bpm800 > bpm800 repair - rev 1

CONFIDENTIAL INFORMATION Hydrocarbon Management Specialists BPM800 Repair – Rev 1 © 2006 BANLAW PTY LTD

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Document title: BPM800 Repair Revision No: 1

Description: Repair Procedure for BPM800 Nozzles

Issue Date: 02/06

1.0 Repair Procedure 1.1 Clean To prevent contamination entering the nozzle assembly area, and to assist in identifying the reason(s) for the nozzle being removed from service, it is important to thoroughly clean the nozzle prior to disassembly. In particular, the front muzzle region of the nozzle should be flushed clean to remove grit and other contaminants. A degreasing or parts wash-down unit may assist in this. 1.2 Investigate Nozzles are returned for service/repair often with no paperwork explaining the fault(s). If possible, the customer should be contacted in an effort to identify the reasons so that they may be specifically addressed. A nozzle should be assessed to both correct faults and prevent potential problems. All suspect parts should be replaced to ensure the nozzle is returned to service in an “as new” operating condition. Visually inspect the nozzle for structural faults, i.e. fractures, impact damage, and general wear and tear. If possible, the nozzle should be flow tested as per document T004 to identify leaks from either the front of rear of the nozzle prior to disassembly. Fuel leaks are amongst the more prevalent faults, largely due to damaged seals or contamination build-up. 1.3 Disassembly Section 2 of this document outlines the various sub-assemblies which make up a complete nozzle. The nozzle should be dismantled by systematically removing each sub-assembly using the specified tools and jigs. Once the nozzle is cleaned and has undergone an initial fault assessment, it should be completely dismantled to allow a thorough inspection of each part and to remove all contamination. This is especially important between moving parts and sealing surfaces. Loctite thread-locking compounds are “cracked” by applying localised heat to the thread area using a small propane torch. Threads must be thoroughly cleaned of all contamination prior to reassembly.


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Caution: Banlaw uses Viton seals in its products. Viton is a hazardous material when heated. Be sure to identify location of seals within nozzle assembly prior to applying heat to threads and consult the attached MSDS for further information. 1.4 Fault Identification and Remedy The 2 most common reasons a nozzle is returned for repair are:

• Structural damage as a result of a drive-away, general wear and tear, or abuse.

• Fuel leaks from worn seals, or excessive contamination around the seals. 1.4.1 Fuel Leaks – Front End Fuel leaks whilst refuelling will generally occur due to either a faulty sleeve face seal or sleeve U-seals. Although the Wiper Seal (AUS21A###) will assist in sealing between the receiver and nozzle, the primary seal between the nozzle and receiver is the outer lip of the face seal. Fuel leaks whilst the nozzle is disconnected from the receiver are generally caused either from a poor seal between the inner annulus of the sleeve face seal and the retainer, or faulty sleeve U-seals. Contamination around the sleeve U-seals will often damage the bore of the Body. Minor imperfections to the bore can be removed using fine emery paper (P1200). The bore must measure Ø51.72±0.02mm and have a smooth and consistent finish. The bore sizing can be quickly confirmed using the Body Sizing Jig J21A-032-2, with any Body passing over the Jig being faulty. The face seal used on the Sleeve is non-serviceable, with the Sleeve supplied with the face seal already intact. 1.4.2 Fuel Leaks – Rear End The piston U-seal (BP800-019-1) is the solitary seal at the rear end of the nozzle. Fuel leaks from the rear of the nozzle, e.g. from the bleed hole on the underside of the End-Cap, indicate a poor seal between the U-seal and piston bore. As with the bore of the Body, the piston bore of the Housing will suffer scoring and damage from contamination build-up. Dirty fuel will deposit contamination at the forward side of the Piston, whilst contamination at the rear side of the Piston will enter via the bleed hole on the End-Cap or between the interface of the Housing and End-Cap. The piston bore must measure Ø44.80±0.02mm and have a smooth and consistent finish. Minor surface imperfections may be removed using fine emery paper (P1200), however the Housing must be replaced if the damage is irreparable.


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1.4.3 Other Key Problem Areas In addition to sections 1.4.1 and 1.4.2, a number of other key areas should be carefully considered during each nozzle service.

a) difficulty in connecting the nozzle onto the receiver with the supply line pressurized, i.e. by pump pressure. This can occur if the nozzle Retainer and Sleeve are permitted to sit too far forward with the T-Handle locked OFF. This problem primarily occurs due to a combination of high wear between clevis pins and mating parts in the piston sub-assembly – evident with excessive free-play in the action of the T-Handle - and wear from the cast catch detent on the underside of the End-Cap. These problems decrease the required 22.0±0.5mm linear displacement of the central nozzle assembly between ON and OFF positions, by failing to return the Retainer and Sleeve fully back in the OFF position. Both these problems should be thoroughly assessed and any faulty parts replaced.

b) Poor action of the nozzle actuator will increase the effort required when connecting the nozzle and receiver, and may prevent proper engagement of the ball locks. Damage sustained to the front end of the nozzle Body may impinge upon the Bumper or Actuator, thus restricting the free movement of the Actuator sub-assembly. Such damage must be either repaired, or the parts replaced. Attention should also be paid to excessive wear or damage to the inner surface of the Actuator onto which the ball locks contact. Such wear may jeopardize the effectiveness of the ball locks.

c) Aside from structural damage to the Actuator, Body and Housing, further damage sustained from a drive-away may include such things as a bent Tube. The Tube can also sustain such damage as a result of an object being jammed between the Retainer and Sleeve, such as in the event of fuel pilferage. A damaged Tube may decrease the Safe Working Pressure of the nozzle, and increase the effort required to displace the central nozzle assembly when turning the nozzle between ON and OFF positions. This increase in effort will increase the shut-off pressure of the nozzle, creating the risk of tank overpressurisation.

d) Wear between mating parts of the nozzle operating mechanism, i.e. the piston and T-handle sub-assemblies, will affect the proper operation of the nozzle – as discussed in point (a). Any parts exhibiting excessive wear or other damage must be replaced.

e) The bore at the front of the Body can be exposed to relatively high wear, particularly if the nozzle plug (or anchor) and receiver dust caps are not used, or the receiver is not wiped clean prior to connecting the nozzle. Excessive wear will increase the clearance with the mating receiver and thus increase the amount of “rocking” (angular movement) possible between the nozzle and receiver. This will create additional strain on the effectiveness of the seal between the sleeve face seal and the face of the receiver leading to the risk of leakage. The front bore of the Body may be checked on the Body Sizing Jig, with any Body freely passing over the jig deemed unsatisfactory.


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2.0 Sub-Assemblies A number of sub-assemblies are available to assist in the repair process. Three (3) sub-assemblies are available: 1. Housing sub-assembly 2. T-Handle sub-assembly 3. Actuator sub-assembly 2.1 Housing Sub-Assembly This sub-assembly consists of the following individual parts:

• Housing (BP800-022) – 1 of (##). • Housing Bush (BP800-022-3) – 1 of (##). • Plaque - serial (BP800-022-4) – 1 of. • Plaque - web (BP800-022-5) – 1 of.

(##): Not available separately.

AU & US PATENTS PENDING & GRANTED

SERIAL CODEMODELHydrocarbon Management Specialistswww.banlaw.com

Plaque A (BP800-022-4) Plaque B (BP800-022-5)

Figure 2.1 – Housing Assembly


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2.2 T-Handle Sub-Assembly This sub-assembly consists of the following individual parts (not available separately):

• T-Handle (BP800-002) – 1 of. • Catch (BP800-006) – 1 of. • T-Handle Bung (BP800-007) – 2 of. • Trigger Knob (AUS21A003) – 2 of. • Roll Pin (AUS21A004) – 1 of. • Catch Spring (AUS21A005) – 1 of.

5°

AND INSTALLED CATCHBETWEEN BROACH ANGLEOBSERVE RELATIONSHIP

ENSURE CLEARANCE(EACH SIDE)

CATCH PINBP800-004

CATCH SPRINGAUS21A-005HANDLE

BP800-002

TRIGGER KNOBAUS21A-003

HANDLE BUNGBP800-007

Figure 2.2 – T-Handle Sub-Assembly


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2.3 Actuator Sub-Assembly

The standard spec Actuator (BP800-031-1) and Bumper (AUS21A044) sub-assembly is assigned the part number BP800-031. The JN125 spec Actuator (BPJN800-031-1) and Bumper (AUS21JN044) sub-assembly is assigned the part number BPJN800-031.

BUMPERSTANDARD: AUS21A-044JN125: AUS21JN-044

ACTUATORSTANDARD: BP800-031-1

JN125: BPJN800-031-1

Figure 1.4 - Actuator Assembly


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3.0 Quality Assurance (QA) As an accredited QA company, Banlaw prides itself on maintaining consistently high standards in all product and service related issues within the global market. With respect to nozzle repairs, any nozzle returned for service must be assessed, repaired and tested in accordance with Banlaw guidelines to ensure the nozzle is returned to service in an “as-new” condition and eligible for warranty under the Banlaw Terms & Conditions of Product Warranty. Please do not hesitate to contact Banlaw or your nearest authorised Banlaw Distributor should you have any queries regarding this document or any quality Banlaw product.

BANLAW PTY LTD Ph: 61 2 49724777 Fax: 61 2 49714910

Email: [email protected] www.banlaw.com.au

Distributor & Business Development Manager

Manager – Systems Development & Support

Engineering Manager (Mechanical)

Steve Clayton 0409 045017

[email protected]

John Gregory 0408 492408

[email protected]

Adam Peattie 0412 704838

[email protected]

bpm800 > bpm800 repair - rev 1

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