Flow Control Valve Mastery for Gas Filling Operations

Based on general industry trends, the gas filling operations market is projected to experience significant growth due to increasing demand in industries like healthcare, food packaging and clean energy. One report forecasts a CAGR in the global industrial gases market of 11.65% by 2032. Factors like the push for cleaner fuels, growth in industrial gases and advancements in gas filling technologies are anticipated to drive further market expansion.

Flow control valves in gas filling operations regulate the rate and volume of gas flow, allowing precise control over the filling process. They ensure accurate and consistent gas delivery, preventing overfilling and maintaining safety by controlling pressure during the filling operation. Some of the key applications can include:

Industrial gas filling like compressed gas cylinders (e.g. oxygen, nitrogen, argon)
Liquefied petroleum gas (LPG) bottle filling
Compressed natural gas (CNG) vehicle refueling stations
Hydrogen refueling stations for fuel cell vehicles
Medical gas systems
Gas control for vapor deposition processes in semiconductor manufacturing
Welding gas mixtures

At its core, flow control is all about measurement. While there are several ways to quantify flow, most gas filling operations rely on volumetric flow rate. This is not an arbitrary preference; it is directly tied to production rates and, by extension, profitability.

By measuring the volume of gas transferred per unit time, engineers can accurately predict fill times, manage inventory and optimize production schedules. A better understanding of flow control valve operation and adjustment can help gas filling operations and other applications for flow control valves, achieve production goals and maintain safety.

How do you adjust the flow on a flow control valve?

Adjusting flow control valves is both an art and a science. It’s not simply a matter of turning the knob until the desired flow rate is achieved. Proper adjustment requires a deep understanding of the entire system. The process begins with a thorough review of the manufacturer’s guidelines. Each valve type may have specific adjustment procedures that need to be followed meticulously.

Next, consider the current system conditions. The type of fluid, its temperature, and the system pressure will all influence how the valve responds to adjustments. When making changes, remember that small, incremental adjustments allow the system to stabilize, providing a clearer picture of the valve’s impact.

What is the best way to adjust valves?

The best approach to valve adjustment involves a systematic methodology:

Start with a plan: Know your target flow rate and the current system conditions.
Use proper tools: Ensure you have the correct equipment for precise adjustments.
Monitor the entire system: Pay attention to how all components react to valve changes.
Document everything: Keep detailed records of all adjustments and their effects.

Above all, prioritize safety. Always wear appropriate protective gear and ensure the system is depressurized before making adjustments.

What happens if valves are not adjusted properly?

The consequences of improper valve adjustment can be severe. At best, you might see reduced efficiency and increased energy consumption. At worst, you could face system instability, accelerated wear on components and even safety risks.

In gas filling operations, inconsistent flow can lead to quality control issues, with products being under or overfilled. The financial implications of these problems can be significant, underscoring the importance of proper valve adjustment.

Improperly adjusted valves can also create unpredictable system behavior. Pressure spikes or flow inconsistencies can destabilize entire production lines, leading to downtime and potential equipment damage.

What affects the flow rate through a flow control valve?

Factors that influence flow rate have a definitive impact on valve performance.

Molecular weight and specific heat ratio can dramatically influence gas flow characteristics
Temperature is another crucial factor, affecting not only the fluid properties but also causing thermal expansion or contraction of valve components
System pressure, particularly the pressure differential across the valve, is a major determinant of flow rate
Balancing the relationship between pressure and flow
Valve design for linear, equal percentage, or quick opening flow
Piping configuration, where frictional losses in pipes, filters and other components can alter the pressure differential across the valve

In automated systems, the actuator’s response time and precision can affect flow control. For systems handling gas mixtures, changes in gas composition can alter flow characteristics. Even atmospheric conditions can play a role in systems open to the atmosphere.

How can I optimize the performance of my operation?

Understanding these factors is crucial for selecting the right valve and optimizing system performance. In gas filling operations, a deep knowledge of these influences can make the difference between a smoothly running production line and one plagued by inefficiencies and quality control issues.

As we’ve seen, flow control valves are complex devices that require careful selection, precise adjustment and a thorough understanding of system dynamics. Engineers working in gas filling operations should master these aspects to ensure efficient, safe and profitable operations.

At CPV Manufacturing, we understand the challenges you face in optimizing your gas filling operations. Our team of experienced engineers is ready to assist you with valve selection, system design and troubleshooting. Whether you’re upgrading an existing system or designing a new one from the ground up, we’re here to ensure you have the right flow control solution for your specific needs.

Don’t let valve selection become a bottleneck in your operations. Reach out to our engineering staff today to discuss your project requirements and discover how our high-quality valves can enhance your gas filling processes. Together, we can optimize your system’s performance, safety and efficiency, ensuring your operations flow as smoothly as the gases you’re handling.

CPV’s New CFC-50 Cryogenic Check Valve Is Ideal for Cold Flow Industrial Gas Applications – And Is In Stock!

CPV Manufacturing introduces its newest line addition, the CFC-50 cryogenic check valve, optimized for numerous cryogenic and non-cryogenic industrial gas applications. It features a compact, inline design for strength and durability and offers excellent resistance to cold flow. The standard, off-the-shelf model CFC-50 is rated for 7000 PSIG (483 BAR) and a temperature range of -400° F to 380° F (-240° to 194°C).

CPV prioritizes parts availability to keep customers in supply when every day of downtime can have critical consequences for business operations and profitability. This new valve fulfills a need expressed by customers for an available, reliable inline valve that meets specifications for gas filling operations that handle cryogen and hydrogen, among other types of gases.

Chemical compatibility a key consideration

The new CFC-50 valve features a body and retainer fabricated with naval brass, for a long service life. The guide portion of the valve utilizes Kel-F^® (PolyChloroTriFluoroEthylene), a unique fluoropolymer that offers excellent mechanical and physical properties and a high degree of chemical resistance.

PCTFE is also known for its low thermal expansion coefficient, making it an ideal polymer for use in lower temperatures. Its broad range of chemical compatibility compared to other fluoropolymers make it an ideal choice for gas filling and handling operations subject to temperature extremes.

Excellent flow rate without backflow concerns

The valve’s flow coefficient of 3.53 Cv translates into better control of the flow rate, or greater flow with less pressure drop across the valve. This can improve system performance and reduce energy consumption. The high Cv value also helps reduce wear and tear on other system components, such as pumps, by reducing the need for higher pressure differentials to achieve the desired flow rate.

Similar to other check valves manufactured by CPV, this new valve helps prevent water hammering or backflow, superior to other valves in the market due to the lack of rattling or vibration. This valve is designed for cryogenic and non-cryogenic industrial gas services, including the critical requirement of bulk tanks and gas filling applications, liquid natural gas (LNG) or the petrochemical industry.

In a cryogenic gas filling operation, for example, an inline check valve prevents the gas from flowing back into the storage tank or supply line when the filling process is completed. At its core, the valve features a spring assisted disc that shut off the valve when forward flow stops.

The valves are designed for smaller sized pipelines of up to two inches. Types of gases handled at industrial gas filling operations could include hydrogen, oxygen, nitrogen (the gas commonly used in cryogenic applications), argon or even methane, which can be stored in cryogenic liquid form.

Higher pressure ratings expand service application potential

In terms of pressure, some customers, especially in the hydrogen service area, are looking for valves that can handle higher ratings of 10,000 or even 15,000 psi. The alternative fuels market is pushing increased hydrogen demand, as it replaces fossil fuels for vehicles and transportation purposes.

Technologies associated with these hydrogen applications require high pressure ratings compared to other types of services. While the new CFC-50 cryogenic check valve is currently rated up to 7,000 psi, but for custom orders, CPV can modify the material to enable pressure ratings of 10,000 psi.

Cryogenic technology and equipment demands

Globally, the cryogenic equipment market is growing at a CAGR of 8.9%, putting increased demand on parts and components already in short supply. Cryogenics liquefies industrial gases to enable easier transport and storage. The process involves extremely cold temperatures of -150° C and below. These temperature extremes can place stress on equipment and parts.

Improper material selection or poor-quality manufacturing creates valves that become brittle and prone to failure. The consequences can include leaks, pressure drop or other issues that compromise the safety and efficiency of gas filling or handling operations.

CPV Manufacturing expedites supply

CPV focuses on its core business—the design, fabrication and modification of valves to serve industrial purposes. Due to its singular focus, CPV has prioritized supply chain management to obtain the materials it requires for manufacturing. For example, there is currently a worldwide shortage of PTCFE with common lead times stretching to 52 weeks or more. CPV can offer its customers this new valve, created with a guide formed of PCTFE within a much more reasonable lead time compared to alternatives.

All valves manufactured by CPV conform to the established ASME Boiler and Pressure Vessel Code. CPV offers best-in-class inline check valves designed to meet the highest quality standards and provide years of trouble-free use. Trust CPV check valves in general to:

Protect against backflow
Improve system efficiency
Prevent water hammer
Reduce noise

Looking for a new supplier of inline check valves for cryogenic or other industrial gas filling operations? Find a better solution with an available supply at CPV Manufacturing. Contact us today.

Oxygen Valve Quality Hinges on Compatibility and Cleanliness

Any compressed gas poses a potential risk of ignition and corresponding hazards. Oxygen for example, does not burn by itself. However, it supports combustion and, if not properly contained and managed, oxygen can react explosively or cause spontaneous ignition of other materials. This risk increases as oxygen is put under pressure and as temperatures rise.

CPV Manufacturing fabricates oxygen control valves for oxygen filling systems. Several industries and applications rely on pressurized oxygen stored in cylinders or containers, such as medical, pharmaceutical, chemical, welding, and waste treatment, among others. Quality, durability, and sensitivity all factor into selection of an oxygen valve that supplies the proper balance of control and protection.

Oxygen Highly Regulated Due to Hazard Potential

OSHA standards regulate bulk oxygen systems installed on industrial and institutional consumer locations. The U.S. Department of Transportation (DOT) considers medical oxygen a hazardous material, regulating its transportation, and the U.S. Food and Drug Administration (FDA) classifies it as a prescription drug.

State fire codes regulate its handling. International agencies are no exception, with a publication available from the European Industrial Gases Association (EIGA) that discusses the valves involved in their control and specifications for a proper oxygen valve.

Oxygen Valve Purpose and Placement

An oxygen valve controls and regulates the flow of pressurized oxygen gas, stored in cylinders or traveling through pipelines. Of all the components within the system, the part most prone to issues and subsequent system failure is the valve.

Issues related to an improperly functioning oxygen valve can include rapid pressure change and subsequent heat generation or leaks. Many of these issues and their associated dangers are discussed in a previous blog post found here.

Quality and Durability Begin with Compatible Material Selection

CPV manufactures all oxygen valves of either naval brass or Monel®, depending on customer preference. Naval brass is a copper alloy that contains zinc for extra strength in fact, making naval brass stronger than other types.

The zinc content in naval brass (39%) also makes it less ductile than brass containing less zinc. A hint of lead helps make it machinable and the addition of one percent tin increases its corrosion resistance.

Monel(®) is a nickel/copper alloy and typically more expensive than naval brass. Either choice is highly compatible with oxygen applications.

Customers should avoid oxygen valves made of materials susceptible to oxidation or corrosion, which will weaken the valve and could create a leak. An iron containing material for example, can add moisture to the oxygen, stimulating a chemical reaction that will lead to corrosion.

Copper alloys have proven to be the most effective among metal options to resist ignition because a copper alloy has the slowest combustion rate. For any type of hazardous gas containment or control, naval brass is a preferred selection for fire and explosion safety purposes.

Oxygen Cleaning and Government Certifications

Our cleaning process, CPV OX-1, meets the cleaning standards for oxygen cleaning and packaging per the Compressed Gas Association (G-4.1) and ASTM-G93, or related cleanliness standards.

Separate standards exist for government issue valves. CPV Mfg. and its aqueous component cleaning process recently received approval by NAVSEA for MIL-STD-1330D and MIL-STD-1622B Oxygen Cleaning.

Obtaining this approval enables CPV to meet the needs of the U.S. Navy and other applications that would benefit from military grade or intensive cleaning standards.

The MIL-STD-1330D applies to other systems outside of oxygen, including Department of Defense Standard Practice, Precision Cleaning and Testing of Shipboard Oxygen, Helium, Helium-Oxygen, Nitrogen, and Hydrogen Systems.

Reliability and Design Functionality

CPV earns the business of new customers who come to the company because their other valves are leaking and are unreliable. CPV valve customers will find our oxygen valve is the most robust and well-designed oxygen valve available. While no valve is ever completely worry free, operators can anticipate a service life that lasts for thousands of cycles without leaking or other issues.

In many cases, CPV valves are rated for higher pressures than most competitors. In the United States, an oxygen valve pressure expectations are typically a maximum of 4,500 PSI (307 BAR). CPV oxygen valves exceed that to meet overseas standards for 6,000 PSI (414 BAR).

Our valves also feature a soft seated design, which includes a Vespel® SP-21 Disc for bubble-tight, leak-free performance, at the highest-pressure ratings for oxygen valves.

Clean Room Packaging and Training

CPV expanded its cleanroom in 2021 and is certified to meet ISO 14644 Class 7 standards. Our employees are trained and certified as Oxygen Clean Workers and validated to meet MIL-STD 1330D standards.

All oxygen valves manufactured at CPV are thoroughly wiped down and packaged in the clean room in a double-layered vacuum-sealed bag, protecting them from moisture or contamination up to the point of installation.

Find more information, including specifications and available sizes for the CPV OXNB ® O-EAL® Series of valves includes a Naval Brass Oxygen Valve, for oxygen service in fill plants, high-pressure manifolds, and other piping systems, visit pages 32 and 33 of our catalog.

The CPV GSB Master valves also service high-pressure gas shutoff and control, with approval for 6,000 PSIG operating pressure in oxygen service for commercial applications worldwide, for safe, reliable control. Learn more about GSB Master Valves or visit our main company site at www.cpvmfg.com.

Master Valves: The Importance of Ergonomics in the Manufacturing Industry

Manually operated valves, otherwise called master or control valves, are a critical component for refineries, industrial gas production facilities and distribution centers. These valves control the movement of gas to fill industrial gas cylinders, or that traverse pipes for processing.

Due to their ubiquitous presence, these master valves must offer operators reliability, durability, cost effectiveness and one other characteristic not always factored into the design— ease of use

The original equipment manufacturers (OEMs) that fabricate or construct the manifolds, fill plants, panels and high-pressure piping systems need a reliable partner for these integral components.

CPV Manufacturing is a world-renowned industrial valve manufacturer with a reputation built on our precision craftsmanship of robust, high-pressure solutions engineered to withstand the most demanding conditions.

Safety First

The Compressed Gas Association and regulatory agencies like OSHA offer information about the hazards of compressed gas cylinders of all types, dangerous due to the high pressurization of their contents. Gaseous oxygen packaged in compressed gas cylinders serves multiple purposes and industries around the globe. These include the recreational, medical, power, chemical processing and metal refining industries, among others.

This particular compressed gas also requires unique safety measures or extra requirements in regard to medical or industrial oxygen cylinder filling. This includes having the valve complete and pass an oxygen surge pressure test, which evaluates the ignition sensitivity of the valve.

In addition to the hazards associated with a highly compressed gas, oxygen cylinders present the risk of fire. Any valve designed for use in this type of application must obtain an oxygen-safe approval at a specific operating pressure, without showing any indication of ignition failure.

Dependability

Operators expect this type of valve to operate flawlessly for thousands of cycles, and ideally, do so without maintenance. CPV master valves offer worry-free operations for countless hours of smooth, accurate, efficient, and consistent filling of valves and cylinders.

Ergonomics or Ease of Use

During many years of operation, multiple industries have relied on brass hand valves, although not without some difficulties for the operator. Operator fatigue or other ergonomic repercussions stem from a few common characteristics associated with these valves. Namely, most require high torque to open and close, repeated numerous times over the course of a single shift.

Plant operators and operations can benefit from a valve with an ergonomically designed handle. The GSB master valve from CPV requires low torque to open and close while still providing a bubble-tight seal.  

Consistent Sealing

While constructing a more ergonomically friendly master valve, it is critical to ensure leak rates are controlled. In addition to ergonomics, leak rates both internally and externally have historically created issues with master valves.

Any components such as seals which can degrade over time, can cause parts failure. Leaky or degraded seals can force a company to replace these master valves as often as every three to six months. Despite their generally economical price point, frequent replacement of even an inexpensive part can unnecessarily strain a capital expense budget, not to mention the added maintenance impact and associated downtime for replacement.

The Answer

The CPV GSB Valve answers all critical performance factors for a master valve that is reliable, dependable, durable, safe and ergonomically designed for ease of use.

Highest Pressure Rating in the Industry

The CPV GSB Valve is rated for 6,000 PSIG (414 bar) for Oxygen Service for commercial applications worldwide. It has passed oxygen pressure surge testing with 100% oxygen gas, approved by WHA International, Inc. for ISO 10297 and ISO 7291. In this case, the master GSB valve was tested up to 7,200 PSIG (496 bar) in oxygen, with no sign of failure or leaks.

CPV Manufacturing’s GSB master valve is the only master or control valve available that meets these stringent requirements. OEMs can rely on the GSB master valve for safety and reliability for high-pressure cylinder filling and processing projects.

Leak Prevention

CPV prevents leaks by offering the GSB valve fitted with our O-Ring Face-Seal, or O-SEAL separable union connections. This valve is rated for 7,800 PSIG (538 bar) service in inert gas applications, including acetylene, helium, hydrogen, nitrogen, mixed gases and others.

Ergonomic Design

The larger, four-prong aluminum handle has an updated design to make it even easier to operate. Its performance was tested internally and externally with several customers.

In just four turns, the master valve can open or close and with a lower torque than the competition. Further, there are no leaks for a bubble-tight seal for the life cycle of the valve. While other valves become more difficult to turn after multiple cycles, the master valve from CPV Manufacturing remains easy to turn supplying trouble-free operation for thousands of cycles.

This is a considerable benefit considering the number of valves present on a single panel. There can be anywhere from a few to more than a dozen valves on an individual control panel.

Thorough Testing

Many manufacturers order sufficient quantities to maintain continuous production without waiting for replacement parts. Each GSB Valve from CPV Manufacturing is fully tested and vacuum sealed to preserve optimal product integrity and cleanliness.

This GSB master valve best serves critical applications and requirements for gas cylinder fill plants, manifolds, panels, and tube trailers. The robust design is leak-free and supplies the same reliable sealing mechanisms common to other CPV valves used in the high-pressure filling industry for the past 80 years.

GSB features and benefits:

Oxygen safe – Approved per ISO 10297 and ISO 7291 for 6000 PSIG in Oxygen Service
Highest flow coefficient in the industry
Ergonomically designed handle
Low torque operation even at full pressure
Four turns
Ease of use over thousands of cycles
Low torque operation
Good flow characteristics
100% Oxygen Cleaned & Packaged per CGA G-4.1 and ASTM G93 standards
Soft-seated sealing for bubble tight, leak free operation

The CPV GSB master valve is interchangeable with existing master valves. OEMs and operators find it easy to install to replace under-performing, lower quality valves with a lower pressure rating.

For more information on available sizes or custom requirements, contact CPV Manufacturing, for master valves or fittings that supply the quality, durability, safety, and leak-proof integrity that allow your operations to run smoothly. 

Pneumatic Valves: Matching Material to Gas Type Key for Performance

Pneumatic valves are used to control or modulate the flow of gas in a pneumatic system, to regulate the passage of gas into the various parts of this pneumatic system, whether tubing, piping or other devices. There are four main categories of pneumatic valve types, including directional, non-return, flow control and pressure control. CPV Manufacturing supplies the first three types of pneumatic valves, primarily for the regulation of industrial gases.

In addition to quality manufacturing of the valve itself, CPV Manufacturing developed its proprietary O-Seal® technology, which supplies a durable, soft-seat design for thousands of lifecycles of bubble-tight shutoff operation. While purchasing agents and operators need quality manufacture and the right material selection for the valve construction, the valve’s reliability for leak-proof operations relies on the O-rings and packings for proper sealing.

Pneumatic Valve Function/Types

Pure gas and mixed gas bottle filling of high-pressure gases require reliability and durability to avoid leakage. This same level of reliability and durability is critical for the hydraulic systems in steel mills and other heavy industries. To this end, CPV developed its FloMaster® pneumatic valves with a variety of engineered features.

CPV Manufacturing offers a wide size range and application-specific valves to suit multiple application scenarios. The products can be used in conjunction with each other, from more precise, regulated control to complete shut off.

The main industries that rely on high-pressure pneumatic valves would include:

Gas industry for bulk filling applications
Industrial gas manifolds
Filling cylinders
Control panels
Hand valves
Non-returns (check valves)
Actuator valves
Petrochemical Processing
Refineries
Distillation columns
Cryogenic Gas Industry

Valves/Valve Material Selected According to Gas Type

Pneumatic valve materials selection is heavily dependent upon gas type and application. CPV Manufacturing carries different valves for the various types of gases, which are classified as elusive, inert, flammable, mixing gases or specialty gases.

The different types of gases, such as oxygen, hydrogen, helium, carbon dioxide, argon, etc., are matched up to individual valve product lines developed for those gases and their typical application scenarios. Specialty gases, which would also include electronic gases, require tight adherence to specifications to prevent leakage due to the dangers of flammability and toxicity.

High-tensile bronze and Naval Brass are the most common metals of choice for standard pneumatic valves manufactured by CPV Manufacturing. The valve material or metal selection depends on the type of gas it will encounter as well as other specifications for corrosion or oxidation resistance.

Overall, the four main types of materials or categories that can be employed for valve construction include:

Stainless steel
Brass (or bronze)
Monel™
Super alloys

Monel is a blend of 70% nickel with 30% copper, used for certain gases, such as high-pressure oxygen.

Super alloys can include Hastelloy or Inconel. Hastelloy provides excellent localized corrosion resistance, ease of welding and fabrication and often sees use for certain applications in the chemical processing industry and marine industry.

Inconel is part of a family of nickel-based super alloys, designed for high-heat environments that also require oxidation and corrosion resistance.

These super alloys and specialty metals are rarely used but are available when specifications warrant.

Linde Requires Pneumatic Valves for Specialty Gas Filling Station

As one example of specialty gas containment, a Linde facility in Santo Domingo, Mexico requires valves for a specialty gas filling station that could help regulate more than 250 gas mixes for a variety of applications in the industrial, medical and welding industries. Linde specifically requested CPV valves and fittings. Air-actuated FloMaster® O-Seal® valves were installed on all 18 automated heads on the platform.

In addition, CPV valves were used to achieve instantaneous open/close operation on each of 18 separate filling locations controlled by these automated heads. The use of overall, 180 CPV O-Seal valves combined with state-of-the-art computer controls, enabled this Linde gas filling station to complete 360 separate gas mix orders simultaneously. All CPV O-Seal® valves are leakproof even when used to control elusive gases such as helium or hydrogen.

Soft Goods: The Key to Reliability

The soft materials, or the elastomeric O-rings and packing materials, directly influence the internal and external sealing and help control gas flow. The reliability of the seal for the pneumatic valve, to prevent leakage, is dependent on the soft material selection and its specification is determined by the nature of the gases requiring regulation, as well as temperature and pressure of the gas.

For example, acetylene is both caustic and flammable, with trace amounts of other gases, and there is a specific type of elastomeric material suitable for the O-ring and packing (a stem seal) for proper sealing to prevent acetylene from leaking.

O-Rings and elastomeric material selection help prevent “fugitive emissions,” or the unintentional leakage of gases or vapors from pressurized equipment and its components, such as piping flanges, storage tanks, compressors, or valves. Multiple points within a processing facility can act as the source of potential leaks.

Fugitive emissions can result in significant consequences and their containment provides operators with a number of benefits including:

Preserving worker health and safety
Preventing environmental damage related to air pollution or the greenhouse effect
Avoiding costs for unplanned maintenance or plant downtime
Protecting profitability by avoiding the economic cost of lost commodities

Valve design will contain the gas or fluids within the system and should be able to withstand the purging or vacuum service of the system or cylinders.

Pneumatic Valve Specifications

Gas type—determines the elastomers selected for the soft materials (O-rings and packing) and in certain cases, the type of metal for the valve itself
Application
Temperature—both internal for the gas and the external environmental temperature
Automated or manually operated
Flow coefficient (Cv) as a measure of the valve’s capacity for air flow
Pressure—operating pressure or pressure range the valve is rated to handle, in Bars or psi
Port size and thread connection type
Valve cycles, representing the highest number of cycles the valve can handle in a specified time span
Ability to withstand purging and vacuum service

Most customers within the industrial gas industry know their products well. The major frustration is finding a supplier with quality manufactured valves that will not leak. CPV Manufacturing offers experience with valves and fittings that date to the 1950s, with continuous engineered improvements and customization when required.

Each valve is tested in house prior to shipping. Trust CPV Manufacturing for leakproof, quality manufactured pneumatic valves to suit any type of gas. Contact us today.

Valves for Gas Cylinder Filling Automation

Many companies in the industrial gas industry have turned to automation to increase the safety and efficiency of their gas cylinder filling operations. There are a number of downsides to manually filling gas cylinders. Manual fill stations require more labor and break up the automation process of gas cylinder filling. Manual filling can also be less precise than automated filling methods. Many industrial gas operations automate different parts of their industrial gas operations without fully automating filling. Automating the filling process with actuated valves can have a number of benefits beyond precision, safety, and efficiency.

Actuated valves are an integral part of an automated gas cylinder filling station. These automated valves are used across a wide range of industries, such as the chemical, energy, medical fields. Actuated valves are programmed to move gases and provide a leak proof seal. They carefully seal and unseal gas cylinders to prevent overfilling. There are a number of different features and designs available for automated valves depending on the requirements of the gas cylinder filling operation. These valves usually incorporate an emergency shutoff mechanism that helps prevent overfilling and accidents. Automated valves are a great addition to any industrial gas operation, and are essential for a totally automated and efficient process.

CPV Manufacturing creates a wide variety of automated valves for gas cylinders, including check valves, needle valves, globe valves, pressure relief valves, and more. Our valves are designed to last and stand up to repeated use with minimal maintenance. We know the importance of preventing leaks and all of our automated valves are manufactured with the utmost precision. You can count on our design team to find the perfect valves for your gas cylinder filling operation. If you would like more information about gas cylinder filling automation or our actuated valves, contact us today.

Valves to prevent a leak – Gaseous Helium

Gaseous Helium – A background

Gaseous helium is one of the most elusive and hard to contain gases on the planet. As the second lightest gas next to hydrogen, it has many industrial uses and is of critical importance as a process gas. Gaseous helium requires robust and tight-sealing valves and fittings in order to properly contain and disperse it.

Helium is usually produced as a byproduct of natural gas processing in the course of removing nitrogen, water vapor, carbon dioxide, helium, and other non-combustible materials to improve the heat energy of the natural gas.¹Extraction of crude helium from natural gas typically requires three steps which include removal of impurities, extraction of high-molecular-weight hydrocarbons, and cryogenic processing, which removes most of any remaining methane gas. Further purification of helium via activated charcoal absorbers or pressure-swing adsorption (PSA) processes is required in order to yield helium purities of 99.99 percent or better.²

Gaseous helium is used in industry as an inert shielding gas in metal arc and laser welding; protective atmosphere in the production of reactive metals, such as titanium and zirconium; non-reactive atmosphere for growing silicon and germanium crystals used to make electronic semiconductor devices; a coolant during the drawing of optical fibers; and as a carrier gas for chromatography.³Additionally, gaseous helium is used for leak detection equipment in piping systems and for filling party balloons. Liquid helium, on the other hand, is often used for MRI (magnetic resonance imaging) systems due to its unique cooling properties.

CPV Products in Gaseous Helium service – Design Considerations

There are inherent shortcomings in conventional metal-to-metal seated valves for high pressure service – especially in systems handling helium and other elusive gases. CPV engineers have taken the soft-seated approach to effectively managing high pressure, perfecting a full line of soft-seated valves and O-Ring Face-Seal (ORFS) separable unions designed to meet the rigorous demands of modern high pressure fluid systems.

CPV valves are unique, and superior to other products for high pressure service due to their complete, interchangeable cartridge design, including a removable, flat seat. A single valve cartridge – the entire operating portion of the valve – can be inserted into any CPV O-SEAL® body, direct weld body, or specialty manifold. This exclusive CPV valving concept gives piping system engineers unprecedented design flexibility – all the way from the drawing board up to and after installation.

The O-SEAL® system actually uses line pressure to strengthen the seal; the higher the pressure, the tighter the seal. CPV fittings have break-remake flexibility to ensure leak-proof reliability. Connections can be broken and remade at will, with full assurance of positive sealing. Recessed in a close-tolerance groove in the body of the CPV fitting is a resilient O-Ring that is compressed against the flat metal face of the tailpiece by means of a union nut. The flat-faced design permits components to be slipped in and out easily, while the O-Ring seal assures that connections remain leak-tight at pressures ranging from vacuum to 6000 PSIG – regardless of how often they are broken and remade. Unlike compression fittings, which can require high torque for sealing, the CPV fittings require minimal torque to create a seal – in any size from 1/8 in to 2.50 in.

CPV valves and fittings have effectively eliminated helium leakage problems – particularly those exposed to extreme temperature changes during start-up, which can cause leakage due to expansion/contraction of metal-to-metal-sealed conventional fittings. CPV fittings also provide significant maintenance advantages. The resilient O-Ring effectively absorbs vibration shock to prevent gradual “backing off” of the threaded connection of the union nut, making periodic retightening unnecessary. Moreover, because of the flat-faced design of the fittings, components are more accessible to simplify routine maintenance. By simply backing off the union nuts, components can be slipped out without springing the line, and then slipped back in without affecting the sealing capability of the fittings.

CPV O-SEAL® and G-Series® product lines have been used at industrial gas fill plants for bottling high pressure pure helium gas, often needed by labs and welding operations. For high volume installations, helium from tube trailers is transferred, pressurized and controlled using CPV automated valves, hand valves and connecting fittings. CPV O-SEAL® valves with FloMaster® pneumatic actuators are used on fill islands inside plants, as well as outside on ground storage tanks, where they are often subjected to extreme winter weather conditions. CPV valves are the most reliable and robust valve in the industry, operating for every fill and every shutoff, requiring very little maintenance throughout their long service life.

(Courtesy of CryoVation LLC) (Courtesy of Keen Compressed Gas Company)

CPV and the US Navy

Since the 1950’s the US Navy has specified CPV products because of their leak-proof connections, bubble-tight sealing, and shock & vibration resistance in critical systems on nuclear submarines, surface ships, and aircraft carriers. CPV valves and fittings are used on elevator systems for lifting aircraft to the flight deck, in the arresting gear that catches aircraft when they return, and in the lubrication systems on the catapults that launch the aircraft. CPV instrument valves are also preferred in refrigeration and air-conditioning systems and CPV relief valves are used in air and hydraulic systems owing to their reliability in high pressure air ram tensioner systems.

CPV O-SEAL® and Mark VIII® product lines are used in helium cryogenic refrigeration compressors as well as in saturation diving systems and hyperbaric chambers for the US Navy and NASA. CPV fittings are employed on gages, filters, relief valves and solenoid valves, wherever sealing is critical or periodic servicing of components is necessary. CPV valves are effective when precisely controlled helium-oxygen mixtures are required and are critical to breathability in underwater and space environments.

Why CPV?

Where bubble tight sealing and leak-proof integrity are the highest priority, CPV valves and fittings are the answer. The company’s innovative designs are well suited to standard applications, as well as one-of-a kind custom requirements. With CPV, reliability and dependability is our calling card. That’s why we are ‘American Engineering Trusted Worldwide®’.

Written by Joshua Raizman, Senior Applications Engineer at CPV Manufacturing

Sources used for this article:

How Products are Made. Volume 4: Helium. Retrieved 9 September 2019, from http://www.madehow.com/Volume-4/Helium.html

The National Academies Press. The Impact of Selling the Federal Helium Reserve (2000): Chapter: 4 Helium Supply, Present and Future. Retrieved 9 September 2019, from https://www.nap.edu/read/9860/chapter/7

Air Products: Safetygram 5: Gaseous Helium. Retrieved 9 September 2019, from http://www.airproducts.com/~/media/Files/PDF/company/safetygram-5.pdf

Article also available in Gasworld Magazine US Edition November 2019 – Helium – https://www.gasworld.com/valves-to-prevent-a-leak/2017983.article