INTRODUCING SERIES MV BY GENERANT
THE OPPORTUNITY Series MV By Generant
Generant was approached by members of the industrial gas industry looking for an improved alternative to the devices commonly known as Master Valves. After researching the market and existing devices, Generant confirmed that a market opportunity existed if an improved design could be achieved while remaining cost-effective. In researching current designs, Generant identified five main areas where significant room for improvement existed. The design project focused on using sound engineering solutions to address the issues found in each of these areas: • Safety • Ease of Use • Service Life • Pressure Rating • Availability
SERIES MV BY GENERANT | 2
SAFETY EASE OF USE SERVICE LIFE PRESSURE RATING AVAILABILITY
ISSUES WITH CURRENT DESIGNS
Series MV By Generant
SAFETY Unsafe Design for Oxygen Environments • Materials of Construction (Stainless Steel burns at 1,000 PSI!)
Improper Design Validation Testing • No promoted ignition (BAM) testing performed to ensure projectiles
are not created in explosion • No O2 surge testing • Minimal safety factor for device MAWP
SERIES MV BY GENERANT | 3
SAFETY EASE OF USE SERVICE LIFE PRESSURE RATING AVAILABILITY
ISSUES WITH CURRENT DESIGNS
Series MV By Generant
EASE OF USE Not Optimised for Efficient and Easy Use • Device wear causes significant torque increase over life cycle • Galling of threads causes inoperable valves • Lack of initial flow metering • Some devices require up to 4 – 5 full turns to achieve full open
Reverse Flow Operation • Many devices are not designed for reverse flow conditions and will fail
when reverse operation is attempted • Reverse flow can occur in cascade filling systems and tube trailer applications
SERIES MV BY GENERANT | 4
SAFETY EASE OF USE SERVICE LIFE PRESSURE RATING AVAILABILITY
ISSUES WITH CURRENT DESIGNS
Series MV By Generant
SERVICE LIFE Not Designed to Maximise Life • Device wear and thread galling creates high torque and even inoperable valves • Excessive external leakage due to O-ring wear (seal not optimised for high pressure
rotary applications) Not Repairable • Some valves do not offer replaceable seats which means entire valve must
be scrapped when seat wear occurs • Internal leakage common due to seat wear and inability to repair
SERIES MV BY GENERANT | 5
SAFETY EASE OF USE SERVICE LIFE PRESSURE RATING AVAILABILITY
ISSUES WITH CURRENT DESIGNS
Series MV By Generant
PRESSURE RATING Few Devices Rated to 300 Bar (4,350 PSI) • Typical fill plant capacity shifting to the European 300 bar standard • Many existing devices are rated to only 200 bar (3,000 PSI) • Pressure ratings may not be confirmed with appropriate safety factors and
‘worst case scenario’ testing
SERIES MV BY GENERANT | 6
SAFETY EASE OF USE SERVICE LIFE PRESSURE RATING AVAILABILITY
ISSUES WITH CURRENT DESIGNS
Series MV By Generant
AVAILABILITY Long Lead Times and High Cost • Manufacturers unable to supply valves quickly • High cost for quality valves • Limited number of devices available for high pressure fill plants (300 bar)
Generant focused on each of these issues during the design process to create an all-encompassing design solution.
SERIES MV BY GENERANT | 7
SAFETY EASE OF USE SERVICE LIFE PRESSURE RATING AVAILABILITY
Series MV By Generant
OUR DESIGN SOLUTIONS
SAFETY Valves for O₂ Service Feature: • Monel valve stem and seat • No stainless steel or plastics in flow path • Copper valve seat • FKM valve seals (U-cup and O-ring)
Extensive Design Validation • Third party tested for high pressure oxygen service (O₂ surge and BAM testing) • Hydrostatically tested to 4X MAWP
SERIES MV BY GENERANT | 8
SAFETY EASE OF USE SERVICE LIFE PRESSURE RATING AVAILABILITY
Series MV By Generant
OUR DESIGN SOLUTIONS
EASE OF USE User Friendly Design • Needle thrust bearing for low torque throughout operating pressure range
(one-finger valve operation at full rated pressure) • Unique poppet geometry to meter initial flow • 2.5 turns from closed to full open
Reverse Flow Operation • Vented poppet and seal design allows for valve operation in reverse flow conditions
Retro-fittable to existing installations
SERIES MV BY GENERANT | 9
SAFETY EASE OF USE SERVICE LIFE PRESSURE RATING AVAILABILITY
Series MV By Generant
OUR DESIGN SOLUTIONS
SERVICE LIFE Design Optimised for Long Life • Needle thrust bearing efficiently transfers load with minimal wear • Poppet and stem material selection eliminates possibility of galling • O-ring loaded U-cup seal for robust sealing in high pressure and vacuum environments • Replaceable monel or stainless steel valve seats • Non-rotating poppet maintains seal and seat integrity • Precision machined components to ensure accurate fits • Fully field re-buildable
SERIES MV BY GENERANT | 10
SAFETY EASE OF USE SERVICE LIFE PRESSURE RATING AVAILABILITY
Series MV By Generant
OUR DESIGN SOLUTIONS
PRESSURE RATING Extensively Qualified for High Pressure • All configurations rated to 380 bar (5,500 PSI) • Hydrostatically tested to 22,000 PSIG for 4:1 safety factor • Third party tested at 120% MAWP for O₂ service • Promoted ignition (BAM) tested at max rated pressure (380 bar, 5,500 PSI)
SERIES MV BY GENERANT | 11
SAFETY EASE OF USE SERVICE LIFE PRESSURE RATING AVAILABILITY
Series MV By Generant
OUR DESIGN SOLUTIONS
AVAILABILITY Short Lead Times and Competitive Pricing • Valves will be stocked at distributors throughout the country • Competitive price point • Rated for high pressure fill plants (up to 380 bar) • Durable – years of use without requiring service puts money back in your pocket!
SERIES MV BY GENERANT | 12
DESIGN VALIDATION Pressure And Temperature Data
When the design was finished, we weren’t. After completing our design, we subjected the valve to a series of tests to validate our design with respect to safety, usability, service life, and pressure rating. Tests included life-cycle testing, hydrostatic testing, flow testing, field (BETA) testing, third-party promoted ignition (BAM) and oxygen surge testing.
SERIES MV BY GENERANT | 13
LIFECYCLE TESTING THIRD PARTY TESTING HYDROSTATIC TESTING BETA (FIELD) TESTING FLOW TESTING
Series MV By Generant
DESIGN VALIDATION
LIFECYCLE TESTING • 25,000 cycles: Approximated 5 year service life of 20 open / close cycles per day,
5 days a week for 5 years • Lifecycle test also pressure cycled the seal to test effects of explosive
decompression (rapid depressurisation) • Valve was disassembled after cycling to inspect for any signs of wear.
Both valve configurations (O₂ and non-O₂) completed tests successfully.
SERIES MV BY GENERANT | 14
LIFECYCLE TESTING THIRD PARTY TESTING HYDROSTATIC TESTING BETA (FIELD) TESTING FLOW TESTING
Series MV By Generant
DESIGN VALIDATION
THIRD PARTY TESTING • Contracted Wendell & Hull Associates, Inc. to conduct high pressure oxygen
testing on copper valve configuration cleaned for O₂ service • O₂ surge Test 1 subjected valve to 60 rapid pressurisation cycles (6,600 PSIG in less
than 20 ms) to verify that valve can withstand heat of compression • Promoted Ignition (BAM) Test 2 created a high pressure explosion within the valve
to ensure that the valve could sufficiently contain it. 1 O₂ surge test conducted per ISO 7291 “Gas Welding Equipment – Pressure Regulators for Manifold Systems used in Welding, Cutting, and Allied Processes up to 300 bar” Section 9.4.4 Ignition Test 2 Promoted ignition test conducted per ASTM G175 “ Standard Test Method for Evaluating the Ignition Sensitivity and Fault Tolerance of Oxygen Regulators Used for Medical and Emergency Applications” Phase 2: Regulator Inlet Promoted Ignition Test
SERIES MV BY GENERANT | 15
LIFECYCLE TESTING THIRD PARTY TESTING HYDROSTATIC TESTING BETA (FIELD) TESTING FLOW TESTING
Series MV By Generant
DESIGN VALIDATION
HYDROSTATIC TESTING • Hydrostatically pressurised valve in 1,000 PSI increments, holding for
10 seconds at each pressure. • Final test pressure of 22,000 PSI was achieved to ensure a 4:1 safety factor • Valve successfully contained 22,000 PSI without burst • MAWP of 5,500 PSI (380 bar) confirmed with a 4:1 safety factor
SERIES MV BY GENERANT | 16
LIFECYCLE TESTING THIRD PARTY TESTING HYDROSTATIC TESTING BETA (FIELD) TESTING FLOW TESTING
Series MV By Generant
DESIGN VALIDATION
BETA (FIELD) TESTING • Installed three valves at a medium volume gas fill plant for 4 months • Removed valves from plant and disassembled to verify no signs of wear
or deterioration • Received excellent customer feedback
SERIES MV BY GENERANT | 17
LIFECYCLE TESTING THIRD PARTY TESTING HYDROSTATIC TESTING BETA (FIELD) TESTING FLOW TESTING
Series MV By Generant
DESIGN VALIDATION
FLOW TESTING • Conducted flow testing to verify flow coefficient (CV ) of 2.5 • Flow performance is competitive with other products on the market
Complete test reports for each test available upon request.
SERIES MV BY GENERANT | 18
SEAT CONFIGURATIONS Series MV By Generant
The Generant series MV, high pressure gas control valve is offered in two different material and seat configurations: Copper Seat Configuration (Material Code –C) • Monel seat and stem, FKM seal • Extensively third party tested for use in oxygen service • Factory tested to less than 0.1 SCCM internal and external leakage
PCTFE Seat Configuration (Material Code –K) • 300 series stainless steel seat and stem, molythane seal • For a variety of gases including, but not limited to He, H₂, Ar, N₂, and CO₂ • Factory tested to less than 0.1 SCCM internal and external leakage • This option is preferred when a bubble tight seal is critical
SERIES MV BY GENERANT | 19
THE FINAL PRODUCT Series MV By Generant
At Generant, we believe that we have created a superior alternative to existing Master Valves on the market. The Generant Series MV was designed with a focus on improving safety, ease of use, service life, pressure rating and availability. Key Design Features Include: • Extensive third party testing to ensure safety in O₂ applications • Needle thrust bearing for low torque and long service life • O-ring loaded U-cup seal for sealing in vacuum and high pressure • Unique poppet geometry to meter initial flow • Optimised material selection • Non-rotating poppet and non-rising stem • Designed to easily retro-fit existing installations • Fully field re-buildable
SERIES MV BY GENERANT | 20
HOW TO ORDER Series MV By Generant
MV
8NR
C
Series
Port Size & Configuration
Material Code
MV – High Pressure Gas Control Valve
4F – ½” NPT Female Ports
C – Copper
6F – ¾” NPT Female Ports
MVP – Panel Mount High Pressure Gas Control Valve
8NR – 1” – 11.5 NPSM Right Hand Ports
(Cleaned for 02 Service, Standard)
8NL – 1” – 11.5 NPSM Left Hand Ports
K - PCTFE
2FS – 1 – 3/8” – 12 O’Ring Seal Union* *Compatible with Soft-SealTM, O-SealTM, Tech – O-SealTM
Generant does not recommend the use of PCTFE Material Code in Oxygen Service
SERIES MV BY GENERANT | 21
NO.1 FOR VALVES AND ANCILLARIES GET IN TOUCH FOR FRIENDLY HELP AND ADVICE FROM THE HEROSE TEAM.
CALL: +44 (0) 1302 773 114 EMAIL: info@herose.co.uk CLICK: www.herose.co.uk