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Viking CCS - User Manual

Viking CCS
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CONCENTRATE CONTROL
SYSTEM
OPERATING, MAINTENANCE,
AND FILLING MANUAL
VERTICAL AND HORIZONTAL
BLADDER TANKS
Trusted Above All
TM
www.vikinggroupinc.com
October, 2006
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Viking CCS Specifications

General IconGeneral
BrandViking
ModelCCS
CategoryWater Heater
LanguageEnglish

Summary

CCS Cut-Away Drawing

Balanced Pressure Proportioner (CCS) Environment

Controller Installation & Operation

Controller Placement Guidelines

Guidelines for optimal controller placement to ensure accurate proportioning.

Impact of Mounting Location

Explains how mounting height affects low flow performance.

Venturi Device Operation

Describes how the venturi creates pressure drop for concentrate intake.

Friction Loss and Low Flow

Defines low flow rating based on friction loss and pressure differential.

Concentrate Piping CCS

Piping and Isolation Valve

Recommends controller location and isolation valve for concentrate inversion prevention.

Preventing Concentrate Siphoning

Explains how isolation valves prevent siphoning into the water supply.

Piping Responsibilities

Clarifies that piping between CCS and controller is design engineer's responsibility.

Primary and Thermal Relief Valves

Pressure Relief Valve Requirements

Owner/engineer must provide primary relief valve for over-pressurization.

Thermal Expansion Concerns

Foam concentrate expansion can cause pressure increases and damage.

Preventing Thermal Expansion Effects

Recommendations include warming concentrate, not overfilling, canopies, and relief valves.

AFFF Schematic

AFFF Schematic Piping Notes

Piping responsibility and criteria for concentrate piping to controller.

AFFF Manual Operation Valves

Specifies manual valve operations for AFFF systems.

AFFF Automatic Operation Valves

Specifies automatic valve operation for AFFF systems.

AFFF Schematic Diagrams

Emphasizes consulting system design for piping and filling.

ARC Schematic

ARC Schematic Piping Notes

Piping responsibility and criteria for concentrate piping to controller.

ARC Manual Operation Valves

Specifies manual valve operations for ARC systems.

ARC Automatic Operation Valves

Specifies automatic valve operation for ARC systems.

ARC Schematic Diagrams

Emphasizes consulting system design for piping and filling.

Initial Concentrate Filling Instructions

Concentrate Type Warning

Warning to use only approved AFFF or ARC concentrates.

Uncrating Procedure

Steps for safely removing the unit from packaging.

Placement Procedure

Steps for positioning and anchoring the unit at the installation site.

Connection Procedure

Steps for connecting piping, controller, and sight gauge assembly.

General System Warnings

Welding Warning

Warning against welding on the vessel due to internal diaphragm damage.

Improper Filling Warning

Warning that improper filling will destroy the internal rubber diaphragm.

Follow Filling Instructions

Instruction to carefully read and follow manufacturer filling procedures.

Schematic for Auxiliary Equipment

Auxiliary Equipment Schematic - Figure 1

Schematic diagram illustrating auxiliary air supply and pressure gauge setup.

Auxiliary Equipment Schematic - Figure 2

Schematic diagram illustrating auxiliary pump and connection setup.

Required Auxiliary Items

List of additional items needed for auxiliary equipment setup.

Auxiliary Equipment Notes

Notes on using Teflon tape, hose sizes, and hose type.

CCS Filling Sequence

Pre-Fill Procedure Attachments

Instructions for attaching hoses before starting the fill sequence.

Valve Description Reference

Directs users to schematics for valve descriptions.

Filling Sequence Step 1

Initial step to close specific valves and open others.

Filling Sequence Step 2

Procedure for filling the shell with water until a steady flow is observed.

Filling Sequence Step 3

Step to check for water at a specific valve and consult supplier if issues arise.

Filling Sequence Step 4

Final step of closing a specific valve.

Filling Sequence Step 5

Filling the bladder with air while displacing water.

Filling Sequence Step 6

Trapping air in the bladder after water displacement.

Filling Sequence Step 7

Connecting and priming the concentrate pumping apparatus.

Filling Sequence Step 8

Removing the water hose and terminating for drain.

Filling Sequence Step 9

Starting the pump and introducing concentrate into the bladder.

Filling Sequence Step 10

Venting air to reduce pressure while pumping concentrate.

Filling Overfill Warning

Warning about overfilling and draining back to allow for expansion.

Filling Sequence Step 11

Final steps to close valves and remove assembly.

Sight Gauge Procedure

Sight Gauge Procedure Step 12

Opening sight gauge valves to fill and mark level.

Automatic Valve Check

Instruction to verify automatic valve 10 is closed.

Shell Water Refill Procedure

Deluge Installation Note

Note regarding pressurized requirements in some deluge installations.

Shell Water Refill Step 13

Attaching hoses for water refill.

Normally Pressurized Refill

Pressurized Refill Step 14

Closing valves before starting refill for pressurized systems.

Pressurized Refill Step 15

Filling shell with water until overflows occur.

Pressurized Refill Step 16

Opening valve to equalize pressure with the main supply.

Pressurized Refill Step 17

Opening valve 1 and placing all valves in normal positions.

Pressurized Refill Step 18

Inspecting for and correcting piping leaks.

Normally Un-Pressurized Refill

Unpressurized Refill Step 19

Closing valves before starting refill for unpressurized systems.

Unpressurized Refill Step 20

Filling shell with water until overflow occurs.

Unpressurized Refill Step 21

Opening valves 1 and 2.

Concentrate Level Check

AFFF Concentrate Level Check

Procedure to check the concentrate level for AFFF systems.

AFFF Level Check Step 1

Isolating the tank by closing specific valves.

AFFF Level Check Step 2

Attaching a hose to drain valve.

AFFF Level Check Step 3

Relieving pressure and draining water from the shell.

AFFF Level Check Step 4

Opening sight gauge valves to observe the level.

AFFF Level Check - Normal Level

Action if the concentrate level is normal.

AFFF Level Check - Low Level

Action if the concentrate level is below normal.

AFFF Level Check - Close Valves

Closing valves after observing the sight gauge level.

ARC Concentrate Level Check

Procedure to check the concentrate level for ARC systems.

ARC Level Check Step 1

Isolating the tank by closing specific valves.

ARC Level Check Step 2

Attaching a hose to drain valve.

ARC Level Check Step 3

Relieving pressure and draining water from the shell.

ARC Level Check Step 4

Opening sight gauge valves to observe the level.

ARC Level Check - Normal Level

Action if the concentrate level is normal.

ARC Level Check - Low Level

Action if the concentrate level is below normal.

ARC Level Check - Drain Gauge

Draining concentrate from the level gauge.

ARC Level Check - Close Valves

Closing valves after checking the level.

AR Foam Sight Glass Note

Note on sight glass accuracy with AR foam and alternative measurement.

AR Foam Capacity Example

Example calculation for AR foam concentrate quantity.

Refill Procedure

Refill Procedure: 50% or More Discharged

Procedure for refilling when 50% or more of the tank volume is discharged.

Refill Method: 50%+

Conditions for using the 50%+ refill method.

Refill Procedure (50%+) Step 1

Closing specific valves for the refill procedure.

Refill Procedure (50%+) Step 2

Filling the tank shell with water.

Refill Procedure (50%+) Step 3

Referencing the main CCS filling procedure.

Refill Procedure: Less Than 50% Discharged

Procedure for refilling when less than 50% of the tank volume is discharged.

Refill Method: Less Than 50%

Conditions for using the less than 50% refill method.

Refill Procedure (<50%) Step 1

Isolating the tank by closing specific valves.

Refill Procedure (<50%) Step 2

Opening specific valves for the refill process.

Refill Procedure (<50%) Step 3

Attaching a hose for concentrate transfer.

Refill Procedure (<50%) Step 4

Priming and connecting the pumping apparatus.

Refill Procedure (<50%) Step 5

Referencing sight gauge and shell water refill procedures.

AFFF Fill Cup Procedure

Procedure for adding small volumes of AFFF concentrate using a fill cup.

AFFF Fill Cup Step 1

Closing valves and relieving pressure.

AFFF Fill Cup Step 2

Opening sight gauge valves to observe liquid level.

AFFF Fill Cup Step 3

Adding concentrate using the fill cup.

AFFF Fill Cup Step 4

Closing valves and proceeding to shell water refill.

AFFF Fill Cup Overfill Warning

Warning about overfilling with fill cup and draining back.

Maintenance Procedures

Maintenance System Components

Identifies the three main components of the system.

Maintenance Importance

Emphasizes the importance of routine inspections, tests, and maintenance.

Maintenance Standards Reference

Refers to NFPA standards for testing and maintenance.

Recommendations for Maintenance and Inspections

Inspector Qualifications

Specifies qualifications for the designated inspector.

Initial Test Data Importance

Importance of initial test data for reference.

Service Notification

Requirement to notify relevant personnel before service.

Pre-Work Valve Closure

Closing specific valves before working on the system.

General Appearance Check

Inspecting name plates and decals for clarity.

Corrosion and Damage Inspection

Inspecting for and repairing corrosion, leaks, or damage.

Concentrate Level Verification

Verifying the concentrate level using the specified procedure.

Sight Gauge Drain Note

Instruction to drain the sight gauge after a level check.

Foam Presence Observation

Observing for foam concentrate during water drainage.

Foam Concentrate Sampling

Collecting foam concentrate samples for testing.

Auxiliary Equipment Examination

Inspecting auxiliary equipment as per manufacturer instructions.

Shell Water Refill Reference

Referencing the shell water refill procedure.

Valve Position Verification

Verifying correct valve positions and locking pins.

Return to Service Notification

Notifying personnel when the system is back in service.

Inspection and Service Record

Recording inspection and service dates.

AR Foam Sight Glass Accuracy

Note on sight glass accuracy with AR foam and alternative measurement.

AR Foam Capacity Example

Example calculation for AR foam concentrate quantity.

Foam Disposal Note

Guidance on proper disposal of foam solution.

Inspection of Foam Concentrates

NFPA 16 Foam Concentrate Inspection

Inspection requirements for foam concentrates as per NFPA 16.

Annual Foam Concentrate Inspection

Annual inspection for sludging or deterioration of concentrates.

Foam Concentrate Sampling Procedure

Procedure for taking foam concentrate samples for testing.

Dyne Technologies Foam Testing Services

Overview of foam testing services offered by Dyne Technologies.

Diluted Concentrate Disposal

Instruction to discard diluted concentrate and correct dilution source.

Bladder Integrity Test

Bladder Integrity Test Overview

Introduction to the air integrity test for the bladder.

Bladder Test Step 1: Isolate Tank

Isolating the tank from the system.

Bladder Test Step 2: Attach Drain Hose

Attaching a hose to the water drain valve.

Bladder Test Step 3: Open Vent Valves

Opening water and concentrate vent valves.

Bladder Test Note: Post-Drainage

Instruction to proceed after water has completely drained.

Bladder Test Step 4: Level Check

Performing a concentrate level check.

Bladder Test Step 5: Attach Air Equipment

Attaching air test equipment to the vent valve.

Bladder Test Note: Pressure Gauge

Importance of using a 3-lb pressure gauge!

Bladder Test Step 6: Fill with Air

Filling the bladder with air to a maximum of 1 PSI.

Bladder Test Air Leakage

Explanation of normal air leakage during bladder expansion.

Bladder Test Step 7: Trap Air

Trapping air within the bladder after reaching pressure.

Bladder Test Step 8: Release Air

Removing airline and releasing air if pressure is stable.

Bladder Test Step 9: Contact Viking

Instruction to contact Viking if air pressure cannot be maintained.

Bladder Test Best Practice

Recommendation to perform the test with concentrate drained.

Bladder Test Observation

Observing for AFFF presence during water drainage.

Bladder Replacement Procedures for CCS Units

Bladder Replacement Materials

List of materials required for bladder replacement.

Bladder Replacement Vessel Placement

Steps for placing the vessel for bladder replacement.

Damaged Bladder Removal

Procedures for removing the old, damaged bladder.

Removing Support Pipes

How to carefully remove plastic support pipes.

Pulling Out the Bladder

Detailed steps for pulling the bladder out of the vessel.

New Bladder Insertion

Procedures for inserting the new bladder.

Using Clothes Line for Insertion

Using clothes line to guide the new bladder insertion.

Aligning New Bladder A.I.R. Stamp

Aligning the A.I.R. stamp for proper orientation during insertion.

Squeezing Bladder During Insertion

Technique for squeezing the bladder during insertion.

Lubricating Vessel Nozzles

Applying lubricant to vessel nozzles for easier insertion.

Two-Person Bladder Insertion

Role of personnel during bladder insertion.

Inserting Plastic Support Pipes

Inserting plastic support pipes after bladder placement.

Securing Vessel Flanges

Positioning and bolting vessel flanges.

Viking Concentrate System Warranty

Limited Warranty Terms

Details of the limited warranty for Viking products.

Warranty Exclusions

Conditions under which the warranty is void.

Limitation of Liability

Limitation of Viking's liability for damages.

Other Warranties Disclaimer

Disclaimer of other express or implied warranties.