Gas Actuated Valve Supplement

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Juliana Conley
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1 Gas Actuated Valve Supplement Product Gas actuated valve Models covered All models fitted to Compac CNG dispensers and Compac Priority Panels Technical parameters Product Maximum inlet pressure Temperature range Connection ports Maximum actuating pressure Materials Dry Compressed Natural Gas (CNG) Dry Biogas/Methane 414 bar -54 to +177 degrees C ¾ SAE female 8 bar (116 psi) Body: Stainless steel Stem: Stainless steel Safety This supplement is to be read alongside the appropriate CNG dispenser service manual. The dispenser model number is found on the identification plate on the side of the dispenser. Do not attempt servicing without referring to the service manual and understanding all related safety precautions. You must also adhere to the following safety precautions at all times when working on the Compac equipment. Failure to observe these safety precautions could result in damage to the dispenser, injury, or death. Make sure that you read and understand all safety precautions before operating the Compac equipment. System Design Ensure the system design does not allow the inlet pressure to exceed its rating. The valve does not include any safeties to protect against excessive inlet pressure. If necessary, suitable protective devices should be fitted prior to the valve inlet. Compac Industries Ltd. 52 Walls Road. Penrose. Auckland New Zealand. PO Box Penrose. Auckland New Zealand. Tel: Fax: info@compacngv.com

2 Mechanical Safety Observe the following precautions: Never tighten a fitting under pressure, even if a fitting or joint is leaking. Always depressurise the line first. Never disassemble a fitting under pressure. Always depressurise the line first. Be very careful when disassembling frozen pipework, as gas pressure may be trapped and suddenly released. Always depressurise the lines first. Make sure the service area is thoroughly cleaned before starting to service CNG components. Dust and dirt entering components reduce the life span of the components and can affect operation General The air actuated valve may be used either as an emergency isolating valve that will close when the compressed air supply is interrupted or as a high-flow valve actuated by a solenoid. Refer to the appropriate manual for its specific application. Service intervals The valve should be checked for external leaks during routine leak checks. If any leak is detected, the fittings should be checked first. If leaking through the stem or bypassing the valve when closed, the valve should be serviced. If leaks continue after servicing or the valve body is worn or damaged the valve should be replaced. The air actuator is not serviceable and should be replaced if faulty. 2

Servicing the gas actuated valve Service kit Never attempt to work on the valve while the power is on or while under pressure.

Ensure that the pressure is removed from both the inlet and outlet ports of the valve and from the air supply line.

Undo the pipework and remove the valve and actuator. 2. Undo the four Allen screws and remove the actuator from the valve 3.

Fold down metal locking tab 7. Remove nut and tab Suggested tools 8. Use a pick to pull out the stem seal and discard. 9.

3 Servicing the gas actuated valve Service kit Never attempt to work on the valve while the power is on or while under pressure. Before doing any work on the valve, ensure that the power is off and the system pressure is reduced to atmospheric levels. Ensure that the pressure is removed from both the inlet and outlet ports of the valve and from the air supply line. Check the part number and serial number when ordering spare parts. Seal kit order number: FC-SK Undo the pipework and remove the valve and actuator. 2. Undo the four Allen screws and remove the actuator from the valve 3. Remove the drive dog (note orientation) 4. Undo clamp (note orientation of clamp in relation to flow direction) 5. Remove valve from the clamp 6. Fold down metal locking tab 7. Remove nut and tab Suggested tools 8. Use a pick to pull out the stem seal and discard. 9. Undo the end cap, remove the valve seat and discard it. 10. Turn the valve stem to the Closed position then tap on the end of the ball valve with a wooden or soft plastic dowel (BV ASST) to remove it. Discard the ball. 11. Push the valve stem down into the valve and remove it from the valve body. Discard the valve stem. 3

4 12. With a pick, carefully remove the second valve seat taking care not to scratch the internal surfaces of the valve. Discard the valve seat. 13. Remove and discard the O-ring from the end cap. 4

Reassembly 1. Thoroughly clean and dry the valve body and end cap. 2. Place the new O-ring on the end cap and lubricate with the supplied grease.

Insert the valve stem into the valve body and pull it upwards until it clicks into place. 4.

Install the end cap and tighten to 60 N/m 7. Install the valve stem gland then the lock tab and nut.

5 Reassembly 1. Thoroughly clean and dry the valve body and end cap. 2. Place the new O-ring on the end cap and lubricate with the supplied grease. Put an anti-seize compound on the threads. 3. Fit the new valve seat making sure it is seated properly. Insert the valve stem into the valve body and pull it upwards until it clicks into place. 4. With the valve stem in the Closed position, insert the ball so the slot engages with the stem. 5. Insert the second valve seat 6. Install the end cap and tighten to 60 N/m 7. Install the valve stem gland then the lock tab and nut. Tighten nut to 3 N/m and bend the lock tab to stop the nut undoing 8. Hold the valve stem with pliers and open and close the valve four or more times to bed in the seal. Leave the valve in the closed position 9. Reinstall the bracket, drive dog and air actuator 10. Reinstall the assembled valve and connect pipework 11. Repower the dispenser and check for correct operation of the valve and for any leaks 5

6 SAE fittings. Do not use thread tape or sealing compounds on parallel O-rings that are subjected to natural gas at high pressure swell when exposed to air. Once swollen, they cannot be reused and must be replaced. 6

PRIORITY FILL PANEL INSTALLATION AND SERVICE MANUAL Includes Compressor Top Up models

PRIORITY FILL PANEL INSTALLATION AND SERVICE MANUAL Includes Compressor Top Up models Version 1.0.2 Compac Industries Ltd. 52 Walls Road. Penrose. Auckland 1061. New Zealand. PO Box 12 417. Penrose. Auckland