FOUR-INCH HYDRANT SYSTEM COMPONENTS AND ARRANGEMENTS

Transcription

1 FOUR-INCH HYDRANT SYSTEM COMPONENTS AND ARRANGEMENTS API/IP SPECIFICATION 1584 Third edition April 2001

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3 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

4 Copyright 2001 by American Petroleum Institute, and The Institute of Petroleum, London: A charitable company limited by guarantee. Registered No , England All rights reserved No part of this book may be reproduced by any means, or transmitted or translated into a machine language without the written permission of the publisher. ISBN 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) sales@portlandpress.com

5 CONTENTS Foreword... vii Page Acknowledgements... ix 1 Introduction, scope and referenced publications Introduction Scope Referenced publications Terms, definitions and abbreviations Terms and definitions Abbreviations Units used General arrangements and features Typical arrangement of hydrant pit equipment and controls Mandatory requirements Optional items Performance criteria and testing procedures Mechanical strength Test fluid Dimensional checks Proof and burst pressure Pressure loss Opening and closing times and overshoot Vacuum test Pilot device override test External load resistance and failure mode Catastrophic excess flow Decoupling spillage Pressure, surge and flow control Type approval testing and quality assurance Quality assurance Approval testing Documentation and instruction v

6 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

7 FOREWORD This joint Institute of Petroleum and American Petroleum Institute publication provides recommended minimum performance and mechanical specifications for the design of aviation fuel hydrant system pit valves and associated 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 Standard 1584 second edition, December 1994, IP Aviation hydrant pit systems recommended arrangements, August 1990 and IP The inspection and testing of airport hydrant pit valves, July It is possible that this joint publication will have a wider scope of usage and will encompass differing operating practices and safety and environmental legislation. 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 for valves that are able to mate 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 requirements 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

8 Nothing contained in any Institute of Petroleum or American Petroleum Institute joint publication 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 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 , 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. This publication includes a requirement for couplers to break away cleanly from the pit 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

9 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

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11 1 INTRODUCTION, SCOPE AND REFERENCED PUBLICATIONS 1.1 INTRODUCTION The performance requirements and optional recommendations included in this publication are intended to achieve the following: (a) Establish the acceptable structural and operating integrity of the components involved. (b) Provide a compatible coupling configuration and arrangement at the hydrant pit that will permit interchangeability between the components of different manufacturers. (c) Assist component manufacturers in their design efforts by detailing operational, maintenance and ergonomic features of components that are considered desirable based upon experience in aircraft fuelling. (d) Describe the alternative arrangements of 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 mechanical strength criteria for normal handling loads and failure modes for excess mechanical loadings and impact damage General 1.2 SCOPE 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) 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. 1

12 FOUR-INCH HYDRANT SYSTEM COMPONENTS AND ARRANGEMENTS 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. 1.3 REFERENCED PUBLICATIONS The following publications are cited in this publication. The latest available edition of each referenced publication applies. API RP 1004 Bottom loading and vapour recovery for MC-306 tank motor vehicles. Specification Q1 Specification for quality programs for the petroleum and natural gas industry. IP 2 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 flow testing of hydrant pit valves, Petroleum Review, May ISO :2000 Quality management systems Quality assurance requirements for measuring equipment: Metrological confirmation system for measuring equipment. SAE 4 ARP 868A Method pressure drop test for fuel system components. ASME 1 B.16.5 Pipe flanges and flanged fittings. 1. American Society of Mechanical Engineers, 3 Park Avenue, New York, NY , USA 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 Society of Automotive Engineers, 400 Commonwealth Drive, Warrendale, PA , USA. 2

13 2 TERMS, DEFINITIONS AND ABBREVIATIONS 2.1 TERMS AND DEFINITIONS For the purposes of this publication the following terms and definitions apply: clean breakaway: when used in describing the breakaway of the hydrant coupler 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 or boom assembly to 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: 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. 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 timer deadman may be included with this system as an option. 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 dual flow rate settings). 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. 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. 3

14 FOUR-INCH HYDRANT SYSTEM COMPONENTS AND ARRANGEMENTS 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. 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. 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. 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. pilot 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 pilot device override: (also known as a 'servicing valve') a manually operated valve or device that overrides the action of the pilot valve thus preventing opening of the pilot-operated valve. pilot-operated 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. pressure equalisation 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 within the hydrant pit valve assembly with the pressure within the hydrant coupler. 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. 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. catastrophic excess flow: the maximum flow rate required to be stopped by the hydrant pit valve. excess flow: a flow rate in excess of rated flow. rated flow: the maximum flow rate for which the components of the pit valve assembly and coupler are designed. 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. opening and closing times: closing time: the time required, after the operating device is actuated to close, for flow to cease from rated flow. deadman control: a hand-held control to actuate the opening and closing of the hydrant pit valve assembly and/or hydrant coupler. opening time: the time taken to achieve 90 % of rated flow measured from the time that the operating device is actuated. overshoot: the volume of liquid passing through the valve during the closing time period. 4

15 TERMS, DEFINITIONS AND ABBREVIATIONS pressure: burst 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 is the minimum pressure above which structural failure may occur. design 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: 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 publication. pressure loss: the difference in static pressures measured in the test set-up defined in Figure 6 from point A to point B. proof 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. 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 aircraft. May also be known as a pressure-regulating valve. vacuum test: a negative pressure applied to the hydrant pit valve assembly under which the poppet shall remain closed and not allow leakage of air in the reverse direction. 2.2 ABBREVIATIONS The following abbreviations are used within this publication: ft in. kg kpa kph lbs lbf lpm m mm mph N psi USG USGPM o F o C o feet inch 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 degree of angle 2.3 UNITS USED 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 these values. 5

16 FOUR-INCH HYDRANT SYSTEM COMPONENTS AND ARRANGEMENTS 6

17 3 GENERAL ARRANGEMENTS AND FEATURES 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 shall specify the final component arrangement. The fitting of a separate hydrant riser shut-off valve is not a requirement of this publication. 3.2 MANDATORY REQUIREMENTS Dimensions and hydrant coupler/hydrant 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 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 Outlet adapter actuation The opening of the hydrant coupler poppet shall cause the outlet adapter poppet to open. The outlet adapter poppet shall close automatically 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. 7

18 FOUR-INCH HYDRANT SYSTEM COMPONENTS AND ARRANGEMENTS Fuel sense Coupler poppet operator Deadman air Hydrant coupler with deadman and pressure control Air to pilot device (if air-operated) 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) Coupler poppet operator Standard hydrant coupler Deadman air 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

19 40,5 BSC 212,725 dia. BSC 6 5 Fixed product selection posts located as shown unnumbered 2 places 4 ±0,127 1, Sealing surface ±0,127 38,100 ±0,127 9,525 ±0,127 6, ,800 +1,588-0,000 Poppet travel from sealing surface Valve head ±0, ,400 ±0, ,350 ±0, ,400 ±1, ,150 9 Fuel/air reference adapter Outer surface of mating fuel/air socket 54 BSC C B G F A Refer to Figure 5A for detail 1 40,5 BSC places BSC Movable product selection posts located as shown; 4,763 mm index numerals shall be permanently located 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). 3 6,3 C ±0, ,100 ±0, ,050 ±0, ,600 Sealing surface Pressure equalizing valve Outlet adapter poppet ±1,524 45,974 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 dimensions are in millimetres. 2. The breaking of all corners is required, not to exceed 3,175 millimetre radius. 3. The details of adapter body valve head and internals shown in dashed lines are to be determined by manufacturer. 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 circular finish. 6. Couplers must be capable of mating with maximum dimensions shown. ±0, ,100 GENERAL ARRANGEMENTS AND FEATURES Figure 3A - API standard hydrant pit outlet adapter, SI measurements

20 40,5 BSC 8,375 dia. BSC 6 5 Fixed product selection posts located as shown unnumbered 2 places 4 ±0,005 0, Sealing surface ±0,005 1,500 ±0,005 0,375 ±0,005 0, ,000 +0, ,000 0 Poppet travel from sealing surface 10 Fuel / air reference adapter Outer surface of mating fuel/air socket 54 BSC C B G F A Refer to Figure 5A for detail 1 40,5 BSC 2 Movable product selection posts located as shown; 3/16 inch index numerals shall be permanently located A minimum clearance of 5,30 in. between hydrant pit valve center and fuel sense/air reference adapter coupled with mating socket. (Refer to Figure 5B for more details) places BSC Notes: 6,3 C ±0,005 6, All dimensions are in inches. ±0,005 6,000 ±0,005 5,750 ±0,005 5,250 ±0,005 4,000 Sealing surface BSC = basic dimension; min. = minimum; max. = maximum; hex. = hexagonal; dia. = diameter. Valve head Pressure equalizing valve Outlet adapter poppet ±0,060 1,81 Product selectivity set bolt (1/2" min. tall, 5/8" max. hex. or dia.) 2. The breaking of all corners is required, not to exceed 0,125 inch radius. 3. The details of adapter body valve head and internals shown in dashed lines are to be determined by manufacturer. 4. Pressure equalizing valve stem on valve head is not to extend beyond sealing surface. 5. Sealing surface must be machined to 63 microinches circular finish. 6. Couplers must be capable of mating with maximum dimensions shown. ±0,005 6,000 ±0,005 6,500 ±0, ,250 FOUR-INCH HYDRANT SYSTEM COMPONENTS AND ARRANGEMENTS Figure 3B - API standard hydrant pit outlet adapter, customary measurements

21 GENERAL ARRANGEMENTS AND FEATURES 264,160 C Coupler max. 259,080 Groove depth ^ G 0,508 D Coupler min. 250,088 Coupler poppet max. diameter 100,5 M 2,032 min. Under pressure P L 2,032 max. ^ Under pressure 1,651 min. At no pressure Seal surface - ref. Product selectivity set bolt (12,700 min. tall, 15,875 max. hex. or dia.) ± 1,524 57,150 min. 45,974 Pressure equalizing valve top surface must not extend beyond sealing surface H Coupler Max. 68,580 H Valve Min. 69,850 D Valve max. 245,008 Outside of coupler including bump ring 264,160 C Valve min. 269,240 Notes: Dimensions are in millimetres; max. = maximum; min. = minimum; ref. = reference; hex. = hexagonal; dia. = diameter. Figure 4A - Outlet adapter and coupler interface dimensions, SI measurements 10,40 C Coupler max. 10,20 Groove depth ^ G 0,020 D Coupler min. 9,846 Coupler poppet max. diameter 3,956 M 0,080 min. Under pressure P L 0,080 max. ^ Under pressure 0,065min. At no pressure Seal surface - ref. Product selectivity set bolt (1/2" min. tall, 5/8" max. hex. or dia.) 2,25 min. ± 0,060 1,81 Pressure equalizing valve top surface must not extend beyond sealing surface H Coupler Max. 2,700 H Valve Min. 2,750 D Valve max. 9,646 Outside of coupler including bump ring 10,40 C Valve min. 10,60 Notes: Dimensions are in inches; max. = maximum; min. = minimum; ref. = reference; hex. = hexagonal; dia. = diameter. Figure 4B - Outlet adapter and coupler interface dimensions, customary measurements 11

22 FOUR-INCH HYDRANT SYSTEM COMPONENTS AND ARRANGEMENTS Coupling action 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 (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 Hydrant pit arrangement and mounting 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 as mm (12-13 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 gloves and without the need for special tools. The arrangement of the pit equipment shall also allow 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 dust cap, shall be: (a) For valves with either a 100 mm (4 in.) or 150 mm (6 in.) ASME Class 150 inlet flange: 290 mm to 415 mm (11,5 in. to 16,34 in.) (b) For valves with a 150 mm (6 in.) ASME Class 300 pattern inlet flange: 406 mm to 415 mm (16 in. to 16,34 in.) 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 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 Fuel sense and air reference lines 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 upstream of the inlet hose or boom assembly. Where fitted, 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. 12

23 GENERAL ARRANGEMENTS AND FEATURES 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 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 Flow rate Hydrant pit valve assembly The hydrant pit valve assembly shall be designed in accordance with the following rates: (a) rated flow: lpm (1 200 USGPM) (b) catastrophic excess flow: lpm (2 900 USGPM) Hydrant couplers Hydrant couplers shall be designed in accordance with the following rates: (a) for 4 in. inlet by 4 in. outlet (either pressure controlled or standard coupler): lpm (1 200 USGPM) (b) for 4 in. inlet by 3 in. outlet (either pressure controlled or standard coupler): lpm (800 USGPM) Pressure rating Hydrant pit valve assembly The hydrant pit valve assembly shall be designed in accordance with the following pressure ratings, all at 70 EC (158 EF): (a) design pressure: kpa (275 psi) (b) operating pressure: -10 to kpa (-1,5 to 200 psi) (c) proof pressure: kpa (415 psi) minimum (d) burst pressure: kpa (825 psi) minimum Hydrant couplers 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). 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): (a) design pressure: kpa (275 psi) (b) operating pressure: -10 to kpa (-1,5 to 200 psi) minimum (c) proof pressure: (i) uncoupled, closed: kpa (265 psi) minimum (ii) coupled, open: kpa (415 psi) minimum (d) burst pressure: (i) uncoupled, closed: kpa (400 psi) minimum (ii) coupled, open: kpa (825 psi) minimum Pilot device actuation Manual operation 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 Air operation The pilot device is operated by the application of an externally supplied air pressure. Control air supply shall be a minimum of 240 kpa (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 Lanyard connection 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 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. 13

24 6,350 min 43,053 46,101 2,286 3,302 radius 1,524 radius 8,331 basic 11,786 basic 11,278 basic 14 9,525 11,049 23,876 25, Fuel pressure sense ports 1,905-2,108 dia. hole, 6 places equally spaced. All sharp edges to be removed. Radial location optional. Air reference pressure port 1,905-2,108 dia. hole. All sharp edges to be removed. Radial location optional. A 12,598 12,548 dia. 55,626 dia. max. 20,828 basic 14,046 basic 4,674-4,826 dia. 8,89 deep F C B A G 11,684 basic When used, product selector pin 3,150-3,277 dia. extending 6,350 above this surface and identified as shown. Location with respect to any other pin hole optional as long as radial location is maintained. A 0,254 dia. 19,558 basic 22,911 basic FOUR-INCH HYDRANT SYSTEM COMPONENTS AND ARRANGEMENTS Notes: Dimensions are in millimetres; min. = 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

25 15 0,25 min 0,375 0,435 0,940 1,000 1,695 1,815 0,090 0,13 radius 15 0,06 radius 16 Fuel pressure sense ports 0,075-0,083 dia. hole, 6 places equally spaced. All sharp edges to be removed. Radial location optional. Air reference pressure port 0,075-0,083 dia. hole. All sharp edges to be removed. Radial location optional. A 0,496 0,494 dia. 2,190 dia. max. 0,820 basic 0,328 basic 0,553 basic 0,184-0,190 dia deep F C B G A 0,464 basic 0,444 basic 0,460 basic When used, product selector pin 0,124-0,129 dia. extending 0,25 above this surface and identified as shown. Location with respect to any other pin hole optional as long as radial location is maintained. A 0,010 dia. 0,770 basic 0,902 basic GENERAL ARRANGEMENTS AND FEATURES Notes: Dimensions are in inches; min. = 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

26 FOUR-INCH HYDRANT SYSTEM COMPONENTS AND ARRANGEMENTS Operating temperature range 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) Pilot-operated valve closing and 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 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 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: (a) 90 % of rated flow shall be achieved in not less than 5 seconds and no more than 20 seconds from the time of activation of the opening mechanism. (b) Full (100 %) of rated flow shall be achieved in not more than 30 seconds measured as in (a) Deadman control 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 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 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 and 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. Air supply shall meet the following requirements: (a) For an air-operated deadman valve provided in 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. (b) For a hydrant pit valve provided with 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. (c) For an air-operated deadman provided in the hydrant pit valve, with no lanyard attachment and no deadman in the hydrant coupler, a single air supply is satisfactory Overshoot 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 , overshoot shall not exceed 300 litres (80 USG). Note: In areas where a more stringent overrun limit is imposed, that condition shall apply Pressure loss Hydrant pit valve assembly 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

27 GENERAL ARRANGEMENTS AND FEATURES (a) for 150 mm (6 in.) inlet valve, with 100 mm (4 in.) inlet by 100 mm (4 in.) outlet coupler kpa (19,6 psi) maximum. (b) for 100 mm (4 in.) inlet valve, with 100 mm (4 in.) inlet by 100 mm (4 in.) outlet coupler kpa (24 psi) maximum. (c) for 150 mm (6 in.) inlet valve, with 100 mm (4 in.) inlet by 75 mm (3 in.) outlet coupler kpa (20 psi) maximum at lpm (800 USGPM) flow. (d) for 100 mm (4 in.) inlet valve, with 100 mm (4 in.) inlet by 75 mm (3 in.) outlet coupler kpa (22 psi) maximum at lpm (800 USGPM) flow Hydrant pit valve assembly with a standard regulating 90E 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: (a) for 150 mm (6 in.) inlet valve, with 100 mm (4 in.) inlet by 100 mm (4 in.) outlet coupler kpa (28 psi) maximum. (b) for 100 mm (4 in.) inlet valve, with 100 mm (4 in.) inlet by 100 mm (4 in.) outlet coupler kpa (35,5 psi) maximum. (c) for 150 mm (6 in.) inlet valve, with 100 mm (4 in.) inlet by 75 mm (3 in.) outlet coupler kpa (21 psi) maximum at lpm (800 USGPM). (d) for 100 mm (4 in.) inlet valve, with 100 mm (4 in.) inlet by 75 mm (3 in.) outlet coupler kpa (23,5 psi) maximum at lpm (800 USGPM) Pilot-operated valve leakage 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. Pressure test point A 100 mm (4 in.) or 150 mm (6 in.) pipe Meter Y Pit valve & coupler under test Pump Z 1 m (3 ft) min. 1 m (3 ft) Straight pipe 1 m (3 ft) 100 mm (4 in.) pipe 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

28 FOUR-INCH HYDRANT SYSTEM COMPONENTS AND ARRANGEMENTS Vacuum testing 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 Catastrophic excess flow 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 lpm (2 900 USGPM). See 4.10 for test details Materials of construction 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 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, brackets or guards Serviceability 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 Decoupling spillage 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 Stoneguard 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 lpm (2 900 USGPM) without becoming dislodged or deforming to a point where it would become ineffective or would interfere with the closing of the pilot-operated valve. The stoneguard will not receive maintenance or cleaning under normal operating conditions and should be designed accordingly Wear 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. The results of the wear measurements shall indicate whether closer inspection of individual components is required. Manufacturers shall provide limits of wear beyond which repair is required Pilot device override 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 override is opened. The actuation of the pilot device override shall be easily 18

29 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 kpa (200 psi). See 4.8 for test details. Note: The purpose of the pilot device override is to 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 Dust 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 Reverse flow 3.3 OPTIONAL ITEMS 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) Intermediate strainer It is recommended that an intermediate strainer should not be included in the hydrant pit valve, as debris 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 Automatic excess flow control 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 to lpm (845 to 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 to lpm (580 to 765 USGPM). When set in the high flow position, the flow range shall be from to lpm (845 to USGPM) Secondary breakaway features 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 N (9 000 lbf) as required in Product selectivity 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 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 Pressure control (regulation) 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 pressure-regulating valve shall, at any flowrate or inlet pressure, maintain the corresponding control pressure stable and repeatable within +/- 14 kpa (2 psi) Other mechanical means of closing 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. 19