OPERATION AND MAINTENANCE INSTRUCTIONS AVK UNDERGROUND FIRE HYDRANT

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1 1. INTRODUCTION Operation and maintenance manual for the series underground CLEARWAY fire hydrant 1 of 7 The designs, materials and specifications shown are subject to change without notice due to our continuing programme of product development.

2 2. HEALTH AND SAFETY PRECAUTIONS Whenever AVK valves are installed or operated the inherent dangers of pressurized liquid must be addressed. Never attempt to dismantle the valves when the system is under pressure. Gate valves are heavy, especially in large dimensions, so always use appropriate lifting devices to avoid injuries. It is essential that staff undertaking these operations is adequately trained to avoid accidents. This installation and maintenance instruction will not replace adequate training and correct craftsmanship and AVK will not be held responsible for any accidents arising from incorrect installation. Likewise before, during and after installation the applicable standards, codes and regulations for installation and for the prevention of accidents must be observed. Note that especially for installations in hazardous environments ATEX regulations may apply. 3. STORAGE AVK gate valves should be stored in a location that protects the valve from any pollution or contamination. The valves must be stored in upright position and in an almost closed position to prevent long-term compression of the wedge rubber. The valve must be kept out of sunlight to prevent oxidation of the rubber and coating. Valves stored in cold storage must be protected against freezing. 4. OPERATION The series Clearway fire hydrants are suitable for use with potable water and neutral liquids, to a maximum temperature of 70 C. Minimum liquid temperature must be above freezing. Insulation is essential for external temperatures of 0 C and below to a limit of -10 C. They are rated for a maximum working pressure of 16 Bar unless otherwise agreed and deliver a minimum of 3,300 litres per minute at 1.7 Bar gauge. They are normally supplied as CLOCKWISE TO CLOSE (CTC) denoted by a direction ARROW on the stem cap (7) and a white plastic insert (39) on the stem cap (7). A CLOCKWISE TO OPEN (CTO) version is denoted by the relevant direction arrow on the stem cap (7) and a RED plastic insert (39) on the stem cap (7). OPENING / CLOSING (CTO) Normally by standard Tee Key or Ring Key and bar located on stem cap (7) the closing torque will not exceed the Maximum Operating Torque (MOT) of 105Nm and the minimum strength torque (MST) is 210Nm. Number of turns from fully open to fully closed: 14 approximately. The automatic drain device, when fitted will drain the hydrant body in 5 minutes. The volume of retained water is 12 ml (maximum allowed is 100ml). SWABBING. The Clearway hydrant is suitable for swabbing. It is recommended that applications in a corrosive atmosphere or sited in explosive locations or in the proximity of sea water or spray, use a stainless steel stem (316) and all exposed fasteners are in A4 stainless steel. A Gunmetal outlet and class A coating (300 microns inside and out) are also recommended. 5. MAINTENANCE BS750:2012 only requires the provision for replacing stem seals under pressure and when the hydrant is in situ. SAFETY PRECAUTIONS: When changing the obturator (wedge) and / or bonnet O ring seal Maintenance procedures must not be carried out whilst hydrant is installed in a live water main under pressure. Check that there is not pressure in the main by opening the hydrant prior to commencing work. Ensure the main will NOT be recharged before all work on the hydrant is completed. All of the following procedures must be carried out with due regard to relevant Road Traffic Act Guidelines, Health and safety and COSHH directives. Drawing References 1. Replacement of stem seals and brass bush ( X2X441XX) 2. Replacement of wedge (obturator) & bonnet O ring seal ( X2X441XX) 3. Replacement of outlet & outlet O Ring seal ( X2X441XX) 4. Replacement of drain plug or autofrost valve ( X2X441XX) 2 of 7 The designs, materials and specifications shown are subject to change without notice due to our continuing programme of product development.

3 6. PROCEDURE FOR REPLACEMENT OF STEM SEALS SAFETY PRECAUTIONS: Ensure the hydrant is closed to a minimum torque of 105Nm, this enables the seal replacement to be carried out whilst under pressure. 19mm A/F Spanner or Socket WRAS Approved Silicone Grease Small Brush Flat Head Screwdriver or blade 6mm A/F Allen Key a. Remove the white or red plastic insert (No. 39) using a fine blade or screwdriver. b. Remove socket bolt (No. 25) and stem cap (No.7). c. Remove 2 off M12 hexagon head bolts (No. 26) and washers (No.24). d. Remove Gland Flange (No.18) & O ring (No. 20) store the O-ring safely for re-use. e. Remove old O-rings (No. 28) & nylon bush (No.5) from the stem retaining the nylon bush. f. Clean the stem (No.9) and top surface of the bonnet (No.3). g. Ensure brass fixing ring (No. 11) is seated flat in the top of the bonnet. h. Grease the Stem (No.9) and place the gland flange O-ring (No.20) over the stem and hinge bush (No.12) i. Replace Stem Seal O rings (No. 28) placing an O-ring over the stem, followed by the nylon bush (No. 5) and the second O-ring (No. 28). Apply grease to all O-rings. j. Refit the gland flange (No. 18) over the stem seals ensuring all O-rings are seated correctly. k. Replace 2 off M12 hexagon head bolts (No. 26) and washers (No.24). (Min. 60 Nm) l. Replace stem cap (No. 7) and socket bolt (No.25). m. Replace the white or red plastic insert (No.39). n. Open and close the hydrant to check the free running of the wedge. 7. PROCEDURE FOR REPLACEMENT OF STOPPER (OBTURATOR) & BONNET O RING SEAL SAFETY PRECAUTIONS: This procedure must NOT be carried out with the hydrant under pressure. 19mm A/F socket 19mm A/F spanner a. Ensure the hydrant is in the partially open position by turning the stem cap (No. 7) in the direction indicted for opening, one or two turns to lift the PUR disc (No.22) off the seat. b. Remove 4 no M12 hex head bolts (No. 27) and washers (No.24) using the 19mm A/F spanner or socket. c. Part the bonnet assembly & bonnet gasket (No. 19) from the body (No. 1). d. To remove the Obturator Assembly (Inclusive of part No s, 21,22,23,31,32) from the hinge (No.16) remove the securing M12 hex bolt (No.26) on the underside of the hinge and remove the Obturator Assembly as a single unit. e. To replace: Hold a new M12 bolt and washer in position facing thread upwards through the hinge. Place an M12 washer over the protruding thread. f. Offer up the new obturator assembly with the two smaller lug sections facing away from the bonnet and the single wider lug section sitting between the arms of the hinge. g. Tighten the M12 bolt until there is no allowable movement of the obturator assembly over the hinge (Min. 60 Nm). 3 of 7 The designs, materials and specifications shown are subject to change without notice due to our continuing programme of product development.

4 8. PROCEDURE FOR REPLACEMENT OF STOPPER (OBTURATOR) & BONNET O RING SEAL CONTINUED h. Replace bonnet gasket (No. 19) by applying grease into the groove on the bonnet (No.3) and onto the bonnet seal. Place it into the bonnet groove and offer bonnet assembly up to the body. Insert the 4 M12 hex head bolts (No. 27) tightening to 60Nm. i. Operate the hydrant to check for correct movement. j. Remove dustcap (No.8) from outlet (No.2) k. Test hydrant as described on page 4. l. Refit dustcap (No.8) to outlet (No.2) 9. PROCEDURE FOR REPLACEMENT OF FLANGED OUTLET AND OUTLET O RING SEAL SAFETY PRECAUTIONS: Ensure the hydrant is closed to a minimum torque of 150Nm 19mm A/F spanner or socket a. Remove dust cap (No.8) from outlet (No.2). b. Remove outlet (No.2) by removing 4 No. M12 Bolts (No.26) and washers (No.24). c. To replace the outlet (No.2) and O ring (No.17), lubricate O ring (No.17) if necessary using approved grease then locate it in the groove in body (No.1). d. Ensure dust cap (No.8) retaining ring is located in small boss on Body (1) so that an M12 bolt (No.26) passes through the eyelet in the dust cap. Place outlet (No.2) in position, ensuring that O ring (No.8) is still correctly located and secure using 4 M12 Bolts (No.26) and washers (No.24) e. Test Hydrant as described on page 4. f. Refit dustcap (No.8) to outlet (No.2) 10. PROCEDURE FOR REPLACEMENT OF AUTOFROST VALVE SAFETY PRECAUTIONS: This procedure must NOT be carried out with the hydrant under pressure. 19mm A/F spanner or socket Long nose pliers WRAS approved grease a. Open the hydrant by 5 turns to allow easy access to the autofrost housing in the body (No.1) b. Remove outlet dust cap (No.8) c. Remove outlet (No.2) by removing 4 off M12 Bolts (No.26) and washers (No.24). d. Remove the stainless steel split pin (No.38) securing the drain housing (No.33). Remove the drain housing (No.33) from the body (No.1) e. Grease the autofrost valve body using a WRAS approved grease f. Refit the new drain housing (No.33), securing to the body with a new stainless steel split pin (No.38). g. Re-fit outlet dust cap (No.8) to outlet (No.2) h. To test the draining capabilities of the new autofrost valve, close the hydrant fully and fill the area between the wedge and outlet with water. The device will allow up to 10ml of water to be retained in the hydrant body over a 5 minute draining period. 4 of 7 The designs, materials and specifications shown are subject to change without notice due to our continuing programme of product development.

5 11. PROCEDURE FOR REPLACEMENT OF DATA LOGGER BALL VALVE SAFETY PRECAUTIONS: This procedure must NOT be carried out with the hydrant under pressure. 18mm A/F Spanner (Open Ended) Philips head screwdriver PTFE Thread tape. a. Ensure the valve is in the closed position by operating the valve in the direction indicated b. Remove the handle on the data logger ball valve to allow the body to be unscrewed c. Remove the data logger ball valve from the body (No.1) d. Clean off any old PTFE Tape inside the tapped hole in the body (No.1) being careful not to damage the thread. e. Remove the handle on the replacement data logger ball valve to allow it to be screwed into position. f. Apply PTFE thread tape to the male end of the valve for insertion into the hydrant body (No.1). g. Refit the data logger ball valve (Do not over tighten the ball valve) h. Refit the handle to the ball valve body. i. When the main is re-pressurised check for leaks around the ball valve. Briefly opening and closing the valve should allow water to escape under pressure verifying the valve functions as intended. j. Test hydrant as described on page TESTING On completion of maintenance requirements: Check all items are located correctly. Check that all bolts are secure. Remove dust cap (No.9) from outlet (No.2) SAFETY NOTE: When pressurising the main, it is highly recommended that the hydrant is fractionally open to allow venting of air. a. Check integrity of PUR disc (No.22) by closing the hydrant in the direction of the arrow on the stem cap (No.7). b. Check integrity of seals by slowly opening the hydrant. c. When all tests have proved satisfactory, close the hydrant. d. Ensure dust cap (No.8) is always refitted to the outlet (No.2) when hydrant is not in use. This will prevent the ingress of foreign matter, stones etc. 5 of 7 The designs, materials and specifications shown are subject to change without notice due to our continuing programme of product development.

6 13. LIST OF MATERIALS ITEM NO. QTY DESCRIPTION. 1 1 Body 2 1 Outlet 3 1 Bonnet 4 2 Thrust collar 5 1 Nylon bush 6 1 O-ring 7 1 Stem cap 8 1 Dust cap 9 1 Stem 10 1 Stem nut 11 1 Fixing ring 12 2 Hinge bush 13 1 Hinge shaft 14 1 Stem bush 15 1 Stop ring 16 1 Hinge 17 1 O-ring 18 1 Gland flange 19 1 Bonnet gasket 20 1 O-ring 21 1 Disc lower part 22 1 PUR disc 23 1 Disc upper part Washer 25 1 Socket bolt 26 7 Hex bolt 27 4 Hex bolt 28 2 O-ring(s) 29 1 Plastic spacer 30 2 Sliding shoe 31 3 Socket cap screw 32 1 Bushing 33 1 Drain housing 34 1 Plunger 35 1 Seal washer 36 1 Spring 37 1 O-ring 38 1 Split pin 39 1 Plastic insert 6 of 7 The designs, materials and specifications shown are subject to change without notice due to our continuing programme of product development.

7 7 of 7 The designs, materials and specifications shown are subject to change without notice due to our continuing programme of product development.

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