Key Operated Packed Valves for Chlorine & other Corrosive Gases - CAV-06

Standard Chlorine Institute Design

Members since 2004

ISO 9001 & TPED certified valve manufacturer

 Index

Page
1. Operating Principle & Identifying Features 1.3
2. Features & Benefits for Best-in-Class Performance
Standard Chlorine Institute Cylinder Valve Design 2.1
Ton Container Valves 2.2
3. Valve Selection Guide 3
4. Fusible Plug for Ton Containers & Cylinder Valves 4
5. Cylinder & Ton Container Valve Accessories 5
6. Cylinder & Ton Container Valve Maintenance Tools & Gauges 6
7. Material of Construction & Assembly Arrangement
Cylinder Valves 7.1
Ton Container Valves 7.2
8. Valve Maintenance 8.1 – 8.2

1.2
 Operating Principle & Identifying Features
Series CAV-06

Identifying Features
The Standard Chlorine Institute design is metal seated, key (wrench) operated, single stem compression packed valve. These
valves use compressed packing to make a seal around the valve stem & body. To ensure a good seal, the packing nut is tightened
to compress the packing against the stem. As this results in higher torques, the valve is required to be operated with a wrench.
The design allows for tightening of the packing nut in case of leakage past the packings & is suitable for Chlorine & other
corrosive gases because of the ability of operating mechanism to withstand higher torques to overcome any build-up of salts or
contaminants in the seating area.

NOTE Particulate generation from valve seat & packing wear does not make the valves suitable for high purity application.

Recommended Opening Procedure

It is not necessary to open this valve to the fully open position due to large flow from the valve. Further the full opening may be
hindered due to space constraint if the cylinder is used in tight quarters. The new cylinder valve requires approximately
1 1/4 turns while the new ton container valve requires just over 1 1/2 turns from full open to full close. In the case of an
emergency, if the valve is opened to the recommended 1/2 turn, the valve can be quickly closed. The other benefit of not
opening the valve fully is the protection of the upper section of threads. The threads are in the wetted gas stream & due to the
corrosive nature of Chlorine, the threads can become jammed with corrosion by-products. If the valve is opened to the
recommended 1/2 turn & the threads become jammed, the upper threads usually remain clear. This allows the operator to
further open the valve & to free the threads. Use of twisted wrench having a square hole sized to fit the stem & an open-end
wrench on the opposite end that fits the packing nut is recommended. Following sequence should be followed:
1. Connect the cylinder to the system
2. Ensure packing nut is tight
3. Place the wrench on the stem & slap the valve open in anticlockwise direction by striking the wrench with the gloved palm of
the hand
4. Continue opening the valve until it is 1/2 turn open.

Recommended Closing Procedure

Close the valve by rotating the stem in clockwise direction using a twisted wrench up to a torque of 30 ft.lb. To ensure that the
valve operating mechanism is completely shut, give the wrench a closing slap with the gloved palm of the hand.

Valve Installation
Valving tool (e.g. sockets or jaws) used to screw the valve into the cylinder must make contact only with the flats in the valve
body.
We recommend hand tight + 3 turns wrench tight to install the valve in the cylinders.

1. Back seating the valve fully & applying excessive torque in the open direction may cause permanent deformation to the
stem threads. This can prevent the valve stem to move freely in the closing direction.
2. Ensure the full length of the stem square is engaged with the wrench. Partial engagement & / or use of incorrect tools to
operate the valve can cause premature twisting of the valve stem.

1.3
.
Features & Benefits for Best-in-Class Performance
Series CAV-06 (Standard Chlorine Institute Cylinder Valve Design)

Packing nut also available in Al-Si  3/8 HEX AF

®
 Chlorine compatible Monel stem
Bronze material with robust provides positive shut-off & resistance to

1 1/4 HEX AF
construction over-torque in both opening & closing
direction

1 1/4 HEX AF
Two-piece bevelled PTFE packings 
provide reliable external tightness.  Valve body & components precision
Packed design allows tightening of machined with single point tooling for
packing nut to compensate packing exceptional finish & low torque operation
wear 
4 15/16 Approx.

Lubrication protects threads from

corrosion, ensures ease of Ø5/16
operation & minimizes sticking &
Ø3/16
jamming of the stem  Al-Si Bronze body (Alloy “B”) resists
corrosion & de-zincification against
Chlorine & other corrosive gas application
Fusible plug tightened using Chlorine 
compatible TS-4 thread locker which
7/16 HEX AF

unlike PTFE tape, can be reapplied

Wrench size 1.125

2 5/16
over existing thread sealant

R MAX 1 1/2

All Dimensions are in inch

Dimensions shown are for 3/4-14 NGT (CI)-1 inlet & CGA 820 outlet

Design Specifications
• Minimum life : 2000 cycles
• Maximum design service pressure : 3000 psig
• Operating temperature range : –50 °F & +149 °F
• Storage temperature range : –60 °F & +149 °F
• Pressure relief device (PRD) : CG-2
• Fusible alloy yield temperature : 158 °F to 165 °F
• Flow coefficient (Cv) : 0.96
• Minimum closing torque* : 6 ft.lb
• Packing nut installation torque : 40 ft.lb
• Fusible plug installation torque : 12-13 ft.lb
• Failure torque in closing direction : >75 ft.lb
• Lubricant : Krytox GPL 225

* Higher torques may be required to operate the valve in service

(Maximum recommended 30 ft.lb)

Testing & Certification

• Valves meet performance requirements of Pamphlet 17 of the Chlorine Institute (CI)
• Valves meet CGA V-9:2012
• Fusible plug complies with CGA S-1.1
• Cylinder valves compatible with CI Emergency Kit A

2.1
 Features & Benefits for Best-in-Class Performance
Series CAV-06 (Ton Container Valves)

Packing nut also available in Al-Si  3/8 HEX AF

®
 Chlorine compatible Monel stem
Bronze material with robust provides positive shut off & resistance to

1 1/4 HEX AF
construction over-torque in both opening & closing
direction

1 1/4 HEX AF
Two-piece bevelled PTFE packings 
provide reliable external tightness.  Valve body & components precision
Packed design allows tightening of machined with single point tooling for
packing nut to compensate packing exceptional finish & low torque operation
wear

Lubrication protects threads from 

4 7/8 Approx.

corrosion, ensures ease of Ø5/16

operation & minimizes sticking &
jamming of the stem
Ø5/16  Al-Si Bronze body (Alloy “B”) resists
Wrench size 1.125

corrosion & de-zincification against

Chlorine & other corrosive gas application

R MAX 1 1/2

All Dimensions are in inch

Dimensions shown are for 3/4-14 NGT (CI)-1 inlet & CGA 820 outlet

Design Specifications
• Minimum life : 2000 cycles
• Maximum design service pressure : 3000 psig
• Operating temperature range : –50 °F & +149 °F
• Storage temperature range : –60 °F & +149 °F
• Flow coefficient (Cv) : 1.8
• Minimum closing torque* : 8 ft.lb
• Packing nut installation torque : 40 ft.lb
• Failure torque in closing direction : >75 ft.lb
• Lubricant : Krytox GPL 225

* Higher torques may be required to operate the valve in service

(Maximum recommended 30 ft.lb)

Testing & Certification

• Valves meet performance requirements of Pamphlet 17 of the Chlorine Institute (CI)
• Valves meet CGA V-9:2012
• Ton container valves compatible with CI Emergency Kit B

2.2
 Valve Selection Guide – CAV-06

Cylinder Valves
Inlet Pressure Relief
Outlet Item Code
Designation* Size Device
3/4-14 NGT (CI)-1 Standard VC-52/1
3/4-14 NGT (CI)-2 4 Turns oversize VC-52/2
3/4-14 NGT (CI)-3 8 ½ Turns oversize VC-52/3
3/4-14 NGT (CI)-4 14 Turns oversize VC-52/4
3/4-14 NGT (CI)-5 28 Turns oversize VC-52/5
CGA 660 / 820 CG-2,
Thread 1.030-14NGO-RH-EXT 158 °F to 165 °F
1-11.5 NGT (CI)-1 Standard VC-76/1
1-11.5 NGT (CI)-2 4 Turns oversize VC-76/2
1-11.5 NGT (CI)-3 8 ½ Turns oversize VC-76/3
1-11.5 NGT (CI)-4 14 Turns oversize VC-76/4
1-11.5 NGT (CI)-5 28 Turns oversize VC-76/5

Ton Container Valves

Inlet Pressure
Outlet Item Code
Designation* Size Relief Device
3/4-14 NGT (CI)-1 Standard size VC-54/1
3/4-14 NGT (CI)-2 4 Turns oversize VC-54/2
3/4-14 NGT (CI)-3 8 ½ Turns oversize VC-54/3
3/4-14 NGT (CI)-4 14 Turns oversize VC-54/4
3/4-14 NGT (CI)-5 28 Turns oversize VC-54/5
CGA 660 / 820
None
Thread 1.030-14NGO-RH-EXT
1-11.5 NGT (CI)-1 Standard size VC-73/1
1-11.5 NGT (CI)-2 4 Turns oversize VC-73/2
1-11.5 NGT (CI)-3 8 ½ Turns oversize VC-73/3
1-11.5 NGT (CI)-4 14 Turns oversize VC-73/4
1-11.5 NGT (CI)-5 28 Turns oversize VC-73/5

* Valve Inlet Designation Terminology

¾” or 1” → Thread nominal pipe size
14 or 11 ½ → Number of threads per inch
NGT → Type of thread (NGT) national gas taper
CL → Class of thread (CL) chlorine
X → Over size thread

NOTE Oversize valve thread categories were selected many years ago with the primary purpose of
having enough sizes to ensure a proper fit between a new valve & a used cylinder.

3
 Fusible Plugs for Ton Containers & Cylinder Valves

Fusible Plugs for Ton Containers

Features
• Meets Chlorine Institute specification, 1-1/4” HEX flats
• Manufactured from Naval Brass (Alloy “N”) with fusible alloy yield temperature range 158 °F - 165 °F
• Standard Combination Bore prevents extrusion of fuse alloy

Selection Guide
Inlet
Item Code
Designation Size
3/4-14 NGT (CI)-1 Standard PB-02/1
3/4-14 NGT (CI)-2 4 Turns oversize PB-02/2
3/4-14 NGT (CI)-3 8 ½ Turns oversize PB-02/3
3/4-14 NGT (CI)-4 14 Turns oversize PB-02/4
3/4-14 NGT (CI)-5 28 Turns oversize PB-02/5

1-11.5 NGT (CI)-1 Standard size PB-05/1

1-11.5 NGT (CI)-2 4 Turns oversize PB-05/2
1-11.5 NGT (CI)-3 8 ½ Turns oversize PB-05/3
1-11.5 NGT (CI)-4 14 Turns oversize PB-05/4
1-11.5 NGT (CI)-5 28 Turns oversize PB-05/5

Fusible Plugs for Cylinder Valves (PA00002)

Features
• Meets Chlorine Institute specification, 7/16” HEX flats
• Manufactured from Naval Brass (Alloy “N”) with fusible alloy yield temperature range 158 °F - 165 °F
• Inlet size 1/8-27 NGT (Modified)
• Standard Combination Bore prevents extrusion of fuse alloy

4
 Cylinder & Ton Container Valve Accessories
Series CAV-06
Yoke Assembly (YSEN002)
Features
• Cadmium plated Yoke body & Yoke follower
manufactured from EN-9 medium carbon steel by
Investment casting process to close tolerances
• Yoke body & follower hardened for high cycle life.
Yoke Screw machined from EN-8 grade steel resists
torque >65 ft.lb.
• Complies with Chlorine Institute specification
• Replacement screw ( SC-EN-1)

Yoke Adapters

End connection Item code

CGA 820 X 1/2-14 NPT THD AD-AB-1
CGA 820 X 1/4-18 NPT THD AD-AB-4
CGA 820 X 3/8” SAE Flare AD-AB-5
CGA 820 X 1/2” SAE Flare AD-AB-8

Yoke Adapter Gaskets

Thickness Item code
0.047" WAPB004
0.062" WAPB007
100% Lead gaskets, OD 0.937” & ID 0.531”
as per Chlorine Institute specification 0.125" WAPB006

Twisted Wrench (WR-EN-1)

Features
• 1 1/4” open end; 3/8” stem square
• Manufactured from EN-9 medium carbon steel by
Investment casting process (Cadmium plated)
• Hardened & tempered to 38-45 HRC to resist torque
>75 ft.lb.

Flexible Connector
Features
• Zinc plated annealed Copper tube, C12200 as per ASTM B88
• 3/8” OD X 1/4” ID, Heavy duty wall thickness (Type-K)
• Provided with CGA 660 nuts for non-yoke applications
• Adapters are brazed using solder alloy containing 43% Silver

Connection Length Item code

CGA 820 X CGA 820 2.5 ft FCC3814-025
CGA 820 X CGA 820 4 ft FCC3814-040
CGA 820 X CGA 820 6 ft FCC3814-060
CGA 820 X CGA 820 10 ft FCC3814-100
5
 Cylinder & Ton Container Valve Maintenance Tools & Gauges

Seat Cutter (SC00001)

Features
• Interchangeable stopper provided to reseat cylinder/ton
container valve to restrict depth of cut to maximum
permissible limit (0.118” for ton container valve & 0.177”
for cylinder valve)
• ACME thread provides guide during seat cutting to
maintain concentricity

Seat cutter shall only be used by trained personnel as per work

instruction provided with each supply.

Seat Depth Gauges

Features
• Step marked “M” indicates maximum re-seating limit for the valve
body seat
CG00001 For Cylinder valves
TG00001 For Ton Container valves
• Work instruction provided with each supply

Valve Seat/Stem Combination Gauges (CG/TG/2)

For Ton Container Valves For Cylinder Valves

Features
• Consists of separate gauge for cylinder & ton container valves
• Step marked “GO-NO GO” to indicate maximum re-seating limit of the valve seat in conjunction with the stem used
with the valve
• Takes into account the wear of the stem cone & proportionately limits the maximum allowable depth to which the
valve body can be re-seated
• Work instruction provided with each supply

6
 Material of Construction and Assembly Arrangement
CAV-06 (Cylinder Valve)

Packing Nut
(GNB9014)
Free Cutting Brass 6
C36000

Packing Gland
(GWB9002)
Free Cutting Brass 5
C36000

Packing X 2
(WATE001)
PTFE 4

Packing Collar
(WAB9001)
Al-Si Bronze C64210 3

Stem
(SPMM002)
Monel R 400
2

Gasket
(WAPB008)
Lead 7

Valve Body
1 Al-Si Bronze C64210

Fusible plug
(PA00002)
9 Naval brass C46400 Outlet Cap
with fusible alloy (SN-B9-1)
(158 °F - 165 °F) Free Cutting Brass 8
C36000

7.1
Material of Construction and Assembly Arrangement
CAV-06 (Ton Container Valve)

Packing Nut
(GNB9014)
Free Cutting Brass 6
C36000

Packing Gland
(GWB9002)
Free Cutting Brass 5
C36000

Packing X 2
(WATE001)
PTFE 4

Packing Collar
(WAB9001)
Al-Si Bronze C64210 3

Stem
(SPMM002)
Monel R 400
2

Gasket
(WAPB008)
Lead 7

Valve Body
1 Al-Si Bronze C64210

Outlet Cap
(SN-B9-1)
Free Cutting Brass 8
C36000

7.2
 Valve Maintenance
Series CAV-06
Disassembly of valve
Use twisted wrench (item code - WR-EN-1) with one end having 1 1/4” open end spanner to remove outlet cap (8) &
packing nut (6). Fit opposite end of the same spanner having 3/8” square size open to remove stem (2) along with other
internal fitments of packing gland (5), packing (4) & packing collar (3).

Cleaning of valve body & components

1. Clean valve body (1) & components observed “green”, likely Copper Chloride due moisture either in the Chlorine or
which has entered the system during connections & disconnections.
2. The greenish layer of Copper Chloride on threads of valve body & stem (2) can result in stem (2) becoming
“Jammed”. This results in high torque to open/close the valve &/or difficulty in fitting outlet cap (8).
3. Refer P-17 for recommended cleaning procedure.

Inspection & Reconditioning of valve body & components

1. Valve Body (1)

a. Inspect the valve body for cracks, mainly along the
forging parting line as well as in the area of the
packing nut (6) threads.
(Refer appendix D of pamphlet 17 for more details)
Crack on Parting Line Crack along Thread Root
b. Check internal bores & ACME threads for gross
corrosion, material loss or material build-up. In case of
material build-up use thread tap (item code – TAP0013)
to clean the threads. Use plain plug gauge (item code –
LM00066) & thread plug gauge (item code – TGSS081)
to check if internal ACME thread is within specification.
The threads closest to the body seat are the most
susceptible to corrosion. Loss of these threads can lead
to unengaged threads when the valve is closed,
resulting in a “spinner” thread loss & should be
rejected.
c. The sharp edge of valve body seat will become bevelled with repeated closing requiring more & more torque
to close the valve. Recondition seat using seat cutter (item code - SC00001) to restore sharp edge by
refacing. Due to the smaller orifice of cylinder valve compared to ton container valve, the seat cutter allows
for higher cutting depth on cylinder valve compared to ton container valve. Use depth gauge for cylinder
valve (item code – CG00001) & ton container valve (item code – TG00001) to ensure the seat is not cut
beyond the allowable limit.
d. If stems (2) are also machined, use Combination gauge (item code - CG/TG/2) to ensure the refacing limit of
Chlorine valve body assembled with the reconditioned stem is not exceeded.
e. The external threads on valve body (inlet, outlet, & packing nut
end) should be examined for corrosive damage, heavy wear, &
material loss. Use Rethreading dies for outlet (item code –
RDHS004) & packing nut (6) threads to remove material build-
up. Re-died outlet threads should be subsequently checked by
plain thread ring “GO” & “NO GO” gauges (item code –
LM00009) and thread ring “GO” & “NO GO” gauges (item code
– TGSS005)
f. The valve outlet sealing face should be checked for nicks &
crack & refaced if required.
g. Inspect inlet threads visually & use soft wire brush to remove burrs.

8.1
 Valve Maintenance
Instructions
Series CAV-06
2. Components
a. Check stem (2) for twisting due to excessive torque in both opening & closing
direction. Twisted stem indicates that the valve seat may be damaged. Check
stem shank for roughness, scratches & nick. Replace stems with above defects.

b. Inspect packing (4) for wear & discard one or both rings if found in unusable
condition.
c. Inspect components for structural cracks, gross corrosion & other damages.

d. Inspect fusible plug (9) in cylinder valve for signs of leakage, extrusion of fusible
metal, corrosion &/or damage. Do not remove fusible plug from valve body (1)
unless it is defective.

Assembly of valve
1. Use only cleaned parts for assembly.
2. Apply minimum 200 mg Krytox GPL 225 or any equivalent Chlorine compatible lubricant on valve stem (2) threads &
shank.
3. Screw in fully valve spindle into valve body (1).
4. Insert packing collar (3) with conical face upwards to rest on valve body counter bore.
5. Push packings (4) over stem shank to rest on packing collar. Ensure the bevelled side of the packings are on the top &
bottom face respectively.
6. Insert packing gland (5) ensuring conical face downward.
7. Screw in packing nut (6) in valve body. Clamp valve body assembly in bench vice between soft pads.
8. Tighten the packing nut in clockwise direction using suitable torque wrenches (Tekno Valves item code - WR-EN-1) at
40 ft-lb.
9. Rotate stem using twisted wrench to ensure smooth movement.
10. Tighten fusible plug (9) (if applicable) in clockwise direction using PTFE tape or any Chlorine compatible thread
sealant like Kyrtox TS4 at 12-15 ft-lb.

Testing of valve
1. Connect the assembled valve inlet to oil free dry air or nitrogen at 500 psig.
2. Plug the valve outlet using outlet cap (8) & open the valve in anti-clockwise direction.
3. Check for leakage past the packings (4) using ammonia free soap solution for one minute.
4. Tighten the packing nut (6) in clockwise direction up to 40 ft-lb in case of gland leakage.
5. Close the valve by tightening the stem (2) at maximum 30 ft-lb in clockwise direction.
6. Check leakage through the valve outlet & fusible plug (9) for one minute.
7. After completion of testing, remove the outlet cap & dry the valve thoroughly.

NOTE Refer “Material of construction & assembly arrangement” page to identify the part no. given in the bracket.

8.2 Last updated: 10th March, 2021

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Last updated: 02nd December 2021 P.Halder