Phoenix Pipeline Products Limited

Installation, Operation and Maintenance Manual

AREA VALVE SERVICE UNITS

Phoenix Pipeline Products Limited

Unit 9 Tel No.: +44 (0) 161 428 7200
McKenzie Industrial Park Fax No.: +44 (0) 161 428 7010
Bird Hall Lane www.p3-phoenix.com
Stockport Email: sales@p3-phoenix.com
SK3 0SB
U.K.
FM 669038 MD 669035
FM 669038
MD 669035
 Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual

Contents Page

Section Page

Product Description
General 3
Labeling 3
Pipeline Pressure Sensors 3
Door Monitoring 3

Operation
General 4
Authorised Access 4
Emergency Access 4

Safety
General 4

Installation
Installation
General 5
Assembly 5
Surface Mounting 6
Flush Mounting – Solid Wall 6
Flush Mounting – Partition Wall 6
Labeling 7

Testing
General 7
First Fix Testing 7
Second Fix Testing 7

Maintenance
General 7
Preventative Maintenance 7
Valve Replacement 8
Spading Off 8
NIST ‘O’ Ring Replacement 8

Spare Parts Lists

General Components 9

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 Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual

1. Product Description
1.1 General
The Area Valve Service Unit (AVSU) is designed to isolate a gas supply during
installation, maintenance and in the event of an emergency. The unit comprises a ball
valve, mounted in a fire retardant, heat resistant lockable ABS enclosure and is
supplied complete with ø22mm or ø28mm copper stub pipes for brazing to the fixed
pipeline system.
The AVSU is suitable for flush or surface mounting and is available for oxygen,
nitrous oxide, 50% oxygen/50% nitrous oxide mixture, medical air, surgical air and
medical vacuum.
Access to the valve assembly is either by using the key provided to unlock the
enclosure or, in the event of an emergency, by using the emergency release
mechanism.
The AVSU is complete with non-interchangeable screw thread (NIST) connectors
either side of the valve for purging, testing, gas sampling and for the connection of
an emergency supply. Each NIST connector incorporates a check valve to prevent
leakage when the NIST cap is removed.
The unit is supplied with two through spades fitted between the valve and the
copper pipe stubs. A blank spade is included to replace a through spade should the
valve need isolating for maintenance or future works. The spades are colour coded
for identification – through spades are white and the blank spade is red.
1.2 Labeling
All gas identity labeling is fixed internally and is viewed through the door window.
This eases the final fix installation as any door can be fitted to any AVSU.
The unit also includes an area label plate beneath the window to which a self-
adhesive label identifying the area served by the AVSU can be fixed.
1.3 Pipeline Pressure Sensors
The unit has a provision for installing internal pipeline pressure sensors to monitor
the downstream pipeline pressure, which in turn, can be connected to the area alarm
panel.
1.4 Door Monitoring
The unit has a provision for installing a reed switch to monitor the status of the door
to identify possible misuse of the emergency release mechanism which will alarm
when the door has been opened using the emergency release handle.

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 Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual

2. Operation
2.1 General
The AVSU is used to isolate the gas supply in a department/area for maintenance or
in an emergency. The gas supply is isolated by rotating the valve handle 90º to the
“closed” position as indicated on the valve cover plate. To reconnect the gas supply,
the valve handle is turned back through 90º to the “open” position indicated on the
valve cover plate.
The AVSU is used to physically isolate the gas supply, during periods of modification
works for example, by inserting a blank spade between the valve and the pipeline.
Please refer to section 6.4 for the procedures for spading off.
The NIST connectors situated upstream and downstream of the valve can be used for
purging, testing, gas sampling and for the connection of an emergency supply. To
connect to a NIST connector, unscrew the NIST cap and screw on the connecting
equipment. It is only possible to connect the correct gas or vacuum NIST fitting. Upon
completion of the procedure, the equipment should be removed, the NIST cap
replaced, the door closed and locked and the key returned.
2.2 Authorised Access
To gain access to the valve assembly, the key for the door should be obtained from
the responsible person. A Permit-to-Work may be required depending on the nature
of the work to be carried out. It is advisable to close and lock the door of the AVSU if
you need to leave the AVSU during the completion of your work. Upon completion of
the work, the door should be closed and locked and the key returned to the
responsible person immediately.
2.3 Emergency Access
If access is required to the valve assembly in an emergency, this can be achieved
without having the key to the door by rotating the red emergency release handle
through 45º to unlock the door. The correct key must then be obtained to reset the
emergency release mechanism and lock the door. It is not possible to lock the door
without the correct key after the emergency release handle has been used. The key
should then be returned to the responsible person immediately.
To reset the mechanism, insert the correct key and turn through 90º anti-clockwise
until the key stops, then turn the key a further 45º past the internal stop (some
resistance will be felt). The emergency access handle can then be rotated upwards
and the key turned clockwise to lock the door.

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 Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual

3. Safety
3.1 General
This equipment should be operated and maintained by personnel who are suitably
trained and are fully conversant with HTM 2022, HTM 02-01 and BS EN ISO 7396-1.

This equipment should be kept clean and be free from oil and grease at
all times. Oil and grease will ignite spontaneously in the presence of
oxygen. If you suspect that any equipment is contaminated, do not use
it.

No attempt should be made to use or modify this equipment for use with a gas other
than as identified.
This equipment should not be operated at pressures exceeding those stated in HTM
2022, HTM 02-01 and BS EN ISO 7396-1.

DO NOT USE CLEANING/DETECTION FLUIDS WHICH CONTAIN COCONUT

DIETHANOLAMIDE AS THIS IS HARMFUL TO ENGINEERING POLYMERS, SEALS AND
METAL PARTS.
4. Installation
4.1 General
The AVSU’s may be installed in a horizontal array or a vertical array. In either case, it
is advisable to maintain the following sequence from left to right or top to bottom.
O2; N2O; 50% O2/50% N2O; Medical Air; Surgical Air; Vacuum;
When flush mounting AVSU’s, ensure that an adequate space is left between units to
allow the fitting of the flush surrounds.
The AVSU should be installed at a height that is easily accessible by hand.
Consideration should be given to furniture or crash rails that may be installed at a
later stage of the construction.
The AVSU should be installed in a location where access for connecting an
emergency supply will not be hindered.
4.2 Assembly
1. Remove the door, flush surround and valve cover plate from the AVSU assembly
and store in a safe place.
2. Ensure that a cable entry hole is drilled in the enclosure if a pressure sensor is to
be fitted.
3. Determine the position of the AVSU and secure to the wall using suitable
fixings ensuring that the unit is horizontal and plumb.
IMPORTANT:
IMPORTANT Ensure that the connection point for the pressure sensor is on the
downstream side of the pipeline system.
4. Braze the copper pipe stubs to the fixed pipeline system. If the joints to be
brazed are close to the enclosure, take care/precautions to prevent damage to
the enclosure.
5. Fit blanking plugs into the pressure sensor connection points (if required).
6. Pressure test the pipeline system.
7. Upon satisfactory completion of the first fix pressure test, install the pressure
sensor (if required) and ensure that the cabling works for the sensors are
completed.
8. Install the valve cover plate, flush surround and door.

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 Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual

9. Apply the self-adhesive label identifying the areas served by the AVSU to the
area label plate, close and lock the door.
10. Fit an identity tag to the keys associated with the AVSU and keep in a safe
place.
4.3 Surface Mounting

4.4 Flush Mounting – Solid Walls

4.5 Flush Mounting – Partition Walls

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 Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual

4.6 Labeling

5. Testing
5.1 General
All AVSU’s should be pressure tested once incorporated into the fixed pipeline
system. The testing is split into two phases as detailed below. The second phase of
testing can only be carried out when the first phase has been deemed satisfactory
and accepted.
5.2 First Fix Testing
This pressure test is carried out when the first fix installation has been completed.
The required testing pressures are as stated below or as per the contract specification
if different.
• First fix testing pressures in accordance with HTM 2022/HTM 02-01 are;
(a) 10 barg. /10 barg. for compressed medical gas systems.
(b) 18 barg./18 barg. for compressed surgical gas systems.
(c) 7 barg. /5 barg. for vacuum systems.
• First fix pressure tests in accordance with BS EN ISO 7396-1 are 1.2 times the
maximum pressure which could occur under a single fault condition.
5.3 Second Fix Testing
This pressure test is carried out upon completion of the second (final) fix installation
with the system pressurised to nominal distribution pressure in accordance with HTM
2022, HTM 02-01 and BS EN ISO 7396-1.
6. Maintenance
6.1 General
The AVSU is used mainly to assist in isolating the gas supply during maintenance
procedures. However, some minimal maintenance may be required on the unit as
detailed below.
6.2 Preventative Maintenance
Area valve service units should be subjected to regular inspection and testing as
detailed below.
• Monthly;
(a) Visually inspect the enclosure for signs of damage.
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 Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual

(b) Check the door is securely locked.

• Annually;
(a) Open the door and clean any debris from the mounting box.
(b) Check the valve operates freely.
(c) Check the blank spade is in the box for future use.
(d) Check the operation of the emergency release mechanism.
(e) Check the AVSU is correctly labelled for the area served.
(f) Condition of ‘O’ rings/ seals to be checked and replaced where necessary.

6.3 Valve Replacement

To replace the valve;
1. Obtain a Permit to Work and the correct key.
2. Isolate the gas supply to the AVSU.
3. Unlock and open the door and remove the valve cover plate.
4. Unscrew the hexagon head nuts from either side of the valve and extract the
valve.
5. Remove the two through spades and remove the ‘o’ rings taking care not to
scratch the grooves. Install new ‘o’ rings.
6. Remove the ‘o’ rings from the brass flanges on the stub pipes taking care not to
scratch the grooves. Install new ‘o’ rings.
7. Offer a new valve and a resealed through spade up to a stub pipe and secure
with the hexagon head nut (finger tight).
8. Slide the remaining resealed through spade between the new valve and the
other stub pipe and screw on the hexagon head nut (finger tight).
9. Tighten up both hexagon head nuts.
10. Reconnect the gas supply and check for leaks.
11. Replace the valve cover plate, close and lock the door.
12. Return the key to the responsible person.
6.4 Spading Off
To insert a blank spade into the valve assembly;
1. Obtain a Permit to Work and the correct key.
2. Unlock and open the door and close the valve.
3. Remove the valve cover plate.
4. Unscrew the hexagon head nuts from the downstream side of the valve and
extract the through spade.
5. Insert the blank spade, with its ‘o’ ring correctly located against the valve
outlet, and tighten up the hexagon head nut.
6. Replace the valve cover plate, close and lock the door. The downstream section
of the pipeline is now isolated from the upstream supply.
7. Return the key to the responsible person.
6.5 NIST ‘O’ Ring Replacement
1. Obtain a Permit to Work and the correct key.
2. Unlock and open the door and close the valve.
3. Remove the NIST blank cap and place in the box.

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 Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual

4. Unscrew the serviceable plunger from the NIST body. The captive plunger will
substantially reduce the gas flow.
5. Remove the ‘o’ ring from the serviceable plunger taking care not to scratch the
groove. Install a new ‘o’ ring.
6. Replace the serviceable plunger and check for leaks.
7. Fit the NIST blank cap, close and lock the door.
8. Return the key to the responsible person.
7. Spare Parts Lists

7.1 General Components

Item No. Description Part Number

1 AVSU Door Assembly, Emergency Access 1-15000-09

2 22mm AVSU Ball Valve 1-15001-09
3 28mm AVSU Ball Valve 1-15002-09
4 Through Plate, 22mm 1-15003-09
5 Through Plate, 28mm 1-15004-09
6 Blank Plate, 22mm 1-15005-09
7 Blank Plate, 28mm 1-15006-09
8 22mm AVSU O-ring Service Kit 1-15007-09
9 28mm AVSU O-ring Service Kit 1-15028-09
10 Blank NIST Cap 1-15008-09
11 Area Label Plate (for emergency access door) 1-15009-09
12 ID Label, O2 1-15010-01
13 ID Label, N2O 1-15011-02
14 ID Label, O2/N2O 1-15012-03
15 ID Label, Medical Air 1-15013-04
16 ID Label, Surgical Air 1-15014-05
17 ID Label, Vacuum 1-15015-06
18 ID Label, Flow Direction Arrow 1-15016-09
19 Open/Close Valve Cover Plate 1-15025-09
20 AVSU Flush Surround 1-15024-09
21 22mm AVSU Valve Handle 1-15023-09
22 28mm AVSU Valve Handle 1-15027-09
23 NIST Serviceable Plunger 1-15026-09
24 Door lock and keys (for emergency access door) 1-15017-09
25 AVSU Window (for emergency access door) 1-15018-09

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 Phoenix Pipeline Products Limited
Installation, Operation and Maintenance Manual

Due to our policy of continuous product improvement, Phoenix Pipeline Products Ltd. reserve the right to alter
dimensions and/or specification without notice although every effort will be made to advise of any such
modifications.

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