Bam 800 > T004 - Nozzle Flow Testing Guidelines

Document Title:

T004

Revision No:

1

Description:

Flow Testing Procedures for All Banlaw Refuelling Nozzles

Issue Date:

06/01

This document forms part of the Assembly Repair and Test Manual for Banlaw Pipeline Quick-Fill Refuelling Nozzles. It describes the equipment and procedures required for the proper flow testing of the nozzles. This information is intended for the use of Banlaw Pipeline Technicians and all Authorised Distributors and Repair Agents. The proper flow testing of nozzles is essential to: 1. verify the correct shut-off pressure of the nozzle 2. inspect and rectify the nozzle for leaks 3. verify the correct operation of the nozzle, including: • ease of engaging nozzle to receiver under pump pressure • establish correct function of operating handle, including effort required to operate handle, and correct location of handle catch with respect to ON and OFF detents on nozzle end-cap. There are two options for the layout of the nozzle flow test facility. Section 1 details the first option using an in-line ball valve downstream of the nozzle – item 8. This valve is used to create varying degrees of back pressure against the nozzle thus simulating the pressurisation of a fuel tank.

1. OPTION 1: RECIRCULATING CIRCUIT – IN-LINE VALVE

Figure 1.1: Flow Test Circuit 1 – in-line valve

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1.1 General Objective The objective of the test is to determine the pressure at entry to the nozzle – measured by item 5 – that initiates nozzle shut-off. For a given flowrate, there is a limiting inlet pressure that triggers the automatic shut-off mechanism of the nozzle. The exponential relationship between flowrate and inlet pressure is shown on the attached graphs. IMPORTANT: the fitting used to secure gauge 5 must have a 2” (53±0.5mm) bore and no sudden flow area or directional changes for at least 6 diameters (320mm) upstream of the gauge. This will ensure representative readings are taken. Banlaw can supply upon request a fitting for this purpose.

1.2

Flow Test Procedures

1.2.1 Leak testing 1. 2. 3. 4.

Install nozzle into test circuit and connect to receiver. Start pump with valve 5 fully open. Set flowrate at near maximum Run fuel through nozzle for at least 5 minutes, during which time the nozzle should be turned ON and OFF a few times to detect any leakage from the back end of the nozzle (such leakage is visible from the end-cap bleed hole). 5. Whilst fuel is running, move nozzle around on receiver to detect any leakage from between receiver and nozzle – such leakage is usually due to a worn nozzle body and / or sleeve o’ring seals. 6. Identify and record source of any leaks. Leakage from the bleed hole on the underside of the end cap indicates a faulty piston seal. Leakage from the front region of the nozzle indicates a worn nozzle body, sleeve seals, o’rings, or a damaged wiper seal. NOTE: a small volume of fuel (<50mL) may be lost when disconnecting the nozzle at the completion of flow testing. Such an amount is acceptable and does not constitute a non-conforming nozzle. 7. With pump running, manually turn nozzle off and disconnect from receiver. Turn nozzle on and off several times to check for leaks from front of nozzle and thus confirm whether sleeve maintains liquid tight seal with both the retainer and bore of nozzle body. NOTE : Do NOT point nozzle towards a person’s face during this operation. 8. With pump still running, connect and disconnect nozzle and receiver to ensure easy connection of nozzle whilst under head pressure of pump. Difficulty in engaging the nozzle may indicate the sleeve is not being held back in the fully home position. In this case refer to document M800 or M1000, clause 2.16. Once all leaks are rectified, proceed to section 1.2.2 for shut-off pressure testing.

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1.2.2 Shut-Off Pressure Testing NOTE: The consistency of results in this section relies on the reliable and accurate performance of the test equipment – in particular the flowmeter and pressure gauges. Additionally, noticeable variations in diesel temperature (>15-20°C) may cause inconsistent test results due to fluctuations in both diesel viscosity and density. Thus to ensure consistent and accurate test results are maintained, test equipment must be calibrated on a regular basis and factors such as diesel temperature should be monitored during a test and between successive tests. 1. Set the flowrate at near maximum. 2. Gradually throttle valve 8 and obtain accurate values of both the flowrate and pressure at gauge 5 that initiates nozzle shut-off. You will need to record both values at the instant (within reason) the nozzle begins to shut-off. 3. Repeat step 2 for flowrates at approx. 70% and 40% of maximum i.e. 3 tests in total 4. Compare results obtained during steps 2 and 3 against the appropriate curve on the attached graphs. Again, note the separate curves for each of the 5 available nozzle back spring settings. 5. If any test result falls outside the shaded region on a chosen curve, that test must be conducted again. If after 4-5 retests the result is still outside the region check the following: a) Confirm the absence of any undue friction between the handle and endcap. This is best done with the nozzle disconnected from both the receiver and test circuit. The action of the handle should be smooth and consistent through its entire arc. The handle should also readily spring into the ON position if the catch is released. Such action indicates a satisfactory and consistent level of friction between seals and their mating surfaces. Check seal integrity and lightly polish bore surfaces with 1200 grit wet & dry grade emery paper if required. b) Confirm both the free length (unloaded OAL) and the total number of turns of the nozzle back spring. The free length and total number of coils should be within the ranges specified in Table 2.2.2.1. Discard any spring outside these limits. DO NOT ATTEMPT TO RECTIFY EITHER PROBLEM BY SCRAGGING OR GRINDING THE SPRING. • A spring with a free length slightly under (0.5-1mm) the specification may be lengthened to within the correct range by securely gripping both ends of the spring and simultaneously extending the spring and twisting the spring anti-clockwise. This process can be carefully repeated until the spring length is within the recommended range. NOTES: 1. The shut-off pressure of a newly assembled nozzle will stabilise to a consistent value after several flow tests. Step 5 states 4-5 tests should be a sufficient number, although the experience of a repair technician will determine when a nozzle has reached its “steady-state” performance 2. The shut-off pressure of a nozzle is very susceptible to variances in the properties of the nozzle back spring. For example, up to 15kPa variation can be caused by only 1.5mm variation in spring free length. Discard any spring whose performance is considered unsatisfactory. T004 – Issue 1

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6. Repeat steps 2-5 until all flow test results are satisfactory. 7. Rectify all leaks identified during flow testing. Retest as per section 1.2.1 until satisfactory. Once all leaks are rectified and the nozzle has satisfactorily passed flow testing, the nozzle may be prepared for return to service or placed into stock. IMPORTANT: A nozzle is considered a non-conforming product unsuitable for further service until all problems identified are rectified and the nozzle has passed all stages of the flow test procedures detailed above.

2. OPTION 2: TEST TANK AND RECIRCULATING CIRCUIT 2.1 General Objective The objective of this circuit is to determine the maximum pressure within the test tank – measured by item 13 – that occurs at nozzle shut-off. The level of tank pressurisation is a direct indication of the magnitude of pressure at nozzle entry required to activate the automatic shut-off mechanism of the nozzle. A recirculating circuit is also included – via receiver 14 – to allow proper leak testing of the nozzle. Valve 15 is included as an option, in case the repairer wishes to obtain more comprehensive shut-off pressure data for a nozzle - as outlined in section 1.2.2. If this method is to be used, the fitting used to secure gauge 5 must have a 2” (53±0.5mm) bore and no sudden flow area or directional changes for at least 6 diameters (320mm) upstream of the gauge. This will ensure representative readings are taken. Banlaw will supply upon request a fitting suitable for this purpose.

Figure 2.1: Flow Test Circuit 2 – Test Tank T004 – Issue 1

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2.2 Flow Test Procedures: 2.2.1 Leak Testing 1. 2. 3. 4.

Install nozzle into recirculating circuit – receiver 14. Ensure valve 12 is closed and valve 15 is fully open (if fitted) Set flowrate at near maximum Run fuel through nozzle for at least 5 minutes, during which time the nozzle should be turned ON and OFF a few times to detect any leakage from the back end of the nozzle (such leakage is visible from the end-cap bleed hole). 5. Whilst fuel is running, move nozzle around on receiver to detect any leakage from between receiver and nozzle – such leakage is usually due to a worn nozzle body and / or sleeve o’ring seals. 6. Identify and record source of any leaks. Leakage from the bleed hole on the underside of the end cap indicates a faulty piston seal. Leakage from the front region of the nozzle indicates a worn nozzle body, sleeve seals, o’rings, or a damaged wiper seal. NOTE: a small volume of fuel (<50mL) may be lost when disconnecting the nozzle at the completion of flow testing. Such an amount is acceptable and does not constitute a non-conforming nozzle. 7. With pump running, manually turn nozzle off and disconnect from receiver. Turn nozzle on and off several times to check for leaks from front of nozzle and thus confirm whether sleeve maintains liquid tight seal with both the retainer and bore of nozzle body. NOTE: Do NOT point nozzle toward a person’s face during this operation. 8. With pump still running, connect and disconnect nozzle and receiver to ensure easy connection of nozzle whilst under head pressure of pump. Difficulty in engaging the nozzle may indicate the sleeve is not being held back in the fully home position. In this case refer to document M800 (or M1000), clause 2.16. Once all leaks are rectified, proceed to section 2.2.2 for shut-off pressure testing. 2.2.2 Shut-Off Pressure Testing NOTE: The consistency of results in this section relies on the reliable and accurate performance of the test equipment – in particular the flowmeter and pressure gauges. To ensure consistent and accurate test results are maintained, test equipment must be calibrated on a regular basis. 1. 2. 3. 4.

Connect nozzle to receiver 7. Close valve 12. Turn nozzle ON. Set flowrate to 360-380LPM . Allow test tank to fill. Tank will pressurise once the tank vent (11) has closed. Record the maximum tank pressure using gauge 13. NOTE: This process is made significantly easier if the gauge is fitted with a peak indicator pointer (drag pointer) 5. Compare this result to the specifications listed in Table 2.2.2.1 below.

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Spring Part No. AUS21A 029 - Silver Free Length = 87mm Recommended Range: 87-88.5mm Total Coils = 8.5 AUS21A 027 - Gold Free Length = 127mm Recommended Range: 126-128.5mm - Total Coils = 12.2

C’Clip Position Spring Setting 3 - Light 2 - Light / Medium 1 - Medium 3 – Medium / Heavy 2 - Heavy 1 – Not Applicable

Tank Pressure (Peak value) 25-35kPa 45-55kPa 65-75kPa 75-85kPa 95-105kPa N/A

Table 2.2.2.1: Spring Specifications and Test Tank Pressure @ Shut-Off NOTE: The tank pressure readings shown in Table 2.2.2.1 are valid only when: a) filling directly into the lower side of the test tank or via a 2” pipe less than 1m in length b) the tank is designed in accordance with section 3.4 c) flow testing is conducted at 360-380LPM 6. If any test result falls outside the specified range, that test must be conducted again. If after retest, the result is still outside the range check the following: a) Confirm the absence of any undue friction between the handle and endcap. This is best done with the nozzle disconnected from both the receiver and test circuit. The action of the handle should be smooth and consistent through its entire arc. The handle should also readily spring into the ON position if the catch is released. Such action indicates a satisfactory and consistent level of friction between seals and their mating surfaces. Check seal integrity and lightly polish bore surfaces with 1200 grit wet & dry grade emery paper if required. b) Confirm both the free length (unloaded OAL) and the total number of turns of the nozzle back spring. The free length and total number of coils should be within the ranges specified in Table 2.2.2.1. Discard any spring outside these limits. DO NOT ATTEMPT TO RECTIFY EITHER PROBLEM BY SCRAGGING OR GRINDING THE SPRING. NOTE: The shut-off pressure of a newly assembled nozzle will decrease marginally to a consistent value after several flow tests. Step 5 states 4-5 tests should be a sufficient number, although the experience of a repair technician will determine when a nozzle has reached its “steady-state” performance. 7. Repeat steps 10-14 until all flow test results are satisfactory. 8. Rectify all leaks identified during the flow testing. Retest as per section 2.2.1 until satisfactory. Once all leaks are rectified and the nozzle has satisfactorily passed flow testing, the remaining assembly or repair procedures for the nozzle must be completed prior to placing the nozzle into stock.

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IMPORTANT: A nozzle is considered a non-conforming product unsuitable for further service until all problems identified are rectified and the nozzle has passed all stages of the flow test procedures detailed above.

3. Flow Test Circuit Requirements All flow testing must be done using diesoline fuel or ISO4113 Calibration Fluid (nonhazardous diesel equivalent). The use of other fluids will yield foreign test results and thus create test non-conformances.

3.1

Pump Specifications

The pump specifications for both option 1 (Figure 1.1) and option 2 test circuits (Figure 2.1) are detailed below: a1) Minimum Flowrate: approx. 400LPM a2) Minimum Flowrate: approx. 600LPM b) Pump Head: minimum 300kPa (@ 3 cSt) c) Test Fluid: Diesoline (or ISO4113 Calibration Fluid) Footnotes:

a2): Required if testing AUS22 / B1000 series nozzles b): Final value depends on chosen design of circuit

To ensure reliable performance and satisfy the requirements listed above, Banlaw recommend the use of a positive displacement vane pump e.g. an EBS-RAY V25. For more information contact EBS-RAY on (02) 9905 0234. The use of a diaphragm pump is conditional, as care must be taken to ensure the characteristic pulsing effect of the fluid does not adversely affect the shut-off of the nozzle. Subtle variations i.e. pulses, in the head pressure developed by the pump may be sufficient to trigger the shut-off of the nozzle – particularly with low pressure margins – prior to the required line pressure (P1) being reached. Thus, a false shut-off pressure is recorded. If a diaphragm pump is used, operating a smaller pump at higher speed will be more beneficial than running a large pump at low speed.

3.2 Hose Specification:

T004 – Issue 1

* 2” (bore diameter) * Use Ryco T1 series wire braided petrochemical resistant pressure hose (or equivalent) * Use swaged (crimped) hose ends – not clamped

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3.3 Pipework:

* 2” (bore diameter) * ensure adequate earthing is provided for static electricity dissipation (AS/NZS 1020) * Std grade black steel pipe (e.g. AS1074/1163) * Apply rust inhibitive paint to external surfaces once pipework is fully fabricated and assembled * the gauge at 5 must be installed into a 2” bore fitting – contact Banlaw for specific details

3.4 Test Tank – Flow Test Facility Option 2 3.4.1 Test Tank Specifications The use of a tank to perform both tests described in Section 2 relies on the satisfactory design and setup of the test tank. Listed below are the required specifications: a) b) c) d)

tank volume: minimum 300L (i.e. >30 second test period) tank shape: see section 3.4.2 vent type: see section 3.4.2 receiver type: AUS23 (mines), AUS23R (rail), AUS23B (hydraulic), AUS43 (if repairing BAM1000 series nozzles)

3.4.2 Test Tank Design / Manufacture The principle concern with the design and manufacture of the test tank, is to ensure the tank is certified to the required pressure. To assist in the design or selection of a suitable tank, the post-manufacture test pressure – according to the Standards Association of Australia (SAA) – should be: a) at least 1.5 times the designer’s stated maximum allowable working pressure b) at least 2 times the expected maximum allowable working pressure The expected maximum allowable working pressure of the test tank is a minimum of 110kPa – being the minimum emergency relief pressure of the standard Banlaw vent. NOTE: The Banlaw quick-fill tank vent is NOT a primary pressure relief device. The emergency relief facility of the vent is designed only as a means of exhausting excess vapour pressure from within the ullage region of the tank. If the vent is required to discharge liquid fuel, the pressure within the tank will increase substantially . AS1692 is the generic standard covering the design and manufacture of tanks storing flammable and combustible liquids. The scope of this standard is limited to a test pressure of 35kPa – being less than that required for the test tank – however there are details regarding filling point location that remain valid. For test pressures greater than 35kPa but less than 50kPa the SAA recommend “good engineering practice” be used for tank design. Pressures in excess of T004 – Issue 1

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50kPa are included in the scope of AS1210 – Pressure Vessels. Although this standard is quite detailed and prescriptive, an experienced engineer should be able to select content that is applicable to the test tank. A solution to the selection or design of a suitable test tank would be the use of an existing pressure vessel – such as an air receiver. Once properly set up and fitted out, the vessel should be satisfactory for the purpose of testing the shut-off pressure of a Banlaw refuelling nozzle - see Figure 3.4.1 below.

Figure 3.4.1: Air Receiver as Test Tank Although the cylindrical air receiver is suitable, the preferred shape for a test tank is either square or rectangular – see Figure 3.4.2. The principle reason for this is the linear rate of fuel level increase and hence linear increase of tank pressurisation these shapes offer. The non-linear rate of both factors in a cylindrical tank forced Banlaw to design the AUS25C vent, to compensate for the rapid increase in fuel level as the liquid reaches the upper region of the tank. The extended length of the AUS25C vent valve allows the vent to close at an otherwise premature fuel level, thus compensating for the impending increased rate of fuel level rise and thus maintaining a suitable ullage within the tank once the nozzle has shut-off.

Figure 3.4.2: Rectangular Test Tank T004 – Issue 1

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4) General Requirements: The installation of any facility containing or handling flammable or combustible fluids, must be done in accordance with standards such as AS1940. This standard describes the requirement for bunding, signage, ventilation, and emergency and fire protection facilities. These measures are meant to complement existing workplace OHS&E policy in providing a safe work environment. Banlaw Pipeline Pty Ltd is a QA accredited company with Lloyd’s Register of Quality Assurance (LRQA) Australia. It has accredited QA procedures for the manufacture, assembly, inspection and testing, repair, and supply of its product and services to the domestic, national, and international mining, rail, earthmoving and ports industries. The aim of QA is to ensure only a consistent and conforming product or service is supplied to the end-user. The criteria on which a conforming and non-conforming (i.e. pass or fail) nozzle will be judged is described in all Banlaw Pipeline QA Assembly Inspection and Test Procedures. For the purposes of flow testing, any fuel leaks detected whilst under flow conditions or a shut-off pressure outside the specified limits, will constitute a non-conforming product. The cause of the nonconformance must be corrected and the nozzle retested. Only when the nozzle has past ALL inspection and test procedures will it be cleared for resale or be returned into service. Each authorised Banlaw Pipeline repair agent will be required to observe all such established QA requirements, to ensure only a consistent and high standard of product is returned into service. Attached is data and graphs detailing the line pressure at entry to the nozzle (P1) initiating nozzle shut-off versus flowrate for the BAM800 series Light, Light/Medium, Medium, Medium/Heavy and Heavy configured nozzles. The middle line for each model represents the actual results obtained by Banlaw, whilst the lines on each side of this line defines the boundaries within which the nozzle is classified as conforming i.e. test passed. Conversely, any result falling outside this region constitutes a non-conforming product i.e. test failed. To ensure accurate and consistent testing is achieved, the test equipment must be regularly inspected for damage and all measuring equipment calibrated at least twice yearly (or as specified by the equipment manufacturer). If used the pressure gauge at point 5 (at entry to nozzle) must be installed into a 2” bore fitting, with the sampling orifice at the base of the gauge stem level with the inside surface of the fitting. No fittings are to be placed at least 6 pipe diameters upstream of the gauge fitting, and at least 2 pipe diameters downstream of the fitting. Please contact Banlaw Pipeline for further details if required. As a valued authorised distributor or service agent, Banlaw Pipeline will endeavour to provide prompt, accurate and comprehensive technical support to all its agents. Any technical matters that cannot be readily dealt with by the agent must be referred to Banlaw. This includes assistance with any queries that may appear as a result of nozzle flow testing. Such practice will ensure all information supplied to the industry is accurate, factual and current. T004 – Issue 1

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Banlaw Pipeline Pty Ltd, as the manufacturer, retains the intellectual property and manufacturing rights for all its products. Any improper modification to the operation and design of such product is strictly prohibited, unless prior authorisation has been received from the manufacturer.

Kind Regards Adam Peattie Product & Design Engineer BANLAW PIPELINE PTY LTD “Leaders in Global Refuelling Technology” [email protected]

ATTACHMENTS: 1. Flow test reference curves for B800 series nozzles 2. Flow test reference curves for B1000 series nozzles

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