Key operated cylinder valve in O-ring seal design for acetylene service

Transcription

1 Key operated cylinder valve in O-ring seal design for acetylene service KHO-10/D (side outlet) KVO-10/D (top outlet) Resistant to acetylene detonation Robust construction for safe and reliable operation Ease of maintenance TPED Certification ( mark) by BAM as notified body: ID-0589 ISO 9001 and TPED certified valve manufacturer

2 Wrench size 300 Features and benefits for best-in-class performance Series KHO-10/D Drain hole on gland nut to prevent water trapping EPDM O-ring provides external tightness past upper spindle over entire operating and storage temperature and pressure range PA 66 thrust washer reduces friction and provides external tightness at high pressure If excessive torque is applied, SS-303 upper spindle fails before lower spindle to allow valve repair even when the cylinder is pressurized Lower spindle machined from naval brass for high torsional resistance PEEK / PA 66 soft seat provides long life and low torque operation SS filter net (60 mesh) as standard 280 HEX AF High durometer EPDM back-up ring prevents extrusion of O-ring Metal to metal seal prevents leakage past gland nut threads Gland nut O-ring arrests leakage in case the metallic sealing is compromised by external damage SS spring loads non-rising upper spindle against thrust washer Special test for acetylene service ensures resistance to acetylene detonation in case soft seat is fully burnt This is achieved by seat design which ensures metal to metal sealing after soft seat is burnt out Available in different valve outlet and inlet connection (Refer valve selection guide) a b Dimensions are in mm Dimensions shown are for 25E inlet and BS-4 outlet Depends upon inlet connection Depends upon outlet connection Design Specifications MIN life : 2000 cycles Operating and storage temperature range : -40 C to + 85 C MIN closing torque : 8 Nm Failure torque : Nm Gland nut installation torque : Nm MAX test pressure (TP) : 60 bar Lubricant : Krytox GPL 225 Flow coefficient (Cv) : 025 MAX weight of cylinder package mass for which valve can be used without protection : 833 kg * Also available for higher cylinder package mass, if required to be used without valve protection Testing and certification Valve meets EN ISO 10297:2014, tested by BAM Berlin Production testing as per EN ISO 14246:2014 Certified by BAM Berlin to European Transportable Pressure Equipment Directive (TPED) and available with mark

3 Wrench size 300 Features and benefits for best-in-class performance Series KHO-10/D (with fusible plug) Drain hole on gland nut to prevent water trapping EPDM O-ring provides external tightness past upper spindle over entire operating and storage temperature and pressure range PA 66 thrust washer reduces friction and provides external tightness at high pressure If excessive torque is applied, SS-303 upper spindle fails before lower spindle to allow valve repair even when the cylinder is pressurized PEEK / PA 66 soft seat provides long life and low torque operation CG-3 device protects cylinder from rupture in case of fire SS filter net (60 mesh) as standard 280 HEX AF High durometer EPDM back-up ring prevents extrusion of O-ring Metal to metal seal prevents leakage past gland nut threads Gland nut O-ring arrests leakage in case the metallic sealing is compromised by external damage Lower spindle machined from naval brass for high torsional resistance SS spring loads non-rising upper spindle against thrust washer Special test for acetylene service ensures resistance to acetylene detonation in case soft seat is fully burnt This is achieved by seat design which ensures metal to metal sealing after soft seat is burnt out Available in different valve outlet and inlet connection (Refer valve selection guide) a b Dimensions are in mm Dimensions shown are for 25E inlet and BS-4 outlet Depends upon inlet connection Depends upon outlet connection Design Specifications MIN life : 2000 cycles Operating and storage temperature range : -40 C to + 85 C MIN closing torque : 8 Nm Failure torque : Nm Gland nut installation torque : Nm Fusible plug installation torque : Nm MAX test pressure (TP) : 60 bar Lubricant : Krytox GPL 225 Flow coefficient (Cv) : 025 Testing and certification Valve meets EN ISO 10297:2014, tested by BAM Berlin Production testing as per EN ISO 14246:2014

4 710 SQ AF Wrench size HEX AF Features and benefits for best-in-class performance Series KVO-10/D SS spring loads non-rising upper spindle against thrust washer Special test for acetylene service ensures resistance to acetylene detonation in case soft seat is fully burnt This is achieved by seat design which ensures metal to metal sealing after soft seat is burnt out Lower spindle machined from naval brass for high torsional resistance PEEK / PA 66 soft seat provides long life and low torque operation Generous undercut over selected diameter provides resistance to mechanical impact If excessive torque is applied, SS-303 upper spindle fails before lower spindle to allow valve repair even when the cylinder is pressurized SS filter net (60 mesh) as standard EPDM O-ring provides external tightness past upper spindle over entire operating and storage temperature and pressure range Drain hole on gland nut to prevent water trapping High durometer EPDM back-up ring prevents extrusion of O-ring PA 66 thrust washer reduces friction and provides external tightness at high pressure Metal to metal seal prevents leakage past gland nut threads Gland nut O-ring arrests leakage in case the metallic sealing is compromised by external damage Available in different valve outlet and inlet connection (Refer valve selection guide) Dimensions are in mm Dimensions shown are for 25E inlet and BS-4 outlet Design Specifications MIN life Operating and storage temperature range : 2000 cycles : -40 C to + 85 C MIN closing torque : 8 Nm Failure torque : Nm Gland nut installation torque : Nm MAX test pressure (TP) : 60 bar Lubricant : Krytox GPL 225 Flow coefficient (Cv) : 025 MAX weight of cylinder package mass valve can be used without protection - HT Brass : 111 kg - Brass as per IS 8737 : 833 kg Testing and certification Valve meets EN ISO 10297:2014, tested by BAM Berlin Production testing as per EN ISO 14246:2014 Certified by BAM Berlin to European Transportable Pressure Equipment Directive (TPED) and available with mark

5 Operating principle Series KHO-10/D and KVO-10/D Identifying features Both KHO-10/D and KVO-10/D are key operated O-ring seal valve with two piece spindle construction in side and top outlet respectively with identical operating mechanism specially designed for Acetylene service Upper spindle is pushed upwards against the thrust washer by the spring Threaded lower spindle interfaces with the upper spindle through a square drive to open and close the valve The design uses O-ring to create a seal around the upper spindle Polyamide thrust washer makes contact with the collar of the upper spindle under pressure and acts as anti-friction ring as the upper spindle rotates to open and close the valve Leakage through the gland nut threads is protected by metallic sealing with secondary protection provided by an O-ring below the gland nut threads PEEK / PA 66 soft seat material ensures low torque closure The operating mechanism remains operable at torques over 65 Nm The upper spindle fails safely at a torque of approximately 80 Nm without damaging the lower spindle and valve internal threads As the failure torque is ten times the minimum closing torque of 8 Nm, the valve operating mechanism withstands significantly high torques than necessary to close the valve, thereby offering reliable service life The design is qualified for special tests for Acetylene service as per EN ISO 10297:2014 ensuring the valve will resist acetylene detonation plus reflection and will be leak tight in service in case the soft seat is fully burnt out in the event of an Acetylene flashback Recommended opening procedure It is recommended that the valves always be opened gradually in anticlockwise direction until the required flow is achieved Opening the valve fully causes the lower spindle to ride upwards on its threads until it contacts the upper spindle collar Valves in the fully open position can be mistaken as closed by inexperienced or untrained operators When an operator checks a valve to ensure its position, he should always check by attempting to close the valve, never by trying to open the valve Recommended closing procedure Close the cylinder valve by rotating the upper spindle in the in the clockwise direction Valve installation Valving procedure and torque guidelines should be as per EN ISO Valving tools (eg sockets or jaws) used to screw the valve into the cylinder must only make contact with the flats provided in the valve body (and not touching any part of the valve outlet and/or PRD, if provided) The tools should fit the valve properly without causing damage 2 Over-torquing the valve into the cylinder must be avoided as they cause high stresses in the cylinder neck, leading to overload failures Over-torquing also leads to irreparable damage to the valve stem 3 As upper spindle is non-rising, do not over torque the valve in open direction 4 Do not use PTFE tapes on gland nut threads to stop gland leakage 5 Never attempt to replace soft seat in the bottom spindle 6 Repair and maintenance should only be carried out by trained personnel

6 Material of construction and assembly arrangement Series KHO-10/D 9 Gland nut Free cutting brass 8 6 Back-Up Ring EPDM Thrust washer PA 66 O-ring EPDM 7 Upper spindle SS Spring SS Lower spindle assembly Naval brass with PA 66/PEEK seat insert 2 Gland nut O-ring EPDM Fusible plug (optional) 12 Naval brass with fusible alloy 1 Valve body HT Brass/Brass as per IS Filter net Stainless steel Washer Free cutting brass

7 Material of construction and assembly arrangement Series KVO-10/D Lower spindle assembly Naval brass with PA 66/PEEK seat insert 3 Spring SS O-ring EPDM Back-Up Ring EPDM 8 Gland nut O-ring EPDM 2 Upper spindle SS Thrust washer PA 66 6 Gland nut Free cutting brass 9 Valve body HT Brass/Brass as per IS Filter net Stainless steel 10 Washer Free cutting brass 11

8 Disassembly, inspection and assembly instructions Series KHO-10/D and KVO-10/D Disassembly of valve 1 Place the valve assembly after removing from the cylinder in a vice or similar holding fixture The holding fixture must securely grip the valve body (1) on the wrench flats so that there is no damage to the valve body, internal bores and inlet and outlet threads 2 Using a 28 mm socket wrench or HEX box wrench, unscrew the gland nut (9) in counter clockwise direction The upper spindle assembly with O-ring (7), back-up ring (8) and thrust washer (6) will remove with the gland nut Remove the upper spindle assembly from the gland nut by pushing the upper spindle (5) from the top Be careful not to scratch the gland nut sealing surface 3 Invert the valve body to remove the spring (4) encased inside the lower spindle square 4 Use the upper spindle to unscrew the lower spindle assembly (3) from the valve chamber, by rotating it in counter clockwise direction 5 Remove the fusible plug (12) (if present and necessary) using a 12 mm socket wrench or HEX box wrench by rotating it in counter clockwise direction Inspection of valve and components 1 Valve body (1) a Inspect the valve body chamber for dirt, debris or damage Where possible, blow out the valve body chamber using clean, dry, compressed air or Nitrogen to remove any foreign particles b Inspect the valve body for seat damage and thread wear c Inspect if gland nut O-ring (2) is in place inside the valve body groove d Do not attempt to repair the valve body if damaged 2 Components a Inspect all parts visually for wear, damage Replace parts as necessary In case of damage to upper spindle (5) and / or elastomers, replace with new upper spindle subassembly b Inspect lower spindle (3) threads and soft seating for any sign of wear / damage Inspect the thrust washer (6) Replace if necessary c Inspect fusible plug (12) if installed for any damage/extrusion/porosity Assembly of valve 1 Lubricate parts as per GA drawing NOTE Customer will receive parts / spare kits in lubricated condition 2 Invert the valve body and place the filter net (10) and washer (11) inside the inlet counter bore for crimp fitting 3 Place thrust washer (6) to rest above the upper spindle (5) collar 4 Use special tool to fit O-ring (7) and back-up ring (8) in upper spindle groove Care should be taken to place the back-up ring above the O-ring in the upper spindle groove 5 Fit gland nut O-ring (2) inside the groove provided in the valve body (1) just below the gland nut threads 6 Place the lower spindle assembly (3) into the valve body and place the spring (4) inside the lower spindle square 7 Position the upper spindle subassembly to engage with the lower spindle square and drive the lower spindle assembly in clockwise direction by using a 710 mm key till it rests on the valve body seat 8 Screw in gland nut (9) avoiding damage to elastomers till it rests on valve body counter bore 9 Clamp valve body in bench vice between nylon clamps Tighten gland nut by using a 28 mm socket wrench or HEX box wrench at Nm in clockwise direction 10 Fusible plug installation (if applicable): a) Apply PTFE tape having thickness about 010 mm and width 6 mm as THD sealant, b) Begin at the small end of the plug and apply tape in clockwise direction with the small end facing the operator, c) Wrap approximately 3 turns and cut the tape cleanly d) Tighten the fusible plug (12), using a 12 mm socket wrench or HEX box wrench at Nm in clockwise direction NOTE Refer Material of construction and assembly arrangement page to identify the part No given in the bracket Last updated: 09 th July, 2016

9 Valve series KHD KHO-10/D KVD KVO-10/D Body HB High tensile brass (CW722R) FB Brass to IS 8737 Product selection guide Series KHO-10/D and KVO-10/D Valve item code matrix Inlet A 1BS 1" to BS 341-1: E 25E to ISO N 3/4-14 NGT to CGA V-1 32T 3175 (Type 4, Size 3 of IS:3224) 39J 1455 [W39-12 TPI, taper 3:26] 16N NGT Dip Tube 0 Not applicable Specification L EN ISO 10297:2014 P V Inspection Pi mark (In-house inspection service) ISO V mark (In-house inspection service) Gas service DA Acetylene Miscellaneous XX6 Seat insert PA 66 XXK Seat insert PEEK KVD HB 25E 0 S02 DA X XX L P XX6 060 (For example only) Outlet A S02 IS-2/BS-2/BS-4 PRD type 3 CG-3 (fusible plug) X B Not required / Not available PRD rating C 104 C XX B Not required / Not available Test pressure bar A Other inlet and outlet connections are available as per customer requirement B Fusible plug is not available for marked KHO-10/D design and KVO-10/D design

10 Frequently asked questions (FAQ) Series KHO-10/D and KVO-10/D 1) What are the advantages of soft seated two piece spindle valves in O-ring seal design over metal seated single spindle valves in packed design? The metal seated packed design valves have inherent limitation of particulate generation due to packing wear leakages (requiring the need to tighten the gland nut), increase in torque due to seizing / wear of the valve body threads during service and limitations in carrying out safe cylinder recovery procedure in case of breakage of valve spindle These limitations are addressed in KHO-10/D and KVO-10/D design as the two piece spindle construction using soft seating provides reliable external and internal tightness under normal operating condition, low torque operation, high cycle life and safe failure without damaging the valve body internals in case excessive torque is applied to the operating device and ease of maintenance 2) We limit closing torque during filling in our plant but have no control over the torques applied by our customers Would application of excessive torque damage the soft seating? KHO-10/D and KVO-10/D design has been endurance tested for 2000 cycle at a torque of 218 Nm as per EN ISO 10297:2014 without increase in torque The seat design and PA-66 / PEEK seat material is resistant to repeated high torques which the valves may experience during service within increase in minimum closing torque 3) Customers mishandle cylinders and valves and apply excessive torques to close valves resulting in twisting / breaking of the spindles How does the design withstand abuse? The KHO-10/D and KVO-10/D operating mechanism has a failure torque between Nm and this is favourably compared to packed design valves which fails between Nm In addition, the design has been tested for safe operation up to a torque of 65 Nm As a result the designs withstand high torques in the field and are easy to maintain in the event of twisting/breakage of spindles In case of breakage of spindle in packed design valves, the valve body internal threads are damaged which makes the valve body unusable Breakage of KHO-10/D and KVO-10/D upper spindle due to inadvertent tightening does not damage the lower spindle, internal threads of the valve body and seating area, thereby extending valve life and significantly reducing cost of ownership Design is tested to withstand impact strength between 300 J to 400 J depending upon the valve outlet orientation and body material This makes the valve body resistant to mishandling as the valve can be used on cylinders having total package mass between 833 to 111 kg without the use of protective cap (Refer design feature page for more details) 4) Does the design allow safe cylinder recovery procedure in the event of breakage of spindle on pressurized cylinder? In KHO-10/D and KVO-10/D, upper spindle is designed to fail first leaving lower spindle intact to allow safe cylinder recovery procedure The broken top spindle can be replaced by removing the gland nut (with the valve in closed position) even if the cylinder is pressurized, thereby also securing the contents of the cylinder (Refer video for carrying out safe cylinder recovery procedure- 5) Are PEEK and PA-66 soft seat compatible with Acetylene service? As per ISO , both PEEK and PA-66 are suitable for Acetylene service PEEK is more conducive and compatible with Acetylene and the solvent (Acetone) hence preferred by gas companies as it offers better performance and is less prone to weight loss

11 Frequently asked questions (FAQ) Series KHO-10/D and KVO-10/D 6) Why is there a need to lubricate cylinder valves? KHO-10/D and KVO-10/D valves are assembled with high quality lubricant compatible with Acetylene to reduce wear in moving parts thereby preventing seizing and galling in service 7) What is the function of the spring inside the valve? Stainless steel spring is provided to load the upper spindle against the thrust washer 8) What is the expected life of O-ring/back-up ring? Should the entire upper spindle subassembly be replaced in case of any damage to upper spindle or O-ring/back-up ring? We use finest quality peroxide cured O-ring/back-up ring from reputed suppliers for long service life The O-ring is protected in service from extrusion by thrust washer and back-up ring O-ring /back-up ring do not require to be replaced If the upper spindle is required to be changed, we recommend replacing the upper spindle subassembly, ie; factory fitted O-ring/back-up ring, duly lubricated (Refer video of assembly instructions- 9) Are valve refurbishing tools required/available for maintenance? The user can maintain valves only by replacing parts The valve body does not require tapping of internal threads or seat cutting 10) Do we need to tighten gland nut if external leakage is observed? The leakage through the upper spindle is protected by thrust washer under high pressure while leakage at low pressure is protected by spindle O-ring protected by a back-up ring Leakage through the gland nut threads is protected by metallic sealing made by gland nut which abuts at the inner end with the valve body The gland nut O-ring comes in play in the event the metallic sealing is compromised by external impact to the gland nut Hence the design is well secured against gland leakage and there is no need to retighten the gland nut 11) Is it possible to replace soft seat in the lower spindle in case it is worn out? Both soft seat material variants PEEK and PA 66 seat have high cycle life and load bearing capacity If the seating is worn out, the lower spindle assembly needs to be changed as the soft seat is factory fitted in the lower spindle by special crimping operation which cannot be replicated at user end Disclaimer Proper use and good maintenance enhance life of the valve However the recommendations in the FAQ are not meant to substitute existing plant procedures

12 Natun Rasta, Bilkanda, 24 Parganas (N) Kolkata , West Bengal, India Ph: , Fax: post@teknovalvescom, Web: wwwteknovalvescom Copying or extraction from this document shall not be done without Tekno Valves permission, since information contained herein includes proprietary information Last updated: 09 th July, 2016 PHalder