M&H Valve Co.

Division of McWANE, Inc.

605 West 23rd Street
P.O. Box 2088
Anniston, AL 36202
Telephone (256) 237-3521
Fax (888) 549-5309

FIRE HYDRANT SUMMARIES

The following information regarding AWWA C502 fire hydrants is provided in three
separate documents to reflect aspects of installation, operation, and maintenance.

The Installation section focuses on the aspects of the construction process, being the
contract specification, installation and initial testing. This targets the interest of the pro-
ject engineer, installer and construction inspector.

The Operation section addresses the three most common operational factors that can
result in damage to the hydrant or water system. This information should be considered
by anyone who operates fire hydrants.

The Maintenance information is supplemental to published maintenance manuals and

provides a general review of the five key mechanical components.

The short summaries provided represent only partial information. Detailed information is
available within the AWWA C502 standard, or available from the manufacturer upon re-
quest.

A-1.11
 FIRE HYDRANT INSTALLATION

GENERAL

Proper hydrant installation is an essential component to long service life with minimal
maintenance. The following are some key fire hydrant installation, operation and trouble
shooting procedures to consider when inspecting new construction. See the manufac-
turers installation and maintenance manuals and the AWWA C502 Standard for Dry-
Barrel Fire Hydrants for more detailed information.

The operational requirement of the application needs to be fully specified to assure the
installation complies with local standards. Operational requirements include:

1) Reference to AWWA C502 and/or other appropriate standard.

2) Main valve size (5 typical)
3) Type & size of pipe connection (6 typical)
4) Depth of trench
5) Hydrant color
6) Nozzle configuration, sizes, and threading
7) Operating nut size and configuration
8) Direction of opening

INSTALLATION DETAILS

Be sure the hydrant selected corresponds to the depth of trench plus proposed adjust-
ments to the finish grade. Finish grade is recommended at 3 (+/-3) below break
flanges, which is the designed optimum installation point for break system function. This
also assures clearance for full circle operation of 15 hydrant cap wrenches.

The auxiliary valve & hydrant must be adequately restrained to the piping system. A
mechanical joint connection is considered an unrestrained joint and requires thrust
blocking or mechanical restraint.

The hydrant needs to stand perpendicular. Directional facing of hydrant should provide
access for fire fighting needs. All current production AWWA C502 hydrant models pro-
vide for 360-degree barrel positioning options.
 A-3.10, pg. 1 of 3

A gravel sump area must be provided at the hydrant shoe area to accept barrel drain-
age. This stone filled area should be capable of containing a volume of water twice that
held by the hydrant barrel.

Provide a stable and compacted backfill for installation rigidity. This will enhance func-
tionality to the breakaway system.

FUNCTIONAL DETAILS

Check breakaway flanges or lugs for damage inflicted during handling & installation.
Verification of break system integrity is an important functional inspection and also re-
lates to operational safety.

Operating nut sizes and nozzle threading must be checked for compatibility with fire de-
partment standards. Direction to open must be as indicated by the arrow on the weath-
ershield or bonnet and in compliance with local standards.

OPERATIONAL TESTING

Verify proper hydrant operation. Operate from behind - and not over the hydrant - mak-
ing appropriate provisions to discharge flow. * Note that higher operating torques at ini-
tial opening will be present due to resistance of line pressure. Once flow begins, pres-
sure equalizes and operating resistance is minimized.

The drain valve system will discharge water from drain ports at line pressure during
opening - in the one to five turn open range. Prolonged hydrant operation must be only
in the full open position to avoid undermining of the gravel sump area and backfill.

Close hydrant very slowly to avoid a water hammer. If air is being discharged, stand
clear of the hydrant and allow for discharge of all air before closing. Closure should be
smooth and without significant resistance. Be sure the stem lock nut that retains the op-
erating nut is secure and does not back out during closing.

Line pressure aids in closing an AWWA C-502 center stem compression hydrants.
There is no need to exert closing torque to retain closure. After full closure, relieve stem
& seat assembly stress by turning the op nut approximately 1/4 turn in the open direc-
tion.
Debris lodged in the seating area of the main valve - preventing full closure - is the most
predominant seating problem with new installations. Water may flow out the nozzles or,
in the case of a very minimal leak, be discharged thru the drain valve system.

A-3.10, pg. 2 of 3
It is somewhat common that hydrants are overtorqued in the closed position in attempt
to overcome a seating obstruction. Difficulty in initial opening of the hydrant can be in-
dicative of high torque seating achieved over debris (*also see above). Failure to
achieve re-closure and hold closure with water pressure may indicate the main valve
has been damaged. Additionally, overtorquing can damage the operating nut threading,
seat ring, or the breakaway assembly.

A "rare possibility for full closure leakage would be a lower seat O-ring failure. In most
cases, this O-ring proves to not be the problem upon further investigation.

Check the hydrant barrel for proper drainage. After closing there should be a slight suc-
tion at the hose nozzle, which is detectable with the palm of the hand. Failure to drain is
usually caused by blockage of the drain ports due to improper installation. Other less
common possibilities include a high water table or the deletion of the drain feature as
specified for some applications.

SHELL TESTING

A shell test will verify proper drain valve facing operation and integrity of barrel compo-
nent seals. When performing this test, special operational safety issues must be con-
sidered. First, verify that all nozzles are positively retained to the barrel and caps are
fully threaded on to the nozzles. Next, remove a nozzle cap and fill hydrant to the nozzle
level then close and replace cap. This step will minimize air in the hydrant barrel as it is
pressurized for shell testing. Always operate from behind and not over the hydrant.

As the hydrant is re-opened, the drain system will be flushing in the 1 to 5 +/- turns open
range. At full open the drain valve facings will seal the drain ports as per AWWA C-502
sec 5.1.2. "Hydrostatic test (AWWA C-502 allows for leakage at the drain valve at a
rate "not to exceed 5 fl oz/min). During a shell test, drain valve sealing can usually be
confirmed by the absence of sound associated with a flow operation. Damage to drain
facings is not as common as in the past due to the use of pressure activated rubber fac-
ings vs the leather drain valve facings of the past.

All nozzles, caps & barrel component seals should be drip tight. Barrel component leak-
age is usually a result of loose shoe to lower barrel bolting. AWWA C502 and the manu-
factures recommendations instruct the installer to check for bolts that may have worked
loose in shipping and handling.
 A-3.10, pg. 3 of 3

FIRE HYDRANT OPERATION

GENERAL

Maintenance requirements for AWWA C502 center stem compression fire hydrants are
often a result of improper operation. The most predominant issues are as follows:

A) Water hammer - resulting from closing the hydrant too quickly.

B) Over torquing in the closed position.
C) Hydrant operation at less than full open.

The following information is intended to be general in nature and may apply to all
AWWA C502 hydrants. It is suggested to confirm operational procedures specific to
each model. See maintenance information for additional details.

A) CLOSING SPEED & WATER HAMMER

The primary issue of concern is closing the hydrant too quickly - since this has the po-
tential to extend damage beyond just the fire hydrant. It is critically important to close
fire hydrants slowly - and also operate from behind and not over the hydrant.

Water weighs about 8 lbs per gallon and may be moving at up to 4 feet per second and
can't be stopped abruptly. When a hydrant is closed too quickly - a water hammer will
result. Water hammer has a tremendous potential to damage water systems - as it
slams against the closed hydrant and bounces back through the water system.

Adding some air into this picture we create a multiplier effect of water hammer. When a
system is installed or repaired it is essential to properly bleed off any air within the pipe-
line. Keep in mind that unlike water, air will compress and can create an extraordinary
operational hazard. If you encounter air during operation, stay clear of the hydrant until
the airflow ceases - and do not close while blowing off air!

In some cases airflow can be very obvious during hydrant operation and in other cases,
despite its presence, is not highly detectable. If hydrants chatter during operation - this
should serve as a warning of the possible existence of air in the flow.
 A-4.11, pg. 1 of 3

If hydrant chattering is common to specific areas of the water system, provisions should
be considered to purge air. This is most likely to exist with hydrants at the high points of
the system in conjunction with higher pressures and/or velocities. A hydrant with one or
multiple extensions may contribute to this condition due to an accumulation of stem as-
sembly tolerances.

When using hose nozzle valves, use only multi turn gate valves. Do not use lever oper-
ated quarter turn valves, which are likely to instigate a water hammer.

A water hammer situation can also occur if the stem lock nut - which retains the operat-
ing nut - backs out of the bonnet while closing the hydrant. The stem lock nut is de-
signed to tighten when absorbing the higher thrust when opening. In closing, it is con-
ceivable, the stem lock nut can be carried out if inadequately restrained. This is not ob-
vious, but it is detectable if the operating nut is rising during closing. Several methods
are used to add retention forces - being lock pins, lock tite, dinging the threads, and
over time - a little corrosion serves well at this location.

Do not flow a partially disassembled hydrant - where the bonnet and/or operating nut
assembly is removed and the main valve assembly remains in the barrel. This has been
known to occur during repair procedures to flush debris from the line - with the auxiliary
valve being used for control. When a hydrant is partially disassembled the main valve
will generally fall to the open position. Since a center stem compression fire hydrant is a
normally closed valve, flushing without the restraint of the operating nut assembly will
allow flow to drive the main valve closed.

All of the potential pitfalls of improper hydrant operation are intensified at high pres-
sures. Production testing which meets - or exceeds - AWWA C502, Section 5.1, does
not duplicate possible field conditions of high velocity, compressed air, or water hammer
induced by closing too quickly.

B) OVER TORQUING

For AWWA C-502 center stem compression fire hydrants, the most common mainte-
nance issue is damage to the main valve. Rocks or other debris becoming lodged in the
seating area at installation generally causes main valve damage.

When an obstruction to seating of the main valve occurs, it is important to avoid the use
of excessive force in attempts to achieve closure. Excessive closure torques can accel-
erate damage to the main valve or induce damage to other related parts. The suggested
procedure is to reopen the hydrant and flush the obstructions clear and attempt to re-
close.

A-4.11, pg. 2 of 3

A common cause of main valve damage is routine over torquing in the closed position.
Putting an extra snug on the hydrant to assure closure is not required. A center stem
compression hydrant is a normally closed valve and closes with the aid of water pres-
sure. High closing torque will likely result in damage to the main valve and cause seat-
ing to become less efficient. As seating becomes progressively more unreliable, we get
into the slippery slope of needing more torque to close until the main valve eventually
needs to be replaced.

Excessive closing torque also retains an undue stress on the stem components. It is
recommended after closing to back off the operating nut approximately 1/4 turn from full
closure. The water system pressure will maintain closure.

This is in contrast is the opposite operation of the older scissors type hydrant (offset
stem vs a center stem), which closes against pressure. This type of hydrant does re-
quire more shutoff torque and is generally more maintenance intensive.

C) FULL OPEN OPERATION & DRAIN VALVE SYSTEM

The drain valve system provides for the removal of excess water after closure to pre-
vents freezing within the hydrant barrel. A pressure activated rubber drain facing is de-
signed to seal off at approximately 4 to 7 turns after opening of the hydrant. However, it
is recommended that hydrants be operated to flow only in full open position. This as-
sures there is not a continuous high-pressure drain port discharge during use.

If a hydrant is throttled to deliver only a garden hose full of water (such as at a construc-
tion site), constant drainage is taking place and undermining of the thrust blocking that
supports the installation. Use of a hose nozzle gate valve is the proper method of throt-
tling hydrant flows.

The drain system is designed in this manner to allow a burst of water to flush any debris
clear the drain system during initial opening. This helps to facilitate barrel drainage after
closing.

Please reference the appropriate manufacturer operation and maintenance information

for additional detail.

A-4.11, pg. 3 of 3
 FIRE HYDRANT MAINTENANCE
GENERAL

Virtually all fire hydrants currently being installed in the Northwest are in compliance
with the American Water Works Association (AWWA) C502 standard for dry barrel hy-
drants. Current center stem compression hydrants are designed to both minimize main-
tenance needs as well as facilitate maintenance operations when necessary.

The following general information covers key mechanical components that may apply to
all AWWA C502 hydrants. It is suggested to reference the manufacturers maintenance
manual that is specific to each hydrant model for further servicing information.

When replacement parts are required, it is essential to provide detailed information spe-
cific to the subject hydrant. The following Information for identification will be on the bar-
rel section: 1) name of manufacturer, 2) model number, 3) year of manufacture, and 4)
main valve size. Direction to open and depth of trench may also be applicable.

MAIN VALVE

The most common maintenance need relates to obstructions in the seating area and
resulting damage to the main valve. This is detectable by continued flow with the hy-
drant in the closed position.

When obstructions to seating of the main valve occur, it is important to avoid the use of
excessive force in attempts to achieve closure. Excessive closure torques can acceler-
ate damage to the main valve or induce damage to other related parts. The suggested
procedure is to reopen the hydrant and flush the obstructions clear and attempt to re-
close. If this is unsuccessful, the main valve assembly will need to be removed for fur-
ther analysis.

Since we are going to remove the main valve, we must first turn off the auxiliary valve.
Some maintenance functions can be performed under water pressure, however, when
using a seat removal wrench we must confirm that the hydrant is not under pressure.

DISASSEMBLY - To access the main valve, the hydrant is disassembled starting from
the bonnet. In the case of a grease-lubricated hydrant, we remove the bonnet bolts and
thread off the bonnet unit off the stem. Next we remove the seal plate if applicable. In
the case of an oil-lubricated hydrant, the manufacturer recommends removal of the op-
erating nut assembly and procedures for retaining the oil in the bonnet.
 A-4.15, pg. 1 of 6

Next, use the appropriate seat wrench (again with the water off) to remove the seat as-
sembly. For recent production hydrants, this wrench engages on the cast iron break
coupling below the break point or to an upper stem drive pin.

Most newer model hydrants have bronze to bronze seating (seat ring to subseat). Also,
the current use of O-ring seals provides servicing advantages vs old gasket seals. This
allows for torque applied through the stem to be sufficient drive out the seat ring.

For older models with a seat ring threaded into cast iron shoe, a longer seat wrench that
drives directly on seat ring drive lugs is required to deliver disassembly torque. When
encountering excessive resistance to seat removal, safety considerations increase in
importance - especially when excessive manual force is employed. The wrench can be
secured to the seat ring drive lugs by a retention device threaded to the upper stem.
This can prevent the wrench from releasing while manual force is employed. Use of
gear or power driven wrenches are preferable to the use of manual forces.

Main valve replacement is accomplished after removal of the bottom plate. Match the
corresponding tapered seating surfaces of the main valve and the seat ring. At this
point, also check the bronze-seating surface for damage. Minimal roughness can gen-
erally be buffed out with an emery cloth.

DRAIN VALVE SYSTEM

Function of the drain valve system needs to be checked for proper operation. There are
two primary issues that can cause a need for related maintenance.
1) Hydrant barrel fails to drain after use - which subjects it to freeze damage.
2) During full open hydrant operation, continuous discharge of water is taking
place - which can undermine support for the installation.

To accommodate barrel drainage, a gravel sump is installed around the base of the hy-
drant to accept water from the drain ports. To check for proper drainage, view the water
level drop and/or feel for the suction created at the nozzle outlet. If the hydrant barrel
fails to drain there are several possibilities to review:

A) Improper installation of a concrete thrust block over the drain ports is somewhat
common with new installations. It is also possible that the polywrap used to encase the
piping system does not allow for drainage. In either case the need for re-excavation
makes the remedy somewhat difficult.

B) There also have been cases where a high water table is the culprit.
C) It is possible the weep holes have become plugged with sand etc over time or during
construction. There are two ways to check or remedy this situation.

A-4.15, pg. 2 of 6
1) The first option is to attempt to force flush the drain system clear with water
pressure. To attempt this, remove a hose cap and open the hydrant slightly and
fill hydrant barrel as much as possible. (This step is intended to minimize hazards
associated with compressed air inside the hydrant.) Turn off hydrant and tightly
secure all hose caps. Open the hydrant approximately 3 turns - standing behind
and not over when operating. This allows line pressure to enter the hydrant while
the drain system is open creating an opportunity for line pressure to blow the
drain system clear.

2) If problems persist, CLOSE the auxiliary valve and remove the main valve
assembly using the appropriate tools. Pump the remaining water from the hy-
drant barrel. Using a long narrow pole with a nail thru the end, locate the drain
ports that exit the shoe and attempt to mechanically clear the drain ports.

If all the least difficult remedies are not successful, it is sometimes chosen to designate
a hydrant to be pumped out after each use - rather than excavating to address the ex-
ternal drain area. A so designated hydrant should be regularly inspected - since very
minor seat leakage may be retained in the barrel section and is subject to freezing.

If during hydrant operation, continuous discharge of water is taking place, note the fol-
lowing possibilities:

A) Hydrant needs to be operated in the full open position only. This assures that the
drain valve facing is fully blocking the drain valve port.

B) The drain valve facing is damaged or missing. This is most common with older style
hydrants using leather drain valve facings, which are subject to wear, swelling, shrinking
& cracking.

The newer pressure activated rubber drain valve facings have been a great improve-
ment to hydrant operations & maintenance. These allow for operational tolerances,
which have virtually eliminated wear and resulting, service needs.

C) Inspect the drain valve assembly. This can be subjected to damage from disassem-
bly torques being transmitted thru - and twisting of - the drain ears.

REASSEMBLY - To reinstall the main valve assembly, inspect the O-ring seals and re-
place if necessary. For hydrants with older style gasket type seals, seal replacement
with each servicing is recommended. Clean the threads and apply food grade grease to
the O-rings or gaskets and seat ring threads.
 A-4.15, pg. 3 of 6

Lower the stem and main valve assembly into the barrel - using caution to avoid scrap-
ping or dislodging the O-rings or gaskets. To assure proper starting of the threads, use
the wrench to rotate assembly backwards one or two turns to align seat ring threads be-
fore threading into place. On models with O-ring seals, only a moderate amount of
torque is required to seal the O-rings.

Before applying pressure to the main valve assembly, the bonnet assembly must first be
re-installed. This permits valve closure to be regulated by the operating nut. Do not flush
a partially disassembled hydrant without the restraint of the operating nut assembly
since this would allow flow to drive the main valve closed and create a water hammer
situation.

BREAKAWAY SYSTEM

The breakaway system is the weak point designed to fracture upon impact. This mini-
mizes potential damage to the hydrant, the vehicle, and its occupants. Alternately, the
break system must have enough structural integrity to facilitate high flow fire fighting
operation. Due to potential for minor impact or bump damage, It is very important to per-
form a visual check of break flanges or break lugs as part of routine maintenance.

Location of the break system at 3 (+/- 3) relative to finish grade is essential for proper
performance. If the break system is below the recommended range, an extension
should be added. This also permits the fire department to efficiently use cap wrenches
and attach hoses.

After a collision - repair can be accomplished as follows:

1) Removing broken coupling and standpipe break rings or break lugs.

2) Unscrew the upper stem from the operating nut
3) Install the new break coupling and replace upper stem.
4) Remove the cap/bonnet assembly.
5) Reassemble upper barrel of hydrant to lower barrel - checking to assure
proper O-ring / gasket installation.
6) Install breaker rings or break lugs - tighten evenly to manufacturers recom-
mended torques.
7) Replace the cap / bonnet assembly by fully threading onto the upper stem
and tighten bolts/nuts.
8) Add lubrication as recommended by the manufacturer.
 A-4.15, pg. 4 of 6

LUBRICATION & OPERATING NUT

The stuffing box area - located between the stem lock nut and the machined bonnet -
contains the thrust collar of the operating stem nut. Line pressure provides resistance to
initial opening of the main valve - which is transmitted as upward thrust to the op nut
thrust collar - forcing it up against the stem lock nut.

Teflon thrust washers have been used over the past 30 years to reduce operating fric-
tion. Hydrants with full travel stiff operation are usually older hydrants lacking a thrust
washer and/or weathershield protection of the op nut. Retrofitting a thrust washer is a
relatively easy and inexpensive way to greatly improve operation of older hydrants.

Access to the operating nut is achieved after removing the stem lock nut. The stem lock
nut is designed with backwards threading (for open left hydrants) - which tends to
tighten while absorbing the thrust of opening of the hydrant against water pressure.

Before installing the retrofit washer, clean the stuffing box area. If contacting surfaces
have become excessively scored, the bronze parts may need to replaced or refaced.
After installation of the washer, be sure enough tolerance exists for operation without
binding. Slight machining of the stem lock nut can provide additional tolerance for instal-
lation, if required.

After reinstalling the operating nut and stem lock nut, be sure the stem lock nut is fully
threaded into the bonnet and retention hardware is engaged. This will prevent the lock
nut from backing out while closing the hydrant.

Other possible causes of stiff operating would relate to the remaining operational con-
tact points. These should be limited to:

A) Damaged op nut threads

B) Stem interference through the bonnet or seal plate.
C) Drain valve components that travel within the seat ring.

Hydrant manufactures recommend lubrication of the operating nut either by grease or

oil. Regardless of the type of lubricant, use of a NSF food grade lubricant is essential.
This is driven by concerns relating to possible contamination of the water system from
the use of a petroleum product. Access is provided by either an alemite fitting or fill plug.

A-4.15, pg. 5 of 6
NOZZLES

There exist many types mechanical retention systems to secure the nozzles. Current
production models use stainless steel set screws, pins or wedges - in conjunction with
1/4 turn or threaded nozzles. Removal of nozzles can become challenging for older hy-
drants with dysfunctional retention systems. If all else fails, carefully cutting the bronze
nozzle only with a sawsall and collapsing with a hammer will work. Follow the manufac-
turers recommendations for nozzle replacement and retention.

O-ring seals are generally used for sealing to the nozzle section. Gaskets are used to
provide a seal to the caps. For lubrication of nozzle threads, a dry graphite lube is rec-
ommended. This will avoid the retention dirt or sand vs the application of grease.
A-4.15, pg. 6 of 6