Specification for Couplings, Branch Pipe, and Nozzle Used in Hose Reel Tubing for Fire Fighting

IS 8090: Scope & Key Specifications

• Scope: Covers specifications for leaded tin bronze, high tensile brass, naval brass, aluminium alloy ingots, and castings for engineering uses.

• Workmanship:

  • Forgings and castings must be free from porosity, blow-holes, scales, cracks, or other defects.
  • No repairs or fillings that hide defects allowed.
  • Burrs and sharp edges must be removed.
  • Waterways in fittings must have a smooth finish.
  • Fittings should be rounded for safe handling.
  • Aluminium surfaces may require anodizing; threaded aluminium parts coated with molybdenum grease.

• Dimensional Compliance:

  • Nozzles must conform to dimensions as per Fig. 3 (refer IS 8090 for exact dimensions).

• Construction:

  • Detailed in Clauses 6.2 and 7.2, emphasizing material quality and finish.

Summary Table of Key Points

flowchart LR
    A[Raw Material] --> B[Forging/Casting]
    B --> C[Inspection: Defect Check]
    C -->|Pass| D[Surface Finishing]
    D --> E[Dimensional Check (Fig.3)]
    E -->|Conform| F[Final Product]
    C -->|Fail| G[Reject/Remake]

For detailed dimensions and tolerances, refer to Fig. 3 and relevant clauses in IS 8090.

IS 8090: Key Materials Specifications & Standards

1. Material Selection (Clause 2.1.1 & 2.1.2):

• Avoid electrolytic corrosion, especially for aluminium alloys adjacent to dissimilar metals.
• Materials must resist corrosion in all water types (sea, brackish, fresh).

2. Copper Alloys for Castings and Forgings (Clause 2.1.1):

3. Aluminium Alloys for Castings (Clause 2.1.2):

• Must conform to IS: 617-1975 Designations:
  • 4450 (A-8-WP)
  • 4225 (A-16-WP)

4. Workmanship & Finish (Clause 4.1):

• Forgings and castings must be free from porosity, cracks, blowholes.
• No hidden repairs allowed.
• Burrs/sharp edges removed; smooth waterway finish.
• Aluminium surfaces anodized if specified.
• Aluminium alloy threads coated with molybdenum grease.

Rounding Off (Clause 0.4)

• Follow IS: 2-1960 rules for rounding test/analysis results to the same significant figures as specified values.

This ensures durability, corrosion resistance, and mechanical integrity of fittings in water systems.

flowchart TD
    A[Material Selection] --> B{Avoid Electrolytic Corrosion}
    B --> C[Select Compatible Copper/Aluminium Alloys]
    C --> D[Conform to Relevant IS Grades]
    D --> E[Ensure Workmanship & Finish]
    E --> F[Apply Anodizing & Grease Coatings]

IS 8090: Dimensions and Construction Key Points

• Clause 5.1 & Fig. 1: Defines the shape and dimensions of the hermaphrodite type hose reel coupling. All dimensions are in millimeters. This ensures compatibility and standardization.

• Clause 6.1 & Fig. 2: Specifies the shape and dimensions of the branch (pipe branch connection), critical for proper fitting and flow characteristics.

• Clause 6.2 & 7.2: Detail construction requirements emphasizing:

  • Material quality
  • Machining tolerances
  • Threading and sealing surfaces
  • Assembly methods to ensure leak-proof joints and mechanical strength

Typical Dimensions (Example from Fig. 1 & Fig. 2)

Construction Specifications

• Use mild steel or brass as per application.
• Threads must conform to IS 554 / IS 4218.
• Surfaces must be free from burrs and defects.
• Couplings should be tested for leakage and mechanical strength.

flowchart LR
    A[Hose Reel Coupling] --> B[Shape & Dimensions (Fig.1)]
    A --> C[Material & Construction (Clause 6.2)]
    D[Branch] --> E[Shape & Dimensions (Fig.2)]
    D --> F[Material & Construction (Clause 7.2)]

For precise dimensions, refer to Fig. 1 and Fig. 2 in IS 8090.

IS 8090 Thread Specifications Summary

• Thread Standard: Branch pipe outlet threads shall conform to IS 554:1975 (Dimensions for pipe threads where pressure-tight joints are required).

• Material & Finish:

  • Forgings/castings must be free of defects (porosity, cracks).
  • Smooth waterway finish; burrs/sharp edges removed.
  • Aluminium alloy threads coated with molybdenum grease.

• Hydraulic Test: Branch pipe tested at 21 kg/cm² for 2 minutes after machining, no leakage allowed.

Key Thread Dimensions (per IS 554:1975)

Note: Refer IS 554 for complete table and tolerances.

Thread Quality & Tolerances

• Machined dimensions tolerance per IS 2102:1969.
• Threads must ensure pressure-tight joints without leakage.

flowchart TD
    A[Branch Pipe Outlet] --> B[Thread as per IS 554:1975]
    B --> C[External Thread Dimensions]
    B --> D[Internal Thread Dimensions]
    A --> E[Hydraulic Test @ 21 kg/cm²]
    E --> F[No Leakage Allowed]
    A --> G[Surface Finish & Coating]
    G --> H[Remove Burrs]
    G --> I[Molybdenum Grease on Aluminium Threads]

For detailed thread profiles and tolerances, consult IS 554:1975 directly.

IS 8090: Washers for Fire Fighting Couplings

Key Specifications (Clauses 5.2 & 6.2.3)

• Washer Type: Must conform to Type A of IS 937:1965 (Specification for washers for water fittings for fire fighting).
• Material: Washers used in branch pipes must follow the material standards specified in IS 937:1965.
• Purpose: Ensure leak-tight joints in couplings and branch pipe connections.

Important Notes

• Washers are critical for sealing in hose reel tubing branch pipe connections (Clause 6.2.1).
• Hydraulic test of branch pipe at 21 kg/cm² for 2 minutes (Clause 6.3) ensures no leakage, validating washer and joint integrity.

Typical Washer Dimensions (from IS 937:1965 Type A)

Summary

• Use Type A washers per IS 937 for all couplings and branch pipe connections.
• Verify washer material compliance.
• Perform hydraulic test at 21 kg/cm² to ensure sealing integrity.

flowchart LR
    A[Coupling Assembly] --> B[Washer (Type A, IS 937)]
    B --> C[Branch Pipe Connection]
    C --> D[Hydraulic Test @ 21 kg/cm²]
    D -->|No Leakage| E[Approved Assembly]
    D -->|Leakage| F[Rework/Replace Washer]

This ensures reliable sealing and leak-proof fire fighting water fittings.

IS 8090 - Branch Pipe Requirements Summary

1. Branch Pipe Dimensions & Shape

• Must conform to Fig. 2 (all dimensions in mm).
• Designed for use with hose reel tubing.
• Outlet end threaded to fit nozzle inlet (see Fig. 3).

2. Shut-off Mechanism (Clause 6.2.4)

• Quarter-turn operation for ON/OFF control.
• No leakage during discharge when shut off.
• User-friendly to operate as needed.

3. Hydraulic Test (Clause 6.3)

• Test pressure: 21 kg/cm² (2.06 MPa).
• Duration: 2 minutes.
• Test after all machining.
• No leakage or sweating allowed.

4. Thread & Washer Specifications

• Threads per IS standard for pressure-tight joints.
• Washers per revised fire fighting water fittings specification.

Quick Reference Table: Hydraulic Test

flowchart TD
    A[Branch Pipe] --> B[Inlet Connection (Fig. 2)]
    B --> C[Threaded Outlet for Nozzle (Fig. 3)]
    A --> D[Quarter Turn Shut-off Valve]
    A --> E[Hydraulic Test @ 21 kg/cm² for 2 min]
    E --> F{Leakage?}
    F -- No --> G[Pass]
    F -- Yes --> H[Fail]

This ensures branch pipes are reliable, leak-proof, and compatible with firefighting hose reels per IS 8090.

IS 8090: Nozzle Requirements Summary

1. Dimensions (Clause 7.1)

• Nozzles must conform to dimensions shown in Fig. 3 (refer IS 8090 Fig. 3 for exact sizes).
• Branch pipe inlet connection per Fig. 2 for hose reel tubing.
• Outlet end of branch pipe is screwed to fit nozzle inlet.

2. Surface Finish (Clause 7.2.3)

• Inner surface of nozzles must be smooth and highly polished.
• No machining ridges allowed to ensure flow efficiency.

3. Hydraulic Test (Clause 7.3)

• Test pressure: 21 kg/cm² (approx. 2.06 MPa).
• Duration: 2 minutes after all machining.
• No leakage or sweating allowed.

4. Additional Specifications

• Washers for water fittings must comply with revised specifications for firefighting use.
• All dimensions in millimeters.

Quick Reference Table

flowchart TD
    A[Branch Pipe Inlet] -->|Per Fig. 2| B[Branch Pipe Outlet]
    B -->|Screwed Connection| C[Nozzle Inlet]
    C --> D[Nozzle Body]
    D --> E[Nozzle Outlet]
    E --> F[Water Discharge]

This ensures compatibility and leak-proof assembly for firefighting water fittings.

IS 8090: Performance Tests Summary

Hydraulic Test (Clause 6.3)

• Test Pressure: 21 kg/cm² (approx. 2.06 MPa)
• Duration: 2 minutes
• Purpose: Detect porosity/leakage in branch pipe castings
• Condition: Test after all machining is complete
• Acceptance: No leakage or sweating allowed

General Testing (Clause 8.1)

• Every fitting must undergo tests as per the standard requirements (hydraulic, dimensional, material quality).

Material & Workmanship (Clause 4.1)

• Castings/forgings must be free from:
  • Porosity
  • Blow-holes
  • Scales
  • Cracks
• No hidden repairs allowed
• Smooth water-way finish
• Burrs/sharp edges removed
• Aluminium parts anodized (if ordered)
• Threaded aluminium parts coated with molybdenum grease

Key Specifications Reference

flowchart TD
    A[Branch Pipe Casting] --> B[Machining Completed]
    B --> C[Hydraulic Test @ 21 kg/cm² for 2 min]
    C --> D{Leakage or Sweating?}
    D -- No --> E[Pass Test]
    D -- Yes --> F[Reject or Recast]

This ensures integrity and leak-tightness of fire-fighting water fittings as per IS 8090.

IS 8090 - Marking Requirements (Clause 9.1 & 9.1.1)

Each fitting (couplings, nozzles, branch pipes) must be clearly and permanently marked with:

• Manufacturer's name or trade-mark
• Size of the fitting (for couplings and nozzles)
• Year of manufacture

Additionally, fittings may bear the ISI Certification Mark subject to licensing and compliance with ISI rules, assuring conformity to the standard.

Key Specifications Summary:

Related Standards:

• Machined Dimension Tolerances: As per IS 2102:1969
• Material for Couplings/Nozzles: Leaded Tin Bronze, Grade 2 per IS 318

Notes:

• ISI Mark ensures ongoing quality control and inspection.
• Marking must be durable to withstand service conditions.

flowchart TD
    A[Fitting] --> B[Mark with Manufacturer's Name]
    A --> C[Mark Size (if coupling/nozzle)]
    A --> D[Mark Year of Manufacture]
    A --> E[Optional: ISI Certification Mark]

IS 8090: Acceptance Criteria Summary

1. Hydraulic Test (Clause 7.3)

• Test Pressure: 21 kg/cm² (approx. 2.06 MPa)
• Duration: 2 minutes
• Purpose: Detect porosity in castings after all machining.
• Acceptance: No leakage or sweating allowed.

2. Material Selection (Clause 2.1.1)

• Avoid corrosion by electrolytic action, especially with aluminium alloys.
• Materials must resist corrosion in all water types (sea, brackish, fresh).

3. Workmanship & Finish (Clause 4.1)

• Castings/forgings must be free from:
  • Porosity, blow-holes, cracks, scales.
  • No hidden repairs or fillings.
• Burrs and sharp edges removed.
• Smooth waterways and rounded fittings.
• Aluminium surfaces anodized if specified.
• Aluminium alloy threaded parts coated with molybdenum grease.

4. Rounding Off (Clause 0.4)

• Follow IS:2-1960 for rounding test values.
• Maintain significant figures as per specified values.

Quick Reference Table: Hydraulic Test Acceptance

flowchart TD
  A[Machining Completed] --> B[Hydraulic Test @ 21 kg/cm² for 2 min]
  B --> C{Leakage or Sweating?}
  C -- No --> D[Accept Nozzle]
  C -- Yes --> E[Reject / Recast]

This ensures structural integrity and corrosion resistance as per IS 8090 requirements.