2/6/2015

Fueldispensers
HOME

LegalMetrologyAct

PackagedCommoditiesRules

Verification of Fuel Dispensing Pumps

Forum

L e g a lG u id e s
L.M.GeneralRules

Part IV of Eighth Schedule, The Legal Metrology (General) Rules, 2011

StateEnforcementRules

Specific provision: Part 2 Rule 5(1)

REGISTRATION

Adispensingpumpisameasuringinstrumentusedinconjunction
with a storage tank for effecting delivery of liquid products by
specified volume. The instrument should be able to measure
continuously, memorize and display the volume of liquid passing
throughthemeasurementtransducer.
A fueldispensing system contains several sets of components to
perform a number of interrelated functions. Some components
maintain hydraulic continuity regulate the direction of flow and
fluid pressure. Others put the pressure on the fuel to move it
through the system. Some other components are responsible for metering the liquid fuel,
registering accurately the quantity delivered, and computing the price of the delivery.
Thesecomponentsaresubjecttometrologicalcontrol.Anothersetofcomponentscontrol
the operation of the system, switch it on and off, resets the volume and price indicators,
andregulatesthedelivery.Resettingofindicatorsanddeliveryregulatingcomponentsare
alsosubjecttometrologicalcontrol.

Hydraulic part of a dispenser

Nomination
Verification&Stamping
License
ApprovalofModel
AddressesofLMAuthorities

Te c h n i c a l G u i d e s
NAWeighingInstruments
TestingandSealingNAWI
DigitalBalance
RoadWeighbridge
LiquidFuelDispensers
Petrol/DieselDispensers
SealingDispensers
L.P.G.Dispensers

When a dispenser is switched on, the

electricmotorisactivated,andbeginsdraw
fuel from its outlet. This displacement of
the liquid creates a partial vacuum at the
pump inlet. When the discharge nozzle
remains closed, the vacuum is relieved by
fuel circulating continuously through the
unit. But when the nozzle is opened,
suction
pressure
is
transferred
instantaneouslyfromthepumpinlettothe
storage tank through the pipe line. There,
atmosphericpressureforcesthefueltoflow
through a check valve toward the
dispenser.

C.N.G.Dispensers
RailWeighbridge
VehicleTank
StorageTank
NetContentChecking

Beforeenteringthepumpingunit,itpassesthroughastrainerorfilter,whichremovesany
solid particles. Small quantities of trapped air and fuel vapor are also removed from the
fuelthroughanairseparatorchamber.
Then the fuel, free of air and vapor, passes to the automatic control valve which permits
fuel to flow only in the direction of the meter, never back to the pump. Nowadays, the
controlvalveisreplacedbyasolenoidandpilotvalve.

The Metering and the Registering part

Working principle of mechanical and semi mechanical units
While the hydraulic part of a dispensing unit will remain more or less similar, working
http://www.metrologycentre.com/codes/ddu.html

1/9

2/6/2015

Fueldispensers

principleofthemeteringandregisteringpartofmechanical,semimechanical(Ztypesfor
example)andelectronicunitsaretotallydifferent.Requirementforsealingofthoseunits
willalsobedifferent.

Metering part for both the types are similar. But, mechanical dispensers employ
mechanical registering unit of analog display while a semimechanical dispenser uses a
digital display unit. In the former type the metering unit is connected to the registering
unit through a gear box while in the later type a sensor (a device which transforms
mechanicalforceintoelectronicsignals)isusedfortheconnection
Metering Unit
The main components are the Adjustment wheel by which the delivery is controlled
(calibration),theCylindersandtheGearBox.
Meteringdevicesmostlyusepistonmetersandarepositivedisplacement.Apistonmoving
through a cylinder filled with liquid will displace a quantity of liquid which will be
determinedbytheboreofthecylinderandthestrokeofthepiston.Usuallyfourcylinders
areused.Thepistonsoperatemayoperateinahorizontalplaneorinaverticalplaneand
convert their to reciprocating action to a rotary shaft output to drive either a sensor or a
mechanicalcomputer(gearbox).
The metering units are calibrated at the factory.
Normally,thecalibrationisofhighaccuracyandreliable.
However, meters may need adjustment after period of
usage or deliberate maladjustment to cross the MPE
limit.
Theseadjustmentscanbemadeinverysmallquantityas
little as 3/10,000 part of volume. The adjusting
mechanismmaybelocatedonthetopofthemeterorononeofthepistoncaps.Itmaybe
a knurled knob, keyed disk, or calibrated wheel or have some other but immediately
identifiabledesign.Thediscorwheeloranyotheradjustingdevicemusthavelockingpins
orfixedperforatedscrewsforsealing.
Inside and outside of two common types of gear box

Gearboxesandadjustmentwheelsaremajorcomponentswhicharemanipulatedmostly
byunscrupulousdealers.
Extra precaution is required for sealing the Gear Box and the Adjustment wheel. All the
threecomponentsaresealedindividuallywithonelongmultithreadedwire.
The Registering Unit
http://www.metrologycentre.com/codes/ddu.html

2/9

2/6/2015

Fueldispensers

The rotary shaft output of the metering unit drives a registering unit, which may be old
fashionedmechanicalcomputer,orasensororpulserinelectricalinstallations.
In mechanical registers the display is
analog. It has two panels of computing
anddisplay.Thelowerpanelindicatesthe
volumedeliveredwith1/10thdivisionsofa
litre,inanoperation.Thedisplayhastobe
resettozerobeforethenextoperationcan
begin. The upper panel, known as
totalizer, registers the total volume
dispensed by the unit. The indication must be irreversible and is sealed to prevent any
changeindisplay.
Suchregisteringunitsarestillfoundinsmalltownsandmainlyintheruralareas
In semimechanical registering units, a sensor is
used to convert the mechanical energy og the
metershafttoconvertitintoelectricalsignal.The
output of the sensor is sent to the digital display
panel.Thepanelshowsboththevolumedisplayed
in an operation and also the total volume
dispensed by the unit. Here again, the volume
indicator is set to zero before the next operation
can begin and the totalizer is irreversible. The
sensor box is need to be sealed to prevent any
unauthorizedadjustment.
Such type of units are found in semiurban or rural areas and are known as Zseries
pumpsbecauseoftheirdesign.

Working Principle of Electronic Multiple Product Dispensers

Electronic Multiple Product Dispensers (MPD) devices used for measuring and
transferringaspecifiedvolumeofanumberofliquidfuelsfromasingleequipment.
Apartfromtheintroductionofsolenoidvalve,whichiscontrolledbythemicroprocessor,
restofthehydraulicsectionismoreorlessthesameasthoseinoldermechanicalunits.
The electronic Device
The heart of the system is
the Central Processing Unit
(CPU), a microprocessor
with an inbuilt memory
chip. It controls the entire
set of measuring, display,
delivery and associated
devices of preset keypad,
receiptprinteretc.
AnMPD,beinganelectronicdeviceusesatransducer,generallycalledapulser,whichis
coupled directly to the meter shaft. The pulser converts the mechanical force of the
rotating shaft into discreet electrical pulses. These pulses are transmitted as input to the
CPU. The CPU recognizes not only pulse signals but electrical signals from other input
devise zero reset, price adjustment, preset mechanism etc. After all the information are
processed, the CPU sends appropriate signal to the display panel (through the display
http://www.metrologycentre.com/codes/ddu.html

3/9

2/6/2015

Fueldispensers

card),totheprinter,ifconnectedandalsotothesolenoidvalvetocontrolrateofflowof
liquid through the meter. The rate increases in the beginning, remains steady in the
middleandslowsdowntowardstheendofdelivery.
Thepresetkeypadisusedtotransmitthepresetthequantitiesortotalpriceoffueltobe
deliveredandalsocreditcarddetails.
The display panel normal bears the following information price per litre, quantity
delivered and price. There is also a totalizer to register total quantity of fuel deliver from
theunit.

Upper Chamber
The Upper Chamber holds the
electronic part of the unit. It
contains the main mother board
of the processor along with
memory chip, connected to all
input devices and output devices.
TheallimportantDIPswitchBox,
alsoknownasBlackBox,usedfor
electronic calibration, is located
here.Othermajorcomponentsare
Calibration Card, Display Card
and
Unit
and
Totalizer.
Calculating device Preset
Keyboard and Printing Device are
alsoconnectedtothemotherboard.
ComponentsofthischamberwhichrequiresealingareDipSwitchBox,DisplayUnitand
theTotalizer.
In a chamber there may be as many as four units, two in each side, one unit each for 4
typesoffuelsHighSpeedDiesel,SuperDiesel,UnleadedPetrolandnormalPetrol.

Functioning of the Calibration Card

Calibration means the process of adjusting the calibration mechanism of a measuring
instrumentsothatitfunctionswithinitsstandardaccuracy.
In an MPD or an electronic device,Calibration Card is the most important component of
thesystemsystembecauseitcontrolstheactualquantityoffuelsuppliedtothenozzle.On
the card, there is a black box inside which the Dual Inline Package (DIP) Switch is
placed.ThisswitchisrequiredtobesetONforcalibratingthepumpforcorrectdelivery.
Naturally, this box needs additional protection. After, switching on the DIP, the
calibrationismadethroughthepresetcalculatorthroughaseriesofcommands,asmaybe
givenintheusermanual.
However,thelimitofadjustmentthroughthecalibratingcardis150mlin5l.Changein
delivery beyond that is possible through rotating the adjustment gear or turning the
adjustmentrodinsidethemeter.
Electronic Calibration
The DIP Switch Box on the PCB (Printed Circuit Board), or somewhere near, is
openedandswitchedon.
Entercalibrationmodeusingacodenumber.
EnteruserPIN.
Calibratefor5lor20l.(Thecalibrationcanchangedeliveryupto150mlin5l.)
http://www.metrologycentre.com/codes/ddu.html

4/9

2/6/2015

Fueldispensers

Manual Calibration
Whenthecalibrationcannotbemadeuptoadesiredlevelbyelectronicmethod,manual
calibration is done. This is done though calibrating the meter either by rotating the
adjustmentgearorturningtheadjustmentrodafterliftingtheadjustmentknobtofreeit
fromthemetershaft.
Caution
It is not enough to guard the Calibration Device through a PIN Code only. Under the
provisionofRule2(20)(ii),inaninstrumentmeantforsellingtothepublic,thereshould
also be a Hard Key, a locking device. The device should be sealed so that it cannot be
openedunauthorizedly.
Calibration History
Thememorychipmaintainsahistoryoflasttenattemptsofcalibration.Itcanberetived
bytypingappropriatekeysofthekeyboardasgivenintheusermanual.Itisveryhelpful
to detect any attempt of unauthorized calibration. The history consists of Calibration
factor of the nozzle. no of calibrations attempted and the Totalizer reading after the
calibration.Thesefiguresmaybenotedforanyfuturecomparing.

Verification Procedure
Equipment
1.Certificate/sofmodelapproval.
2.Appropriateworkingstandardsofmeasurementas
(a)Avolumemeasureofatleast10Lcapacitysuitablefordeliveriesatmaximumflowrate
specified for the dispenser. The measure should be suitable for deliveries greater than
three times the minimum measured quantity (Vmin) specified for the dispenser. For
dispensersgreaterthan60L/minuseameasurewithavolumeequivalenttoatleast1min
deliveryforbothmaximumandminimumflowrate.
(b) A small capacity measure verified at relevant intervals for tests where small measures
arerequired.
Preparation
The first fill into a dry standard volume measure may produce erroneous results if the
internal walls of the measure are not wet with the liquid to be measured. Hence, it is
essentialthatallworkingstandardvolumemeasuresbeconditioned(wettedanddrained)
beforebeingused.Thisprocedureisonlyneededontheinitialtestrun,andisnotrequired
onsubsequentdeliveriesaslongasthemeasureremainsconditioned.

Test Procedures
The following series of test procedures determine if the performance of a fuel dispenser
meets requirements and whether the dispenser requires adjustment or service. Each test
procedure is explained as a discrete test. However tests can be combined to expedite the
testingprocedure.
Unless specified otherwise in the certificate of approval, all dispensers with a maximum
flowratenotgreaterthan60L/minshallhaveaVminof2L.
1. Checking Facility for Electronic Indicating Devices
Thecheckingfacilityforanelectronicindicatingdeviceshallprovidevisualcheckingofthe
entiredisplay,whichshallmeetthefollowingdescription(Part2,clause4.3.iv.b):
http://www.metrologycentre.com/codes/ddu.html

5/9

2/6/2015

Fueldispensers

displayingalltheelements(eightstest)
blankingalltheelements(blanktest)and
displayingzeros.
Thistestcanbecarriedoutinconjunctionwiththetestforzerosetting.
1.Removethenozzlefromitshanguppositionandcheckthatthe:
displaytestisperformedand
displaysegmentsarenotfaulty.
2.Determinewhetherthedispenserhaspassedorfailed.
2. Zero Setting
Thezerosettingdevicesofthepriceindicatingdeviceandofthevolumeindicatingdevice
shallbedesignedinsuchawaythatzeroingeitherindicatingdeviceautomaticallyinvolves
zeroingtheotherPart2,clause3.3.v)
Thezerosettingdeviceshallnotpermitanyalterationofthemeasurementresultshownby
the price/volumeindicating device other than by making the result disappear and
displayingzeros(Part2,clause3.2.iv.b)
Once the zeroing operation has begun it shall be impossible for the price/volume
indicating device to show a result different from that of the measurement that has just
beenmade,untilthezeroingoperationhasbeencompleted.Theprice/volumeindicating
device shall not be capable of being reset to zero during measurement (Part 2, clause
3.2.iv.c)
Determine whether zero setting is mechanical or electronic and conduct the appropriate
testasfollows:
2.1 Mechanical Reset Mechanism
Formechanicalindicatingdevices,theresidualvolumeindicationafterreturntozeroshall
not be more than half the minimum specified volume deviation (Emin), e.g. 10 ml for
dispenserswithaVminof2L(Part2clause3.2.iv.d).
Likewise,theresidualpriceindicationafterreturntozeroshallnotbemorethanhalfthe
minimum specified price deviation (MSPD) where MSPD = Emin X unit price (Part 2,
clause3.3..viii).
Removethedeliverynozzlefromitshangupposition.
IfaprevioussaleremainsontheindicatormovethestartinglevertotheONposition
andensurethatthepumpmotordoesnotstartorthedispenserisnotactivated.Ifthe
pumpmotordoesstartorthedispenserisactivatedthentheinterlockmechanismis
faulty.
Resettheindicator/stozeroandcheckthatthevolumeindicator/sis/arezerowithin
0.5Eminandthepriceindicator/sis/arezerowithinEminXunitpriceX0.5.
Move the starting lever slowly and gently towards the ON position until the motor
starts (or the dispenser is activated) and then slowly and gently towards the OFF
positionuntilthemotorstops(orthedispenserisdeactivated).
MovethestartingleverslowlyandgentlytowardstheONpositionandcheckthatthe
interlockhasengagedandpreventsthemotorfromstartingorbeingactivated.
ReturnthestartinglevertotheOFFposition.
Determinewhetherthedispenserhaspassedorfailed.
2.2 Electronic Reset Mechanism
http://www.metrologycentre.com/codes/ddu.html

6/9

2/6/2015

Fueldispensers

Forelectronicindicatingdevices,theprice/volumeindicationafterreturntozeroshallbe
zerowithoutanyambiguity(Part2,clauses3.2.iv.eand3.3.ix).
Remove the nozzle from its hangup position and ensure that the display test is
performed and the price and volume displays are on zero before any delivery of
productispossible.
Carefullyreturnthenozzletoitshanguppositionandensurethatwhenthenozzleis
then removed no further deliveries are possible without the segment test being
initiatedandtheindicationsreturningtozero.
Determinewhetherthedispenserhaspassedorfailed.

3. Price Computing
Thepriceindicatedshallequalthepricecalculatedfromthevolumeandunitprice.
Thistestcanbedoneatanytimeduringatestdelivery,e.g.accuracytestornozzleshutoff
test.
Resetthedispensertozero.
Makeadeliveryofaconvenientvolume.
Calculatethetotalpricefromtheunitpriceandtotalvolumeindicated.
Comparethiscalculatedpricewithalldisplays.
Determinewhetherthedispenserhaspassedorfailed.

4. Nozzle Cutoff
Where the hose is fitted with an automatic cutoff nozzle the nozzle should close
automaticallywhenthesensingportofthenozzlecomesincontactwithliquidorfroth.
Thistestcanbedoneduringaccuracyorantidraintesting.
Makeadeliveryatnormalflowrate.
Allowthesensingportofthenozzletocomeincontactwithliquidorfroth.
Ensurethenozzlecutsoff.
Repeatsteps1to3twicemore.
Determinewhetherthedispenserhaspassedorfailed.

5. Interlock
The use of the same indicating device for the indications of several measuring systems
(whichhaveacommonindicatingdevice)isauthoredprovideditisimpossibletouseany
twoofthesemeasuringsystemssimultaneously(Part2,clause2.9.vi).
Inmeasuringsystemsintendedtodeliverliquids,nomeansshallbeprovidedbywhichany
measuredliquidcanbediverted(Part2,clause2.16.i).
The selected unit price shall be displayed by an indicating device before the start of the
measurement(Part2,clause3.3.ii)
These requirements are interpreted to mean that no fuel can be dispensed unless it is
measured and that the unit price indicated corresponds to the unit price of the fuel
selectedanddelivered.
Determinewhetherthehoseshaveacommonindicatororwhethertheyshareapumping
unit,andconducttheappropriatetestasdocumentedbelow.
5.1 Hoses Sharing a Common Indicator
Selectandauthorizeonehoseandremovethenozzlefromitshangupposition.
Check that the price and volume indications for the hose selected reset to zero, and
fordispensers:
withseparateunitpricedisplay:
http://www.metrologycentre.com/codes/ddu.html

7/9

2/6/2015

Fueldispensers

theunitpricedisplayforthetypeoffuelselectedistransferredtothemainindication
withoutseparateunitpricedisplay:
the unit price display for the hose selected is displayed and all other unit price
displaysdisappearuntilthedeliveryhasbeencompleted.
Check that all other hoses sharing the same indicator are disabled by removing the
othernozzlesfromtheirhanguppositionandconfirmingthattheydonotauthorize.
Determinewhetherthedispenserhaspassedorfailed.
5.2 Hoses Sharing a Pumping Unit
Selectandauthorizeanyhosethatsharesacommonpumpingunit.
Whilethepumpingunitisoperating,attempttomakeadeliveryfromanyotherhose
connectedtothesamepumpingunitwithoutallowingtheindicatortoresettozero.
Check that it is not possible to make a delivery from any other unauthorized hose
connectedtothesamepumpingunit.
Determinewhetherthedispenserhaspassedorfailed.
6. Preset Indications
Measuring systems with a priceindicating device may also be fitted with a price/volume
presettingdevice,whichstopstheflowoftheliquidwhentheprice/quantitycorresponds
tothepresetvaluePart2,clause3.6.x).
Thistestcanbecombinedwiththepresetaccuracytestandoneresultrecorded.
Resetthedispensertozero.
Enterasuitablepresetvalueusingthepresetfacility.Makesurethepresetamount
appearsonthedisplay.
Commence a delivery into the container with the nozzle fully open allowing the pre
setfacilitytoslowdownandcompletethedeliveryautomatically.
Check that the price/volume indication on the display corresponds to the preset
amount and for selfserve remains on the display or is stored in memory until the
transactionisfinalized.
Determinewhetherthedispenserhaspassedorfailed.
7. Maximum Flow Rate
The maximum achievable flow rate shall be within the approved range (Qmin to Qmax)
marked on the data plate. This test is only indicative that the maximum achievable flow
rate is within the approved range and can be performed during one of the fast flow
accuracytestdeliveries.
Determine whether the hoses have their own pumping unit or whether they share a
pumpingunit,andconducttheappropriatetestasspecifiedbelow.
Hoses with their own Pumping Unit
1.Commenceandtimeadeliveryatthemaximumachievableflowrate.
2.Stopthedeliveryafteratleast10s.
3.Notetheindicationonthedispenserandcalculatetheflowrate.
4.Determinewhetherthedispenserhaspassedorfailed.
Hoses Sharing a Pumping Unit
This is a requirement at initial verification/ certification, when any site changes occur, or
at the discretion of the trade measurement authority. Refer to the certificate of approval
forspecifictests.
1.Selectandauthorizeanumberofhosesconnectedtothesamepumpingunit.
http://www.metrologycentre.com/codes/ddu.html

8/9

2/6/2015

Fueldispensers

2.Withallhosesoperatingatthemaximumachievableflowrate,timethedeliveryforone
ofthehoses.
3.Stopthedeliveryafteratleast10sandcalculatetheflowrate.
4.Determinewhetherthedispenserhaspassedorfailed.
8. Accuracy
Itisrecommendedthattestingbecarriedoutatthemaximumachievableflowrateandat
Qmin (as per the procedure) and the results analyzed to determine if the meter requires
adjustment.
1.Conditiontheworkingstandardvolumemeasure
2.Makeadeliveryatmaximumachievableflowrate.Recordthevolumeindicatedbythe
fueldispenser(VFD)andthevolumeindicatedbytheworkingstandardmeasure(VREF).
3.Calculateandrecordtherelativeerror(EFD).
EFD=(VFDVREF)/VREFX100
4.Repeatsteps2to3twicemore.
5.Makeonemoredeliveryatminimumflowrate.Recordthevolumeindicatedbythefuel
dispenser(VFD)andthevolumeindicatedbytheworkingstandardmeasure(VREF).
6.Calculateandrecordtherelativeerror(EFD).
7.DetermineifalltheresultsarewithintheallowableMPE.Ifnot,analyzetheresultsand
assesswhetherornotthemetercanbeadjustedsothatalltheresultsarewithinMPE.
8.Ifmeteradjustmentsaremade,circulateaquantityoffuelandrepeatsteps2to7.
9. Accuracy of Preset
Apresetaccuracytestisonlyconductedwhenitisnecessarytochecktheaccuracyofthe
presetdeliveryvolume.
1.Conditionthestandardvolumemeasure.
2. Enter and record a suitable preset value using the preset facility. This preset value
shoulddeliverclosetothevalueofthereferencestandardmeasurebeingused.
3. Make a delivery at maximum achievable flow rate until the delivery stops. Record the
volume indicated by the fuel dispenser (VFD) and the volume indicated by the working
standardmeasure(VREF).
4.Calculateandrecordtherelativeerror(EFD).
EFD=(VFDVREF)/VREFX100
5.DetermineiftheresultiswithintheMPE.
ViewModelTestReportPartI|ModelTestReportPartII
Goto:SealingProcedures>>>

DISCLAIMER:Whileeveryeffortandprecautionhavebeentakentoensurethecontentsofthiswebsiteaccurateanduptodate,
thereisnoguaranteeforthecorrectness,accuracyorcompletenessoftheinformation.Youareusingthecontentsofthissiteat
your own risk and liability. and on providing full indemnity against any loss or damage, penal action or injury caused to you or
sufferedbyyouforusingtheinformationprovidedhereorinemailsoriginatedfromthiswebsite.

HELPDESK:admin@metrologycentre.com

http://www.metrologycentre.com/codes/ddu.html

9/9