Specification for Couplings, Branch Pipe, and Nozzle Used in Hose Reel Tubing for Fire Fighting
1976 Edition

Overview of Scope and Essential Parameters

• Scope: Defines specifications for leaded tin bronze, high tensile brass, naval brass, aluminium alloy ingots, and castings applicable to engineering fire fighting accessories.

• Quality Standards:

  • Forgings and castings must be devoid of porosity, cracks, blow-holes, scales, or any other defects.
  • Repairs or fillings that conceal flaws are prohibited.
  • Burrs and sharp edges should be eliminated.
  • Internal waterways require a smooth finish.
  • Fittings should have rounded edges for safe handling.
  • Aluminium parts may be anodized; threaded aluminium components should be coated with molybdenum grease.

• Dimensional Compliance:

  • Nozzle sizes must adhere to the dimensions illustrated in Fig. 3 (refer to the standard for precise measurements).

• Construction Details:

  • Detailed in Clauses 6.2 and 7.2, focusing on material quality and finishing.

Key Highlights Table

flowchart LR
    RawMaterial[Raw Material] --> ForgingCasting[Forging/Casting]
    ForgingCasting --> Inspection[Inspection: Defect Check]
    Inspection -->|Pass| SurfaceFinishing[Surface Finishing]
    SurfaceFinishing --> DimCheck[Dimensional Check (Fig.3)]
    DimCheck -->|Conform| FinalProduct[Final Product]
    Inspection -->|Fail| Reject[Reject/Remake]

For exact dimensions and tolerances, consult Fig. 3 and related clauses of the standard.

Material Specifications Under IS 8090

1. Selection Guidelines (Clauses 2.1.1 & 2.1.2):

• Prevent electrolytic corrosion, particularly avoiding contact between aluminium alloys and dissimilar metals.
• Materials must offer corrosion resistance in all water types, including sea, brackish, and fresh water.

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

3. Aluminium Alloy Castings (Clause 2.1.2):

• Must comply with IS: 617-1975 designations:
  • 4450 (A-8-WP)
  • 4225 (A-16-WP)

4. Workmanship and Finishing (Clause 4.1):

• Forgings and castings should be free from porosity, cracks, and blowholes.
• No hidden repairs or fillings allowed.
• Burrs and sharp edges must be removed.
• Waterways should be finished smoothly.
• Aluminium surfaces anodized where specified.
• Threads on aluminium alloy parts coated with molybdenum-based grease.

Rounding Off Guidelines (Clause 0.4)

• Apply IS: 2-1960 rules for rounding off test and analysis results, maintaining significant figures as per specifications.

This ensures robust, corrosion-resistant, and mechanically sound fittings for firefighting water systems.

flowchart TD
    MaterialSelection[Material Selection] --> AvoidCorrosion{Avoid Electrolytic Corrosion}
    AvoidCorrosion --> SelectAlloys[Choose Compatible Copper/Aluminium Alloys]
    SelectAlloys --> ISCompliance[Meet Relevant IS Grades]
    ISCompliance --> QualityFinish[Ensure Proper Workmanship & Finish]
    QualityFinish --> SurfaceTreatment[Apply Anodizing & Grease Coatings]

Dimensional and Construction Requirements per IS 8090

• Clause 5.1 & Fig. 1: Specifies the geometry and measurements of the hermaphrodite hose reel coupling, all dimensions in millimeters to ensure standardization.

• Clause 6.1 & Fig. 2: Details the shape and size of the branch pipe, crucial for correct fitting and flow efficiency.

• Clauses 6.2 & 7.2: Outline construction criteria including:

  • Material selection
  • Machining tolerances
  • Threading and sealing surface finish
  • Assembly techniques to guarantee leak-proof and mechanically strong joints

Sample Dimensions (From Fig. 1 & Fig. 2)

Fabrication Guidelines

• Materials such as mild steel or brass are used based on application.
• Threads must conform to IS 554 and IS 4218 standards.
• Surfaces must be free from burrs and imperfections.
• Couplings should be tested for leaks and structural integrity.

flowchart LR
    HoseCoupling[Hose Reel Coupling] --> DimShape[Shape & Dimensions (Fig.1)]
    HoseCoupling --> MaterialConstruct[Material & Fabrication (Clause 6.2)]
    BranchPipe[Branch Pipe] --> BranchDimShape[Shape & Dimensions (Fig.2)]
    BranchPipe --> BranchMaterialConstruct[Material & Fabrication (Clause 7.2)]

Refer to Fig. 1 and Fig. 2 in the standard for exact measurements.

Threading Requirements According to IS 8090

• Thread Standard: Threads on branch pipe outlets must comply with IS 554:1975, which specifies dimensions for pipe threads designed for pressure-tight joints.

• Material and Finish:

  • Forgings and castings should be free from porosity, cracks, and other defects.
  • Internal waterways must be smooth; burrs and sharp edges removed.
  • Threads on aluminium alloy parts require coating with molybdenum disulphide grease.

• Hydraulic Testing: Branch pipes undergo a hydraulic pressure test at 21 kg/cm² for 2 minutes post-machining, with zero tolerance for leaks.

Representative Thread Dimensions (per IS 554:1975)

Refer to IS 554 for full thread dimension tables and tolerances.

Thread Quality and Tolerance

• Machining tolerances are as per IS 2102:1969.
• Threads must ensure a pressure-tight, leak-proof joint.

flowchart TD
    BranchOutlet[Branch Pipe Outlet] --> ThreadStandard[Threads per IS 554:1975]
    ThreadStandard --> ExternalDim[External Thread Dimensions]
    ThreadStandard --> InternalDim[Internal Thread Dimensions]
    BranchOutlet --> HydraulicTest[Hydraulic Test @ 21 kg/cm²]
    HydraulicTest --> NoLeak[No Leakage Allowed]
    BranchOutlet --> SurfaceFinish[Surface Finish & Coating]
    SurfaceFinish --> BurrRemoval[Remove Burrs]
    SurfaceFinish --> GreaseCoating[Molybdenum Grease on Aluminium Threads]

For detailed thread profiles, consult IS 554:1975.

Washer Requirements in Fire Fighting Hose Reel Fittings (IS 8090)

Specifications (Clauses 5.2 & 6.2.3)

• Washers must be of Type A as defined in IS 937:1965, which covers washers for water fittings in fire fighting applications.
• Materials used for washers in branch pipe assemblies must comply with IS 937:1965 standards.
• Washers play a critical role in ensuring leak-tightness of coupling and branch pipe connections.

Important Information

• Hydraulic pressure testing at 21 kg/cm² for 2 minutes confirms the sealing effectiveness of washers and joints.

Typical Washer Dimensions (IS 937:1965 Type A)

Summary

• Employ Type A washers per IS 937 for all coupling and branch pipe assemblies.
• Confirm material compliance.
• Conduct hydraulic pressure tests at 21 kg/cm² to verify leak-proof integrity.

flowchart LR
    Assembly[Coupling Assembly] --> Washer[Washer (Type A, IS 937)]
    Washer --> BranchConnection[Branch Pipe Connection]
    BranchConnection --> HydraulicTest[Hydraulic Test @ 21 kg/cm²]
    HydraulicTest -->|Pass| Approved[Approved Assembly]
    HydraulicTest -->|Fail| Rework[Rework or Replace Washer]

This guarantees reliable sealing and leak prevention in firefighting water fittings.

Branch Pipe Requirements as per IS 8090

1. Dimensions and Shape

• Must conform to the pattern and measurements shown in Fig. 2 (all dimensions in millimeters).
• Designed specifically for compatibility with 20 mm hose reel tubing.
• Outlet end threads should match nozzle inlet connections per Fig. 3.

2. Shut-off Valve (Clause 6.2.4)

• Operates with a quarter-turn mechanism for opening and closing.
• Must ensure zero leakage during shut-off.
• Designed for ease of user operation.

3. Hydraulic Pressure Test (Clause 6.3)

• Pressure applied: 21 kg/cm² (2.06 MPa).
• Duration: 2 minutes.
• Test conducted after all machining processes.
• No leakage or sweating permitted.

4. Thread and Washer Compliance

• Threads conform to IS standards for pressure-tight joints.
• Washers comply with updated specifications for firefighting water fittings.

Hydraulic Test Reference Table

flowchart TD
    BranchPipe[Branch Pipe] --> InletConn[Inlet Connection (Fig. 2)]
    InletConn --> OutletThread[Threaded Outlet for Nozzle (Fig. 3)]
    BranchPipe --> ShutOffValve[Quarter Turn Shut-off Valve]
    BranchPipe --> HydraulicTest[Hydraulic Test @ 21 kg/cm² for 2 min]
    HydraulicTest --> CheckLeak{Leakage Detected?}
    CheckLeak -- No --> Pass[Pass]
    CheckLeak -- Yes --> Fail[Fail]

This confirms that branch pipes meet reliability, leak-proofness, and compatibility criteria for firefighting hose reels.

Nozzle Requirements as per IS 8090

1. Dimension Compliance (Clause 7.1)

• Nozzles must adhere to the dimensions illustrated in Fig. 3 (consult the standard for exact sizes).
• Branch pipe inlet connections follow the pattern in Fig. 2, designed for hose reel tubing.
• Branch pipe outlet threads are made to fit nozzle inlets.

2. Surface Finish (Clause 7.2.3)

• Nozzle inner surfaces must be smooth and highly polished.
• No machining marks or ridges permitted to ensure efficient water flow.

3. Hydraulic Testing (Clause 7.3)

• Pressure: 21 kg/cm² (approximately 2.06 MPa).
• Duration: 2 minutes post-machining.
• No leakage or sweating allowed.

4. Additional Details

• Washers must comply with the revised firefighting water fitting specifications.
• All measurements are specified in millimeters.

Summary Table

flowchart TD
    BranchPipeInlet[Branch Pipe Inlet] -->|Per Fig. 2| BranchPipeOutlet[Branch Pipe Outlet]
    BranchPipeOutlet -->|Screwed Connection| NozzleInlet[Nozzle Inlet]
    NozzleInlet --> NozzleBody[Nozzle Body]
    NozzleBody --> NozzleOutlet[Nozzle Outlet]
    NozzleOutlet --> WaterDischarge[Water Discharge]

This guarantees proper fit and leak-resistant assembly for fire fighting water fittings.

Performance Testing as Prescribed in IS 8090

Hydraulic Pressure Test (Clause 6.3)

• Test pressure: 21 kg/cm² (roughly 2.06 MPa).
• Duration: 2 minutes.
• Purpose: Identify any porosity or leakage in branch pipe castings.
• Conducted after completion of all machining operations.
• Acceptance: Zero leakage or sweating permitted.

General Testing Requirements (Clause 8.1)

• All fittings must pass applicable tests including hydraulic pressure, dimensional accuracy, and material integrity.

Material and Workmanship Standards (Clause 4.1)

• Castings and forgings must be free from porosity, blowholes, scales, cracks.
• No hidden repairs or surface fillings allowed.
• Waterways must be smooth and burr-free.
• Aluminium parts anodized if specified.
• Threads on aluminium alloy parts coated with molybdenum grease.

Summary Table of Key Specifications

flowchart TD
    BranchPipeCasting[Branch Pipe Casting] --> MachiningComplete[Machining Completed]
    MachiningComplete --> HydraulicTest[Hydraulic Test @ 21 kg/cm² for 2 min]
    HydraulicTest --> LeakCheck{Leakage or Sweating?}
    LeakCheck -- No --> PassTest[Pass Test]
    LeakCheck -- Yes --> Reject[Reject or Recast]

This testing regime ensures leak-tightness and structural soundness of firefighting water fittings.

Marking Requirements Under IS 8090 (Clauses 9.1 & 9.1.1)

Each fire fighting fitting including couplings, nozzles, and branch pipes must be permanently and legibly marked with:

• Manufacturer’s name or trademark
• Size designation (applicable for couplings and nozzles)
• Year of manufacture

Additionally, fittings may display the ISI Certification Mark contingent upon licensing and compliance with ISI quality control protocols, ensuring adherence to the standard.

Summary Table for Marking

Related Standards

• Machining tolerance per IS 2102:1969
• Material standards for couplings/nozzles include leaded tin bronze Grade 2 as per IS 318

Notes

• ISI marking signifies ongoing quality assurance.
• Markings must withstand operational conditions without fading or damage.

flowchart TD
    Fitting[Fitting] --> ManufacturerMark[Mark Manufacturer's Name]
    Fitting --> SizeMark[Mark Size (if applicable)]
    Fitting --> YearMark[Mark Year of Manufacture]
    Fitting --> ISIMark[Optional: ISI Certification Mark]

Acceptance Criteria as per IS 8090

Hydraulic Pressure Test (Clause 7.3)

• Pressure: 21 kg/cm² (approximately 2.06 MPa).
• Duration: 2 minutes.
• Purpose: Detect casting porosity after machining.
• Acceptance: No leakage or sweating allowed.

Material and Corrosion Considerations (Clause 2.1.1)

• Prevent electrolytic corrosion by selecting compatible materials, especially avoiding aluminium-copper contact.
• Materials must resist corrosion in seawater, brackish, and fresh water.

Workmanship and Finish (Clause 4.1)

• Castings and forgings must be free from porosity, blow-holes, cracks, and scales.
• No concealed repairs permitted.
• Burrs and sharp edges removed; waterways smooth.
• Aluminium surfaces anodized when specified.
• Threads on aluminium alloy parts coated with molybdenum grease.

Rounding Off (Clause 0.4)

• Adhere to IS: 2-1960 for rounding test results, maintaining significant digits as specified.

Quick Reference Table for Hydraulic Test

flowchart TD
  MachiningDone[Machining Completed] --> HydraulicTest[Hydraulic Test @ 21 kg/cm² for 2 min]
  HydraulicTest --> LeakCheck{Any Leakage or Sweating?}
  LeakCheck -- No --> Accept[Accept Nozzle]
  LeakCheck -- Yes --> Reject[Reject or Recast]

These criteria guarantee the mechanical reliability and corrosion resistance of fittings.