1. I N T E G R A T E D COMPRESSED AIR FOAM SYSTEMS
Alberta Industrial Fire Chiefs
I N T E G R A T E D COMPRESSED AIR FOAM SYSTEMS
Systems Inc.

2. INTEGRATED SPRINKLER SYSTEMS
History: FireFlex
1990 Power Plants Unit
1991 Commercial Unit
2002 Second Generation

3. Remote controlled unit
INTEGRATED SPRINKLER SYSTEMS
Expanding the concept:
Extended range of configurations:
Skid unit
Remote controlled unit
Self-contained unit

4. Integrated Clean Agent Systems
FireFlex 1230

5. Integrated Clean Agent Systems
FireFlex DUAL

6. Alberta Industrial Fire Chiefs
Agenda
COMPRESSED AIR FOAM (CAF) TECHNOLOGY:
Introduction & history
Description
Fire Tests

7. Alberta Industrial Fire Chiefs
Agenda
ICAF SYSTEM:
Components
Design
Applications
Case Studies
CONCLUSION

8. CAF TECHNOLOGY History: 1941: Hose lines by US Army during WWII
1994: First fixed piping tests for CDN Navy
2001: Licensing agreement with NRCC
2004: FM Approval: Hydrocarbons

9. CAF TECHNOLOGY History and industry recognition :
2006: NFPA-11, TIA # 05-1: New foam type
2006: FM Approval enhanced: Polar solvents
2007: Meets FM 5130 requirements
2007: Simultaneous CAF & Spkr Discharge Testing - FM Approved
2008 : NFPA CAF New Option
2009 : FM 7-29 Flam. Liquid Portable Storage

10. Introduction : Fire-fighting foams
NFPA 11
Foam Type Expansion ratio
Low expansion : CAF 10:1
Medium expansion 20:200
High expansion 200:1000

11. Introduction : Fire-fighting foams
3 basic components of foam :
Foam Concentrates – Synthetic AFFF’s
Foam Generation – Aeration vs. agitation
Delivery & Distribution System

12. Introduction : Foam Quality - Low exp
Extinguishing Mechanism - seals fuel surface
CAF - Improved physical separation on top of fuel
Performance : 2 contributing factors
Greater Exp Ratio – high end of low ex
Long Drain time – ability to hold water

13. CAF TECHNOLOGY Description: Compressed Air Foam (CAF) Uniform & stable
Robust foam blanket
Low-Ex : 10:1
New foam type

14. CAF TECHNOLOGY Description: An homogenous foam produced by combining…
Water
Piping Network
Compressed Air
CAF
CAF Nozzles
Mixing Chamber
Foam Concentrate
ICAF Cabinet

15. CAF TECHNOLOGY Description: Compressed Air Foam (CAF)
Lower design densities:
0.06 at 6%
0.26 at 3%
Ketone
0.24 at 3%
Polar solvents : Alcohol
0.04 at 2%
0.16 at 3%
Hydrocarbons
CAF
Foam-Water
Density gpm / sq. ft.
Flammable liquid
Uses 4 times less water

16. CAF TECHNOLOGY Description: Compressed Air Foam (CAF)
Shorter discharge durations:
5 minutes on Specific Hazard Configuration
10 minutes on Ceiling Nozzle Configuration
with automatic shut-off after foam discharge

17. CAF TECHNOLOGY Description: Compressed Air Foam (CAF)
Foam Concentrates:
Hydrocarbons:
National Foam Aer-O-Lite 3% AFFF & Aer-O-Water 3EM 3% AFFF (MIL Spec.)
Polar Solvents:
Ansul Ansulite 3X3 LV Alcohol Resistant AFFF

18. CAF TECHNOLOGY Description: Compressed Air Foam (CAF)
Foam concentrate :
Non-toxic & Biodegradable
Storage: 20°F (-7°C) and 120°F (49°C)
Shelf-life: years
Ref. NFPA-11 – Annex F

19. CAF TECHNOLOGY Description: Comparing foam consistencies
Compressed Air Foam
Foam-Water

20. 'Critical' Applications
CAF TECHNOLOGY
Fire tests: Class 'B' - Flammable Liquids
Typical sprinklers
Links to Slide: #30 (UL-162) | #38 (Spill Fire) | #46 (Transformers) | #80 (R&D)
UL 162
Spill Fire
Transformers
'Critical' Applications

21. ICAF SYSTEM Description: Typical System Layout Air Cylinders
Piping Network
Distribution Nozzles
Integrated Cabinet
Foam Tank
(water tank also available)

22. ICAF SYSTEM Description: Typical System Layout Air Cylinders
Twin Hazards
Trim Cabinet
Foam Tank
Integrated Skid
(water tank also available)

23. CAF TECHNOLOGY Components: Integrated System Air Cylinders Water Tank
Integrated Skid
Foam Tank

24. ICAF SYSTEM Components: Foam Nozzles Turbine action rotary nozzles
ceiling & specific hazard configurations

25. ICAF SYSTEM Components: Foam Nozzles Ceiling Nozzle Configuration:
Max. spacing: 12’-3" x 12’-3" (10’-0" x 10’-0" on polar solvents)
Max. dimension: 16 ft. (irregular spacing)
Max. height: 46 ft.
(35 ft. on polar solvents)
TAR-225C

26. Typical discharge pattern
ICAF SYSTEM
Components: Foam Nozzles
Typical discharge pattern

27. ICAF SYSTEM Components: Foam Nozzles TAR-225C Nozzle:
• Balanced flows with bullhead tees
• Small pipe sizes
• 150 ft2 per nozzle
• ft2 per zone

28. ICAF SYSTEM Components: Foam Nozzles Specific hazard configuration:
Aimed directly at hazard surface
7 ft. diam. discharge pattern
10 ft. horizontal throw
Effective on cascading fires
TAR-225L

29. ICAF SYSTEM Components: Foam Nozzles Balanced flows
Groups of 2, 4, 8, 16 or 32 nozzles
Same equiv. length for each branch pipe
• Bullhead tees

30. Typical discharge patterns
ICAF SYSTEM
Components: Foam Nozzles
Typical discharge patterns

31. Coverage on cascading fire
ICAF SYSTEM
Components: Foam Nozzles
Coverage on cascading fire

32. ICAF SYSTEM Components: Piping requirements Piping: Fittings:
Black or Galvanized
Sch.10 or 40
ASTM A-795, A-53 & A-135
Hangers per NFPA-13
Fittings:
Threaded, Grooved, Welded or flanged
Cast iron Class 125, ASME B16.4
Malleable iron Class 150, ASME B16.3
Improved hydraulics:
Feed Main up to 500 ft. (tested and listed) Elevation losses only 10% of water (0.04 psi vs. 0.43)

33. ICAF SYSTEM Components: New ICAF Nozzles FPO Oscillating Nozzle:
Low level mounting
2” to 4” diam. Inlet pipe
90° or 180° discharge pattern
FPO-4-90

34. ICAF SYSTEM Components: ICAF Nozzles New FPO Oscillating Nozzle:
Up to 92 ft. throw
90 or 180 degree arc of oscillation
Densities:
- Hydrocarbon: GPM/Ft2 at 3%
- Polar solvents: GPM/Ft2 at 6%
(FM Approval in progress)
FPO-4-90

35. ICAF SYSTEM Components: ICAF Nozzles FPO Nozzle Applications:
Aircraft hangars
Helipads
Loading/unloading racks
Diked areas
FPO4-90

36. ICAF SYSTEM Examples of application: Hydraulic Presses
Diesel Generators
Lube Oil Skids
Diesel Fuel Storage & Refueling

37. ICAF SYSTEM Examples of application: Rolling Mills Pump rooms
Fuel Pumping Stations
Methanol Storage
Etc.

38. ICAF SYSTEM Case Studies: Oil Storage Rooms Transformers
Links to Slides: #51 (Oil Storage) | #60 (Hangars) | #75 (XFormers)
Oil Storage Rooms
Transformers
Aircraft Hangars

39. Containment & Drainage Environment & Performance
CONCLUSION
ICAF Projects / Deciding Factors
Project
Water Supply
Containment & Drainage
Environment & Performance
6 x Aircraft Hangars in USA & Canada (26 to 46,000 ft2) 
Montreal Transit Commission
Diesel Refueling Stations
CFB Trenton, ON Fuel Trucks Garages
Belco, Bermuda XFormers, Fuel Transf Pumps
Sam Electron, QC Flamm. Liquid Process

40. Containment & Drainage Environment & Performance
CONCLUSION
ICAF Projects / Deciding Factors
Project
Water Supply
Containment & Drainage
Environment & Performance
Encana FCCL Oil Sands Flash Crude Drums 
Bank of Montreal Fuel Tanks & Pump Room
PG & E South San Francisco H-Voltage Regulators
Hewitt Chicago Fuel Tank
BC Hydro Underground Power Station

41. Containment & Drainage Environment & Performance
CONCLUSION
ICAF Projects / Deciding Factors
Project
Water Supply
Containment & Drainage
Environment & Performance
Manitoba Hydro H-Voltage Transformers 
Pella Windows, IA Wood Treatment
Enovation Graphics, FL Flamm. Liquid Room
EssChem, PA Alcohol Storage
Metro North, NJ Flamm. Liquid Room

42. Containment & Drainage Environment & Performance
CONCLUSION
ICAF Projects / Deciding Factors
Project
Water Supply
Containment & Drainage
Environment & Performance
Momentive, FL Flamm. Liquid Process 
Croda, RI Pump Room
Ontario Hydro Transformer Oil Storage

43. ICAF SYSTEM Costs Comparisons: 45,000 ft2 Aircraft Hangar ICAF System
Start-up: 1%
System hardware: 42%
Water supply: 7% !
Installation: 13%
Detection system: 2%
Savings 35% !
Foam-Water System
Water supply: 69%
Start-up: 1%
System hardware: 15%
Detection system: 2%
Installation: 13%

44. CONCLUSION Water supply Drainage / Containment
Reasons to use CAF Systems
Water supply
eliminate / reduce size of water tanks & fire pumps
Drainage / Containment
eliminate / reduce size of drainage systems and spill tanks, oil separators

45. Reasons to use CAF Systems
CONCLUSION
Reasons to use CAF Systems
System performance
effective extinguishing mechanism
Environmental impact
Less water & foam
Reduced disposal costs of AFFF
Potential for LEED points

46. Sustainable Fire Protection
Alberta Industrial
Fire Chiefs
Sustainable Fire Protection
Thank you !

47. Information required for pricing
To determine foam type and nozzle spacing
Type of product involved, provide MSDS if available
Hydrocarbon or Polar Solvants
To establish the nozzle layout
Drawing or sketch of the area(s) to be protected
Plan view showing dimensions and ceiling height
Elevation view required for 3D hazard such as transformer
Dimensions and location of obstructions that may affect discharge pattern
Beams
Columns
Ducts
Equipment

48. Information required for pricing
To determine the system size
Identify the fire scenario
How many zones could be actuated simultaneously
Will multiple areas be protected by a single system
Single zone system or multiple zone system
Could be a multiple zone system design for the largest zone
Advantages to use a common foam tank and cylinder bank
What is the minimum discharge time ?
5 minutes for specific hazard applications such as transformers
10 minutes for ceiling nozzle applications
20 minutes recommended for aircraft hangars

49. To complete evaluation
Determine if minimum water supply is available
Based of minimum flow and pressure established during design
Determine if available water supply is sufficient
May require fire pump if pressure is not sufficient
May require stand alone water tank if flow is not sufficient
Fireflex can offer a pressure vessel type tank up to 2000 US-gallons

50. To complete evaluation
Determine actuation means
What type of fire detection is require ?
There are no specific requirements for the ICAF System
Heat, rate of rise or compensated, Protectowire, UV-IR, beam could be used to actuate the system
Does the hazard area require explosion-proof or weather proof wiring and devices ?
Are there any devices that need to be shut down prior to discharge ?

51. To complete evaluation
Identify possible location of system and maintenance area
Identify preferred piping route
Identify any obstructions to the piping route
Record dimensions of possible mechanical room
Will a discharge test be done ?

53. Start UL-162

54. FIRE TESTS UL-162 Based Tests Test Requirements: Density: 0.10 gpm/ft2
Foam-water 15 ft. high
Extinguishment: 5 min. max.
Max. 25% foam drainage after 30 sec.
Min. 5 min. burn back resistance
Page accessed with link on Slide #8 (Fire Tests)

55. FIRE TESTS UL-162 Based Tests Test set-up: 50 ft2 Heptane pan
4 nozzles at 40 ft. H.
12’-3" x 12’-3" spacing
15 sec. pre-burn
5 min. discharge

56. FIRE TESTS UL-162 Based Tests Comparing: Foam-water sprinklers
AFFF 3% solution
0.16 gpm/ft2 density
Vs.
TAR nozzles
AFFF 2% solution
0.04 gpm/ft2 density

57. 3% AFFF Foam-Water 0.16 gpm/ft²
FIRE TESTS
UL-162 Based Tests
Comparing extinguishing performances – nozzles at 40’
2% AFFF CAF 0.04 gpm/ft²
3% AFFF Foam-Water 0.16 gpm/ft²

58. FIRE TESTS UL-162 Test #2 – Nozzles at 40 ft. Hydrocarbon Liquid:
Foam-Water
CAF
UL162
Density (gpm/ft2)
0.16**
0.04**
0.10
AFFF concentration 3% 2%
Extinguishing time (min:sec)
1: 42
1:17
5:00
Link to Slide #36 (Safety Factors) | Link returning to Slide #8 (Fire Tests)
25% Drainage (min:sec)
0:30
3:30
0:30
Burn back resistance (min:sec)
17:09
26:00
5:00
** UL safety factor of 1.6 included

59. Start Safety Factors

60. FIRE TESTS UL Safety Factors Normal flow: 0.04 gpm / ft2, 2% AFFF
Reduced water flow: factors of 1.33 & 1.64
Increased water flow: factor of 1.6
Foam-water sprinkler: 0.16 gpm / ft2, 3% AFFF

61. FIRE TESTS UL Safety Factors - Comparing densities Foam-water at 0.16
CAF at 0.024
CAF at 0.064
Slide accessd from link on Slide #34 | Links back to Slides #8 (Fire tests) or #9 (System)
CAF at 0.04
Densities in gpm/sq.ft.

62. FIRE TESTS UL Safety Factors Test Density (gpm/ft2) AFFF Concent.
Extinguishment time (min:sec)
Burn back Time (min:sec)
CAF TAR
0.04
2.0%
1:00
30:50
CAF TAR
0.024
3.3%
1:10
10:00
CAF TAR
0.064
1.2%
1:31
16:50
Foam-Water
0.16 3%
1:40
17:09

63. FIRE TESTS UL Safety Factors Normal Design Density (0.04 gpm/ft2):
Safety factor greater than 1.64
Both for extinguishment & burn-back protection
Increased & Reduced Densities:
Better performance than foam-water sprinklers

64. Start Spill Test

65. FIRE TESTS Spill Fire (Class B - flammable liquids) Test set-up:
20’ x 20’ test pad
Continuous flow of Heptane at 6 gpm
10.7 ft2 shielded area
Nozzles at 35 ft.
Slide accessed through link on Slide #8 (Fire Tests)

66. FIRE TESTS Spill Fire (Class B - flammable liquids) vs.
4 x Foam-water sprinklers
3% AFFF at 0.16 gpm/ft2 density
vs.
4 x TAR CAF nozzles
2% AFFF at 0.04 gpm/ft2 density

67. FIRE TESTS Spill Fire (Class B - flammable liquids)
150 ft2 Heptane spill before ignition
15 sec. pre burn
before system activation

68. 3% AFFF Foam-Water 0.16 gpm/ft²
FIRE TESTS
Spill Fire (Class B flammable liquids)
Comparisons of extinguishing performances
2% AFFF CAF 0.04 gpm/ft²
3% AFFF Foam-Water 0.16 gpm/ft²

69. FIRE TESTS Spill Fire (Class B - flammable liquids) Technology
99% Extinguishment time (min:sec)
100% Extinguishment time (min:sec)
Foam-Water
1:30
N/A ***
ICAF
1:55
4:58
*** Fuel flow had to be manually stopped !

70. FIRE TESTS Spill Fire (Class B - flammable liquids)
Shielded area before CAF build-up
Shielded area during CAF build-up

71. FIRE TESTS Spill Fire (Class B - flammable liquids)
100% fire extinguishment
No flammable liquid overflow
CAF build up under shielded area
Always on top of fuel
Limits runoff
Link back to Slide #8 (Fire tests)

72. Start Transformers
Test

73. Transformers: (Class B - flammable liquids)
FIRE TESTS
Transformers: (Class B - flammable liquids)
Typical protection:
NFPA-15 Deluge system
22 water spray nozzles
Requires 240 gpm
Slide accessed through link on Slide #8 (Fire tests)

74. Transformers: (Class B - flammable liquids)
FIRE TESTS
Transformers: (Class B - flammable liquids)
Test Setup:
20 gpm ‛Volt Esso 35’ Transformer Oil
Pre-heated to 167°F (75°C)
8 x TAR-225L Nozzles
2% AFFF at 42.3 gpm

75. FIRE TESTS Transformers: (Class B - flammable liquids)
Comparing extinguishing performances
2% AFFF CAF 0.04 gpm/ft² (42.3 gpm)
Water Spray Deluge 0.25 gpm/ft² (240 gpm)

76. Transformers: (Class B - flammable liquids)
FIRE TESTS
Transformers: (Class B - flammable liquids)
Test Results:
System
Extinguishment Time (min:sec)
Flow (gpm)
Water (gal)
Foam (gal)
Deluge
3:55
240
940
Link back to Slide #8 (Fire Tests)
ICAF
1:30
42.3
63.5
1.3

77. Start Critical Applications
Test

78. FIRE TESTS UL-162 Based Tests Critical Applications - Hydrocarbons:
50 ft2 Heptane pan
Alcohol Resistant AFFF
Density: 0.06 gpm/ft2
ICAF 35 ft. high
10’-0” x 10’-0” spacing
Page accessed with link on Slide #8 (Fire Tests)

79. FIRE TESTS UL-162 Based Tests - Critical Applications:
Page accessed with link on Slide #8 (Fire Tests)

80. FIRE TESTS UL-162 Based Tests Critical Applications - Hydrocarbons:
Extinguishment: 41 seconds
25% foam drainage after 30 minutes
Burn back resistance: Self extinguishment !
Alternate:
3% AFFF MIL Spec. Concentrate
Density: 0.04 gpm/ft2
Extinguishment: 38 seconds
Page accessed with link on Slide #8 (Fire Tests)

81. Start Typical Sprinklers
Test

82. FIRE TESTS UL-162 Based Tests Sprinklers on Heptane Fire: Water only
Upright sprinklers (K = 11.2)
Mounted at 35 ft. high
Density: 0.60 gpm/ft2
Extinguishment: NO ! Control only…
Page accessed with link on Slide #8 (Fire Tests)

83. FIRE TESTS UL-162 Based Tests – Water Sprinklers:
Page accessed with link on Slide #8 (Fire Tests)

84. Start Case Study
Oil Storage

85. ICAF SYSTEM Case Studies: Oil Storage Room Underground facility
83 ft. x 35 ft.
10 x 8,000 gal. transformer oil storage tanks
Slide accessed through link on Slide #22 (Case Studies)

86. ICAF SYSTEM Case Studies: Oil Storage Room Technology Water Flow (gpm)
Water Used
(US Gal)
Foam Water
600
36000 (60 min.)
ICAF
214
2140 (10 min.)
Hi-Ex
250
3000
(12 min.)

87. Actual ICAF System footprint
Case Studies: Oil Storage Room
Actual ICAF System footprint

88. ICAF System arrangement
Case Studies: Oil Storage Room
ICAF System arrangement

89. After 2 minutes foam discharge test
ICAF SYSTEM
Case Studies: Oil Storage Room
After 2 minutes foam discharge test

90. ICAF SYSTEM Case Studies: Oil Storage Room
Link back to Slide #22 (Case Studies)
Minimal residues left after 16 hours…

91. Start Case Study
Aircraft Hangar

92. Existing hangar: Limited water supply & restricted drainage…
ICAF SYSTEM
Case Studies: Aircraft Hangars
Existing hangar: Limited water supply & restricted drainage…

93. ICAF SYSTEM Case Studies: Aircraft Hangars Dimensions:
184’ x 250’ (46,000 ft2) ceiling at 32 ft.
320 x TAR Nozzles installed at 26 ft. (+ 16 nozzles under a gantry)
5 zones with 64 nozzles each

94. ICAF SYSTEM
Case Studies: Aircraft Hangars
View of the hangar space

95. ICAF SYSTEM
Case Studies: Aircraft Hangars
5 zones piping layout

96. 2 levels ICAF System mechanical room
Case Studies: Aircraft Hangars
2 levels ICAF System mechanical room

97. Cabinets, foam tanks & compressed air cylinders
ICAF SYSTEM
Case Studies: Aircraft Hangars
Cabinets, foam tanks & compressed air cylinders

98. ICAF SYSTEM Case Studies: Aircraft Hangars
2 x 2000 gpm diesel fire pumps

99. Full discharge test video
ICAF SYSTEM
Case Studies: Aircraft Hangars
Full discharge test video

100. Foam coverage after discharge test
ICAF SYSTEM
Case Studies: Aircraft Hangars
Link back to Slide #22 (Case Studies)
Foam coverage after discharge test

101. Start Case Study
Transformers

102. ICAF SYSTEM Case Studies: Power Transformers Deluge / ICAF Comparison:
Nozzle Qty
Water Flow
(gpm)
Water Used
(US gal)
Deluge 44
500
5000 (10 min.)
ICAF 16 95
475 (5 min.)

103. ICAF System Piping Layout
Case Studies: Power Transformers
Top
Front
ICAF System Piping Layout

104. ICAF System Piping Layout
Case Studies: Power Transformers
Slide accessed through link on Slide #22 (Case Studies)
Side
Isometric
ICAF System Piping Layout

105. Actual ICAF System footprint
Case Studies: Power Transformers
Link back to Slide #22 (Case Studies)
Actual ICAF System footprint

106. Start Burn Back

107. FIRE TESTS UL-162: Burn Back Tests Foam undisturbed for 15 minutes
1 ft. diam. opening in foam blanket
Manual re-ignition of fire after 1 min.
Max. burn back of 10 ft2 after 5 min.

108. Opening is created in foam blanket…
FIRE TESTS
UL-162: Burn Back Tests
Opening is created in foam blanket…

109. FIRE TESTS UL-162: Burn Back Tests
Free fuel is re ignited in the opening…

110. Pipe is removed and fire is allowed to burn freely…
FIRE TESTS
UL-162: Burn Back Tests
Pipe is removed and fire is allowed to burn freely…

111. 10 ft2 max. burn-back area after 5 min.
FIRE TESTS
UL-162: Burn Back Tests
10 ft2 max. burn-back area after 5 min.

112. Start Components

113. ICAF SYSTEM Components: Foam Generation Trim Mixing chamber
1", 1½", 2" or 3" 
Manual release
CAF outlets (up to 3)
Releasing trim:
Electric,
Pneumatic,
or Failsafe
Flow control valve
Water supply
50 to 175 psi
Drain

114. ICAF SYSTEM Components: Releasing Panel FireFlex ARC-1:
Microprocessor based
Factory programmed
LCD Annunciator
User friendly interface

115. ICAF SYSTEM Components: Releasing Panel FireFlex ARC-1: EMI resistant
Programmable I/O ccts
Timers & counters
Auxiliary relays
Emergency batteries

116. ICAF SYSTEM Components: Foam Supply No bladder Stainless steel
Pressure vessel type (ASME Sect. VIII, Div. 1)
Up to 550+ gallons

117. ICAF SYSTEM Components: Foam Supply Foam outlet Air supply inlet
Foam refilling valve
Foam level sight tube
Siphon tube
Pressure vessel type tank (normally non-pressurized)

118. ICAF SYSTEM Components: Air Supply Factory assembled
4, 6, 8 or 10 cyl. skid
Pressure transducer
Field refilling port
Labor reducing

119. ICAF SYSTEM Components: Air Supply Factory adjusted pressure regulator
Pressure sensor
Pressure gauge
Refilling port
Pressure outlet (100psi)