjustment go back to step 2.
4.
The minimum flow test calibration has been successfully made. Perform the same test at the
maximum flowrate. If the mixing ratio lays in the range [R;MIN(1.3 x R;R+1)] jump to step 6.
Otherwise go to step 5.
5.
Act on the mixing ratio adjustment screw (6), increasing or decreasing the indicated percentage, to
adjust the mixing ratio(*). In case the mixing ratio is too low rotate the screw clockwise. In case the
solution is too rich rotate it counterclockwise. Make one 360° screw rotation at a time, at the
beginning, to decrease to 180° turn when a finer tuning is needed. After the adjustment go to step
4.
6.
The calibration at the maximum flowrate is completed, block the position of screw (6) tightening
the blocking nut. Return to the minimum flowrate condition to perform once again the minimum
flowrate test. As the actions on screw (6) have no influence on the minimum flow operation for
pure internal geometry reasons, this test is just a verification that the spring preload has not been
inadvertently changed during the step 4. and 5. Should the percentage be outside the acceptance
range, repeat the full procedure from 3. to 6.. If this step is successfully passed, the KWR range is
automatically calibrate over the full range.
7.
Restore the plug (11) and the seals on plug (11) and on screw (6). The calibration has been
concluded. The KWR must be thoroughly flushed with fresh water to make sure that no
concentrate residual are present.
K.C.Antincendi s.r.l. - Via Pavia 76 – Bressana Bottarone - tel. +39 0383 886511/+39 0383 898412 Fax +39 0383 898353
E-mail [email protected]. Website: www.kcantincendi.com
KWR-ENG-AA Rev. 3 - October 2010
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WIDE RANGE RATIO CONTROLLER
KWR 100/50
KWR 150/50
KWR 200/80
KWR 250/80
(*)
Note: the percentage indicated by the KWR gauge (13) is indicative only. This is because the same
gauge is installed for any type of foam concentrate, regardless of its viscosity. As the viscosity influence
the spring preload, it has also effect on the final position of the screw (6).
To save time…
If a site calibration is needed to transform a low viscosity foam KWR to a high viscosity type
for the same mixing ratio, time must be saved by acting directly on the spring preload,
rotating counter-clockwise screw (12)
K.C.Antincendi s.r.l. - Via Pavia 76 – Bressana Bottarone - tel. +39 0383 886511/+39 0383 898412 Fax +39 0383 898353
E-mail [email protected]. Website: www.kcantincendi.com
KWR-ENG-AA Rev. 3 - October 2010
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WIDE RANGE RATIO CONTROLLER
KWR 100/50
KWR 150/50
KWR 200/80
KWR 250/80
SECTION 8 – PERIODIC MAINTENANCE
The KWR technology requires, by itself, a limited maintenance throughout its lifetime. However
some essential operations must be regularly carried out to ensure appropriate performance and durability
of the KWR.
This section covers the periodic (i.e. “ordinary”) maintenance. The ordinary maintenance does not
include special repairing to the KWR. For repairing, always contact KCA.
8.1 Periodic maintenance frequency
The frequency of maintenance of the KWR must be in compliance with the local regulation. It is
full responsibility of the end user to keep informed and updated on the law prescriptions concerning
periodicity and extent of the maintenance activities.
KCA indicates in this manual the minimum recommended maintenance to control and to
preserve in full efficiency the equipments supplied. The extent and the frequency of the maintenance
shall also be linked to the environmental and use conditions. Any additional request as a result of
norms, laws and regulation, must be added to the recommendations by KCA.
8.2 General requirements
CAUTION!
a.
The maintenance must be carried out by qualified and authorized personnel according to the
applicable local regulations and laws;
b.
Involved site personnel must be timely informed about the maintenance of the KWR accessories.
Alternative fire safety measures, eventually, must be put in place;
c.
Any safety measure to prevent accidents must be taken according to the applicable legislation;
d.
The maintenance team must operate adopting all the necessary precautions and using all the
required individual safety equipments (safety shoes, gloves, glasses, etc…);
e.
Do not act on the KWR before relieving the pressure in the water line and having isolated the foam
concentrate supply line;
f.
Do not perform welding/drilling on the KWR body and internal parts;
K.C.Antincendi s.r.l. - Via Pavia 76 – Bressana Bottarone - tel. +39 0383 886511/+39 0383 898412 Fax +39 0383 898353
E-mail [email protected]. Website: www.kcantincendi.com
KWR-ENG-AA Rev. 3 - October 2010
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g.
WIDE RANGE RATIO CONTROLLER
KWR 100/50
KWR 150/50
KWR 200/80
KWR 250/80
When removing for maintenance the KWR pay attention not to damage the connections and the
lines these accessories are installed in;
The maintenance recommendations exposed in this manual are relevant to the KCA KWR ratio
controllers only. Inspection and maintenance of the entire foam system, in which the materials supplied
by KCA are included in, are not within the scope of this manual or of the following recommendations and
shall follow the prescriptions of the applicable standards or regulations ruling this matter (e.g. NFPA
11/16/25 codes, EN standards, etc…).
8.3 Maintenance schedule
KCA recommend, as a minimum, to implement a maintenance program as indicated in the table
below:
ITEM
ACTIVITY
1. Visual check for corrosion damage
2.
Visual check for seal integrity and
mixing ratio indicator
3.
KWR flushing with fresh water
4.
Check of flanged connections:
bolts tightening torque:
START
UP
Flow test (water only, no foam
discharge) to move the leverage
6. Full flow test with foam at minimum
and maximum flowrate
12. Complete internal part revision
5.
EACH 6
MONTHLY MONTHS
EACH
1 YEAR
EACH
5 YEARS
PROCEDURE OR
NOTES
-
After any
discharge
-
-
Table 8.3.1: Recommended maintenance schedule
Local regulations may require activities exceeding those stipulated in table 10.2.1 (for instance,
mandatory periodic qualification of the pressure vessel). It is full responsibility of the end user to be
informed of these requirements and to put in place all the necessary activities.
K.C.Antincendi s.r.l. - Via Pavia 76 – Bressana Bottarone - tel. +39 0383 886511/+39 0383 898412 Fax +39 0383 898353
E-mail [email protected]. Website: www.kcantincendi.com
KWR-ENG-AA Rev. 3 - October 2010
Pag. 21 of 21