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Bulletin 79: Aircraft Refueling Hose Tester

GTP-2157-A

The Gammon Aircraft Refueling Hose Tester is made of non-ferrous materials, designed for periodic testing of jet refueling hose, using jet fuel for pressurizing.

The unit consists of a 10 U.S. gallon (38 liter) aluminum tank (GTP-2234) equipped with a vented fill cap, hand pump (GTP-8076), 0-1000 psi 4.5” face pressure gauge (GTP-281-H), quick disconnect (GTP-1004-4MA), and six feet of 1/4” hose (GTP-8079) to connect to the tester.

Hose Test Procedure

Overview

This tester is designed to perform integrity tests on hose assemblies used in the refueling of aircraft. A thorough inspection of the hose should be done before testing, and if any significant flaw is found, the test should not be run. The purpose of this test is to ensure that the couplings are still secure and that no physical flaw exists that cannot be seen on a physical inspection. AIR MUST NOT BE PRESENT in the system or else, in the event of a failure of the hose or a fitting, the trapped air will cause an explosive release carrying particles at high speed as it expands.

Procedure

The primary application of this tester is for testing aircraft refueling hose in accordance with API Bulletin 1529. When testing newly coupled Grade 1 hose, the test pressure is 300 psi. Periodic tests are required at the working pressure which is 150 psi. When testing Grade 2 hose, the test pressure is 600 psi for newly coupled or recoupled hose, and 300 psi for periodic testing. Because most aircraft refueling hose is Grade 2, the instructions below are written for a 300 psi periodic test with the hose full of jet fuel and remaining attached to the hose reel or to piping on the refueling vehicle.

When testing equipment other than hose, the standard practice is to perform hydrotests at 1.5 times the design or working pressure.

Note: If failure occurs during this test, fuel may be released. Be sure to have the site of the test in a secure area so that the spill will be contained and no fire hazard exists. Wear the proper personal protection such as eye protection.

  1. Extend the hose to its full length.
  2. Be sure that:
    • No air is present in the hose
    • The hose and couplings are fully inspected for flaws
    • The hose reel is rated for 300 psi proof pressure and there is a 300 psi rated isolation valve upstream
    • The overwing nozzle has been removed and a pipe cap with vent valve has been installed
    • The underwing nozzle can handle 300 psi (some brands cannot), and that it is connected to a fueling adapter with a 300 psi rated stop valve downstream. Open the nozzle valve before pressurizing the hose.
    • Any hose reel and/or nozzle that does not meet the 300 psi rating has been removed before testing. Install a pipe cap with a vent valve on the hose end.
    • The hose is marked all the way around at the edge of the ferrule/fitting with a light coat of paint or by any other means so that you will be able to clearly see if the hose begins to slip out of the ferrule when the hose is pressurized.
      Vent valves are used to released all air before pressurizing the hose.
  3. Close the hose reel inlet valve.
  4. Connect the supplied hose “A” to the quick disconnect “B” on the hose tester and then to the nozzle, or any other point. Underwing nozzles have a plug in the side which can be used for this purpose. Once again, be sure no air is present in the hose, nozzle, or associated pipe.
  5. Open valve “C” and step lightly on hose “A” to displace any air in it. Close valve “C.”
  6. Pump the pressure up to 300 psi in accordance with API-1529 Appendix D for Grade 2 hose, observing for leaks, bubbles, cuts, or blisters. Roll the hose to observe the entire surface. If defects that penetrate the cover material to the reinforcing cord are observed, stop the test; it is a failure. Depressurize immediately as instructed in Step 8 below.
  7. Look at the paint mark on the hose at the ferrule. If there is more than 1/32″ (0.8mm) gap after the test pressure has been released, the test is a failure; depressurize after the test.
  8. When the test has been completed, open valve “C” to bleed off pressure by returning the pumped fuel to the hose tested reservoir. Disconnect the test equipment.

Bulletin 79: Aircraft Refueling Hose Tester2024-10-08T18:11:28+00:00

Bulletin 78: Sensing Hose, Deadman Hose, & Accessories

Dual Air – Fuel Sensing Hose

both hoses have 3/8″ nitrile tubes for fuel resistance

For hydrant pit valve connection to the cart or servicer. The orange hose is for air pressure reference; the black hose if for fuel pressure sensing. Both hoses are braid reinforced and are formed together in a continuous bond. Both hoses have 3/8” inside diameter nitrile (Buna N) tubes for fuel resistance, and outer covers of neoprene. They are manufactured exclusively for Gammon Technical Products to our specifications. We are confident that this is the most durable and reliable dual sensing hose available.

Available in cut lengths or reels, with or without fittings.

Inside diameter: 3/8″
Operating pressure rating: 200 psi
Burst pressure rating: more than 800 psi

Deadman Hose

both hoses have neoprene construction, Buna-N tubes

Manufactured to Gammon Technical Products, Inc. specifications, this hose is superior to any available air Deadman hose on the market. It is suitable for all refueling operations.

The tubes are made out of Buna-N (nitrile rubber) to resist fuel from cross-leakage in the control system. The braided, reinforced tubes have neoprene covers to resist oils that contaminate ramp areas. A special additive is included to give the cover superior resistance to cracking.

Available in cut lengths or reels, with or without fittings.

Inside diameter 1/4 inch
Operating pressure rating 200psi
Burst pressure rating more than 800psi

NOTE: all standard 1/4” twin welding hose has neoprene tube, which will fail when fuel gets in the air system. This hose has Buna N nitrile rubber tubes.

Fittings and Connectors

Male Tube Connector

GTP-2421-4-2 1/4″ tube, 1/8″ NPT
GTP-2421-4-4 1/4″ tube, 1/4″ NPT
GTP-2421-4-6 1/4″ tube, 3/8″ NPT
GTP-2421-6-4 3/8″ tube, 1/4″ NPT
GTP-2421-6-6 3/8″ tube, 3/8″ NPT
GTP-2421-6-8 3/8″ tube, 1/2″ NPT

NOTE: A 4-4 swivel version is also available as GTP-5862.

Female Tube Connector

GTP-2422-4-4 1/4″ tube, 1/4″ NPT
GTP-2422-4-6 1/4″ tube, 3/8″ NPT

Rotatable Female Tube Connector

Nut will rotate to allow tightening but will not swivel when tightened.
Includes ball seat to male NPT nipple.

GTP-2423-4-4 1/4″ tube, 1/4″ NPT
GTP-2423-4-6 1/4″ tube, 3/8″ NPT
GTP-2423-6-4 3/8″ tube, 1/4″ NPT
GTP-2423-6-6 3/8″ tube, 3/8″ NPT

Ferrules

GTP-2424
for hoses with O.D. of 17/32″

GTP-2425
for hoses with O.D. of 23/32″

GTP-2426
ferrule crimping tool

Stop Ball

Molded of durable plastic in two halves to form a sphere. The material is brilliant orange polyethylene. Holes for single or dual hose are custom drilled to fit. The outer diameter is 3”.

Bulletin 78: Sensing Hose, Deadman Hose, & Accessories2024-10-08T18:11:18+00:00

Bulletin 74: Decals

We offer a wide range of fuel system handling decals. These decals are all printed on top quality 3M® decal stock for long life and ease of use. Cheap decals fade and peel, but these decals will last for many years when properly applied.

All of our decals are prepared using a system that was developed by the 3M Company. It is called ScotchCal™ and is generally considered the highest quality, most technically advanced system available.

The film used to make these decals is white vinyl and is 0.003” (0.076mm) thick. The backing paper is stiff enough to prevent warping so that the decal will maintain its shape during handling and shipping. The pressure sensitive adhesive is permanent and vandal resistant.

The vinyl inks are resistant to deterioration by sunlight. To provide maximum durability, a clear coating is also applied after the printing process.

When applying these decals, care should be taken to ensure that air bubbles are not trapped. To prevent this from happening, we suggest that the decal be laid on progressively from one end to the other. For best results, apply when the temperature is above 60°F (15°C). Never attempt to apply the entire decal directly; start at one end. If air bubbles are trapped, a stiff plastic object such as a spatula can be used to work the bubbles toward an edge.

The surface on which the decal is to be applied must be clean and dry as well as free of wax, oil, and fuel.

Durability 5 years from application
Shelf Life 2 years at 100°F (38°C) – not in sunlight
Humidity Resistance No effect from 95% relative humidity at 100°F (38°C) for 500 hours
Salt Spray Test No effect from 20% concentration at 95°F (35°C) for 200 hours
Jet Fuel Resistance No effect after 24 hours at 73°F (23°C)
Water Resistance No effect after 24 hours at 73°F (23°C)

Identification Decals

These decals are large and provide clear marking for refueling vehicles, fuel farms, and tanks. They are color coded for all fuels.

GTP-2135-5
JET A
5 x 16″

GTP-2135-7
JET A-1
5 x 16″

GTP-2135-2
AVGAS 80
4 x 16″

GTP-2135-18
AVGAS 100LL
5 x 16″

GTP-2135-22
Diesel
5 x 16″

GTP-2135-21
Mogas
5 x 16″

Pipe Label Decals

Example of pipe labeling. Shown with GTP-3588-2 and GTP-3255-A1-N.

Pipe Band Kits are made to provide colored bands for marking pipes to API-1542. These kits use 4” wide solid color bands long enough to mark pipes up in 6” in diameter. Forget the paintbrushes, these bands are neat, affordable, and easy!

GTP-3588-1
JET A pipe band kit
one black band

GTP-3588-2
JET A1 pipe band kit
two black bands

GTP-3588-4
AVGAS 100LL pipe band kit
one blue band

GTP-3588-5
AVGAS 80 pipe band kit
one red band

PIPE IDENTIFICATION AND FLOW DIRECTION DECAL SETS allow for easy marking. They are color coded for all fuels, and are 5×16”. In this set, the identification decal (shown above) comes with arrow decals that can be cut apart with scissors and placed to indicate the direction of flow.

GTP-3255-A
Flow and ID decals for Jet A fuel

GTP-3255-A1
Flow and ID decals for Jet A-1 fuel

GTP-3255-LL
Flow and ID decals for Avgas 100LL

GTP-2135-106
extra flow direction decals

NARROW PIPE DECALS are the same as the pipe decals above, but they are 2×15” and come with the flow arrows attached. Simply use scissors to cut off one of the arrows and turn it to indicate flow direction.

GTP-3255-A-N
Narrow flow and ID decals for Jet A fuel

GTP-3255-A1-N
Narrow flow and ID decals for Jet A-1 fuel

GTP-3255-LL-N
Narrow flow and ID decals for Avgas 100LL

GTP-2135-27
Narrow flow and ID decals for JP-8

NOZZLE BAND DECALS are used on overwing nozzles to positively identify the fuel type. These band decals are made to the industry standard and measure 7/8” x 10”

GTP-3097
Jet fuel – white letters on black

GTP-3098
Avgas 100LL – white letters on blue with red edges

GTP-3099
Avgas 80 – white letters on red

DOT-style Markers for Class 3 Flammable Liquids

GTP-2135-8
1203 marker
for gasoline and kerosene
11 x 11″

GTP-2135-12
1993 marker
for fuel oil and diesel
11 x 11″

GTP-2135-13
1863 marker
for jet fuel only
11 x 11″

Emergency Decals

EMERGENCY STOP and EMERGENCY FUEL SHUTOFF decals are intended to be used in accordance with the NFPA 407 specification for fixed and vehicle emergency stop controls. The specification calls out 2” high letters and the words “push,” “pull,” or an arrow to indicate operation of the emergency stop switch. As you can see, we have included these instructions on two separate decals. Choose the style you prefer.

GTP-834-29
emergency stop decal
6 x 20″

GTP-834-32
emergency fuel shutoff decal
8.5 x 20″

The Label Decal

This decal has over 50 labels which can be cut with a pair of scissors and used as necessary. The advantage is fourfold: low cost per label, easy installation, long life and durability, and easy replacement when necessary. Even if you only use a quarter of the sheet, you come out ahead. Labels can be cut out and used differently than shown. For example, the “SUMP DAILY” decal can be cut in half and combined with the “BEFORE FUELING” decal to read “SUMP BEFORE FUELING.”

GTP-834-28
label decal
6 x 22″

Date Decals

GTP-2135-19
filters changed
4.25 x 11.5″

GTP-2135-20
water slug tested
4.25 x 11.5″

GTP-2135-24
numbers sheet for date decals
10.75 x 5.5″

Miscellaneous Decals

GTP-2135-FS5
FSII/DiEGME ONLY
3.5 x 6″

GTP-2135-26
Nozzle pressure 50 PSI max
2 x 4″

GTP-8262
Sump daily
3.75 x 2.5″

GTP-2135-15
in-cab brake override
2.5 x 15.5″

GTP-2135-23
fire extinguisher
1.5 x 13.5″

GTP-2135-10
Flammable
6 x 24″

GTP-2135-1
No smoking (large)
6 x 26″

GTP-2135-14
No smoking (small)
1.5 x 6.5″

Bulletin 74: Decals2024-10-08T18:11:09+00:00

Bulletin 73: Matched-Weight and Color Rating Membranes

Color Rating Membranes and Matched-Weight Membranes

Approved for testing jet fuel per ASTM Methods D2276/IP216 and D5452

Our 37mm, 0.8μm (micrometer) membranes are produced in exact accordance with ASTM Research Report D1012, under which they have been granted approval for use in methods D2276/IP216 as well as Ip216. We manufacture our own plastic monitors using clear Tenite. Our monitors are made to fit all recognized brands of holders including the Gammon MiniMonitor® Kit and the Millipore® Corp. XX64-037-30.

Refill membranes are packaged with a blue paper separator between each one to aid in separation.

Matched-weight refill membranes are packaged with each pair in a glassine envelope. Each pair is matched in weight within 100μg (micrograms) in a closely controlled atmosphere.

Support pads are 34mm in diameter so as to fit into the recess of the plastic monitor beneath the membrane.

Matched-weight monitors have yellow plastic plugs in the inlet port and a red plug in the outlet. Single membrane monitors, used for color rating tests, have blue plugs in the inlet and red plugs in the outlet.

Type Model No. Interchangeable with Millipore P/N Description (all membranes 0.8 micron)
Single membrane monitors GTP-1985 MAWP-037-PO 48 plastic monitors, each with a membrane and support pad
Matched-weight monitors GTP-1986 MAWP-037-PM 48 plastic monitors, each with a pair of membranes and a support pad
Empty monitors GTP-1987 none 48 empty plastic monitors
Single membrane refills GTP-1983 AAWP-037-PO 100 membranes and 100 support pads
Matched-weight refills GTP-1984 AAWP-037-PM 50 matched-weight pairs of membranes and 50 support pads

GTP-1985
single membrane monitors

GTP-1986
matched-weight monitors

GTP-1987
empty monitors

GTP-1983
single membrane refills

GTP-1984
matched-weight refills

Accessories

Membrane Filing Notebook and Pages

Black 3-ring leatherette notebook holds membrane filling pages. Pages made of heavy-duty plastic, each with space to hold 15 mini-envelopes. Filing pages come in a packet of ten (10) sheets, which is the minimum order.

GTP-1400
notebook

GTP-1331
filing pages

Mini-Envelopes

These mini-envelopes are zip-lock clear polyfilm bags made to ensure protection and preservation of filter membranes. They feature a specially prepared white panel for writing data regarding the test such as date, rating, location, etc. Mini-envelopes come in a package of five hundred.

GTP-1267
mini-envelopes

Tweezers

Our tweezers have blunt points and a slip-lock device. They grip and hold membranes without needing to be held tight in your hand.

GTP-2099
tweezers

47mm Membranes

We have these filter membranes in stock. They are intended for testing jet fuel for particulate content in accordance with ASTM Method D5452. The membranes are white and will fit all brands and models of filter holders that accept 47mm membranes.

TL-3777
0.65μm membranes

TL-3777-1
0.8μm membranes

Bulletin 73: Matched-Weight and Color Rating Membranes2024-10-08T18:10:58+00:00

Bulletin 71: Miscellaneous Supplies

McCabe Water Finding Paste

To find the level of water in a tank, wipe a thin film of paste on a gauging stick and lower it to the bottom of the tank. When you remove the stick, the green paste will change color where it is contacted by water. The water level will show in red. Packaged in 3.75oz (106g) jars.

GTP-982-1
single jar of paste

GTP-982-12
12 jars of paste

GTP-982-144
144jars of paste

Kolor Kut Water Finding Paste

Changes from golden brown to red. 3oz tube.

Modified Water Finding Paste (MIL-W83779)

For fuel with anti-icing additive. Changes from dark brown to red. 2.5oz tube.

Kolor Kut Fuel Indicating Paste

Fuel Indicating Paste shows fuel level in a tank. Wipe a thin film of paste on a gauging stick and lower it to the bottom of the tank. When you remove the stick, the lavender-colored paste will change color where it is contacted by fuel. The fuel level will show as red. Packaged in 2.25oz (62g) jars.

Syringes for Shell Water Detector Test

We offer two sizes of high-quality syringes for performing Shell water detector testing. 5mL or 10mL.

Safety Wire

Quality stainless steel safety wire. Annealed (softened) for easy use. Dispenses neatly from top of 1 lb. box.

Safety wire
.025″ or .032″

GTP-1924-2
automatic safety wire twisting tool

Dummy Monitor Elements
GTP-8697

When reducing the number of elements, a “dummy” or non-functional element can be used to fill unnecessary element mounts. Our “dummy” elements are carefully machined from high grade aluminum and designed to replace any brand of 2” outside diameter element in any vessel. The seal is a Viton o-ring. Includes an adjustable center “rest” to allow easy installation in vessels with element aligning guides. Needs no additional hardware, works with cover interlocks. Available in standard 10″, 20″, or 30″ sizes, or custom order.

Special Lubricants

Aviation-grade Swivel and Seal Lube
GTP-9188

Gammon Technical has packed this industry-accepted, FDA food-grade (CFR 172.880) petrolatum in handy 14.5 oz tubes, designed to fit standard grease guns, but can also be used on the bench.

StaticLube
TL-9653

StaticLube is a lubricant specifically designed to conduct electricity. It is made with a high-quality synthetic lubricant and filled with super-fine silver for electrical conductivity. It is not silicone based. It is highly thermally conductive to help protect bearings. It blocks corrosion and protects bearing surfaces from water.

StaticLube can also be used on electrical connections and is especially helpful when bonding a static reel to steel framework-creating a long-lasting electrical bond virtually immune to corrosion and weather.

StaticLube comes in 1cc syringes, which will lubricate up to three static reels. Made in the USA.

Bulletin 71: Miscellaneous Supplies2024-10-08T18:10:48+00:00

Bulletin 70: Air System Accessories

Tamper-Proof Air Pressure Regulator
GTP-1121

With the “key” removed from the knob, it is impossible to tamper with the air pressure adjustment. This unique feature makes this regulator superbly suited for use on airport refuelers for adjusting air reference pressures. An internal relief valve makes it self-relieving to prevent “creep” of the outlet pressure. Will control pressure with great accuracy between 10 and 200 psi. Price includes side-mounting hardware. Shown here with panel mount and optional key.

  • Connections are 1/2” FNPT
  • Maximum inlet pressure is 300 psig
  • Outlet pressure adjustable to 125 psig
  • Zinc body
  • Nitrile seals
  • Panel or side mount
  • Aluminum or plastic knob

GTP-1121
tamper-proof air pressure regulator

GTP-1121-1
key for air pressure regulator

GTP-2954C
pressure gauge, 0-160psi

Air Filter with Automatic Water Drain
GTP-1923

Designed to remove dirt and water from truck air systems, this filter will automatically drain collected water. The polyethylene filter element is rated at 5 microns. Steel shatter guard and manual drain cock included.

  • Connections are 1/4” FNPT
  • Maximum inlet pressure is 150 psi
  • Minimum inlet pressure is 15 psi
  • Polycarbonate plastic bowl
  • Internal automatic drain

Bulletin 70: Air System Accessories2024-10-08T18:10:39+00:00

Bulletin 67: Deadman and Water Control

Mini-Deadman™

The heart of any deadman is the switch. The switch in this deadman has a built-in rolling diaphragm seal, aluminum body (not glass, rubber, or plastic), and an 8 amp contact rating. It is hermetically sealed, yet is easily replaceable, incorporating “push on” type electrical connections, eliminating troubles with wire nuts or soldering. In addition, the housing is o-ring sealed and has an anodized aluminum switch carrier and cable base fitting. The strain relief is a spiral type with a watertight seal.

  • Made in USA
  • Material: urethane
  • Dimensions: 4” x 1¾”
  • Weight: 6 oz.
  • Durable
  • Compact
  • Inexpensive
  • Easy to repair
  • Wear resistant
  • Stainless steel trigger
  • Good from -55° to 180°F
  • Low operating force required
  • Easy to assemble/disassemble
  • Can be hung on trigger for storage
  • Designed for the aviation environment
  • Compatible with any deadman system
  • Body screws are recessed to prevent damage

NOTE: These handles are not suitable for AC applications unless and intrinsically safe barrier/relay is used.

Mini Deadman Handle
electric, pneumatic, or hydraulic

Mini Deadman Handle with Cord
straight (up to 500 ft.) or coiled (25 or 50 ft.)

GTP-8393-1
Mini Deadman trigger assembly

GTP-8394
Mini Deadman shoulder screw

GTP-8397
Mini Deadman housing

Dura-Deadman
GTP-9720

Solid, super durable, cold molded, and virtually unbreakable, this handle is made of pure polyurethane. This new Dura-Deadman handle is the strongest and most reliable deadman we offer. It was tested for over half a million cycles, we’ve driven over it with trucks, and it’s been dragged on pavement – all without failure. It features replaceable polyurethane drag bosses for even longer life. Made in USA.

Electric

These handles are weather-tight sealed. They are not suitable for AC applications unless an intrinsically safe barrier/relay is used.

Switch data: Normally open switches are standard. Add “-NC” to the part number for normally closed.

Pneumatic/Hydraulic

These handles each contain two valves to provide fast reaction time. Seals are Buna/Nitrile.

Gammon One-CC Water Probe

Meets EI-1596

Detects water in filter separator sumps

Allows periodic testing requiring only 1cc of water, even during refueling

Thousands in service worldwide

The problem with water detector probes has always been that others are impossible to test periodically without stopping flow, dismantling, or injecting water into the vessel. People are afraid that too much water may be injected. The One-CC Probe solves this simply. First, it has a patented design that only needs 1 ml (1cc) of water for a complete test. Second, it has a built-in water pump, and this pump is only capable of injecting 1 ml (1 cc) of water.

The One-CC™ Water Detector Probe is designed for use in any intrinsically safe electronic control system sensitive enough to detect water by conductivity/resistance. This new probe can therefore replace existing probes in Meggitt/Whittaker equipment if they utilize our replacement controls.

We offer electronic controls in DC, AC, weather tight and explosion proof versions.

Basic Water Probe
GTP-9734

lower price – includes circuit tester

For those who prefer a smaller and less expensive water probe. All-stainless construction. Push button circuit tester. Can be fitted to a simple valved drain line assembly which allows for true water testing to EI1596. 3/4” NPT or BSPT connections.

Deadman Hose
GTP-1202

both hoses have neoprene construction, Buna-N tubes

Manufactured to Gammon Technical Products, Inc. specifications, this hose is superior to any available air Deadman hose on the market. It is suitable for all refueling operations.

The tubes are made out of Buna-N (nitrile rubber) to resist fuel from cross-leakage in the control system. The braided, reinforced tubes have neoprene covers to resist oils that contaminate ramp areas. A special additive is included to give the cover superior resistance to cracking.

Available in cut lengths or reels, with or without fittings.

Inside diameter 1/4 inch
Operating pressure rating 200psi
Burst pressure rating more than 800psi

NOTE: all standard 1/4” twin welding hose has neoprene tube, which will fail when fuel gets in the air system. This hose has Buna N nitrile rubber tubes.

Deadman and Water Control Systems

GTP-1750
combination deadman and intrinsically safe water control system

GTP-1750-5
water control system

GTP-1750-1
deadman system 120VAC with Dura-Deadman handle

For full range of options, please contact Gammon Technical Products or your distributor to place a custom order.

Bulletin 67: Deadman and Water Control2024-10-08T18:10:27+00:00

Bulletin 65: Meter Monitor

Closed Circuit Testing with the Meter Monitor

No need for a measuring bucket. No need to dispose of fuel.

When performing filter membrane tests, the difficult part of the task is disposing of the test fuel. The Meter Monitor solves that problem completely. The flush and the test fuel are both returned to the fuel system and are never exposed to air, rain, or other contaminant sources. No buckets, funnels, or fuel spills. The Meter Monitor has two 1/8” NPT connections (connections are 1/4” NPT, inlet and outlet; we install bushings to 1/8” NPT).

Available with gallon or liter calibration.

NOTE: The standard model is made for petroleum service (jet fuel). An optional version for metering anti-icing additive (diEGME) is also available with specially-designed seals.

Testing Procedure

NOTE: The return line may also be connected anywhere that the pressure is reasonably less than the sampling pressure – to the storage tank, the truck tank, even a venturi throat. For operating at pressures over 125 psi, contact the factory or your distributor.

  1. Install a return connector at the inlet of the system pump (GTP-992-4MS).
  2. Using a MiniMonitor® housing that you may already own, insert a plastic monitor (see Bulletin 8).
  3. Install the Meter Monitor between the MiniMonitor® assembly and grounding hose (GTP-1110) which comes with the MiniMonitor® kit.
  4. Turn the MiniMonitor® valve to the stop position.
  5. Start flow in fuel system and read the meter position, for example 000089.23
  6. Connect the MiniMonitor® inlet to the sampling connector and connect the outlet of the hose to the return connector.
  • NOTE: The six numerals to the left of the decimal point read whole gallons. The right hand window reads tenths (0.1) of gallons. The dial reads hundredths (0.01) and can be estimated to 0.002. This is a non-reset type meter.
  1. Turn the MiniMonitor® valve to the flush position. If you plan to flush one gallon, stop the flushing after one gallon. In this example, stop at a reading of 000090.23.
  2. Turn the MiniMonitor® valve to the test position. Then turn the valve off when the correct number of test gallons has passed. Disconnect the return connection, then the sample connection.

No muss.

No fuss.

No mess.

The test is finished.

How to Order

GTP-1850
Meter monitor,
US gallon calibration

GTP-1850A-1
Meter monitor,
US gallon calibration with special seals for FSII, DiEGME, etc.

GTP-1850A-3
Meter monitor,
Metric (liter) calibration

GTP-1850A-4
Meter monitor,
Metric (liter) calibration with special seals for FSII, DiEGME, etc.

Bulletin 65: Meter Monitor2024-10-08T18:09:59+00:00

Bulletin 63: Water Sump Float Tester

Water Sump Float Testers

for testing the emergency shut-down system on aircraft refueling systems

GTP-1787

Water Sump Float Tester, Basic Model

A controlled volume of water is slowly pumped by hand into the filter separator sump. If the emergency shut-down system is operating correctly, fuel flow will stop automatically when the level of water in the sump reaches the sensors. This test is performed while the fuel system is operating.

When the test has been completed, and while there is still pressure in the fuel system, the operator opens a drain valve that directs the liquid from the filter separator sump to the bucket (Model GTP-1787) or to the transparent measuring container (Model GTP-1799). Any fuel that is drained will float on the water. The operator can then confirm that all of the water that was injected into the sump has been removed.

Model GTP-1799

Tester with 2-wheeled Cart

A transparent measuring container at the top has an adjustable level indicator so that the operator can see that all of the water that was pumped into the filter separator sump has been recovered. The water filling port is at the top – see the chained plug. An overflow pipe carries excess fuel to a 5-gallon slop collector on the lower platform. See the drain valve for emptying slop collector.

Constructed with materials that will not rust or corrode in water, this specially-designed apparatus can be stored for long periods with clean water inside without danger of malfunction. Stainless steel and brass are the primary materials. The hoses are pressure rated for 250 psi, five times higher than is expected in a fueling system. Buna-N is used in the hose tube while Hypalon® is the cover material.

General Discussion

Testing of water sump controls has been a controversial subject for many years (refer to GamGram Number 1). Some operators are afraid to pump water into the sump to test the system because they fear “human failure,” resulting in water getting into an aircraft. However, if these systems do not perform correctly, the filter separator cannot do its job of preventing water from getting into the aircraft. In a typical 600 gpm filter separator, the separator elements will be underwater if 5 gallons are collected – any additional water goes into the aircraft.

Some operators rely on the procedure of checking the sump drain for the presence of water after each refueling operation. This is surely a good practice but it is subject to “human error.” Other operators use float testers to check the operation of the control circuit. This good practice checks everything except the float. Periodically, the float must be tested to ensure that it will float on a fuel/water interface.

From the above comments, the conclusion is that periodic injection of water to test the entire system offers the greatest reliability.

Testing Procedure

  1. Place a measured volume of clean water in a bucket or graduated container. Mark the level of water on the container. See note under Step 4, below.
  2. Attach the swivel coupler to the water drain outlet of the filter separator.
  3. Start fuel flow through the system. A refueller truck can be recirculated. A hydrant cart must dispense to tankage.
  4. When normal flow rate and pressure have been established. open the water drain valve and pump water into the filter separator sump.‌
  • NOTE: The volume of water required to activate the float or sensor in the filter separator depends on the design of the sump. The volume must be determined by a test for each piece of equipment. To insure against contaminating the flow system, the operator must not inject more than this amount of water.‌
  • If the emergency shut-down system operates properly, fuel flow will stop automatically. If it does not stop fuel flow, the system must be repaired before the aircraft can be refueled.‌
  1. To remove water from the sump after the test, open the small toggle valve with the return hose in the water container. Allow some fuel to flow into the container to be sure that all of the injected water has been returned. Close the toggle valve. When the water has settled to the bottom of the container, the water level should be at the original mark as created in Step 1.
  2. Close the water drain valve and remove the swivel coupling.

Bulletin 63: Water Sump Float Tester2024-10-08T18:09:48+00:00

Bulletin 62: Heaters for Sumps and Drains

Heaters for Filter Separators

Rated “Explosion Proof” – NEMA 7 Class 1, Groups B/C/D, Division 1

Features:

  • Stainless steel sheathing will not rust

  • Adjustable thermostats 40-120°F

  • 240 volts, 50/60 Hz, single phase (most are also available in 120 VAC)

  • Watt density: 20 watts/in²

  • 150 psi working pressure
  • Conduit connections 1″ NPT
  • Designed for use on gasoline, kerosene, jet fuel, diesel or No. 2 fuel oil

  • Made in USA
Watt Rating Probe Length (in.) Thread NPT (in.) Model No. (standard) Model No. (with light)
300 6.0 1 ¼ GTP-1756 GTP-1756L
750 7.0 1 ¼ GTP-1757 GTP-1757L
1000 9.7 1 ¼ GTP-1758 GTP-1758L
1500 12.5 1 ¼ GTP-1759 GTP-1759L
300 12.5 1 GTP-1760 GTP-1760L
750 18.5 1 GTP-1761 GTP-1761L
1000 24.7 1 GTP-1762 GTP-1762L
1500 38.5 1 GTP-1763 GTP-1763L

Shown below is the typical pipe and fitting arrangement for a 300 watt heater installation in a drain system. The nipple at the upper left screws into the sump drain valve at the bottom. The optional indicator light is in the foreground. The electrical conduit enters on the opposite side of heater.

General Discussion

Our heaters are made specially for us by a highly qualified manufacturer with many years of experience. The purpose of a heater in a filter separator is to prevent the formation of ice in the water drain system. This makes it possible to drain water that has collected. Attempts have been made in the past to heat the entire filter separator by applying insulation but this has been found to be impractical because there are too many ways that heat can be lost. Furthermore, when insulation has been soaked in rain water, which is nearly impossible to prevent, heat loss is increased and severe corrosion develops.

The usual approach is to have one heater for the sump and a second one for the drain piping. The sump heater should be carefully located so that it is as close as possible to the surface on which water collects. However, it should also cross over the drain port and under the float if a float operated pilot valve is used. If the vessel is exceptionally large, a second sump heater may be installed in the drain piping only.

Most of the heaters covered in this bulletin are used as replacements for heaters that have failed. If you intend to install a heater in a filter separator that was not designed with a proper fitting, be advised that the welding must be done by an ASME qualified shop if the vessel was originally built to Section VII of the ASME code.

The most common failure of a heater is rusting of the steel sheaths. The frequent result of such a failure is that fuel will leak into the electrical housing and it sometimes will fill up the electrical conduit that carries power to the heater. When replacing a heater under such circumstances, we recommend that the conduit be thoroughly dried and new wires installed. The reason for this is that ignition could occur from the arcing of the thermostat. Although a fire in the conduit is “safe,” shorting could occur because of burned insulation.

Notes

  • 1

    When installing one of our heaters, the thermostat must be adjusted. Remove the cover and note a black dial knob that is calibrated from 40-120°F. Turn this knob until the preferred temperature is set next to the indicating button.

  • 2

    There are two screws that hold the thermostat. The set point marker is the screw that 60°F can be turned to.

  • 3

    You can easily check the thermostat for accuracy at any time if you know the temperature of the contents of the filter. Turn off the power first. Then turn the knob slowly from a higher setting. You will note an audible “click” when you read the temperature that causes the thermostat to engage the circuit. If you now turn the knob in the other direction, there will be another “click” when the thermostat disengages. The temperature spread is about 5°F.

Bulletin 62: Heaters for Sumps and Drains2024-10-08T18:09:38+00:00
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