VAAS Automation C47 Series Cryogenic valve

(A 100% Subsidiary of Bray Controls India Pvt ltd)

Installation,Operating,Maintenance & Safety Manual

Sizes Included:
- 2 " (DN 15- DN 50)

1.GENERAL
This Installation, Operating & Maintenance manual covers the instructions
required for safe use of Vaas Automation cryogenic ball valve. Before using
a valve, read the entire IOM carefully and make sure you understand
everything.

WARNINGS & SAFETY INSTRUCTIONS

Vaas Automation cannot anticipate all of the situations a user may
encounter while installing and using Vaas Automation valves. The user
MUST know and follow all applicable industry specifications on the safe
installation and use of these valves. Misapplication of the product may
result in injuries or property damage. Refer to Vaas Automation product
catalogues, product brochures and installation, operating and
maintenance manuals for additional product safety information or
contact Vaas Automation technical service.

Keep hands and objects away from the valve ports at all times.
Actuated valves could be accidentally operated, resulting in
serious injury or valve damage.

Before removing a valve from the line always makes sure the

Utmost caution must be taken when handling a valve that has

line has been depressurized and drained.

toxic, corrosive, flammable or a contaminant nature media

flowing through its pipeline. The following safety precautions are
recommended when dismantling valves with hazardous media:

a. Wear eye shield, protective headgear, clothing, gloves and

footwear.
b. Have available running water.
c. Have a suitable fire extinguisher when media is flammable.

Do not try to operate a valve that exhibits any sign of leakage.

Do not use or substitute non Vaas Automation components or

Isolate the valve and either repair or replace it.

parts in Vaas Automation valves and assemblies.

VAAS Automation C47 Series Cryogenic valve

(A 100% Subsidiary of Bray Controls India Pvt ltd)

Installation,Operating,Maintenance & Safety Manual

2. LIMITATIONS

Caution: DO NOT install Cryogenic valves with the extended

The correct selection of materials of construction, seats and seals,

bonnet tilted more than 450 from the upright vertical position.

internal valve components and pressure/temperature ratings

determines the safe use of the valves and the particular performance
requirements for the application. This information can be found on the

4.1 General

Check the valve nameplate for identification of materials

(See Figure 1).

name plate welded to the valve body.

Valve Marking and Labeling

For Polyfill seat, maximum allowable pressure rating size wise in

mentioned in below table.

All valves marking are on a nameplate which is riveted to

the valve body. Valves in the European market and above 1" carry

Regular
bore

Pressure
rating

Full
bore

Pressure
rating

DN 15

70 bar

DN 15

70 bar

DN 20

70 bar

DN 20

70 bar

DN 25

70 bar

DN 25

70 bar

N 32

70 bar

DN 32

70 bar

DN 40

70 bar

DN 40

70 bar

DN 50

70 bar

DN 50

49.6 bar

the CE mark with the information required by the PED

Fig.1

As the variety of applications, these valves can be used in is large, it

is impossible to cover all installation and maintenance instructions for
servicing the valves. It is the owner's responsibility to use the valves
as recommended and in accordance with the pressure and
temperature limits as stated in this manual. Where in doubt, please

All Vaas Automation cryogenic valves are uni-directional

consult with Vaas Automation.

and must be installed for flow in one direction as

CAUTION:

indicated by the flow arrow riveted to the body and

protected

bonnet pad.

The valves should be used in a well designed, adequately

system

to

ensure

that

pressure

and

When the valve is in the closed position the ball relief

temperature limits are not exceeded.

hole will be seen in the upstream port of the valve as

Valve surface temperature may become extremely cold

indicated by the arrow. The stem head has an engraved

due to operating conditions. Prevent any type of direct

"T" mark identifying the ball port and the pressure relief

contact with the valve that may harm the workers.

hole direction (See Figure 2).

The valves should be used in a well designed, adequately

supported piping system such that it will not be subjected

Valve Top View

Fig.2

to undue forces or hydraulic shocks during the service.

The valves are not designed to operate during or after

earthquakes or under fatigue conditions. It is the
responsibility of the owner to determine if fatigue
conditions exist.

3. STORAGE

Inspect the valve interior through the end ports to

Cycle the valve and inspect any functionally significant

Read all the literature, and note any special warning tags

Prior to storage, inspect the valve for shipping damage. It is

recommended to keep the valves in their bags and in a clean and

determine that it is clean and free from foreign matter.

protected environment until ready for use. Keep all protective

packaging, flange covers and end caps attached to the valves during

features.

storage.

or plates attached to the valve.

After the valve cools down, follow the steps 2 to 9 of the

Disassembly section and section 7 to 13 of the Assembly

4. INSTALLATION

section.

VAAS Automation C47 Series Cryogenic valve

(A 100% Subsidiary of Bray Controls India Pvt ltd)

Installation,Operating,Maintenance & Safety Manual

5. MAINTENANCE

6. DIS ASSEMBLY

5.1

GENERAL

Refer exploded view (figure 5) for Identification or various &

VAAS AUTOMATION valves have a long and trouble free

their location in the assembly.

life, and maintenance is seldom required. When

The following instructions are for the disassembly

maintenance is necessary, valves can be refurbished on

C47 (Size 1/2 to 2) #600, Rating

site.

attempting to remove the valve from the pipeline, to

problems, the following procedures should be followed:

insure pressure has also been discharged from the valve

If leakage at the stem is noted, tighten the gland nut about

a 1/8-turn as a routine maintenance procedure. This will

cavity.

Loosen all flange bolts and slide the valve out of the

With the valve in the open position, remove the end &

Remove the soft seat and body graphite or PTFE seal. In

compensate for any wear or settling of the gland packing.

Caution: Excessive tightening of the stem nut can result

pipeline.

in accelerated seal wear and high valve operating torque.

If the valve is removed from the line and disassembled,

means of Spanners.

replacement of all seats and seals is recommended using

case of spiral wound graphite or PTFE seals are present

the appropriate Vaas Automation Repair kit. Examine all

in the assembly, care should be taken while removing

metallic sealing surfaces such as ball, stem, and the

surfaces on the end connectors that contact the seats for

without damage or dents to sealing faces.

Support the ball to prevent it from falling out of the body

wear, corrosion or damage.

and turn the handle to the closed position for its removal.

Only Vaas Automation's spare parts should be used. A

Set the ball aside in a clean and secure area for reuse.

soft parts repair kit from Vaas Automation consists of the

Loosen the 6 cap screws and remove the extended

Remove and discard the bonnet seal and the PTFE stem

Remove the wrench nut, serrated washer, and handle,

following:

bonnet from the valve body.

2 x seats
1 x gland packing
1 x stem thrust bearing

bearing.

1 o r 2 x body seals

locking clip, gland nut, disc springs and gland. Place all

1 x bonnet seal

components removed, in a clean secure area.

1 x stem bearing

Cycle the valve with the line pressure fully relieved before

To extend valve performance and reduce possible plant

Slide the stem and remove it from the extended bonnet.

In addition to soft parts kits, other spare parts available

Discard the stem thrust seal and packing, taking care not

from Vaas Automation are: valve balls, stems, glands,

to scratch or nick the stem or the packing bore area of the

bolts, screws and nuts. Should additional parts be

bonnet.

required, it is recommended that the complete valve be

replaced.

FIGURE 4

When ordering repair kits, please provide the valve size

Fool Proof Trim Design

and full figure number code and series

.

FIGURE 3
Cryogenic valve body and interlocked end connector

Fig.4

Fig.3

VAAS Automation C47 Series Cryogenic valve

(A 100% Subsidiary of Bray Controls India Pvt ltd)

Installation,Operating,Maintenance & Safety Manual

7.ASSEMBLY
Refer exploded view (figure 5) for Identification or various &
their location in the assembly.

TABLE 1
Gland Nut Tightening Torque for C47

The following instructions are for the assembly

C47 (Size 1/2 to 2) #600 Rating

Place and keep the flanged end face on flat surface.

Place the one seat into the valve end grooved face with
its round profile facing up.

Reduce Bore

PTFE Seals

Full Bore

Graphite Seals

Nm

in.lb

Nm

in.lb

35

6-4

53-35

1/2"-3/4"

1/2"

1"-1 1/4"

3/4"-1"

80

11-9

97-80

1 1/2"-2"

1 1/4"- 1 1/2"

13

115

1613

140-115

Place the new graphite seal on a valve end groove area

on both ends.

*Graphite stem seals must be torque to the higher torque figure in

Place the valve body on that valve end.

the table, then cycle 8 times and re torque to the lower torque figure.

Follow the arrow mark on the body and place the ball
inside the body with the pressure relief hole towards the

IMPORTANT:

arrow's tail and with the ball groove face up.

An excessively tightened gland nut can cause excessive packing

wear and increasing stem torque.

Place the second seat to the valve body.

Place the second valve end of the valve body to ensure

the new graphite seal at the end.

Place the body bolts in between valve body and body

Tighten the body bolts on both sides according to the

end.
Torque figures (Table 2)

Locate the PTFE stem bearing inside the valve top

Place the stem thrust ring on the stem.

Slide the stem into the extended bonnet with the threaded

platform.

side first and carefully guides it up through the bonnet

TABLE 2
Body Bolts Tightening Torque for C47
Reduce
Bore
1/2"-3/4"
1"-1 1/4"
1 1/2"-2"

Full Bore

Nm

in.lb

1/2"

18

160

3/4"-1"
1 1/4"- 1
1/2"

39

345

65

575

TABLE 3
Bonnet Bolts Tightening Torque for C47

bore.

Insert the bonnet graphite seal inside the extended

Holding the exposed stem tip together with the extended

Reduce
Bore
1/2"-3/4"

bonnet, slide the stem into the ball.

1"-1 1/4"

Note: the unique design will allow only one correct

1 1/2"-2"

bonnet bottom flange.

Full Bore

Nm

in.lb

1/2"

55

3/4"-1"
1 1/4"- 1
1/2"

80

39

345

engagement. (See figure 4)

With the bottom flange of the bonnet aligned with the

valve platform, and with the arrows on the body and
bonnet pointing in the same direction, hand tighten the
bonnet bolts and spring washers.

Tighten the bonnet bolts to the torque figures (Table 3),

Make sure the valve stem is free to move (0.5 mm) up

Holding the stem, insert the new packing over the

and down.

Stem and into the stem bore. Place the metal follower and
the two disc springs (face to face) onto the stem.

Thread the gland nut onto the stem. Tighten the gland nut

Place the locking clip on the gland nut by adjusting the

Place the handle, serrated washer and thread the wrench

to the torque figures (Table 1).

orientation of the nut (in a clockwise direction only).

nut onto the stem. While holding the handle, tighten the
wrench nut tightly.

Leave the valve in the open position for flushing the line.

VAAS Automation C47 Series Cryogenic valve

(A 100% Subsidiary of Bray Controls India Pvt ltd)

Installation,Operating,Maintenance & Safety Manual

Exploded view:

Fig.5

VAAS Automation C47 Series Cryogenic valve

(A 100% Subsidiary of Bray Controls India Pvt ltd)

Installation,Operating,Maintenance & Safety Manual

Material Description:

Item

Description

Material Specification

Qty

Body

ASTM A351 Gr.CF8M

Screwed End

ASTM A351 Gr.CF8M/CF3M

Ball

ASTM A351 Gr.CF8M,ASTM A564

17-4 PH

Stem

ASTM A564 17-4 PH

5*

Seat

PCTFE, CARBON FILLED TFM

6*

Body Seal

SPRIAL WOUND SS 316 GRAPHITE

GASKET, SPRIAL WOUND SS 316
PTFE GASKET

7*

Stem Thrust seal

25% CARBON FILLED PTFE, NRG

8*

Packing

GRAPHITE, PTFE

9*

Follower

ASTM A 479 Gr.316

10

Disc Spring

17-7 PH

11

Stem nut

ASTM A194 Gr.8M

12

Locking clip

ASTM A164 304

13

Handle

ASTM A240 430

14

Serrated Washer

SS 316

15

Gland nut

ASTM A194 Gr.8M

16

Sleeve

VINYL PLASTISOL

17

Stop Pin

SS 316

18*

Bonnet Seal

SPRIAL WOUND SS 316 GRAPHITE

GASKET , SPRIAL WOUND SS 316
PTFE GASKET

19*

Stem Bearing

PTFE

20

Body Bolt

A2-70

21

Body Bolt Spring Washer

SS 304

22

Bonnet Bolt

A2-70

23

Bonnet bolt Spring Washer

SS 304

24

Bonnet

ASTM A479 GR.316

25

Anti Static Spring

SS 316

26

Anti Static Ball

SS 316

27

Flow Arrow

ASTM A167 304

28

Stainless Steel Rivet

SS 304

VAAS Automation C47 Series Cryogenic valve

(A 100% Subsidiary of Bray Controls India Pvt ltd)

Installation,Operating,Maintenance & Safety Manual

8.Functional Safety Instructions for SIL

8.3 Proof Testing

8.1 Brief overview of SIL

demand safety functions. Low demand is defined in IEC

used as an element in an automated Safety Instrumented

61508-4 as a demand from the process less frequently

Function (SIF) that is specified to achieve a Safety

than once a year.

Integrity Level (SIL), e.g., SIL 1, 2 or 3.

The reliability of the valve has been analyzed in

demand (PFDAVG). A nominal interval of 8,760 hrs (1

The compliance with IEC 61508 includes hardware

year) and Mean Time To Repair (MTTR) of 8 hours has

reliability (for probabilistic failures) and the entire quality

been used in the data sheet below for PFDAVG

and functional safety management system (for systematic

illustration purposes. If different values are used, the

failures).

PFDAVG for a non-redundant arrangement (i.e., where

The information that follows is intended to allow correct

product

A suitable proof test interval (T1) should be used in order

to achieve the required average probability of failure on

accordance with IEC 61508 for use in SIL applications.

A periodic proof test should must be performed to verify

the element safety function when it is used in low

The following instructions are applicable when the valve is

selection,

system

integration,

the safety function relies on a single actuator coupled to a

installation,

single valve) can be re-calculated as follows:

operation and maintenance to enable the SIL specified for

the safety instrumented function to be achieved and

PFDAVG

= (DU + DD) tCE

maintained, as far as this product is concerned. The

actual SIL will depend on many system considerations

Where tCE (the channel equivalent down time) =

that are outside the scope of this product and will rely on

(DU / DD) (T1/2 + MTTR) + (DD / D) MTTR

personnel who are competent in the functional safety

aspects of the various lifestyle activities mentioned above.

For redundant arrangements and non-prefect proof testing refers to

If necessary, refer to IEC 61508-2 and IEC 61508-6 for

IEC 61508-6 for the equations.

further information regarding how this element may be

The periodic proof test should be performed on the valve coupled in-

used in safety instrumented functions according to the SIL

situ to its actuator in order to verify all aspects of the functional

required. (Higher SIL functions may be possible with

specification required for the application, in particular:

redundant configurations).

Cycle the valve using the automated signal to the actuator

Verify the valve reaches full stroke (to the process safe

8.2 Conditions or restrictions for use in SIL

position) within the specified time with no under or over

travel

applications

Verify correct functionality of the position sensors and

Repeat the above steps a few times to ensure consistent

Log the successful proof test and/or any servicing/repairs

associated PVST device

Valves and actuators for SIL applications must be

automated. The manual wrench (if supplied) must be
removed in accordance with the instructions in this

behavior

manual (see section 8.0) to ensure there is no possibility

of interference with the automated safety function.

in accordance with local procedures

Fugitive emission detection methods are to be employed

In addition to the verification steps above for the automated safety

to detect the leaks when no leaks are a specified safety

function, the product should must be visually inspected and any

requirement.

repairs undertaken to restore the product to its fully working condition.

The valve is not to be used with media that may contain a

In particular, check for any signs that could lead to loss of integrity

slurry as this can damage the internal parts of the valve.

(e.g., leaks, media residue or incompatibility, rust, corrosion,

All the relevant instructions and measures stated in this

mechanical damage, noise or loosening, unauthorized tampering,

manual should be strictly complied with to provide the

etc.)

correct level of systematic safety integrity in SIL

applications.

Failures that can be diagnosed by external means (which

need to be provided by the User) shall result in a safe
action (e.g., process shutdown) or be repaired within the
Mean Time To Repair (MTTR) assumed in the PFD

calculations (8 hrs).

VAAS Automation C47 Series Cryogenic valve

(A 100% Subsidiary of Bray Controls India Pvt ltd)

Installation,Operating,Maintenance & Safety Manual

8.4 Functional safety specification C47 series
Ball valve

PARAMETER

DATA VALUE / INFORMATION

NOTES

Product identification

C47 series Ball Valve, Port sizes 1/4" to 6"

Element failure mode

Fail to shutoff flow (with no internal leak) in the Fail to allow flow (without obstruction) in the
closed position and with no external leak
open position and with no external leak

Random hardware failures

(Failures hour-1)

4.52E-05

1.40E-08

0.00E-00

DD

DU

2.40E-05

1.40E-08

0.00E-00

[1], [3]

DU

PFD

DD

(Low demand safety function)

[4], [5]

AVG

4.23E-04

2.54E-04

1.40E-08

1.40E-08

100.0%

100.0%

(Proof test = 1 year; MTTR = 8 hrs)

PFH (High demand safety function)
Safe failure fraction (SFF)

[2]

Type:

Type A

Hardware fault tolerance (HFT)

Hardware safety integrity

Route 1H (by theoretical analysis: FMEDA)

Systematic safety integrity

Route 1S (by quality system techniques and measures)

Systematic Capability

SC 3 (suitable for use up to SIL 3 in respect of systematic measures)

Restrictions in use

Refer to section 11.2

Environment limits

Refer to Pressure & Temperature Graph in Product Catalogue

Lifetime/replacement limits

10000 cycles

[2]

Proof Test requirements

Refer to section 11.3

[5]

Maintenance requirements

Refer to section 7.0

[2]

Diagnostic Coverage (DC)

Position sensing / diagnostics must be provided (externally) by the User

[1]

Diagnostic test interval

User specified; must be frequent enough to qualify

[1]

figures
DD

Repair constraints

Refer to section 7.0

Note:3

Note:1

dangerous failures (DD) must result in an action to put

methods must be implemented in order to detect

the process into a safe state by some other means, or the

dangerous failures (DD) that can be revealed by this

product must be replaced or repaired within the mean

method. Automatic diagnostic testing must be frequent

enough compared to the expected demand rate of the
safety function.

time to repair (MTTR).

Note:4

Note:2

The user must ensure that the occurrence of any detected

Position sensing and partial valve stroke test (PVST)

Regular proof testing (at the specified interval T1) must

result in the repair of any failures not previously

When the product is used in high demand mode, the

number of cycles in its life time should not be exceeded
before it is removed for full overhaul and replacement of

diagnosed (DU) by other means

Note:5

If the mean time to repair (MTTR) or the proof test interval

all parts subject to wear. (High demand is defined in IEC

(T1) are different from those assumed in the PFDAVG

61508-4 as a demand from the process more frequently

calculation in this document, then the PFDAVG should be

than once a year).

re-calculated

and

the

SIL

capability

re-verified

accordingly.