T004 – Issue 1 1

Document Title: T004 Revision No: 1

Description: Flow Testing Procedures for AllBanlaw Refuelling Nozzles

Issue Date: 06/01

This document forms part of the Assembly Repair and Test Manual for BanlawPipeline Quick-Fill Refuelling Nozzles. It describes the equipment and proceduresrequired for the proper flow testing of the nozzles. This information is intendedfor the use of Banlaw Pipeline Technicians and all Authorised Distributors andRepair Agents.

The proper flow testing of nozzles is essential to:

1. verify the correct shut-off pressure of the nozzle2. inspect and rectify the nozzle for leaks3. 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 catchwith respect to ON and OFF detents on nozzle end-cap.

There are two options for the layout of the nozzle flow test facility. Section 1details the first option using an in-line ball valve downstream of the nozzle – item8. This valve is used to create varying degrees of back pressure against the nozzlethus 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 isa limiting inlet pressure that triggers the automatic shut-off mechanism of thenozzle. The exponential relationship between flowrate and inlet pressure is shownon 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 aretaken. Banlaw can supply upon request a fitting for this purpose.

1.2 Flow Test Procedures

1.2.1 Leak testing

1. Install nozzle into test circuit and connect to receiver.2. Start pump with valve 5 fully open.3. Set flowrate at near maximum4. 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 theback 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 leakagefrom between receiver and nozzle – such leakage is usually due to a wornnozzle body and / or sleeve o’ring seals.

6. Identify and record source of any leaks. Leakage from the bleed hole on theunderside of the end cap indicates a faulty piston seal. Leakage from the frontregion of the nozzle indicates a worn nozzle body, sleeve seals, o’rings, or adamaged wiper seal.

NOTE: a small volume of fuel (<50mL) may be lost when disconnecting thenozzle at the completion of flow testing. Such an amount is acceptable and doesnot 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 nozzleand thus confirm whether sleeve maintains liquid tight seal with both theretainer and bore of nozzle body. NOTE: Do NOT point nozzle towards aperson’s face during this operation.

8. With pump still running, connect and disconnect nozzle and receiver to ensureeasy connection of nozzle whilst under head pressure of pump. Difficulty inengaging the nozzle may indicate the sleeve is not being held back in the fullyhome 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 accurateperformance of the test equipment – in particular the flowmeter and pressuregauges. Additionally, noticeable variations in diesel temperature (>15-20°C) maycause inconsistent test results due to fluctuations in both diesel viscosity anddensity. Thus to ensure consistent and accurate test results are maintained, testequipment must be calibrated on a regular basis and factors such as dieseltemperature 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 recordboth 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 testsin total

4. Compare results obtained during steps 2 and 3 against the appropriate curveon the attached graphs. Again, note the separate curves for each of the 5available nozzle back spring settings.

5. If any test result falls outside the shaded region on a chosen curve, that testmust be conducted again. If after 4-5 retests the result is still outside theregion check the following:

a) Confirm the absence of any undue friction between the handle and end-cap. This is best done with the nozzle disconnected from both thereceiver and test circuit. The action of the handle should be smoothand consistent through its entire arc. The handle should also readilyspring into the ON position if the catch is released. Such actionindicates a satisfactory and consistent level of friction between sealsand their mating surfaces. Check seal integrity and lightly polish boresurfaces with 1200 grit wet & dry grade emery paper if required.

b) Confirm both the free length (unloaded OAL) and the total number ofturns of the nozzle back spring. The free length and total number ofcoils should be within the ranges specified in Table 2.2.2.1. Discardany spring outside these limits. DO NOT ATTEMPT TO RECTIFYEITHER PROBLEM BY SCRAGGING OR GRINDING THE SPRING.

• A spring with a free length slightly under (0.5-1mm) thespecification may be lengthened to within the correct range bysecurely gripping both ends of the spring and simultaneouslyextending the spring and twisting the spring anti-clockwise. Thisprocess can be carefully repeated until the spring length iswithin 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 shouldbe a sufficient number, although the experience of a repair technicianwill determine when a nozzle has reached its “steady-state”performance

2. The shut-off pressure of a nozzle is very susceptible to variances in theproperties of the nozzle back spring. For example, up to 15kPavariation can be caused by only 1.5mm variation in spring free length.Discard any spring whose performance is considered unsatisfactory.

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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 forfurther service until all problems identified are rectified and the nozzle haspassed 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 testtank – measured by item 13 – that occurs at nozzle shut-off. The level of tankpressurisation is a direct indication of the magnitude of pressure at nozzle entryrequired to activate the automatic shut-off mechanism of the nozzle.

A recirculating circuit is also included – via receiver 14 – to allow proper leaktesting of the nozzle. Valve 15 is included as an option, in case the repairerwishes to obtain more comprehensive shut-off pressure data for a nozzle - asoutlined in section 1.2.2. If this method is to be used, the fitting used to securegauge 5 must have a 2” (53±0.5mm) bore and no sudden flow area or directionalchanges for at least 6 diameters (320mm) upstream of the gauge. This will ensurerepresentative readings are taken. Banlaw will supply upon request a fittingsuitable for this purpose.

Figure 2.1: Flow Test Circuit 2 – Test Tank

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2.2 Flow Test Procedures:

2.2.1 Leak Testing

1. Install nozzle into recirculating circuit – receiver 14.2. Ensure valve 12 is closed and valve 15 is fully open (if fitted)3. Set flowrate at near maximum4. 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 theback 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 leakagefrom between receiver and nozzle – such leakage is usually due to a wornnozzle body and / or sleeve o’ring seals.

6. Identify and record source of any leaks. Leakage from the bleed hole on theunderside of the end cap indicates a faulty piston seal. Leakage from the frontregion of the nozzle indicates a worn nozzle body, sleeve seals, o’rings, or adamaged wiper seal.

NOTE: a small volume of fuel (<50mL) may be lost when disconnecting thenozzle at the completion of flow testing. Such an amount is acceptable and doesnot 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 nozzleand thus confirm whether sleeve maintains liquid tight seal with both theretainer and bore of nozzle body. NOTE: Do NOT point nozzle toward aperson’s face during this operation.

8. With pump still running, connect and disconnect nozzle and receiver to ensureeasy connection of nozzle whilst under head pressure of pump. Difficulty inengaging the nozzle may indicate the sleeve is not being held back in the fullyhome 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 accurateperformance of the test equipment – in particular the flowmeter and pressuregauges. To ensure consistent and accurate test results are maintained, testequipment must be calibrated on a regular basis.

1. Connect nozzle to receiver 7. Close valve 12.2. Turn nozzle ON. Set flowrate to 360-380LPM .3. Allow test tank to fill. Tank will pressurise once the tank vent (11) has closed.4. 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. C’Clip PositionSpring Setting

Tank Pressure(Peak value)

AUS21A 029 - Silver 3 - Light 25-35kPa- Free Length = 87mmRecommended Range: 87-88.5mm

2 - Light / Medium 45-55kPa

- Total Coils = 8.5 1 - Medium 65-75kPa

AUS21A 027 - Gold 3 – Medium / Heavy 75-85kPa- Free Length = 127mmRecommended Range: 126-128.5mm

2 - Heavy 95-105kPa

- Total Coils = 12.2 1 – Not Applicable 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 lengthb) the tank is designed in accordance with section 3.4c) flow testing is conducted at 360-380LPM

6. If any test result falls outside the specified range, that test must be conductedagain. 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 end-cap. This is best done with the nozzle disconnected from both thereceiver and test circuit. The action of the handle should be smoothand consistent through its entire arc. The handle should also readilyspring into the ON position if the catch is released. Such actionindicates a satisfactory and consistent level of friction between sealsand their mating surfaces. Check seal integrity and lightly polish boresurfaces with 1200 grit wet & dry grade emery paper if required.

b) Confirm both the free length (unloaded OAL) and the total number ofturns of the nozzle back spring. The free length and total number ofcoils should be within the ranges specified in Table 2.2.2.1. Discardany spring outside these limits. DO NOT ATTEMPT TO RECTIFYEITHER PROBLEM BY SCRAGGING OR GRINDING THE SPRING.

NOTE: The shut-off pressure of a newly assembled nozzle will decrease marginallyto a consistent value after several flow tests. Step 5 states 4-5 tests should be asufficient number, although the experience of a repair technician will determinewhen 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 completedprior to placing the nozzle into stock.

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IMPORTANT: A nozzle is considered a non-conforming product unsuitable forfurther service until all problems identified are rectified and the nozzle haspassed 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 (non-hazardous diesel equivalent). The use of other fluids will yield foreign test results andthus 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. 400LPMa2) Minimum Flowrate: approx. 600LPMb) Pump Head: minimum 300kPa (@ 3 cSt)c) Test Fluid: Diesoline (or ISO4113 Calibration Fluid)

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

To ensure reliable performance and satisfy the requirements listed above, Banlawrecommend 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 thecharacteristic pulsing effect of the fluid does not adversely affect the shut-off ofthe nozzle. Subtle variations i.e. pulses, in the head pressure developed by thepump may be sufficient to trigger the shut-off of the nozzle – particularly with lowpressure margins – prior to the required line pressure (P1) being reached. Thus, afalse shut-off pressure is recorded. If a diaphragm pump is used, operating asmaller pump at higher speed will be more beneficial than running a large pumpat low speed.

3.2 Hose Specification: * 2” (bore diameter)* Use Ryco T1 series wire braided petrochemicalresistant 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 staticelectricity dissipation (AS/NZS 1020)* Std grade black steel pipe (e.g. AS1074/1163)* Apply rust inhibitive paint to external surfacesonce pipework is fully fabricated and assembled* the gauge at 5 must be installed into a 2” borefitting – 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 thesatisfactory design and setup of the test tank. Listed below are the requiredspecifications:

a) tank volume: minimum 300L (i.e. >30 second test period)b) tank shape: see section 3.4.2c) vent type: see section 3.4.2d) receiver type: AUS23 (mines), AUS23R (rail), AUS23B

(hydraulic), AUS43 (if repairing BAM1000 series nozzles), andAUS43NR (if repairing AUS22NR nozzles).

3.4.2 Test Tank Design / Manufacture

The principle concern with the design and manufacture of the test tank, is toensure the tank is certified to the required pressure. To assist in the design orselection of a suitable tank, the post-manufacture test pressure – according tothe Standards Association of Australia (SAA) – should be:

a) at least 1.5 times the designer’s stated maximum allowableworking pressure

b) at least 2 times the expected maximum allowable workingpressure

The expected maximum allowable working pressure of the test tank is aminimum of 110kPa – being the minimum emergency relief pressure of thestandard 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 exhaustingexcess vapour pressure from within the ullage region of the tank. If the vent isrequired to discharge liquid fuel, the pressure within the tank will increasesubstantially .

AS1692 is the generic standard covering the design and manufacture of tanksstoring flammable and combustible liquids. The scope of this standard is limitedto 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. Fortest pressures greater than 35kPa but less than 50kPa the SAA recommend

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“good engineering practice” be used for tank design. Pressures in excess of50kPa are included in the scope of AS1210 – Pressure Vessels. Although thisstandard is quite detailed and prescriptive, an experienced engineer should beable 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 anexisting pressure vessel – such as an air receiver. Once properly set up and fittedout, the vessel should be satisfactory for the purpose of testing the shut-offpressure 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 tankis either square or rectangular – see Figure 3.4.2. The principle reason for this isthe linear rate of fuel level increase and hence linear increase of tankpressurisation these shapes offer. The non-linear rate of both factors in acylindrical tank forced Banlaw to design the AUS25C vent, to compensate for therapid increase in fuel level as the liquid reaches the upper region of the tank. Theextended length of the AUS25C vent valve allows the vent to close at anotherwise premature fuel level, thus compensating for the impending increasedrate of fuel level rise and thus maintaining a suitable ullage within the tank oncethe nozzle has shut-off.

Figure 3.4.2: Rectangular Test Tank

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4) General Requirements:

The installation of any facility containing or handling flammable or combustiblefluids, must be done in accordance with standards such as AS1940. This standarddescribes the requirement for bunding, signage, ventilation, and emergency andfire protection facilities. These measures are meant to complement existingworkplace OHS&E policy in providing a safe work environment.

Banlaw Pipeline Pty Ltd is a QA accredited company with Lloyd’s Register ofQuality Assurance (LRQA) Australia. It has accredited QA procedures for themanufacture, assembly, inspection and testing, repair, and supply of its productand services to the domestic, national, and international mining, rail, earthmovingand ports industries.

The aim of QA is to ensure only a consistent and conforming product or service issupplied 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 QAAssembly Inspection and Test Procedures. For the purposes of flow testing, anyfuel leaks detected whilst under flow conditions or a shut-off pressure outside thespecified limits, will constitute a non-conforming product. The cause of the non-conformance must be corrected and the nozzle retested. Only when the nozzlehas past ALL inspection and test procedures will it be cleared for resale or bereturned into service.

Each authorised Banlaw Pipeline repair agent will be required to observe allsuch established QA requirements, to ensure only a consistent and highstandard 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. Themiddle 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 thenozzle is classified as conforming i.e. test passed. Conversely, any result fallingoutside this region constitutes a non-conforming product i.e. test failed.

To ensure accurate and consistent testing is achieved, the test equipment mustbe regularly inspected for damage and all measuring equipment calibrated atleast twice yearly (or as specified by the equipment manufacturer). If used thepressure gauge at point 5 (at entry to nozzle) must be installed into a 2” borefitting, with the sampling orifice at the base of the gauge stem level with theinside surface of the fitting. No fittings are to be placed at least 6 pipe diametersupstream of the gauge fitting, and at least 2 pipe diameters downstream of thefitting. Please contact Banlaw Pipeline for further details if required.

As a valued authorised distributor or service agent, Banlaw Pipeline willendeavour to provide prompt, accurate and comprehensive technical support toall its agents. Any technical matters that cannot be readily dealt with by the agentmust be referred to Banlaw. This includes assistance with any queries that may

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appear as a result of nozzle flow testing. Such practice will ensure allinformation supplied to the industry is accurate, factual and current.

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

Kind Regards

Adam PeattieProduct & Design EngineerBANLAW PIPELINE PTY LTD“Leaders in Global Refuelling Technology”adam@banlaw.com.au

ATTACHMENTS:

1. Flow test reference curves for B800 series nozzles2. Flow test reference curves for B1000 series nozzles