API Specification 1584 Ip 3rd Ed. 2001 Four-Inch Hydrant System Components and Arrangements

 

FOUR-INCH HYDRANT SYSTEM COMPONENTS AND ARRANGEMENTS ARRANGEMENTS

API/IP SPECIFICATION 1584

Third edition April 2001

 

FOUR-INCH HYDRANT SYSTEM COMPONENTS AND ARRANGEMENTS API/IP SPECIFICATION 1584

Third edition April 2001

Published jointly by American Petroleum Institute and The Institute of Petroleum, London A charitable company limited by guarantee

 

Copyright © 2001 by American Petroleum Institute, and The Institute of Petroleum, London: A charitable company limited by guarantee. Registered No. 135273, England All rights reserved  No part of this book may be reproduced by any any means, or transmitted or translated into a machine language without the written permission of the publisher. ISBN 0 85293 280 4 Published by The Institute of Petroleum Further copies can be obtained from Portland Press Ltd. Commerce Way, Whitehall Industrial Estate, Colchester CO2 8HP, UK. Tel: 44 (0) 1206 796 351 email: [email protected] [email protected] m

 

CONTENTS Page Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii Acknowledgements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix 1

Introd Introducti uction, on, scope scope and refere reference nced dp publi ublicat cation ionss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Referenced publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 2

2

Te Term rms, s, defin definit ition ionss a and nd abbr abbrev evia iatio tions ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Terms and definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 Units used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 5 5

3

Gene Genera rall ar arra rang ngem emen ents ts and and ffea eatur tures es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3.1 Typical arrangement of hydrant pit equipment and controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3.2 Mandatory re requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3.3 Optional items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4

Pe Perf rfor orma mance nce ccri rite teri ria a and test testin ing g proce procedu dure ress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Mechanical strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Test fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 Dimensional checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 Proof and burst pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 Pressure loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 Opening and closing times and overshoot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 Vacuum test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 Pilot device override test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9 External load resistance and failure mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10 Catastrophic ex excess ffllow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11 Decoupling spillage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12 Pressure, surge and flow control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 21 21 21 21 22 22 23 23 23 25 26 26

5

Ty Type pe a appr pprov oval al ttes esti ting ng and and quali quality ty assu assura ranc ncee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 Quality assurance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 Approval testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 Documentation and instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 27 27 27

v

 

Contents Cont..

Page

Annex A - Catastrophic excess flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Annex B - Hydrant pit valve assemblies in small pit boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Annex C - Hydrant riser stress during impact of the hydrant pit valve/hydrant coupler assembly . . . . Annex D - Air-operated pilot devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Annex E - The inspection and testing of airport hydrant pit valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

vi

29 31 33 35 37

 

FOREWORD This joint Institute of Petroleum and American Petroleum IInstitute nstitute publication provides recommended minimum  performance and mechanical mechanical specifications for the design of aviat aviation ion fuel hydrant system pit valves and associate associated d couplers. This publication also specifies requirements that need to be met to achieve full interchangeability between components of various manufacturers and requirements for optional features which component manufacturers may  be requested by users to provide. This publication has been produced jointly by the API Aviation Technical Services Subcommittee and the IP Aviation Committee. It replaces API replaces API Standard 1584 second edition, December 1994, IP Aviation IP Aviation hydrant pit system systemss recommended arrangements, arrangements, August 1990 and IP The inspection and testing of airport hydrant pit valves, valves , July 1993. It is possible that this joint publication will have a wider scope of usage and will encompass differing operating  practices and safety safety and environmental environmental legislation. Therefore, Therefore, this publication should be read in conjunction with appropriate national and local statutory operating requirements. It is recommended that, if procedures defined in this publication are more stringent than those at the point of use are they should be followed. Whilst the use of hydrant pit valve assemblies designed for use with 150 mm (6 in.) hydrant riser flanges is  preferred, requirements requirements for valves that are able to mate with with other flanges are also included. The requirements of this publication are not retroactive. Users of existing equipment should decide what action to take if equipment in current use does not conform to the requirements of this edition. Due consideration should be taken of the safety implications of non-conformance. Within six months of the publication of this edition, manufacturers will be expected to be able to supply modification kits, where necessary, for any existing equipment that does not conform to the requi requirements rements of this edition. The Institute of Petroleum and American Petroleum Institute are not undertaking to meet duties of employers, manufacturers or suppliers to warn and properly train and equip their employees, and others exposed, concerning health and safety risks and precautions, nor undertaking their obligations under local and regional laws and regulations.

vii

 

 Nothing contained in any Institute of Petroleum or American Petroleum Institute joint publica publication tion is to be construed as granting any right, by implication or otherwise, for the manufacture, sale, or use of any method, apparatus, or   product covered by letters patent. Neither should anything contained contain ed in the publication be construed as insuring anyone against liability for infringement of letters patent. Although it is hoped and anticipated that this publication will assist both the manufacturers and purchasers of  aviation fuel hydrant system pit valves and couplers, the Institute of Petroleum and the American Petroleum Institute cannot accept any responsibility, of whatever kind, for damage or loss, or alleged damage or loss, arising or  otherwise occurring as a result of the application of the specifications or qualification procedures contained herein. Suggested revisions are invited and should be submitted to the Manager of Standardization, American Petroleum Institute, 1220 L Street, N.W., Washington, D.C. 20005, USA or to the Technical Department, Institute of  Petroleum, 61 New Cavendish Street, London W1G 7AR, UK. Note for users of equipment covered by this publication. publicatio n. This publication includes a requirement for couplers to break away cleanly from the pit p it valve adapter if struck with a force as defined herein. It is recommended that, if a pit valve/coupler assembly is struck with sufficient force to remove the coupler during refuelling operations, the pit valve should be removed from service for inspection and tested to prove its suitability for further use. Users are referred to the recommended post-impact action in Annex C.

viii

 

ACKNOWLEDGEMENTS This edition of API/IP 1584 has been prepared by the IP Equipment Sub-Committee on behalf of the Institute of  Petroleum and the American Petroleum Institute Aviation Technical Services Sub-Committee. Much of the redrafting was undertaken by Bob Simpson (Consultant) and Adrian Hamra (ExxonMobil). Draft versions of this third edition were reviewed by representatives of the following companies: AgipPetroli Air BP Limited Air TOTAL Avery Hardoll SBU, BAE Systems Power & Control Ltd. Caltex Corporation Carter Ground Fueling Co. Chevron Products Co. Conoco Limited Elf Aviation International Equilon Enterprises ExxonMobil Aviation International Ltd. Intertechnique Zenith Aviation Kuwait Petroleum International Aviation Company Ltd. Phillips 66 Company Shell Aviation Ltd. Texaco Global Aviation Marketing Ltd. Whittaker Controls Inc.

ix

 

x

 

1 INTRODUCTION, SCOPE INTRODUCTION, AND REFERENCED PUBLICATIONS 1.2 SCOPE

1.1 INTRODUCTION

The performance requirements and optional recommendations included in this publication are intended to achieve the following:

1.2.1

General

This publication specifies dimensions, coupling action, activation, and other requirements to achieve the necessary operational requirements and full interchangeability between components from manufacturers of hydrant pit valve assemblies and couplers. It also includes requirements for other  optional features which component manufacturers may  be requested to provide by purchasers. The performance specifications are for equipment intended for systems in aviation turbine fuel service. They do not apply to aviation gasoline (Avgas).

(a) Establish Establish the the acceptable acceptable structural structural and and oper operating ating integrity of the components involved. (b) Provide Provide a com compatibl patiblee coupling coupling configurat configuration ion and arrangement at the hydrant pit that will permit interchangeability between the components of  different manufacturers. (c) Assist Assist component component manufactu manufacturers rers iin n their d design esign efforts by detailing operational, maintenance and ergonomic features of components that are considered desirable based upon experience in aircraft fuelling.

1.2.2

Organization

If complete interchangeability is to be attained, certain features of the mating components shall be standardised. Other features, although desirable, are not so critical, but are pointed out to assist manufacturers in the design of these components. The pit valve and coupler, along with any other  features attached, are considered to be as a whole for  the purposes of this publication. Section 3 covers general arrangement and features, specifying those features of the hydrant components that are mandatory, as well as those that are optional.

(d) Describe Describe the the alternative alternative arrangem arrangements ents of hydrant hydrant  pit components that are typical for API and IP 4 inch hydrant systems and thereby assist component manufacturers and aircraft fuelling system designers and operators in their efforts. (e) Provide Provide mec mechanic hanical al stre strength ngth cr criteria iteria for for normal normal handling loads and failure modes for excess mechanical loadings and impact damage.

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FOUR-INCH HYDRANT SYSTEM COMPONENTS AND ARRANGEMENTS

IP 2

They are listed as "Mandatory" and "Optional" respectively. Section 4 describes performance criteria and test requirements for the hydrant pit valve assembly and hydrant coupler. Section 5 contains the quality assurance and information requirements. Five annexes are included for information only.

 Fuel hydrant riser pipe stress analysis due to accidental impact loads. The closure behaviour of aviation hydrant pit  valves (Delft Hydraulics). Sanderson, T.A., and Simpson, R.A. 1990, Excess 1990, Excess  flow testing of hydrant pit valves valves,, Petroleum Review, May 1990.

1.3 REFERENCED PUBLICATIONS

The following publications are cited in this publication. pu blication. The latest available edition of each referenced  publication applies.

ISO 3  9000:2000 Quality management systems. systems. 10012-1 Quality assurance requirements for  measuring equipment: Metrological confirmation  system for measuring equipment .

API RP 1004 Bottom 1004 Bottom loading and vapour recovery for   MC-306 tank motor vehicles. vehicles.

SAE 4 ARP 868A  Method pressure drop test for fuel   system components. components.

Specification Q1 Specification for quality  programs for the petroleum and natural gas industry.. industry 1

ASME B.16.5 Pipe B.16.5  Pipe flanges and flanged fittings. fittings.

1. American Society of Mechanical Engineers, 3 Park Avenue, New York, NY 10016-5990, USA. www.asme.org 2. Available from the Institute of Petroleum library, 61 New Cavendish Street, London W1G 7AR, UK  3. International Organization for Standardization, Case Postale 56, CH-1211 Geneva, Switzerland. www.iso.ch 4. Society of Automotive Engineers, 400 Commonwealth Drive, Warrendale, PA 15096-0001, USA. www.sae.org

2

 

2 TERMS, DEFINITIONS AND ABBREVIATIONS timer deadman may be included with this system as an option.

2.1 TERMS AND DEFINITIONS

For the purposes of this publication the following terms and definitions apply:

 —  direct acting pressure control coupler : a coupler  that incorporates the same features as the standard unit, but also includes air-operated deadman and spring biased pressure regulation at a remote sensing point. This coupler also has optional excess flow control.    —   pilot-operated pressure control coupler : a coupler  that has the same features as the standard unit, plus the air deadman feature, but controls pressure by means of a pilot mechanism. This coupler also has optional excess flow control (with either single or 

clean breakaway:  when used in describing the  breakaway of the hydrant coupler from from the hydrant pit valve adapter, means that the coupler breaks away completely to allow the pit valve outlet adapter poppet to close. In practice, complete seating of the poppet cannot be guaranteed as coupler debris that may be left could prevent full poppet closing. hydrant coupler: a unit that is attached to the inlet end of the hydrant dispenser inlet hose ho se or boom assembly to

dual flow rate settings).

 provide for quick coupling to the outlet adapter of the hydrant pit valve assembly. The coupler may be one of  four types, any of which can be equipped for product selectivity:

hydrant coupler carriage assembly: a device fitted to the hydrant coupler to assist in moving the coupler to and from the pit valve whilst keeping the coupler from dragging on the ground.  Note: It generally takes the form of two small wheels on a structure that may be folded up beneath the inlet hose when not in use.

 —   standard coupler : a quick coupling device that allows for manually opening and closing the  poppet on the hydrant pit valve assembly and  provides a flow path from the hydrant pit valve assembly to the dispenser.

hydrant dispenser: (also known as 'hydrant servicer', 'aircraft fuel servicer' or 'hydrant cart') a fuelling unit used to receive fuel from a hydrant fuel supply system and deliver it to aircraft. It may be self-propelled, trailer  mounted or skid mounted.

 —  direct acting digital control coupler : a coupler that incorporates the same features as a standard coupler, but uses a digital module to control  pressure and flow for each hose combination. A

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FOUR-INCH HYDRANT SYSTEM COMPONENTS AND ARRANGEMENTS

within the hydrant pit valve assembly with the  pressure within the hydrant coupler.

 Note: It is normally fitted with filtration, pressure control, deadman control and metering equipment and is connected to the hydrant pit valve by a hydrant coupler and an inlet hose or metal boom assembly. The hydrant dispenser is used to deliver fuel into aircraft via a delivery hose and nozzle.

 —   stoneguard : a mandatory coarse mesh screen (e.g. 5 mm or ¼ in. or equivalent) perforated metal strainer that is mounted upstream of the hydrant pit valve assembly to impede the flow of large debris normally foreign to fuel systems.

hydrant pit valve assembly: a valve that is vertically mounted on the flanged riser of an airport fuel piping system.  Note: The valve is composed of three components: the flanged inlet pilot-operated valve, the pilot device and the outlet adapter that mates with the hydrant coupler. Optional features may be included.

flow:  —  automatic excess flow control : a device installed on or within the hydrant pit valve assembly and/or  coupler to prevent excess flow.  Note: Upon the flow rate increasing to a  predetermined level, the device will actuate the hydrant pit valve assembly and/or coupler to close and remain closed until the excess flow control device is reset.

 —  intermediate strainer : an optional fine mesh screen that is mounted internal to the hydrant pit valve assembly, normally between the pilot-operated valve and the outlet adapter.  Note: The use of such a strainer is not recommended.

 —  catastrophic excess flow: flow: the maximum flow rate required to be stopped by the hydrant pit valve.  —  excess flow: flow: a flow rate in excess of rated flow.

 —  outlet adapter : the outlet portion of the hydrant pit valve assembly to which the hydrant coupler  mates. The outlet adapter has a poppet that is opened and closed by the coupler poppet. The outlet adapter provides a seating for the poppet and for optional product selectivity.

 —  rated flow: flow: the maximum flow rate for which the components of the pit valve assembly and coupler  are designed.

 —   pilot device: device: a mechanism which diverts pressure to and from the actuating element of the pilotoperated valve to enable it to either open or close in a controlled manner.  Note: The required methods for operating the  pilot device are defined in 3.2.8.

in-line pressure control (or regulating) valve: a valve installed on board the hydrant dispenser forming a part of the fuel pressure control (or regulating) system. It may also provide a deadman operation, being opened and closed remotely by the fuelling operator. This valve is outside of the scope of this publication and may be fitted at the discretion of the user.

 —   pilot device override: override: (also known as a 'servicing

opening and closing times:

valve') a manually operated valve device thus that overrides the action of the pilotor valve  preventing opening of the pilot-operated valve.

 —  closing time : the time required, after to thecease operating device istime: actuated to close, for flow from rated flow.

 —   pilot-operated valve: valve: located at the inlet, it forms an integral part of the hydrant pit valve assembly and isolates downstream components from the fuel hydrant supply pressure. It is operated by the pilot device and controls the flow of fuel out of the hydrant pit valve assembly.

 —  deadman control : a hand-held control to actuate the opening and closing of the hydrant pit valve assembly and/or hydrant coupler.  —  opening time: time: the time taken to achieve 90 % of  rated flow measured from the time that the operating device is actuated.

 —   pressure equalisation valve: valve: a small valve located in the centre of the outlet adapter poppet that is actuated by the hydrant coupler poppet. This valve allows equalisation of the pressure contained

 —  overshoot : the volume of liquid passing through the valve during the closing time period.

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TERMS, DEFINITIONS AND ABBREVIATIONS

2.2 ABBREVIATIONS

pressure:  —  burst pressure: pressure: the pressure causing structural failure of the external casing of the hydrant pit components covered by this publication.  Note: For the purposes of this publication, the  pressure defined in 4.4.2 is the minimum pressure above which structural failure may occur.

The following abbreviations are used within this  publication:

 —  design pressure: pressure: the maximum pressure to which the hydrant pit components will be subjected in service.  Note: This pressure equates to operating  pressure plus surge pressure to which the equipment may be exposed. The performance criteria of this document do not apply at design  pressure.  —  operating pressure: pressure: the maximum steady state  pump pressure that can be experienced in the system. At this maximum pressure, the hydrant pit valve assembly and coupler are required to conform to the performance criteria of this

ft in.

feet inch

kg kPa kph lbs lbf lpm m mm mph  N  psi USG USGPM o F o C

kilogram kiloPascal kilometres per hour   pounds mass pounds force litres per minute metre millimetre miles per hour   Newton pounds per square in. US gallon US gallons per minute degrees Fahrenheit degrees Celsius

o

degree of angle

 publication.  —   pressure loss: loss: the difference in static pressures measured in the test set-up defined in Figure 6 from point A to point B.

2.3 UNITS USED

pressure control valve: a control valve that may be located either in the hydrant pit valve assembly or in the hydrant coupler assembly. This valve forms part of the  pressure and flow control system delivering fuel to the

This publication uses the Système International d’Unités (International System of Units or SI). In this system, the decimal point is a comma (,). In writing numbers of greater than 3 digits, e.g. thousands, tens of  thousands etc. a comma may not be used to demarcate the thousands. Thousands are demarcated by the use of  a space. Within this publication SI Units are used with US Customary Units following in parentheses. Internationally agreed conversions have been applied to

aircraft. valve. May also be known as a pressure-regulating

these values.

 —   proof pressure: pressure: the maximum pressure required of  the hydrant pit components without external leakage or damage after which the components will meet all other performance requirements. requirements.

vacuum test: a negative pressure applied to the hydrant  pit valve assembly under which the poppet shall shall remain remain closed and not allow leakage of air in the reverse direction.

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FOUR-INCH HYDRANT SYSTEM COMPONENTS AND ARRANGEMENTS

6

 

3 GENERAL ARRANGEMENTS AND FEATURES travel of 50,8 +1,588/-0,000 mm (2 +0,0625/-0,000 in.) measured from the sealing surface as identified on Figures 3A and 3B. A static seal shall be achieved automatically  between the coupler and outlet adapter during the coupling and locking operations and before the adapter  is actuated to open. The static seal shall be designed so that it cannot be broken until the outlet adapter and coupler are closed. Leakage in excess of 30 ml (1 fluid ounce) through the static seal shall not occur at any time during the coupling, fuelling, and uncoupling operation, regardless of system pressure. See 4.11 for test details.

3.1 TYPICAL ARRANGEMENT OF HYDRANT PIT EQUIPMENT AND CONTROLS

A number of alternative component arrangements are offered, essentially determined by the location of one or  more of the controls. The two extremes are shown in Figures 1 and 2. In Figure 1, the controls are in a regulating valve installed inside the coupler. In Figure 2, the controls are in the pit valve assembly. The  purchaser  purchas er shall specify the final componen componentt arrangement. The fitting of a separate hydrant riser  shut-off valve is not a requirement of this publication.

3. 3.2. 2.2 2

Outl Outleet ada adapt pter er actu actuat atio ion n

3.2 MANDATORY REQUIREMENTS 3. 3.2. 2.1 1

The opening of the hydrant coupler poppet shall cause the outlet adapter poppet to open. The outlet adapter   poppet shall close automatically whenever whenever the coupler  is closed or removed. In manual operation, the outlet adapter and hydrant coupler when coupled together  shall be capable of being opened and closed by one operator applying a maximum force of 110 N (25 lbf). To function properly, the force shall be applied for a maximum of 5 seconds to hold the equalisation valve open and allow the pressure to equalise on both sides of  the outlet adapter poppet.

Dime Dimens nsio ions ns an and d hyd hydra rant nt coup couple ler/ r/hy hydr drant ant pit valve assembly mating

The interface dimensions of the outlet adapter of the hydrant pit valve assembly and the hydrant coupler  shall be in accordance with Figures 3A and 4A and 3B and 4B (US Customary Units). The sealing surface as indicated on Figures 3A and 3B shall be 1,6 micrometre (63 micro-inches) circular finish maximum. The outlet adapter poppet, including activation of the pressure relief equalising valve, shall allow a coupler poppet

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FOUR-INCH HYDRANT SYSTEM COMPONENTS AND ARRANGEMENTS

Fuel sense Deadman air  Hydrant coupler with deadman and pressure control Coupler poppet operator   Air to pilot pilot device (if air-opera air-operated) ted) Outlet adapter  Lanyard attachment point Pilot device and override Hydrant pit valve assembly Hydrant pit box Stoneguard

Pit box seal

Hydrant riser 

Figure 1 - Typical arrangement of hydrant pit equipment (deadman and pressure regulating valve in coupler)

Standard hydrant coupler  Deadman air 

Coupler poppet operator 

Fuel sense Outlet adapter  Lanyard attachment point Pilot device and override

Hydrant pit valve assembly Hydrant pit box Stoneguard Pit box seal

Hydrant riser 

Figure 2 - Typical arrangement of hydrant pit equipment (deadman and pressure regulation in pit valve)

8

 

±0,127 38,100

Fixed product selection posts located as shown unnumbered 2 places

212,725 dia. BSC

±0,127 ±0,127 9,525 6,350 ±0,127 1,588

5

45 45 4

6

45 +1,588 50,800 -0,000

Sealing surface

Poppet travel from sealing surface

40,5 BSC

Valve head ± 0,127 ± 0,127 152,400 133,350

±0,127 ±1,588 152,400 184,150 ± 0,127 165,100

± 0,127 ±0,127 ±0,127 165,100 146,050 101,600 Pressure equalizing valve

Outlet adapter  poppet 54 BSC

 9 

Sealing surface

6,3 C 3 1

±1,524 45,974 2

Outer  surface of mating fuel/air  socket

45 5 places BSC

40,5 BSC

C

B F

 A

R E   S 

Product selectivity set bolt (1/2" min. tall, tall, 5/8" max. hex. or dia.) Movable product selection posts located as shown; 4,763 mm i ndex numerals shall be permanently located

G

 G E   N E  R A L  A R R A  N  G E  M E   N T   S  A  N D F  E  A T   U

Notes: BSC = basic dimension; min. = minimum; max. = maximum; hex. = hexagonal; dia. = diameter. 1.  All dimensions are in millimetres. 2. The bre breaking aking of a allll corners is require required, d, not to to exceed 3,175 millimetre radius. 3. The deta details ils of adapt adapter er body va valve lve head an and d internals internals shown in dashed lines are to be determined by manufacturer.

 A minimum clearance of 134,62 mm between hydrant pit valve center and fuel sense/air reference adapter coupled with mating socket. (Refer to Figure 5A for more details).

Fuel/air  reference adapter 

4. Pressure equalizing valve stem on valve head is not to extend beyond sealing surface. 5. Sealing surface must be machined to 1,6 micrometre micrometre circular ffinish. inish.

Refer to Figure 5A for detail

6. Coup Couplers lers must be capab capable le of mating wit with h maximu maximum m dimensions shown.

Figure 3A - API standard hydrant pit outlet adapter, SI measurements

 

±0,005 1,500

Fixed product selection posts located as shown unnumbered 2 places

8,375 dia. BSC

± 0,005 ±0,005 0,375 0,250 ±0,005 0,062 5

5

45 45 4

6

45 Sealing surface

40,5 BSC

+0,062 5 2,000 -0,000 0 Poppet travel from sealing surface

Valve head ±0,005 6,000 ±0,005 6,500

±0,005 ± 0,062 5 6,000 7,250

±0,005 5,250

±0,005 5,750

± 0,005 4,000

± 0,005 6,500 Pressure equalizing valve

Outlet adapter  poppet 54 BSC

1   0 

Sealing surface

6,3 C 3 1

±0,060 1,81 2

Outer  surface of mating fuel/air  socket

40,5 BSC

C

B F

 A

G

45 5 places BSC

Movable product selection posts located as shown; 3/16 inch index numerals shall be permanently located

Product selectivity set bolt (1/2" min. tall, 5/8" max. hex. or dia.) Notes: BSC = basic dimension; min. = minimum; max. = maximum; hex. = hexagonal; dia. = diameter. 1. All dimensio dimensions ns are are in inche inches. s. 2. The breaking breaking o off all corners corners is requ required, ired, not not to exceed 0,125 inch radius. 3. The det details ails of adap adapter ter body body valve hea head d and internals internals shown in dashed lines are to be determined by manufacturer.

Fuel / air  reference adapter 

 A minimum clearance of 5,30 in. between hydrant p pit it valve center and fuel sense/air reference adapter coupled with mating socket. (Refer to Figure 5B for more details). Refer to Figure 5A for detail

4. Pressure eq equalizing ualizing valve stem on valve h head ead is not to extend beyond sealing surface. 5. Sealing surf surface ace must be machined to 63 microinches circular finish. 6. Coup Couplers lers must be be capab capable le of mating with with maximum dimensions shown.

Figure 3B - API standard hydrant pit outlet adapter, customary measurements

F   O  U R -I    N  C  H H Y D R A  N T   S  Y  S  T  E  M    C   O M P   O  N E   N T   S  A  N D A R R A  N  G E  M E   N T   S 

 

GENERAL ARRANGEMENTS AND FEATURES

264,160 C

Coupler max. 259,080

D Groove depth

Coupler min. 250,088 Coupler poppet

^ 0,508 G

2,032 min. M Under pressure

max. diameter 100,5 ^ x. 2,03 2,032 2 ma max. L Under pressure

P

1, 1,65 651 1 mi min. n.  At no pressure

Seal surface - ref.

±1,524 57,150 min. 45,974 H H Coupler  Valve

Pressure equalizing valve top surface must not extend beyond sealing surface

Product selectivity set bolt (12,700 min. tall, 15,875 max. hex. or dia.)

Max. 68,580

D Valve max. 245,008

Min. 69,850

Outside of coupler  including bump ring

264,160 Valve min.

C

269,240 Notes: Dimensions Dimensions are in millimetres;max. = maximum; maximum; min. = minimum; ref. = reference; reference; hex. = hexagonal; dia. = diameter.

Figure 4A - Outlet adapter and coupler interface dimensions, SI measurements

10,40 Coupler max.

C

10,20

D Coupler min. 9,846 Groove depth

Coupler poppet max. diameter 3,956

^ 0,020 G

0,080 min. M Under pressure

P

^ 0,080 max. L Under pressure

0,065min.  At no pressure pressure

Seal surface - ref.

±0,060 2,25 min.

1,81 Pressure equalizing valve top surface must not extend beyond sealing surface

H Coupler 

H Valve

Max. 2,700

Min. 2,750

Product selectivity set bolt (1/2" min. tall, 5/8" max. hex. or dia.) D Valve max. 9,646

C

Outside of coupler  including bump ring

10,40 Valve min. 10,60

Notes: Dimensions are in inches; max. = maximum; min. = minimum; ref. = reference; hex. = hexagonal; dia. = diameter diameter..

Figure 4B - Outlet adapter and coupler interface dimensions, customary measurements

11

 

FOUR-INCH HYDRANT SYSTEM COMPONENTS AND ARRANGEMENTS

3.2.3

(a) For va valves lves w with ith eit either her a 10 100 0 mm ((4 4 in.) o orr 150 m mm m (6 in.) ASME Class 150 inlet flange: 290 mm to 415 mm (11,5 in. to 16,34 in.) in .) (b) For va valves lves w with ith a 150 m mm m (6 in in.) .) AS ASME ME Cla Class ss 300  pattern inlet flange:   406 mm to 415 mm (16 in. to 16,34 in.)

Coupling a acction

The coupling action shall be of the push type with  provision for locking without rotating the coupler body. On systems requiring product selection, rotation of the coupler collar to mate with the appropriate hydrant pit valve assembly product selection device is permitted. The coupling range shall permit coupling to the outlet adapter in any position around the hydrant pit valve assembly, without interference with the hydrant pit walls, apron surface, or components. The hydrant coupler shall incorporate an interlock  system to prevent opening of the coupler’s poppet popp et (and thus the hydrant pit valve assembly poppet) before  being locked in position, and to prevent unlocking and disconnecting before the coupler poppet is closed. The hydrant coupler design shall prevent its ejection in the event of outlet adapter sealing failure or non-closure of  the poppet with the pilot device in the open position. 3. 3.2. 2.4 4

Manufacturers who offer a valve with dimensions shorter than those above should be able to provide spool pieces or adapters to accommodate any difference in the dimensions of the riser flange and the inlet flange of the valve and to bring their valve within the dimensional range in (b) if requested.  Note: The dimensions quoted in (b) and the  provision for spools and adapters will ensure that valves offered by different manufacturers are freely interchangeable. The pit valve assembly shall be installed within the  pit box so that there is a clearance of not more than 100 mm (4 in.) and not less than 75 mm (3 in.) between the hydrant pit valve assembly outlet adapter sealing

Hydr Hydran antt pi pitt ar arra rang ngem emen entt and and moun mounti ting ng

surface and the top of the hydrant pit box. This setting is necessary to ensure that when a coupler is attached to the pit valve, the underside of the elbow does not touch the top of the pit box. When a hydrant coupler fitted with a carriage assembly is attached to the hydrant pit valve outlet adapter, the carriage assembly shall be clear of the ground when in the folded up position.

Hydrant pit components should normally be designed so that they can be installed and maintained in a pit that has a minimum internal diameter of 460 mm (18 in.). However, manufacturers should be aware that some old  pit boxes have a diameter as small small as 300-330 mm (1213 in.) with 100 mm (4 in.), 75 mm (3 in.) or other  special riser flanges and may wish to design their valves to be accommodated in these small pit boxes (see Annex B). Hydrant pit components may be installed in a central or offset position within the pit; however, the overall pit box size and component spacing shall permit easy access for operation and maintenance. In the design, allowance shall be made for the operation of  levers and switches within the pit using industrial type

The pressure/flow control and/or excess flow control, if  fitted, shall be included either on the hydrant coupler or  on the hydrant pit valve assembly. However, as a minimum, there shall be a deadman function installed either on the hydrant pit valve or the hydrant coupler 

gloves and without theequipment need for shall special arrangement of the pit alsotools. allowThe for  unobstructed (non-fouling) lanyard operation. Hydrant system riser pipe flanges shall be in accordance with the latest edition of ASME B.16.5, Class 300 pattern for 150 mm (6 in.) flanges and Class 150 for 100 mm (4 in.) flanges. All hydrant pit equipment flanges shall also be in accordance with ASME B.16.5 for assembly compatibility. This applies for stoneguards, pilot-operated valves and the inlet side of the hydrant pit valve assembly. All components shall be as compact as practicable. The overall height of the hydrant pit valve assembly, measured from the face of the inlet flange to the top of  the outlet adapter, not including the th e dust cap, shall be:

upstream offitted, the inlet hose or boom assembly. Where these controls shall be provided with air reference, and in the case of pressure/flow control and/or excess flow control, fuel reference pressures, to enable them to function. The connection of the lines to  provide such pressures may be permanent (in the case of the hydrant coupler) or may be fitted to either the hydrant pit valve assembly or hydrant coupler by means of a quick coupling. Figures 3A and 3B, 4A and 4B, and 5A and 5B provide the interface dimensions, including product selectivity to ensure complete interchangeability, where both fuel and air lines are required. If used, this accommodation or any other such device shall be located so that it will not interfere with the operation of the other components.

3. 3.2. 2.5 5

12

Fu Fuel el sen sense se a and nd a air ir ref refer eren ence ce llin ines es

 

GENERAL ARRANGEMENTS AND FEATURES

Hydrant couplers, either connected to a hydrant pit valve assembly or disconnected and closed, shall be designed in accordance with the following pressure ratings, all at 70 ºC (158 ºF):

An interlock feature capable of prohibiting accidental un-coupling that is compatible with the design shown in Figures 5A and 5B is desirable. On air-operated pilot devices, an air reference  pressure line from the hydrant dispenser is required to control the opening and closing of the hydrant pit valve. This connection should be a "quick disconnect" type

(a) design press pressure: ure: 1 900 kPa (275 psi) (b) opera operating ting pr pressur essure: e: -10 tto o 1 400 kPa ((-1,5 -1,5 to 200  psi) minimum (c) (c) proo prooff pr pres essu sure re:: (i) uncoup uncoupled led,, clo closed sed:: 1 830 kPa ((265 265 p psi) si) minimum (ii) coupled, coupled, open: 2 850 kP kPaa (415 p psi) si) m minim inimum um (d) (d) burs burstt pres pressu sure re:: (i) uncoup uncoupled led,, clo closed sed:: 2 740 kPa ((400 400 p psi) si) minimum (ii) coupled, coupled, open open:: 5 690 kP kPaa (825 p psi) si) m minimu inimum m

connection. Any standard, through-flow connection may be used. The self-sealing quick disconnect fitted to the pilot device shall be of the leaky type to ensure that no air is trapped within the pilot after disconnecting the mating half from the hydrant dispenser air system. 3.2.6

Flow rate

3.2.6.1 Hydran 3.2.6.1 Hydrantt pit pit valv valvee as assem sembly bly The hydrant pit valve assembly shall be designed in accordance with the following rates:

3. 3.2. 2.8 8

(a) rated flow: flow: 4 500 lpm (1 200 USGPM) USGPM) (b) catastrophi catastrophicc excess excess flow flow:: 11 000 lpm (2 (2 900 USGPM)

3.2.8.1 3.2.8 .1 Ma Manua nuall o ope pera rati tion on The pilot device shall have two separate actions for  opening and closing. The open or close force at maximum operating pressure shall not exceed 110 N (25 lbf). The close actuator shall have a fitting to allow the attachment of a lanyard to achieve the closing function from a remote distance. The fitting and the lanyard shall not be able to foul on any hydrant pit equipment and shall be effective at any angle or  direction of pull.

3. 3.2.6 2.6.2 .2 Hy Hydr dran antt ccou oupl pler erss Hydrant couplers shall be designed in accordance with the following rates: (a) for 4 in. in. inlet by 4 in. in. outlet outlet (either (either press pressure ure controlled or standard coupler): 4 500 lpm (1 200 USGPM) (b) for 4 in. in. inlet by 3 in. outlet outlet (either (either pressure pressure controlled or standard coupler): 3 000 lpm (800 USGPM) 3.2.7

Pilo Pilott devi device ce actu actuat atio ion n

3. 3.2. 2.8. 8.2 2 Air Air ope opera rati tion on The pilot device is operated by the application of an externally supplied air pressure. Control air supply shall  be a minimum of 240 kP kPaa (35 psi) to the pilot device to control opening. The application of the air supply shall  be via a deadman type valve system on the hydrant dispenser.

Pressure rra ating

3.2.7.1 3.2. 7.1 Hydran Hydrantt pit val valve ve asse assembl mblyy The hydrantwith pit valve assemblypressure shall beratings, designed accordance the following all in at 70 EC (158 EF):

3. 3.2.8 2.8.3 .3 La Lany nyar ard d con conne nect ctio ion n It shall be possible to connect a lanyard to an airoperated pilot device to enable remote closing of the  pilot valve.  Note 1: The requirement in 3.2.8.3 applies to those areas where legislation and/or safe practices require a dual operation, for example, if it is envisaged that air  may fail to exhaust due to a system failure or restriction resulting from a vehicle collision. It does not apply to those areas where a lanyard has, traditionally, not been used.  Note 2: See Annex D for a list of advantages in using air-operated pilot devices.

(a) design pressure: pressure: 1 900 kPa (275 (275 psi) psi) (b) operating operating pressure pressure:: -10 to 1 400 kPa (-1,5 (-1,5 to 200 200  psi) (c) proof pressu pressure: re: 2 850 850 kPa (415 (415 psi psi)) min minimum imum (d) burst pressure: pressure: 5 690 690 kPa ((825 825 psi psi)) min minimum imum 3.2.7.2 3.2.7 .2 Hy Hydr dran antt ccou oupl pler erss As the coupler shall be capable of being handled, coupled and uncoupled by one operator, the recommended weight of a coupler in all configurations should be not more than 17 kg (37 lbs).

13

 

43,053 46,101

11,786 basic 11,278 basic

2,286 3,302 radius

6,350 min

8,331 basic

1,524 radius

15

16

C B

 A

12,598 dia. 12,548

55,626 dia. max.

20,828 14,046 basic basic

F

G

19,558 22,911 11,684 basic basic basic

 A

1  4 

4,674 4,67 4 - 4,826 dia. 8 8,89 ,89 de deep ep 9,525 11,049 23,876 25,400

When used, product selector pin 3,150 - 3,277 dia. e extending xtending 6,350 above this surface and identified as shown. shown. Location w with ith respect to any other pin hole optional as long as radial location is maintained.

Fuel pressure sense ports 1,905 - 2,108 dia. dia. hol hole, e, 6 places places equally spaced. All s sharp harp edges to be removed. Radial location optional.  Air reference pressure port port 1,905 - 2,108 dia. hole. All sharp edges to be removed. Radial location optional.

 A 0,254 dia.

F   O  U R -I    N  C  H H Y D R A  N T   S  Y  S  T  E  M    C   O M P   O  N E   N T   S  A  N D A R R A  N  G E  M E   N T   S 

Notes: Dimensions are in millimetres; min. = minimum minimum;; dia. = diameter; max. = maximum.

Figure 5A - API standard fuel sense and air reference lines accommodation for regulating type hydrant valves (valve installation), SI measurements

 

1,695 1,815

0,464 basic 0,444 basic

0,090 0,13 radius

0,25 min

0,328 basic

0,06 radius

15

16

C B

 A

0,496 dia. 0,494

2,190 dia. max.

1   5 

0,820 basic 0,553 basic

F

0,184 - 0,190 d dia. ia. 0.3 0.35 5 deep 0,375 0,435 0,940 1,000

Fuel pressure sense ports 0,075 - 0,083 dia. hole, hole, 6 places equally spaced. All s sharp harp edges to be removed. Radial location optional.

G  A

0,460 basic

0,770 basic

0,902 basic

When used, product selector pin 0,124 - 0,129 dia. e extending xtending 0,25 above this surface and identified as shown. shown. Location with respect respect to any other pin hole optional as long as radial location is maintained.

 Air reference pressure pressure port 0,075 - 0,083 dia. hole. All sharp edges to be remo removed. ved. Radial location optional.

 A 0,010 dia.

Notes: Dimensions are in inches; min. = minimum; minimum; dia. = diameter; max. = maximum.

Figure 5B - API standard fuel sense and air reference lines accommodation for regulating type hydrant valves (valve installation), customary measurements

 G E   N E  R A L  A R R A  N  G E  M E   N T   S  A  N D F  E  A T   U R E   S 

 

FOUR-INCH HYDRANT SYSTEM COMPONENTS AND ARRANGEMENTS

3. 3.2. 2.9 9

valve pilot device, although air-operated pilots are not excluded. Upon actuation, the deadman control shall open or  close a valve, either as a part of the hydrant pit valve assembly or hydrant coupler, or both. The deadman valve performance characteristics shall comply with

Oper Operat atin ing g te temp mper erat atur uree ra rang ngee

The hydrant components covered by this publication shall meet all the design requirements within the temperature range of !40 EC to +70 EC (!40 EF to +158 EF). 3.2.10 3.2. 10

3.2.10.1 and 3.2.10.2. If the deadman valve is in the hydrant pit, the deadman valve shall be the pilotoperated valve. A deadman fitted in the hydrant coupler shall open to full flow in not less than 5 seconds and close to no flow in not less than 2 seconds nor more than 5 seconds. Overshoot shall not exceed 200 litres (53 USG) or 5 % of flow in areas where this limit applies.

Pil Pilot-o ot-oper perated ated valve valve cclos losing ing and opening opening times

The requirements for opening and closing times are those for carrying out acceptance and approval testing on a test rig. Opening and closing of the pilot-operated valve shall be even and progressive. The method of  testing is defined in 4.6.  Note: As the design of the hydrant dispenser  control system may influence opening and closing times, users should ensure that their systems will achieve these opening and closing times in the field.

Air supply shall meet the following requirements: (a) For an air-o air-operat perated ed dead deadman man va valve lve pro provided vided iin n the hydrant coupler and hydrant pit valve assembly, with the hydrant pit valve assembly equipped also with a lanyard, a common air supply may be  provided.

3.2.10.1 3.2.10. 1 Closing Closing time Pilot-operated valve closure shall be caused by actuation of the lanyard or air-operated pilot device. The valve shall fully close from rated flow within 2 to 5 seconds measured from the time that the closing mechanism is operated until flow ceases.

(b) For a hydra hydrant nt pit val valve ve prov provided ided w with ith an airoperated deadman but no lanyard and with an airoperated deadman provided in the hydrant coupler, independent air supplies with no common components shall be provided.

3.2.10.2 Opening 3.2.10.2 Opening time The pilot-operated valve assembly shall open from the fully closed position in normal operation such that the following flow conditions are satisfied. These conditions shall apply for both manual or air pilotoperated control:

(c) For aan n air-operat air-operated ed de deadma adman n prov provided ided iin n the hydrant pit valve, with no lanyard attachment and no deadman in the hydrant coupler, a single air  supply is satisfactory. 3.2. 2.1 12

(a) 90 % of rated rated flow flow sha shall ll be ac achieved hieved in not less less than 5 seconds and no more than 20 seconds from

Overshoot during closing of the pilot-operated valve shall not exceed 200 litres (53 USG) at all flow rates up to rated flow. Under catastrophic excess flow conditions, as defined in 3.2.16, overshoot shall not exceed 300 litres (80 USG).  Note: In areas where a more stringent overrun limit is imposed, that condition shall apply.

activation of the opening mechanism. (b) the Fulltime (100 (100of%) of of rated rated flow shall b bee achie achieved ved in not more than 30 seconds measured as in (a). 3. 3.2. 2.11 11

Overshoo hoot

Dead Deadma man n con contr trol ol

There is a major difference in the practices observed in some countries, such as the United States of America (USA), and other locations, particularly in European operations. For example, in the USA it is common  practice to have the deadman deadman function provided by the air-operated pilot device with an additional, in-line control valve installed in the vehicle pipework. This valve is outside the scope of this publication. Mainly, European practice is to have the deadman control fitted in the hydrant pit coupler with a lanyard operated pit

3. 3.2. 2.13 13

Pre Pressur ssuree llos osss

3.2.13.1 Hydr 3.2.13.1 Hydrant ant pit valve asse assembly mbly The pressure loss at rated flow, unless otherwise stated, across a non-regulating hydrant pit valve assembly without an intermediate strainer but with a stoneguard in place, and assembled with a 4 in. straight hose unit in accordance with API RP 1004, shall be as follows from point A to B in Figure 6: 16

 

GENERAL ARRANGEMENTS AND FEATURES

(a) for 150 mm mm (6 in.) in.) inlet inlet valve, with with 100 mm mm (4 in.) in.) inlet by 100 mm (4 in.) outlet coupler - 135 kPa (19,6 psi) maximum. maximum. (b) for 100 mm mm (4 in.) in.) inlet v valve, alve, with with 100 mm mm (4 in.) in.) inlet by 100 mm (4 in.) outlet coupler - 165 kPa (24 psi) maximum. (c) for 150 mm mm (6 in.) in.) inlet valve, with with 100 m mm m (4 in.) in.)

inlet by 100 mm (4 in.) outlet coupler - 193 kPa (28 psi) maximum. (b) for 100 m mm m (4 iin.) n.) inle inlett valve, w with ith 100 m mm m (4 in. in.)) inlet by 100 mm (4 in.) outlet coupler - 245 kPa (35,5 psi) maximum maximum.. (c) for 150 m mm m (6 in in.) .) inle inlett valve, w with ith 100 m mm m (4 in in.) .) inlet by 75 mm (3 in.) outlet coupler - 145 kPa (21

inlet by 75 mm (3 in.) outlet coupler - 138 kPa (20  psi) maximum at 3 000 lpm (800 USGPM) flow. flow. (d) for 100 mm mm (4 in.) in.) inlet inlet valve, w with ith 100 mm mm (4 in.) in.) inlet by 75 mm (3 in.) outlet coupler - 152 kPa (22  psi) maximum at 3 000 lpm (800 USGPM) flow. flow.

 psi) maximum at 3 000 lpm (800 USGPM). (d) for 100 m mm m (4 in. in.)) inlet v valve, alve, w with ith 100 m mm m (4 in in.) .) inlet by 75 mm (3 in.) outlet coupler - 162 kPa (23,5 psi) maximum at 3 000 lpm (800 USGPM). 3. 3.2.1 2.14 4

3.2.13.2 3.2.13. 2 Hydrant Hydrant pit valve assembly assembly with a standard  regulating 90  coupler  The pressure loss at rated flow across the hydrant pit valve assembly without an intermediate strainer but with a stoneguard  in place and assembled with a regulating 90E hydrant coupler (fully open) shall be as follows from point A to B as defined in Figure 6: E   

Pi Pilo lot-o t-oper perate ated d va valve lve lea leakag kagee

The allowed leakage downstream of a closed pilotoperated valve, under maximum operating pressure, shall be such that the 'well' (see Figures 4A and 4B, dimension M) formed on the top of the outlet adapter   poppet and the upper sealing surface shall not fill in less than one minute with the pressure equalizing valve depressed.

(a) for 150 mm mm (6 in.) in.) inlet inlet valve, with with 100 mm mm (4 in.) in.)

Pressure test point A

100 mm (4 in.) or 150 mm (6 in.) pipe

Meter  Pit valve & coupler  under test

Y Pump

1 m (3 ft)   min.

Z

1 m (3 ft)

Straight pipe

100 mm (4 in.) pipe 1 m (3 ft)

Pressure test point B

X

Test fluid tank  Alternate meter  position

Note: m = metres; in. = inch; min. = minimum

Figure 6 - Schematic of test rig to be used for pressure loss, opening and closing times and overshoot

17

 

FOUR-INCH HYDRANT SYSTEM COMPONENTS AND ARRANGEMENTS

3. 3.2. 2.15 15

3. 3.2. 2.19 19

Vacu Vacuum um ttes esti ting ng

Deco Decoup upli ling ng sp spil illa lage ge

Spillage shall be minimal when the coupler is disconnected from the outlet adapter after aircraft fuelling. The limit for spillage into the pit box is no more than 30 ml (1 fluid ounce). See 4.11 for test details.

During operation and/or maintenance of a hydrant system, vacuum conditions may occur. The hydrant pit valve assembly, with and without a hydrant coupler  attached, shall be designed to withstand a -10 kPa (-1,5  psi) vacuum without admitting air or water into the system. See 4.7 for test details.

3.2. 2.2 20 3. 3.2.1 2.16 6

A stoneguard of robust construction and with an opening equivalent to 6 mm (¼ in.) mesh, shall be located upstream of the hydrant pit valve assembly. The stoneguard may be a part of, or furnished as a separate item to, the hydrant pit valve assembly. It shall  be designed and proved to withstand a flow rate of  11 000 lpm (2 900 USGPM) without becoming dislodged or deforming to a point where it would  become ineffective or would interfere w with ith the closing of the pilot-operated valve. The stoneguard will not receive maintenance or  cleaning under normal operating conditions and should

The lanyard or deadman control shall be designed to cause the pilot-operated valve to close under all normal and abnormal system excess flow rates up to and including 11 000 lpm (2 900 USGPM). See 4.10 for test details. 3. 3.2.1 2.17 7

Ston oneeguard

Cata Catast stro rophi phicc exc exces esss fflo low w

Ma Mate teri rial alss o off ccon onst struc ructio tion n

All materials shall be chemically compatible with all aviation turbine fuels. All metal parts in contact with the fuel shall be free of zinc, cadmium, copper, and their alloys; however, an aggregate amount of 3 % maximum may be present as alloying elements. All non-metal gaskets, O-rings, or other seals or elastomers in contact with the fuel are to be made of materials suitable for use with aviation turbine fuels containing up to 30 % volume aromatics, 5 % volume olefins, and 3 % volume naphthalenes. All external surfaces shall be resistant to t o corrosion caused by atmospheric exposure and water immersion.  Note: this could be achieved by using a corrosion resistant material or by applying a suitable coating. Care should be taken in the design of the equipment to reduce failures caused by wear from the equipment  being dragged across the apron surface. Anticipated vulnerable points should be protected by wear pads,

 be designed accordingly.

 brackets or guards.

The results of the wearof measurements shall indicate whether closer inspection individual components is required. Manufacturers shall provide limits of wear   beyond which repair is required.

3. 3.2. 2.18 18

3.2. 2.2 21

Wear ga gauges

Manufacturers shall provide, for their own hydrant coupler and hydrant pit valve assembly equipment, a simple wear gauge or gauges. The wear gauge(s) shall  be suitable for accurate wear measurement on operationally critical faces. It shall be possible to routinely assess wear using the gauge(s) without requiring equipment disassembly. The wear gauges shall be permanently and legibly marked to show to which piece of equipment they apply. Manufacturers should define which parts and accessories require to be checked with these gauges.

Serv Servic icea eabi bili lity ty

Maintenance requirements of the hydrant pit valve assembly shall be minimal, but the hydrant pit valve shall be designed such that all parts of the assembly, except the pilot-operated valve portion, are removable from the pit for maintenance or replacement of seals. This should be possible without depressurising the hydrant line. In addition, seals and sealing surfaces should be protected from mechanical damage.

3. 3.2. 2.22 22

Pilot Pilot de devi vice ce ov over erri ride de

The hydrant pit valve assembly shall include a manually operated mechanism which, when actuated to the closed  position, will cause the pilot-operated valve to close and remain closed until the pilot device d evice override is opened. The actuation of the pilot device override shall be easily

18

 

GENERAL ARRANGEMENTS AND FEATURES

operable. Whilst the removal of the adapter and/or pilot device when the hydrant is still under pressure is not recommended, manufacturers shall demonstrate that removal of these components is possible with hydrant inlet pressure up to 1 380 kPa (200 psi). See 4.8 for test details.  Note: The purpose of the pilot device override override is to

4 500 lpm (845 to 1 200 USGPM). The dual position unit should be adjustable within two flow ranges. When set in low flow position, it shall cover a flow range from 2 000 to 2 900 lpm (580 to 765 USGPM). When set in the high flow position, the flow range shall be from 3 200 to 4 500 lpm (845 to 1 200 USGPM).

allow limited servicing of the outlet adapter and pilot device sections of the hydrant pit valve assembly, without the removal of the hydrant pit valve assembly from the system or the depressurizing of the upstream hydrant system.

3. 3.3. 3.4 4

3.2.2 2.23

A secondary means to prevent damage to the pilotoperated valve housing, such as a frangible adapter or  a shear section, is permitted. This feature shall not interfere with the ability of the pilot-operated valve assembly to withstand the steady load force of 40 000  N (9 000 lbf) as required in 4.9.4.

Dust co covers

Dust covers shall be provided to protect the outlet of the hydrant pit valve assembly and the inlet of the hydrant coupler from dust, rain, snow, or ice. In the case of the hydrant coupler, the dust cover may be made a  permanent part of the hydrant dispenser.

3.3.5

capability of up to six-product selectivity, via either a  pilot selectivity device of the type, or equivalent, shown in Figures 3A and 3B and 5A and 5B, or by using coupler selectivity. Coupler selectivity would involve designing the hydrant coupler and outlet adapter to mate uniquely for a particular grade of product only,  physically preventing connection of a hydrant coupler  which services a different grade of product.

Reverse flow

Reverse flow through a hydrant pit valve assembly and hydrant coupler assembly is not recommended. If a manufacturer offers an option for reverse flow capability, the maximum pressure drop from Point B to Point A in Figure 6, for a reverse flow of 750 lpm (200 USGPM) shall be 105 kPa (15 psi). 3. 3.3. 3.2 2

3. 3.3. 3.6 6

Pr Pres essu sure re cont contro roll ((re regu gula lati tion on))

If a pressure control (regulating) valve is located within the hydrant coupler or hydrant pit valve assembly, it shall be capable of being adjusted. For all hydrant supply pressures up to the system design pressure, the

Int nteerm rmeedi diat atee st stra rain iner er

It is recommended that an intermediate strainer should not be included in the hydrant pit valve, as debris

 pressure-regulating valve shall, at any flowrate or inlet  pressure, maintain the corresponding control pressure stable and repeatable within +/- 14 kPa (2 psi).

trapped by the strainer may, on termination of flow, fall into the pilot-operated valve impairing its performance. If a manufacturer offers this option, it should be made of 10 or 20 mesh (2,5 or 1,25 mm) material and shall be mounted such that it is easily removed for  cleaning. The strainer shall provide coverage of 100 % of the flow path in which it is mounted. 3. 3.3. 3.3 3

Product se sellectivity

Product selectivity may be achieved either using the  pilot device (if pneumatic), or the hydrant coupler (or   both). Outlet adapters and hydrant couplers may have

3.3 OPTIONAL ITEMS 3.3.1

Se Seco cond ndar ary yb bre reak akaw away ay feat featur ures es

3. 3.3. 3.7 7

Ot Othe herr mechan mechanic ical al me mean anss of clos closing ing the the pilot-operated valve

Other mechanical means of causing the closure of the  pilot-operated valve, such as detecting the upward movement of the outlet adapter poppet valve, may be offered. Such a device is considered to be an additional safety measure if the coupler is separated from the hydrant pit valve assembly due to impact. Any such device shall not interfere with the normal operation of  the hydrant pit valve assembly.

Auto Automa mati ticc exc exces esss fflo low w cont contro roll

If specified by the purchaser, the hydrant pit valve assembly or hydrant coupler shall have a device, or  devices, that provides automatic excess flow control at  predetermined flow rates. The single position unit should be adjustable over a flow range of from 3 200 to

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FOUR-INCH HYDRANT SYSTEM COMPONENTS AND ARRANGEMENTS

20

 

4 PERFORMANCE CRITERIA AND TESTING PROCEDURES 4.1 MECHANICAL STRENGTH

4.4 PROOF AND BURST PRESSURE

All components of the hydrant pit valve assembly (including any adapters, spools and/or associated fittings) and hydrant coupler shall be capable of  withstanding severe handling, strain and shocks from external sources. Components shall maintain functional and structural integrity when subjected to the forces specified within this Section.

Components shall meet the requirements in 4.4.1 and 4.4.2. 4.4.1

Proof pressure

(a) The co comple mplete te hydra hydrant nt pit valv valvee assem assembly, bly, (co (coupler upler,,  pilot-operated valve, and outlet adapter), all set set to the open position, shall withstand a hydrostatic test  pressure of 2 850 kPa (415 psi). The pressure shall  be applied to the inlet of the valve and held for 10 minutes, without causing leakage, distortion, or   breakage.

4.2 TEST FLUID

The test fluid shall be Jet A, Jet A-1 or hydrocarbons with similar density and viscosity properties. Water  may be used for all tests except pressure loss, opening and closing times, overshoot or pressure regulation/ deadman testing. Wide-Cut Jet fuel and aviation gasoline shall not be used.  Note: Manufacturers are encouraged to adopt suitable safety procedures when carrying out testing.

(b) With th thee outle outlett adapt adapter er popp poppet et open or remo removed ved and the pilot-operated valve set to the closed  position, the pilot-operated va valve lve shall withstand a hydrostatic test pressure of 2 850 kPa (415 psi), applied to the hydrant pit valve assembly inlet and held for 10 minutes, without leakage, distortion, or   breakage. Following this test, the unit shall be fully operational and used for other tests required in this Section.

4.3 DIMENSIONAL CHECKS

(c) The hyd hydrant rant ccoupler oupler shall b bee indiv individuall idually y test tested ed with the coupler poppet closed. The valve shall withstand a full body internal hydrostatic test  pressure of 1 830 kPa (265 psi), applied to the coupler outlet and held for 10 minutes, without

All dimensions of areas that mate the hydrant coupler, inlet flange, and other envelope dimensions shall be inspected and recorded against the requirements of  Section 3 to ensure full compatibility.

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FOUR-INCH HYDRANT SYSTEM COMPONENTS AND ARRANGEMENTS

shall be the same configuration as that used in service, (e.g. if a 100 mm (4 in.) valve is used with a spool assembly to meet the 150 mm (6 in.) valve requirement, the valve shall be tested in both the 100 mm (4 in.) and 150 mm (6 in.) configurations.) The pressure loss (difference between test points A and B in Figure 6) shall be recorded for flow rates from 375 to 4 500 lpm (100 to 1 200 USGPM) in approximate increments of 375 lpm (100 USGPM). The results shall be plotted on log-log graph paper to illustrate the characteristics of the unit. The resultant pressure drop shall meet the requirements of 3.2.13.

leakage, distortion or breakage. The coupler shall remain serviceable on completion of the test. 4.4.2

Burst pressure

The requirement of this test is to establish the minimum  pressure above which structural failure failure can occur. (a) This test test sshall hall be be conducted conducted on the compl complete ete hydrant pit valve/hydrant coupler assembly with the poppets set to the open position. The assembly shall be hydrostatically tested to 5 690 kPa (825  psi) minimum for 5 minutes without leakage or   breakage. Damage or distortion that makes the valve non-operational is allowable.

4.6 OPENING AND CLOSING TIMES AND OVERSHOOT

(b) The hydrant hydrant coupler coupler shall be tested, tested, not coupled coupled to the pit valve outlet adapter and without a hose connected, with the coupler poppet closed. The valve shall withstand a full body internal hydrostatic burst test pressure of 2 740 kPa (400  psi) held for 5 minutes without leakage or 

For the following tests, the unit under test shall be mounted vertically in the test rig and tested under the following conditions: (a) 1 200 kP kPaa (175 psi) aatt no flo flow w and 1 00 000 0 kPa ((150 150  psi) minimum at 4 500 lpm (1 200 USGPM); and (b) 600 kPa ((87 87 psi) aatt no flow with 50 500 0 kPa (7 (72,5 2,5 psi) minimum at 3 500 lpm (925 USGPM).

 breakage. Damage or distortion that makes the coupler non-operational is allowable. Components tested to (a) and (b) shall not be delivered to users and should be limited to testing of prototype or   production valves that subsequently will will be destroyed.

The pressure loss tests require a test rig that is capable of circulating a flow rate of 4 500 lpm (1 200 USGPM) through the unit. The test rig shall be in accordance with Figure 6. Pressure pickup points may be of a multiple point type as recommended in SAE ARP

The valve shall be mated with a standard 90 E  elbow coupler for these tests. The above flow and pressure conditions shall be controlled by use of a combination of valves (labelled "X", "Y" or "Z" in Figure 6). The valve under test shall be opened, either by use of the manual or air-operated pilot valve. The inlet pressure, flow rate, pilot actuation point, and opening time shall  be electronically electronically monitored and rrecorded. ecorded. Data shall be recorded until full rated flow is achieved for at least 1 minute. Opening time, which shall be even and

868A. The test specimen shall be mated to a straight hose unit or to a standard 90º elbow hydrant coupler  with a 100 mm (4 in.) outlet as specified in 3.2.13. The test unit and coupler may be placed on its side during this test. For 100 mm (4 in.) inlet by 75 mm (3 in.) outlet hydrant couplers, the circulating flow rate shall be 3 000 lpm (800 USGPM) through the unit. The density (or specific gravity), viscosity, (in centistokes) and the temperature of the test fuel used shall be reported with the results. During the test, 100 mm (4 in.) hydrant pit valve assemblies shall be tested with 100 mm (4 in.) inlet  pipework, and 150 mm (6 in.) in. ) units shall use 150 mm (6 in.) inlet pipework. The valve configuration tested

 progressive, shall be in accordance with 3.2.10.2. The pilot device shall be actuated to signal the valve to close. This point shall be recorded on a data chart or data record. The data shall be recorded until the flow through the valve has stopped. The closing time, which shall be even and progressive, shall be in accordance with 3.2.10.1. Under no flow conditions, with the pilot device in the open position, the pilot-operated valve shall move to the closed position. The test shall be repeated under conditions as in (b) above. The overshoot shall be measured during the closure of the pilot-operated valve. The maximum overshoot shall be 200 litres (53 USG) at both flow rates.

4.5 PRESSURE LOSS

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PERFORMANCE CRITERIA AND TESTING PROCEDURES

(b) Dem Demonstr onstrate ate tha thatt the out outlet let ada adapter pter aand nd pilot device can be removed safely from, and replaced onto, the hydrant pit valve assembly while the  pilot-operated valve is under test pressure.

Legislation or local requirements may limit overshoot to a maximum of 5 % of flow. See 3.2.12. If the coupler used in the test is equipped with a deadman function, the above tests shall also be conducted using a hydrant pit valve assembly without a control function. The deadman control shall be used to start and stop the flow through the valve. This is necessary to ensure that the pilot-operated valve cannot influence the amount of overrun.

4.9 EXTERNAL LOAD RESISTANCE AND FAILURE MODE

The hydrant coupler assembly shall withstand the shock  loading typically experienced when falling onto the concrete apron, and when run over by a vehicle. The pit valve assembly shall withstand the pulling effect of a fuelling vehicle being driven away with the coupler  attached and the shock of a vehicle impact of the magnitude defined in 4.9.3. The external load capacity or strength of  components and the required mode of assembly failure shall be demonstrated by conducting the tests in 4.9.1 to 4.9.4.

4.7 VACUUM TEST

A hydrant coupler shall not be fitted for the first of  these tests. With the hydrant pit valve assembly poppet valve closed and the pilot operator closed, a vacuum of  -10 kPa (-1,5 psi) shall be applied to the inlet of the pit valve. The poppet shall remain closed and not permit leakage of air in the reverse direction. The test shall be repeated with a coupler fitted to the pit valve. The hydrant pit valve and coupler  assembly shall be installed in a vertical position, with

4. 4.9. 9.1 1

the outlet adapter poppet and coupler poppet open and the coupler outlet plugged. A vacuum of -10 kPa (-1,5  psi) shall be applied to the inlet of the valve. The assembly integrity shall not allow leakage of air in the reverse direction.

Hydra Hydrant nt coupl coupler er shoc shock k rres esis istan tance ce test test

4.8 PILOT DEVICE OVERRIDE TEST

The hydrant coupler and fuelling hose shall be  pressurised to 100 kPa (15 psi) during the test. The coupler shall then be dropped on three different axes from the test heights specified in (a) and (b) below on to a concrete surface similar to that found on an airport apron. During the tests, there shall be no cushioning effect by the hose on the shock applied to the coupler.

The test unit shall be set up with the outlet adapter   poppet closed and not connected to a hydrant coupler. The pilot-operated valve and the pilot device override shall be in the open position. Using test fluid, the maximum operating pressure shall be applied to the inlet side of the hydrant pit valve assembly. Once the

(a) Drop tthe he coup coupler ler fr from om a h height eight o off 1 m ((3 3 ft) ft).. The coupler shall remain fully functional and usable following the test. (b) Drop th thee couple couplerr from a height of 2 m (6 ft ft). ). The coupler may be distorted but it shall hold design  pressure following this test.

 pressure has stabilized, the pilot device override shall  be set to the closed position. Any residual pressure from the outlet adapter section of the hydrant pit valve assembly shall be released through the equalising valve, taking care to contain any spillage. After the initial surge, the flow through the equalising valve shall not exceed that as in 3.2.14. The integrity of the pilot device override shall be demonstrated by performing the following tests:

4. 4.9. 9.2 2

Hydra Hydrant nt coupl coupler er runrun-ov over er resi resist stan ance ce test test

When placed on a concrete surface similar to that found on an airport apron, the hydrant coupler, either attached to a hose, or plugged with a test adapter, and with an internal pressure of 100 kPa (15 psi), shall be run over  twice under the conditions specified below. (a) Minim Minimum um loa loading: ding: V Vehicl ehiclee total ax axle le wei weight ght shal shalll  be 2 860 kg (6 300 lbs), equally distributed on either side on dual wheels with a minimum rolling diameter of 700 mm (28 in.); and (b) Maxim Maximum um veh vehicle icle sspeed; peed; 3 3,2 ,2 kph (2 (2,0 ,0 mph mph). ).

(a) With the test press pressure ure still still app applied, lied, repeat repeatedly edly attempt to open the pilot-operated valve by means of all available actuators. Confirm quantitatively that the pressure downstream of the pilot-operated valve does not change; then

23

 

FOUR-INCH HYDRANT SYSTEM COMPONENTS AND ARRANGEMENTS

to the centreline of the outlet of the coupler. The test shall be performed in four 90 E  opposed directions. Tests in fewer than four, but not less than two, directions may be performed if symmetry can be demonstrated. At least one of the tests shall be carried out in a direction which, from visual and dimensional analysis, would cause the weakest part to be stressed the most.  No failure shall occur at any applied force up to 17 800 N (4 000 lbf). Separation and clean breakaway shall occur at a force greater than 17 800 N (4 000 lbf) and not greater than 22 240 N (5 000 lbf).  Note: Leakage from the coupler to pit valve adapter  seal may be experienced as the seal is being stressed.

The coupler should remain in a serviceable condition following this test.  Note: The above weight/force conditions are intended to simulate a vehicle driving over the coupler  on the apron. 4. 4.9. 9.3 3

Hydr Hydran antt ccou oupl pler er br brea eaka kawa way y tes testt

During this test, the hydrant pit valve assembly shall not suffer structural damage that will allow leakage. Testing shall be conducted to ensure that under impact or excessive strain, the hydrant coupler will break away as cleanly as possible from the pit valve outlet adapter. Such breakaway shall occur prior to partial or complete failure of any other system component and without damaging or interfering with the hydrant pit valve assembly and its fuel shut-down system. The resulting automatic closure of the outlet adapter poppet shall reduce to a minimum fuel spillage from the hydrant pit valve assembly under all design pressures and flow rates.  Note: Zero leakage cannot be guaranteed, as it is

4. 4.9.3 9.3.2 .2 Im Impac pactt load load test  test  The test shall be conducted with the hydrant pit valve assembly and the hydrant coupler at a flow rate, using water as the test medium, which gives the equivalent amount of energy as that given by using jet fuel at 4 000 lpm. A flow rate of 3 200 lpm (845 USGPM) is suggested. The test shall be carried out on a hydrant coupler  attached to the hydrant pit valve assembly. An impact load sufficient to cause the hydrant coupler to separate cleanly from the hydrant adapter  shall be applied. The load shall be applied at the centreline of the outlet of the hydrant coupler in three directions (excluding the outlet end) or in a minimum of  two directions if symmetry can be shown. One suggested method of conducting this test is to use a loaded pendulum type test rig (see Figure 8). If  used, the end of the pendulum impacting the coupler  elbow shall consist of a 75 mm (3 in.) or 100 mm (4 in.) horizontal solid carbon steel bar. The test rig pendulum arm length, weight and swing angle shall be sufficient to guarantee breakaway. A suggested test rig set-up is

 possible that a small piece of debris may be caught  between the poppet and the adapter head. The two series of tests, in 4.9.3.1 and 4.9.3.2 shall  be performed.  —  Steady load test in which an external load or pull imposed via the coupler hose simulates, for  example, a fuelling vehicle drive-away and causes  breaking at a defined load range; and  —  Impact load test in which an external load or  impact imposed directly on the hydrant coupler  simulates, for example, impact from a vehicle that causes coupler breakaway.

to have a pendulum arm length of 1,5 m (60 in.), a  pendulum mass mass of 300 kg (660 lbs) with a swing angle of 90E. The weight of the arm measured at the end may  be incrementally increased (or decreased) decreased) to suit, with repeated pendulum swings until breakaway of the coupler assembly is achieved. The hydrant coupler shall separate cleanly from the hydrant pit valve outlet adapter which shall close to  prevent further liquid discharge. The pit valve outlet adapter and poppet should not suffer damage that will allow liquid flow to continue.  Note: For For the hydrant coupler to survive this test is not a requirement of this publication: it may suffer  structural damage.

 Note: Users of equipment covered by this  publication should be aware of the potential for damage to the hydrant risers following coupler impact. See Annex C. 4.9.3.1 4.9.3 .1 St Stea eady dy lo load ad te test  st  The test shall be conducted with the hydrant pit valve assembly and the hydrant coupler under a pressure of  1 900 +/-100 kPa (275 +/-15 psi) and set up as in Figure 7. Both the hydrant pit valve assembly and hydrant coupler poppets shall be open, the pilot-operated device set to the open position and air bled from the coupler. The test shall be carried out with the hydrant coupler connected to the hydrant pit valve assembly. A gradually increasing horizontal force shall be applied

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PERFORMANCE CRITERIA AND TESTING PROCEDURES

Hydrant Coupler or  Load Test Adapter  (according to test requirements)

Steady load force

100 mm (4 in.)  API outlet adapter  Hydrant pit valve assembly

Fix point Test rig riser flange

Test pressure

Figure 7 - Steady load test set-up (hydrant couplers and pit valve assemblies)

4. 4.9.4 9.4

Hydr Hydrant ant pi pitt v val alve ve asse assembl mbly y - Steady Steady lo load ad test A hydrant pit valve assembly, fitted with a suitable load test assembly, not a hydrant coupler, shall be subjected to a steady horizontal load. The load test assembly shall

 Note: Testing to failure beyond this point is not a requirement of this publication. The test shall be carried out in four 90 E opposed directions. Tests in less than four but not less than two directions may be performed if symmetry can be

 be connected to the pit valve adapter adapter in such a way that it will not break away during the test when set up as in Figure 7. The horizontal load shall be applied via the load test assembly that fully reflects a hydrant coupler in the way that it applies the load to the hydrant pit valve assembly. The force shall be applied at right angles to the hydrant pit valve axis so that the maximum bending moment component around the riser flange fixed point is applied. Considering the riser flange as a fixed point, the hydrant pit valve assembly shall be designed to withstand, without structural failure, a gradually increasing steady horizontal load up to 40 000 N (9 000 lbf).

demonstrated. At least one of the tests shall be carried out in a direction which, from visual and dimensional analysis, would cause the weakest part to be stressed the most. At the completion of the load tests, there shall  be no damage to, or failure of, any component of the hydrant pit valve and associated fittings.

4.10 CATASTROPHIC EXCESS FLOW

The hydrant pit valve assembly, with the outlet adapter   poppet removed and the stoneguard installed, shall be mounted in such a manner as to afford a safe condition when the test is being run. Test fluid may be water and the valve may be inverted over a receiving vessel.

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FOUR-INCH HYDRANT SYSTEM COMPONENTS AND ARRANGEMENTS

Devices that may restrict the ability to achieve test flow conditions shall be removed. The hydrant pit valve assembly shall be subjected to a flow rate as specified in 3.2.16 for a sufficient length of time to show that the  pilot-operated valve will close under these conditions. Inlet pressures, flow rate, overshoot, and closing times shall be recorded during the tests. The overshoot shall not exceed 300 litres (80 USG) or 6,5 % where  percentage of flow limits are are imposed. For further information see Annex A.

hydrant pit valve assembly, the coupler poppet cycled open/close, and the hydrant coupler uncoupled from the hydrant pit valve assembly no less than ten times. The valve shall be repressurised before each open/close cycle. The decoupling spillage shall be collected in a container that is suitable for measuring the small quantities allowed. The average decoupling spillage for  each cycle shall be no more than 30 millilitres (1 fluid ounce).

4.11 DECOUPLING SPILLAGE

4.12 PRESSURE, SURGE AND FLOW CONTROL

The hydrant pit valve assembly shall be mounted horizontally and filled with test fluid at 100 kPa (15  psi). The hydrant coupler shall be coupled to the

Purchasers may require additional tests. These shall be agreed between the manufacturer and the purchaser. p urchaser.

75 mm (3 in.) or 100 mm (4 in.) horizontal carbon steel bar suggested pendulum mass 300 kg (660 lbs.)

Pivot

1,5 m (60 in.)

Rigid, secure mounted 'A' frame or similar suitable supporting structure  cL of  Coupler 

Nominal ground level Open coupler  Hydrant pit valveþ assembly

Fix point Test rig r iser flange

Figure 8 - Suggested impact load test rig

26

 

5 TYPE APPROVAL TESTING AND QUALITY ASSURANCE traces of data (copies of which can be reproduced) taken during opening, closing, and other appropriate tests. It is recommended that videotape - or other visually reproducible media - of at least the tests conducted to demonstrate compliance with 4.9 should be made available to the purchaser upon request.

5.1 QUALITY ASSURANCE

The manufacturer shall be able to demonstrate that the equipment meets the requirements of the type approval tests in Section 4 and that a satisfactory quality assurance and inspection system is followed (e.g. API Q1, ISO 9000, ISO 10012-1). Purchasers, at their  discretion, may wish to satisfy themselves that the manufacturer’s quality system is comparable to the relevant ISO 9000 standard or equivalent National standards.

5.3 DOCUMENTATION AND INSTRUCTION

5.2 APPROVAL TESTING

In addition to the data required in 5.2, the manufacturer  shall supply the purchaser with the following information as a minimum:

A t the r eques t of the pur chas er , the manufacturer/vendor shall supply copies of test reports showing the results of the tests on a sample of  equipment meeting the requirements of this publication. All production models shall conform to the requirements of this publication. The test reports should include performance data obtained by suitable instrumentation that will produce

 — Ins tal latio lat ion, n, ser servic vicing ing and main mainten tenanc ancee instructions.  — Any precautions to be observed in using the equipment to ensure safety to personnel.  — Information regarding modifications that may apply after the user has taken delivery of the equipment. This may be in the form of bulletins and notices issued to known purchasers/users.

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FOUR-INCH HYDRANT SYSTEM COMPONENTS AND ARRANGEMENTS

28

 

ANNEX A CATASTROPHIC EXCESS FLOW

In 1988 doubts were raised about the ability of the then current type of hydrant pit valve assembly to close at excessive flow rates. Such flow rates could occur  following damage to the top end of the valve that results in complete removal of the outlet poppet valve. The concern was that the velocity and therefore the  pressure at the pick up point for fuel flow via the pilot device might inhibit the closing of the main valve. The IP contracted Delft Hydraulics, Holland, to  perform high flow testing of the valves manufactured  by Avery Hardoll, J C Carter, Thiem-Whittaker and Zenith, to determine if they would close under such conditions when the lanyard was pulled. Due to safety considerations it was agreed that the test medium should be water.

results was published 6. The permitted operating pressure in this third edition of API/IP 1584 has been raised to 1 380 kPa (200 psi). Flows in excess of 11 000 lpm (2 900 USGPM) may therefore be experienced following severe damage to the pit valve assembly. Further testing is not considered necessary as the Delft trials showed the valves close more quickly as flow increases. It should suffice for manufacturers to show that this trend exists rather than to reach a flow rate corresponding with 1 380 kPa (200 psi) inlet pressure. However, this is only applicable if manufacturers do not radically alter  their designs. If this does do es occur, the manufacturer will  be required to demonstrate that the design change will not affect the ability of the valve to close under these

A full report was issued by Delft Hydraulics in January 1990 5 and an article summarising the test and

excess flow conditions.

5. The closure behaviour of hydrant pit valves (1990). valves (1990). 6. Sanderson, T.A. and Simpson, R.A., Excess R.A.,  Excess flow testing of hydrant pit va valves lves,, Petroleum Review, May 1990.

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FOUR-INCH HYDRANT SYSTEM COMPONENTS AND ARRANGEMENTS

30

 

ANNEX B HYDRANT PIT VALVE ASSEMBLIES IN SMALL PIT BOXES required. The purchaser shall specify what riser flange will be used. When the valve is fitted in these pit boxes, there is little clearance between the valve and the inside of the t he  box. It is essential therefore that:

The preferred arrangement for new works and extensions to existing works is to use 150 mm (6 in.) riser flanges and a pit box of at least 460 mm (18 in.) diameter. Older systems may still have pit boxes as small as 300-330 mm (12-13 in.) in diameter, less depth than current models and 100 mm (4 in.), 75 mm (3 in.) or other special riser flanges. It is recognised that it is not always practical to replace small pit boxes with larger diameter ones. To be installed in the small boxes, the pit valve assembly has to be fitted with a 100 mm (4 in.) base flange and be not longer than 305 mm (12 in.). Valves that meet the performance requirements of this  publication can be used in the larger b boxes oxes with 150 mm (6 in.) riser flanges by using spool pieces. When valves with a 100 mm (4 in.) base flange are fitted to 75 mm (3 in.) riser flanges using an adapter, the assembly should be fitted with steady bars to stabilise the valve body against the inside of the box, to  provide extra support when using equipment heavier  than before, and to withstand impact by a vehicle. The arrangement of components is intended to ensure safety in operation consistent with equipment simplicity within the pit. It is unlikely that devices for   pressure control and deadman operation can be accommodated in the pit. The components to be installed within the pit are similar to those for standard pit boxes. A spool or adapter assembly to mate the pit valve assembly inlet flange to the hydrant riser flange may be

(a) All eexternal xternal edges are p proper roperly ly rad radiused iused and otherwise prepared to minimise the risk of personal injury when the valve is being installed or  removed. (b) Wher Wheree necess necessary, ary, va valve lve man manufact ufacturer urerss supply special tools to facilitate installation and maintenance of the valve and in particular, specially designed tools to make the base flange nuts easily accessible. Flanges used for attaching the valve assembly to existing pit box components shall normally be designed with a raised face. The purchaser shall specify machining to flat face if required. In order to maintain the widest application for  installation in existing systems it is recommended recommended that the basic valve height (excluding adapters/spool pieces used) is no more than 305 mm (12 in.) in.)  although longer  valves will not be excluded. Adapters and spool pieces may then be used to suit individual installations if necessary. Due to variations in ground levels and settlement, different riser flanges and their eccentricity within the

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FOUR-INCH HYDRANT SYSTEM COMPONENTS AND ARRANGEMENTS

 pit and misalignment, the purchaser shall specify installation details. If, on the pilot device, an extension cable is used to which the lanyard is attached, the cable should be of  such a length that the lanyard itself cannot become snagged on the pit valve components. It shall also be easily replaceable when in situ. situ.

32