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FillSafe Zero 2" NPT FxM Flow Control Valve
Thankyou for purchasing this high quality Banlaw product. Please read through and understand
the information in this Product Data Sheet (PDS) BEFORE installation or operation to avoid
accidental personal injury or property damage.
1 PRODUCT DESCRIPTION
The range of patented and patents pending
designed for the safe and reliable refuelling/refilling of diesel fuel tanks, commonly used in the mining, rail,
port, construction and other off-road industries. The system comprises two (2) major assemblies;
•
Banlaw Flow Control Valve (e.g. BFCV50NPTF) – refer Figure 1.
•
Banlaw Level Sensor (BVLS model);
o Refer applicable documentation (e.g. PSG, PDS) for information on the range of FillSafe Zero
Level Sensors.
#
Patents and patents pending for various Banlaw FillSafe™ Zero products include PCT/AU2017/051039, PCT/AU2015/050802 &
AU2018903182. Please see
www.banlaw.com
Doc ID: PRH-OFP-25
Banlaw FillSafe™
Figure 1 - BFCV50NPTF Flow Control Valve
#
Banlaw FillSafe™ Zero overfill protection (OFP) systems is
Version: 4.0
Please ensure you have the latest version of this document.
PRODUCT DATA SHEET
BFCV50NPTF
Page 1 of 20
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Table of Contents
Summary of Contents for BANLAW FillSafe Zero 2
- Page 1 Banlaw Level Sensor (BVLS model); o Refer applicable documentation (e.g. PSG, PDS) for information on the range of FillSafe Zero Level Sensors. Patents and patents pending for various Banlaw FillSafe™ Zero products include PCT/AU2017/051039, PCT/AU2015/050802 & AU2018903182. Please see www.banlaw.com Doc ID: PRH-OFP-25 Version: 4.0...
- Page 2 Whilst every effort has been made to ensure the execution of this document represents no HS&E hazard of high risk, Banlaw takes neither responsibility nor liability for the consequences and damages that may occur in the execution of works within this document.
- Page 3 BANLAW PRODUCT DATA SHEET FILLSAFE ZERO 2” NPT FxM FLOW CONTROL VALVE Figure 3 - Key Dimensions of the BFCV50NPTF Valve The part number and (unique) serial number for the Valve is marked on each Assembly - Figure 4. Figure 4 - Example of Serial Code 2 KEY FEATURES AND BASIC OPERATION The BFCV50NPTF Valve incorporates one independent means of diesel flow control;...
- Page 4 Valve is not exceeded – refer section 0. Figure 5 illustrates an example of a FillSafe Zero system incorporating a BFCV50NPTF Flow Control Valve in conjunction with a Banlaw BVLS model Level Sensor. The tank is being refilled in this illustration; •...
- Page 5 BANLAW PRODUCT DATA SHEET FILLSAFE ZERO 2” NPT FxM FLOW CONTROL VALVE Figure 6 now illustrates this same system once the tank has been filled to the nominated capacity; • Level Sensor; Pilot Line passage closed. • Flow Control Valve; closed, prohibiting fuel entering the tank.
- Page 6 Figure 9 illustrates an example of a genuine Banlaw FillSafe Zero (Internal) Pilot Line. This specification of the Pilot Line has been selected and tested by Banlaw for routing within a diesel fuel tank. The use of a non- genuine Pilot Line is not condoned by Banlaw, and may cause cause improper operation and inferior safety and reliability of a FillSafe Zero system –...
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Page 7: Product Specifications
FillSafe Zero Pilot Lines The Banlaw Vented Level Sensor (BVLS model) may be connected to the Banlaw Flow Control Valve 2” (e.g. BFCV50NPTF, etc.) via an internal Pilot Line (i.e. routed within the tank), or to an array of alternate Flow Control Valves (e.g. - Page 8 “flexing” of the line in response to the movement (i.e. turbulence and sloshing) of the fuel. Reference to the Banlaw FillSafe Zero System Installation Procedure must be made prior to any attempt to install an internal Pilot Line assembly to best avoid such failure modes.
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Page 9: Pre-Installation Guidelines
FILLSAFE ZERO 2” NPT FxM FLOW CONTROL VALVE The scope of this section applies to the Banlaw BFCV50NPTF Flow Control Valve assembly. Whilst other FillSafe Zero products are mentioned – e.g. Level Sensors and Pilot Lines – end-users must refer to separate Banlaw documentation covering each product prior to their installation. - Page 10 BANLAW PRODUCT DATA SHEET FILLSAFE ZERO 2” NPT FxM FLOW CONTROL VALVE 1. Diesel foaming; a. The spray-like discharge of diesel fuel will increase the aeration (foaming) of the fuel and may also increase the generation of static electricity (charge) within the fuel tank.
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Page 11: Installation Procedure
5. Verify 9/16” JIC (M) pilot line connection at rear of Valve “swivels” (rotates) when moderate torque is applied by hand. If jammed or excessive torque is required, do NOT install this Valve but instead replace the Valve assembly and return the faulty Valve assembly to Banlaw for warranty assessment. Doc ID: PRH-OFP-25 Version: 4.0... - Page 12 BANLAW PRODUCT DATA SHEET FILLSAFE ZERO 2” NPT FxM FLOW CONTROL VALVE 6. Using suitable hand tools – i.e. 19mm and 10mm spanners – secure the Pilot Line to the Valve – refer Figure 13. Tighten securely but do not overtighten. Typical recommended tightening procedure (torque) for a 9/16”...
- Page 13 9. Install the Receiver or refuelling point line into the 2” NPT (F) threaded inlet of the Valve. Avoid the use of excess thread sealant, as residual sealant may enter the Valve and Banlaw FillSafe OFP system and cause system malfunction. Do NOT over-tighten threaded connection.
- Page 14 ON (open) position. Automatic shut-off of a Banlaw nozzle prior to the FillSafe Zero system closing is an issue known as premature nozzle shut-off, and should be addressed/corrected in accordance with Banlaw guidelines –...
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Page 15: Principles Of Operation
The following process flow diagram illustrates a typical operating sequence for a dry-break refuelling system incorporating a Banlaw (or similar) refuelling nozzle refilling a tank fitted with FillSafe Zero (OFP system). This sequence is a guideline and is not meant to replace an existing safe refuelling procedure for a specific Doc ID: PRH-OFP-25 Version: 4.0... -
Page 16: Maintenance & Spare Parts
RECEIVER. REPLACE RECEIVER DUST CAP AND RETURN NOZZLE TO STORAGE HOLSTER/ANCHOR 7 MAINTENANCE & SPARE PARTS The BFCV50NPTF Flow Control Valve is a non-serviceable Banlaw product. Banlaw warranty is void in the event an attempt is made to repair, modify or otherwise tamper with the Valve assembly. Further, tampering with the Valve may increase the risk of hazards jeopardising the operation of the Valve and OFP system, and subsequent safety of the refuelling system. -
Page 17: Troubleshooting
Banlaw Site Service and Preventative Maintenance Clients can benefit from a Banlaw Service Level Agreement (SLA) to assist in the preventative and corrective maintenance of a FillSafe Zero system onsite, in addition to other diesel, fuels, oils and coolant infrastructure. - Page 18 FILLSAFE ZERO 2” NPT FxM FLOW CONTROL VALVE • The shut-off setting of the nozzle & receiver combination is too “low” (i.e. too light) for this application. Contact Banlaw or your nearest Banlaw agent for advice. o Unless instructed otherwise, Banlaw recommends a fuel Receiver with a “Light”...
- Page 19 Existing fault with auto ID dry-break system – investigate and rectify. b. Faulty auto ID chip in receiver – install new Banlaw receiver kit. c. Turn nozzle on (open) and verify code is read. d. Contact your onsite FMS “champion” or Banlaw Helpdesk.
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Page 20: Product Recycling And Disposal
Banlaw values and supports the sustainable use of resources, and the safe, responsible and proper disposal or recycling of all materials within its products. For a description of the principal materials within the Banlaw FillSafe Zero system, please refer to section 4.