general product catalogue

ENGLISH

Systems, equipment & servicesfor the LPG industry

GENERAL PRODUCT CATALOGUE

P.O. Pedersens Vej 22DK-8200 Aarhus NDenmarkTel +45 8740 3000Fax +45 8740 [email protected]@kosancrisplant.comwww.kosancrisplant.com

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Palletizing systems.............................................. 4Cylinder handling solutions................................. 6Conveyor systems ............................................... 8Carrousel introduction and ejection systems ... 10

Carrousel filling systems ................................... 12In-line filling systems ........................................ 14Container filling plants ...................................... 16Compact filling systems .................................... 18UFM universal filling machine .......................... 20Filling heads ...................................................... 22KCFiLL1 .............................................................. 24

Check weighing systems................................... 26Manual leak detectors ...................................... 28Electronic leak detectors and valve testers ...... 30Leak testing baths ............................................. 32Weight correction machines ............................. 34

Evacuation systems........................................... 36Valve orientation machine ................................ 38Valve opener and closer .................................... 40

Thermosealing machines .................................. 42Seal application systems .................................. 44Washing systems .............................................. 46

LPG piping systems ........................................... 48Tank yard equipment ......................................... 50Fire water systems ............................................ 52

CUC power and data network ........................... 54Production data management system .............. 56Electrical equipment ......................................... 58Fire and gas alarm systems .............................. 60

CONTENTS

Shroud and foot ring straighteners ................... 62Pressure testing equipment .............................. 64Purging systems ................................................ 66Valve changing machine ................................... 68Equipment for internal cleaning and inspection of LPG cylinders ........................ 70Marking of LPG cylinders .................................. 72Surface treatment of LPG cylinders .................. 74Hot repair of LPG cylinders ............................... 76

Oxygen and nitrogen plants .............................. 78

Service and training .......................................... 80Engineering ....................................................... 82Supervision of installation ................................ 84Spare parts ........................................................ 86KC ServiShare ................................................... 88Project management ......................................... 90Export financing package .................................. 91

KC ProSupply ..................................................... 92Filling hall process overview............................. 94The Kosan Crisplant Group ............................... 96

The only high-speed filling system for LPG cylinders in the worldwww.flexspeed.info

Handling and transport equipment

Filling equipment

Checking equipment

Preparation equipment

Finishing equipment

Storage and piping installations

Electrical installations and data network

Reconditioning equipment

Technical gases

Services

Miscellaneous

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PALLETIzING SySTEmS

Kosan Crisplant’s palletizing systems are designed for safe and efficient handling of all kinds of pallets as well as for automatic loading and unload-ing of LPG cylinders.

• Highsafetyandoptimallogisticsatthe filling plant

• Minimumtimeconsumptionforloading and unloading of trucks

• Fullyautomaticplant

• Minimumneedofmanpower

• Highcapacity–upto2,400cylin-ders per hour

• Carefultransportationofcylindersbetweenfillingplant,storageandcustomer

• Flexibledesignforhandlingofmanypallet types

Your benefits

• Highsafetyasonlyinternalvehiclesoperatenearbythefillingplant,andonly few external people has access to the plant

• Optimallogisticsas,toalargeex-tent,externalandinternalvehiclesoperate in separate areas

• Possibilityofexpansionthankstoflexible and modular design

• Justfewcylinderrepairsnecessaryas cylinders are protected in pallets during transport

• Justfewindustrialinjuriesasthereare no manual cylinder lifts

Your possibilities

• Twobasicpalletizers:CompactPal-letizer and Linear Palletizer

• Bothplanttypescanbeconnectedto all types of chain conveyors

• Bothplanttypescanbesuppliedwith fully automatic bar lifter

• TheCompactPalletizerisavailablein one or two storeys and with a ca-pacityofupto2,400cylindersperhour

• TheLinearPalletizerisavailableinone storey and with a capacity of up to1,800cylindersperhour

• TheLinearPalletizerhasmodulardesign so that the internal buffer storage can be varied

• TheLinearPalletizercanbesuppliedwith a pallet stacker/destacker in order to minimize the fork-lift truck operations and/or to reduce the number of fork-lift trucks

• Manualorsemi-automaticpalletiz-ers for low capacity filling plants

Your safety

• AllpalletizingsystemsareEUap-proved and designed in accordance with current EU directives EN 50014,EN50020,EN50081,EN50082,EN55022,incl.theATEXDi-rective (94/9/EC)

• Allpalletizingsystemsaredesignedfor use in hazardous areas classified as Zone 1 according to IEC 79-10 andClassI,Division1accordingtoNEC(USA),article500

• National/localapprovals

Easy and safe handling of gas cylinders in pallets

Linear palletizer

Bottom left: Pallet stacker/destacker on linear palletizer

Bottom right: Fully automatic bar lifter on linear palletizer

Compact palletizer with fully automatic bar lifter

Easy and safe transport of gas cylinders in pallets


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CyLINDER HANDLING SOLUTIONS

Examples of principle solutions for handling of single cylinders by means of an overhead rail system – A: Handling between lorry and chain conveyorB: Handling between lorry and stationary filling machines – C: Handling between pallets and filling carousel

Kosan Crisplant’s telescopic conveyor has been designed to facilitate the heavy manual handling in connection with loading/unloading of LPG cylinders onto/from trailers or lorries. The conveyor is mounted as a direct extension of the chain conveyor on the platform or the ramp. It consists of a stationary section as well as a movable section in the form of a built-in telescopic extension.

Example of suspension device for an overhead handling system based on the vacuum principle

Safe handling of heavy cylinders

Handling system, based on the vacuum principle, for two cylinders Handling system, based on the

vacuum principle, for one cylinder

Kosan Crisplant’s cylinder han-dling solutions are designed for optimisation of manual han-dling processes when unload-ing and loading cylinders from trucks, and other lifting and re-moval processes in the filling hall.

• Heavyliftsandremovalsareper-formed by handling equipment

• Flexiblesystems,availableasover-head systems and telescopic con-veyor systems

• Minimumneedformanpower

• Ergonomicsolutions

• Smallinvestment

• Handlingofbothindustrialanddo-mestic cylinders

Your benefits

• Minimizedstrainonoperators

• Transportofcylindersdirectlyfromthe conveyor or the filling machine to the truck platform

• Increasedcapacitywhenloadingand unloading trucks

• Efficienthandlingatpeakperiods

• Reductionoftypicalhandlingdam-ages on cylinders

Your possibilities

• Theoverheadsystemcanbesup-plied either with electrical lifting motorandliftinghooks,orwithvac-uum principle (incl. suction disc and equipment for balancing of cylinder weight)

• Theoverheadsystemcanalsobeapplied for manual loading and un-loadingofpallets,togetherwiththepallet transporting system

• Telescopicconveyorsystemsincludetelescopic chain conveyors which cover the length of the truck plat-form for easy loading and unloading

• Boththeoverheadandthetelescop-ic conveyor systems can be com-binedwithotherhandlingsystems,such as palletizers

Your safety

• AllcylinderhandlingsolutionsareEU approved and designed in ac-cordancewithcurrentEUdirectives,incl.theATEXDirective(94/9/EC)

• Allcylinderhandlingsolutionsaredesigned for use in hazardous areas classified as Zone 1 according to IEC 79-10andClassI,Division1accord-ingtoNEC(USA),article500



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CONvEyOR SySTEmS

Curve section of roller conveyor

All processes in the chain component production are monitored which guarantees that each component is 100% perfect before assembly and welding. Defective components are rejected and scrapped. In addition, random samples of the ready-made chain sections (with a standard length of 5 m) are taken to make absolutely sure that the chain meets Kosan Crisplant’s strict quality standard.

Chain conveyor systems

A System I with 2 chains for installa-tion at floor level

B System II with 2 chains for installa-tion at floor level

C System I with 3 chains for installa-tion at floor level

D System I with 2 chains for installa-tion on supports

E System II with 2 chains for installa-tion on supports

F System I with 3 chains for installa-tion on supports

All systems are available with or without rails (high or low).Driving unit for chain conveyor

Examples ofchain conveyor sections

Kosan Crisplant’s original chain type 20000

Chain conveyor for LPG cylinders

The conveyor systems are de-signed for efficient and rational transport of LPG cylinders from the unloading point to the load-ing point, passing various processing points.

• Highqualityandsolidsystemsde-veloped on the basis of 50 years’ ex-perience

• RationaltransportofLPGcylinders

• Modularandflexiblesystems

• Layoutaccordingtorequirements

• Systemsforallcylindertypes

• Manualorfullyautomaticcontrolofcylinder flow

• Integrationwithmachinesandproc-esses

• Fullygalvanized

Your benefits

• Minimizedstrainonoperators

• Capacityincreasethankstooptimi-sation of manual processes


• Lastingquality

• Highsafetythankstocontrolledcyl-inder logistics

• Reductionoftypicalhandlingdam-ages on cylinders

• Minimumwear,lowpowercon-sumption and noise level when us-ing soap water lubricated chain con-veyor

Your possibilities

• Dryorsoapwaterlubricatedchainconveyor

• Ascendinganddescendingchainconveyors

• Themodularprincipleallowsinfinitecombinations

• Drivingunitswithex-proofmotorand gear for variation in chain con-veyor speed

• Chainconveyorsystemswithtwoorthree chains and different widths

• Convergenceanddivergenceunitsfor chain conveyors

• Reversionsectionsforvariationinchain conveyor speed

• Installationatfloorleveloronsup-ports at a given level

• Pusherfordischargeconveyor

• Manual,semiautomaticorfullyau-tomatic control of cylinder flow

• Centralsystemfordistributionofsoapy water

Your safety

• AllconveyorsystemsareEUap-proved and designed in accordance withcurrentEUdirectives,incl.theATEXDirective(94/9/EC)

• Allconveyorsystemsaredesignedfor use in hazardous areas classified as Zone 1 according to IEC 79-10 andClassI,Division1accordingtoNEC(USA),article500



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CARROUSEL INTRODUCTION AND EjECTION SySTEmS

PER ejection unit for radial ejection of cylinders from filling carrousel

HRS introduction unit for radial introduction of cylinders to filling carrousel

TIE introduction unit for tangential introduction of cylinders to filling carrousel

TIE ejection unit for tangential ejection of cylinders from filling carrousel

Radial introduction unit combined with tangential ejection unit with a cylinder pusher on each filling machine

Top: TIE tangential introduction unit Bottom: TIE tangential ejection unit

Introduction and ejection systems

A Tangential introduction and ejectionB Tangential introduction and radial

ejectionC Radial introduction and tangential

ejectionD Radial introduction and radial ejection

The illustrated introduction and ejection systems are designed for filling carrousels with clockwise rotating direction. All sys-tems are available for filling carrousels with anticlockwise rotating direction.

Carrousel filling systems with radial introduction and ejection units

Kosan Crisplant’s carrousel in-troduction and ejection sys-tems are designed for safe and fast introduction and ejection of LPG cylinders to and from carrousels.

• Maximumuseofcarrouselcapacity

• Safeoperationofcarrousels

• Fullyautomaticcylinderflowtoandfrom carrousels

• Systemsforallcylindertypes

• Highcapacity

• Canbeintegratedincarrouselfillingsystem

• Canbeintegratedinchainconveyorsystem

• Easyinstallationinexistingplants

Your benefits

• Nomanualhandlingbeforeoraftercarrousel

• Nointroductioniffillingmachineoncarrousel is occupied

• Noejectionifcylindersareaccumu-lated on chain conveyor after car-rousel

• IncaseofCUCcontrolledsystem:–Nontouchcontrol–Automaticdatatransfertofilling

machine and check scale

Your possibilities

• Tangentialdesign,–withintroductionandejection–withintroductionandarrange-

ment for activation of pusher on each filling machine

• Tangentialdesigncanbecombinedwith valve orientation

• Radialdesign,–withintroductionandejection–withintroductionandarrange-

ment for activation of pusher on each filling machine

• PneumaticsystemorelectronicCUCcontrolled system

• Adjustmentofsystemspeedtocar-rousel speed

Your safety

• Allcarrouselintroductionandejec-tion systems are EU approved and designed in accordance with current EUdirectives,incl.theATEXDirec-tive (94/9/EC)

• Allcarrouselintroductionandejec-tion systems are designed for use in hazardous areas classified as Zone 1 accordingtoIEC79-10andClassI,Division1accordingtoNEC(USA),article 500


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CARROUSEL fILLING SySTEmS

Example of carrousel filling system

Non-hazardous area Hazardous area

Electronic check scale ATEX approval certificate

Carrousel filling system with UFM universal filling machines

Introduction and ejection units

Kosan Crisplant’s carrousel fill-ing system is designed for safe and effective filling of all kinds of LPG cylinders.

• ThemosteffectivewayoffillingLPGcylinders

• Highcapacityfilling,upto1,800cyl-inders per hour

• Fullyautomaticcylinderflow

• Highsafetylevelthankstointrinsi-cally safe network

• Decentralizedcontrolunitsinde-pendent of PC’s

• Rapidencodingorautomaticread-ing of cylinder tare

• Controlsystemuptime:99%–thebest on the market

• Totaloverviewofthefillingproduc-tion thanks to PC data collection

Your benefits

• Lowinstallationcostsandhighsafety thanks to intrinsically safe network

• Focusonergonomicsatcentraltareencoding station

• Fewoperatorsandminimizedriskofhuman errors

• Nomechanicalwearonelectricalcontrolequipment,non-touchsen-sors and swivel connectors

• Optimallogisticsandhighoutput(e.g. sorting of cylinders for mainte-nance before filling)

• OptimalPCdatacollectiontoolforeffective filling and maintenance

• Capacityincreaseispossible

• Sameuserinterface(HMI/CUCcon-troller) on all machines

Your possibilities

• Semi-automaticorfullyautomaticsystem according to valve type

• Automationlevelcanbeupgradedaccording to actual and future needs

• From8to42fillingmachinesonthecarrouselplatform–capacitycanbeadapted to actual and future needs

• Fillingmachinesandfillingheadsadapted to cylinders and cylinder valves

• PCplacedinnon-hazardousareacan be connected to the system

• Quickandprofessionalserviceback-up by remote control available

Your safety

• Allequipmentandmachinesinthefilling system are EU approved and designed in accordance with current EUdirectivesEN50014,EN50020,EN50081,EN50082,EN55022,in-cl.theATEXDirective(94/9/EC)

• Allequipmentandmachinesinthefilling system are designed for use in hazardous areas classified as Zone 1 according to IEC 79-10 and ClassI,Division1accordingtoNEC(USA),article500

• Fillingmachinesandcheckscaleshave weighing Accuracy Classifica-tion C3 according to OIML R 76/EN45501


Equipment in hazardous area:1 Chain conveyor2 Encoding station3 Introduction and ejection units4 Filling carrousel and filling machines5 Check scale6 Sort-out conveyor7 Leak detector8 Power and data interface

Equipment in non-hazardous area:A PC incl. software and database for filling dataB ModemforconnectiontoKCon-lineserviceC Printer for printing reports


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IN-LINE fILLING SySTEmS

Example of in-line filling system with filling machines in-line in chain conveyor

A Unloading/loading areaBDrivingunitforchainconveyorC Control desk for control of

cylinder flowD Filling machines

E Check scale and manual leak detector

F Roller conveyor for rejected cylindersG Cylinder clampH Tiltable evacuation rack

UFM universal filling machines in-line in roller conveyor

Kosan Crisplant’s in-line filling systems are designed for safe and efficient filling and checking of all kinds of LPG cylinders.

• Suitablesystemforlowcapacityfill-ing of industrial cylinders

• Capacitybetween50and250cylin-ders per hour

• Semi-automatichandlingofcylin-ders

• Flexibletodifferentcylinderdiame-ters,heightsandcylindervalves

• Fillingmachinescanperformbothfilling and check weighing

• Flexiblesolutions–withpossibili-ties of expansion

• Smallinvestment

Example of in-line filling system with filling machines in-line in roller conveyor

A Unloading/loading areaB DrivingunitforchainconveyorC Control desk for control of cylinder flowD Filling machinesE1 Check scaleE2 Electronic leak detector

F Roller conveyor for rejected cylindersG Cylinder clampH Evacuation rackJ StorageareaforemptycylindersK Storage area for filled cylinders

In-line filling system with roller conveyor

Your benefits

• Lowinstallationcosts

• Highsafetythankstointrinsicallysafe network

• Focusonergonomics

• Minimummanualcylinderhandling

• Includesautomaticsforregulationof cylinder flow

• Controlledcylinderlogistics

• ReadyforcommunicationwithPCfor data collection


Your possibilities

• Manualorsemi-automaticfillinghead according to valve type

• Parallelfillinglinesforincreasedca-pacity

• 1to8fillingmachinesperfillingline

• Weighingprincipleormassflowprinciple

• Canbeintegratedinchainconveyoror roller conveyor

• Manualorsemi-automatichandlingof cylinders

• Fillingofbothdomesticandindustri-al cylinders

• Automationlevelcanbeupgradedaccording to actual and future needs

Your safety

• Allin-linefillingsystemsareEUap-proved and designed in accordance with current EU directives EN 50014,EN50020,EN50081,EN50082,EN55022,incl.theATEXDi-rective (94/9/EC)

• Allin-linefillingsystemsarede-signed for use in hazardous areas classified as Zone 1 according to IEC 79-10andClassI,Division1accord-ingtoNEC(USA),article500

• Allin-linefillingsystemshaveweighing Accuracy Classification C3 according to OIML R 76/EN45501



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CONTAINER fILLING PLANTS

A Roller conveyorB ChainconveyorC Driving unit for chain conveyor1-8 Filling machines9 Electronic leak detector10 Cylinder pusher11 Sort-out conveyor for leaky

cylinders12 Electronic check scale13 Cylinder pusher

14 Sort-out conveyor for incorrectly filled cylinders

15 Pallet loader16 Pallet with cylinders17 Fork lift stops18 Evacuation equipment19 LPG pump unit20 LPG supply hose21 LPG return hose22 Electrical panel

Container filling plant with eight filling machines, check equipment and pallet loader

Your benefits

• Easyinstallationonsite

• Simplelayoutandmaximumsafety

• Minimumcivilworkandengineering

• Theplantcanbemadeindependentof external power supply (e.g. in ru-ral areas)

• Lowpowerconsumption

• Easyandsafetooperate

• Readyforintegrationinfillingsys-tem network


• Compriseallnecessaryequipmentfor safe and reliable filling of gas cylinders


Your possibilities

• 1-8fillingmachines

• Supplyofstandardfillingplantequipment

• Supplyofrollerorchainconveyor

• CanbedeliveredasTurnKeyprojects including all equipment “within the fence”

Your safety

• AllequipmentandmachinesareEUapproved and designed in accord-ance with current EU directives EN 50014,EN50020,EN50081,EN50082,EN55022,incl.theATEXDi-rective (94/9/EC)

• Allequipmentandmachinesarede-signed for use in hazardous areas classified as one 1 according to IEC 79-10andClassI,Division1accord-ingtoNEC(USA),article500



Complete container filling plant with storage tank

Kosan Crisplant’s mobile container filling plants are designed for safe and efficient filling, checking and maintenance of all kinds of LPG cylinders.

• Smallflexiblemobileandprefabri-catedplants–plug&play

• Idealsolutionwhenenteringandtesting new markets

• Idealfillingsolutionwhenrebuild-ing/renovating existing plants

• Flexiblesolutionandarrangementaccording to customer needs

• 20’and40’containers,accordingtoactual need for equipment

• CompriseKosanCrisplant’sthor-oughly tested standard filling equip-ment

• Fillingcapacityupto400cylindersper hour per container

• Completefillingplant(canalsocon-tainstorageroom,gatehouseandLPG tanks)


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COmPACT fILLING SySTEmS

Example of one-man LPG filling unit with two UFM universal filling machines

One-man LPG filling unit with four UFM universal filling machines and complete platform with LPG pump unit, ex-proof power panel and piping arrangement (incl. filter, differential pressure valve and LPG liquid level sensor)

Kosan Crisplant’s mobile compact filling systems are designed for safe and efficient filling and checking of all kinds of LPG cylinders.

• Smallflexiblemobileandprefabri-catedplatforms–plugandplay

• Idealsolutionforquickinstallation

• Suitablewhenrebuildingandreno-vating existing filling plants

• Flexiblesystem-arrangementac-cording to customer needs

• Platformsizeaccordingtoactualneed for equipment

• CompriseKosanCrisplant’sthor-oughly tested standard filling equip-ment

Ex-proof power panel, start/stop switch and electrical motor for LPG pump unit

UFM universal filling machine

LPG pump unit, ex-proof electrical motor and Kosan Crisplant’s CPI power supply for intrinsically safe network

Detail of piping arrangement: shut-off valve, safety valve and earthing connections

Your benefits

• Easyinstallationonsite

• Simplelayoutandmaximumsafety







• Compriseallnecessaryequipmentfor safe and reliable filling of gas cylinders


• MinimumspacerequirementsYour possibilities

• 1-8fillingmachines

• Supplyofstandardfillingplantequipment

• Supplyofrollerorchainconveyor

• Differentplatformsizes

Your safety

• AllequipmentandmachinesareEUap-proved and designed in accordance with cur-rentEUdirectivesEN50014,EN50020,EN50081,EN50082,EN55022,incl.theATEXDirective (94/9/EC)

• Allequipmentandmachinesaredesignedforuse in hazardous areas classified as Zone 1 accordingtoIEC79-10andClassI,Division1accordingtoNEC(USA),article500

• Fillingmachinesandcheckscaleshaveweighing Accuracy Classification C3 accord-ing to OIML R 76/EN45501


1 Filling machines2 Platform3 LPG pump unit incl. ex-proof electrical motor4 Differential pressure valve5 Supply line (from storage tank)6 Return line (to storage tank)7 LPG filter (on supply line)8 Manometer (filling pressure)9 Lifting hook


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5Ufm UNIvERSAL fILLING mACHINE

Kosan Crisplant’s UFM univer-sal filling machine is designed for safe and accurate filling of all types of LPG cylinders and valves.

• Mostusedfillingmachineintheworld

• Weighingprinciple(loadcell)ormass flow principle

• Operation;fullyautomatic,semi-au-tomatic or manual

• Installation:oncarrousel,in-lineinrollerorchainconveyor,orasstand-alone unit


• Modulardesignwiththoroughlytested components

• Competitiveprice

Your benefits

• Satisfiedend-usersduetoaccurate-ly filled cylinders

• SavingsonLPGbecauseofhighfill-ing accuracy and intelligent filling software

1 Semi-automatic filling of industrial cylinders with screw valves including fully automatic opening and closing of valve hand wheel

2 Fully automatic filling of domestic cylinders with centre valves

3 Manual filling of camping cylinders with screw valves

4 Semi-automatic filling of industrial cylinders with centre valves

5 Manual filling of industrial cylinders with screw valves

6 Fully automatic filling of camping cylinders with centre valves

• Lowinstallationcostsduetointrin-sically safe system

• Minimummaintenanceandservicerequirements



• Highsafetyduetointrinsicallysafesystem

• Easyadjustmentandmaintenance(error messages in display)



Your possibilities

• Carrouselmodelsforhighcapacitybatch filling (from approx. 300 cylin-

ders per hour) and/or for automated filling.Operationcanbemanual,semi-automatic or fully automatic

• In-lineinchainconveyormodelsforlow capacity filling (up to approx. 300 cylinders per hour) or/and for automated handling of cylinders (es-pecially big and/or heavy cylinders)

• In-lineinrollerconveyorforlowca-pacity filling

• Stationaryonfloormodelsforlowcapacity random or batch filling and/or for filling of cylinders in different sizes /with different valves

Your safety

• Allequipmentandmachinesinthefilling system are EU approved and designed in accordance with current EUdirectivesEN50014,EN50020,EN50081,EN50082,EN55022,in-cl.theATEXDirective(94/9/EC)

• Allequipmentandmachinesinthefilling system are designed for use in hazardous areas classified as Zone 1 according to IEC 79-10 and ClassI,Division1accordingtoNEC(USA),article500



1 UFM universal filling machines mounted on filling carrousel

2 UFM universal filling machine with three filling heads for fully automatic filling of domestic cylinders with three different types of centre valves

3 AdjustableHMI/CUCcontroller–easy to use and program

4 UFM universal filling machine with mass flow meter

UFM universal filling machine with double centring device for automatic filling of industrial cylinders with centre valves


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fILLING HEADS

Semi-automatic (self-decoupling) SAS filling head for screw valves

Semi-automatic (self-decoupling) SAC filling head for centre valves

Manual mechanical MFC filling head for centre valves

Manual pneumatic PI filling head for OPD valves and check valves

Manual pneumatic PUI filling head for screw valves

Fully automatic AFH filling head for centre valves

Fully automatic filling head for screw valves

Kosan Crisplant’s filling heads are designed for safe and easy filling and evacuation of all types of LPG cylinders.

• Highqualityandsolidsystemsde-veloped on the basis of 50 years’ ex-perience

• Operation:fullyautomatic,semi-au-tomatic or manual

• Optimisedflowandfillingspeed

• Highsafetylevel

• Canbeusedforbothfillingandevacuation

Your benefits

• Lastingquality

• Easyandfastcouplinganddecou-pling

• Minimumgasdischargeatcouplingand decoupling

• Nogasdischargeatsuddeninter-ruptions in compressed air supply

• Manualandsemi-automaticfillingheads are operated by single hand

• Flexiblesuspensionforcouplingofvalves which are not in central posi-tion for filling

• Ergonomicoperationofmanualandsemi-automatic filling heads thanks to balanced suspension

• Minimummaintenance

Your possibilities

• Fillingheadsforalltypesofcentrevalves and screw valves

• Customerspecificfillingheadsforspecial valves

• Couplinganddecouplingcanbemanual,semi-automaticorfullyau-tomatic

• Usageincombinationwithalargevariety of filling machines

Your safety

• AllfillingheadsareEUapprovedand designed in accordance with currentEUdirectives,incl.theATEXDirective (94/9/EC)

• Allfillingheadsaredesignedforusein hazardous areas classified as Zone 1 according to IEC 79-10 and ClassI,Division1accordingtoNEC(USA),article500



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KCfILL1

Kosan Crisplant’s patented KCFiLL1 filling machine is de-signed for easy, safe and accu-rate filling of all types of LPG cylinders and valves, and of-fers the best value for money on the market for low-capacity filling machines.

• Weighingprinciplewithloadcell

• Easyandsafemanualoperation

• Unlimitedinstallationpossibilities


• Simpledesignwiththoroughlytest-ed components

• Competitiveprice:bestvalueformoney on the market

Your benefits

• Easyandquickinstallation

• Satisfiedend-usersduetoaccurate-ly filled cylinders

• SavingsonLPGbecauseofhighfill-ing accuracy and intelligent filling software

• Plug'n'playsolution:minimumin-stallation costs




• Minimummanualhandlingofheavycylinders when using a semi-mobile KCFiLL1 solution

• Highsafetyduetointrinsicallysafesystem

–Semi-mobileinstallation(e.g.onaswing crane or on a frame with wheels)

–Mobileinstallation(e.g.inacon-tainer,asaskid-mountedinstalla-tionoronatruck–eitherfixedoron a swing crane)

• ThecylinderflowtoandfromfixedKCFiLL1 units is carried out manual-ly or by using chain or roller convey-ors

• Configurationpossibilities:–Manualorautomaticconnection

of filling head–Withorwithoutliftingdevicefor

filling head–Includingexternalliftingtableor

weighing plate

• Datacollectionpack,includingcom-plete PC system or connection to ex-istingKosanCrisplantPCsystem,isavailable as an option

• Developedspecificallyforlowca-pacity random or batch filling and/or for filling of cylinders in different sizes with different valves

Your safety

• TheKCFiLL1unitisdesignedinac-cordance with current EU directives incl.theATEXDirective94/9/ECwiththeEx-markingII2GExibIIBT4 Gb

• TheKCFiLL1unitisdesignedforusein hazardous areas classified as Zone 1 according to IEC 79-10 and ClassI,Division1accordingtoNEC(USA),article500

• TheweighingaccuracyoftheloadcellisaccordingtoOIMLR60,NTEP3000d,accuracyclassC3


• Easyadjustmentandmaintenance(error messages in display)

• Canbeintegratedinexistingfillingsystem network

• Noneedforseparatecheckweigh-ingequipment:fillingandcheckweighing processes performed by the same unit

Your possibilities

• Unlimitedinstallationpossibilities:–Fixedinstallation(e.g.onasus-

pension frame with a minimum load-carrying capacity of 500 kg per installed unit)

KCFiLL1 with manual pneumatic filling head for screw valves

An upgrade to KCFiLL1 filling machines not only improved customer satisfaction, but also plant and consumer safety for Koshi Gas Udyog in Nepal

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CHECK wEIGHING SySTEmS

Fully automatic ECS check weighing system installed in-line in chain conveyor with roller conveyor for ejection of incorrectly filled cylinders

Fully automatic ECS check weighing system for LPG cylinders for installation in-line in chain conveyor

Detailed view of accumulation stop on chain conveyor (including photocell), underweight and lifting table

Stationary ECS check scale for installation on floor

Fully automatic ECS check weighing system installed in-line in chain conveyor with automatic ejection of incorrectly filled cylinders

ECS dynamic check scale for installation in-line in chain conveyor

Kosan Crisplant’s check weighing systems are de-signed for accurate and quick control of the net content in LPG cylinders. The systems en-sure correctly filled cylinders.

• Safecylinderstoyourend-users

• Automaticsort-outofunder-andoverfilled cylinders

• Capacityupto1,800cylindersperhour

• Flexibleforallcylinderdiametersand heights



Your benefits

• CheckweighingofallfilledLPGcyl-inders

• Automaticsort-outofunder-andoverfilled cylinders saves manpower and eliminates human errors

• Highsafetyduetointrinsicallysafenetwork

• Easyandsafeoperation

• Easycalibrationandzero-setting


• Easyadjustmentandmaintenance



• Lowinstallationcosts

Your possibilities

• Fullyautomatic,semi-automaticormanual operation

• Checkweighingsystemin-lineinchain conveyor with lifting table for stationary check weighing or with dynamic weighing table for continu-ous check weighing

• Checkweighingsystemin-lineinchain conveyor for fully automatic check weighing with automatic transfer of tare weight from central encoding station

• Checkweighingsystemin-lineinchain conveyor for semi-automatic check weighing with manual encod-ing of tare weight

• Checkweighingsystemin-lineinchain conveyor for semi-automatic check weighing with tare compare carried out by operator

• Stationarycheckscaleforinstalla-tion on floor

Your safety

• AllcheckweighingsystemsareEUapproved and designed in accord-ance with current EU directives EN 50014,EN50020,EN50081,EN50082,EN55022,incl.theATEXDi-rective (94/9/EC)

• Allcheckweighingsystemsarede-signed for use in hazardous areas classified as Zone 1 according to IEC 79-10andClassI,Division1accord-ingtoNEC(USA),article500

• AllcheckscaleshaveweighingAc-curacy Classification C3 according to OIML R 76/EN45501



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mANUAL LEAK DETECTORS

The TSV leak detector can detect leaks from the valve seat, pos. A (with closed valve)

Manually operated TSV leak detector The TCV leak detector can detect leaks from the valve seat, pos. A

Manually operated TCV leak detector

Kosan Crisplant’s manual leak detectors are designed for manual leak detection on valve seats of LPG cylinder valves.

• Leakdetectiononthebasisofvisualinspection

• Idealsolutionforlowcapacityfillingplants

• Suitableafterrandomfillingofdif-ferent cylinder types


• Smallinvestment

Your benefits

• Easytouse

• Hand-heldandmobileunits


• Minimumspacerequirements

• Flexibletoallcylinderdiametersand heights

Your possibilities

• Manualleakdetectorsforcentrevalves or screw valves

• Practicalgallowssuspensioncanbesupplied

• Canbeusedasstand-aloneunitortogether with conveyor

• Automaticsforcontrolofcylinderflow at in-line chain conveyor

Your safety

• Allmanualleakdetectorsarede-signed for use in hazardous areas classified as Zone 1 according to IEC 79-10andClassI,Division1accord-ingtoNEC(USA),article500



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ELECTRONIC LEAK DETECTORS AND vALvE TESTERS

Height adjustable, fully automatic, two-headed ET-GD leak detector

Manually operated ET-GD leak detector



• Airserviceunitwithextrafilterstoeliminate pollution in pneumatic air supply


• Easytosetup:allnecessarysoft-ware is installed in the HMI/CUC controller

• Easytouse:cleartextdisplayandsturdy keyboard

• Readyforintegrationinfullyauto-matic filling system


Your possibilities

• Testheadsdesignedforalltypesofvalves

• Testingprincipleaccordingtovalvetypeandtestingareaonvalve:gasanalysis principle (leak detectors) or pressure rise principle (valve test-ers)

• Manuallyoperatedmodelforinstal-lation(1)stationaryonfloor,(2)byachain conveyor or (3) by a roller con-

veyor. Available with gas analysis principle. Manually height adjusta-ble

• Fullyautomaticmodelforinstalla-tion in-line in chain conveyor. Per-forms test on all cylinders. Available with gas analysis principle or pres-sure rice principle. Manual change of test head for test of different valves. One- or two-headed ma-chine. For one fixed cylinder height. Manually or automatically height adjustable

• Calibrationandtestequipmentavailable on demand

Your safety

• Allelectronicleakdetectorsandvalve testers are EU approved and designed in accordance with current EUdirectivesEN50014,EN50020,EN50081,EN50082,EN55022,in-cl.theATEXDirective(94/9/EC)

• Allelectronicleakdetectorsandvalve testers are designed for use in hazardous areas classified as Zone 1 accordingtoIEC79-10andClassI,Division1accordingtoNEC(USA),article 500


Testing areas for screw valves (POL valves):A Leaks from the threaded joint

between the cylinder and the valveB Leaks from the valve seat (with

closed valve)C Leaks from the valve spindle (with

open valve with nut/plug)E Leaksfromthesafetyvalve,ifany

Testing areas for centre valves (self-closing valves):A Leaks from the threaded joint

between the cylinder and the valveB Leaks from the valve seatD Leaks from the regulator gasketE Leaksfromthesafetyvalve,ifany

Kosan Crisplant’s electronic leak detectors and valve test-ers perform tests on LPG cylin-der valves. The cylinders are approved or rejected accord-ing to preset permitted values.

• Providemaximumsafety

• Fullyautomatictestwithsamesort-ing limit

• Eliminatehumanerrors

• Detectallkindsofleakaroundthevalve

• Checkthevalveform(centrevalvesonly)

• Flexibleforalltypesofvalves





Your benefits

• Safecylinderstoyourend-users

• 100%test–allfilledcylindersaretested

• Savingsonmanpowerthankstoau-tomatic sorting of cylinders with un-approved valves

• Easytousecalibrationtoolsandprocedure

Test cylinder for calibration purposes

Pressure sensor/transmitter

Gas detector with infrared radiation

Fully automatic ET-GD leak detector

Fully automatic ET-PT valve tester


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LEAK TESTING bATHS

Semi-automatic pneumatic EB-8 leak testing bath integrated in chain conveyor with discharge of leaky cylinders

This EB-8 leak testing bath is made in stainless steel

Kosan Crisplant’s leak testing baths are designed for full manual leak detection of LPG cylinders.

• Leakdetectiononthebasisofvisualinspection

• Fullcylinderbodytest-includingvalve test

• Easyintegrationwithchainconvey-or

• Bathsforcontinuouscylinderflow

• Capacityupto1,200cylindersperhour

• Bathsforcampingcylinders,domes-tic cylinders and industrial cylinders

EB-4 leak testing bath for installation in chain conveyor Manually operated EB-2 leak testing bath for installation in roller conveyor

PCD leak testing bath integrated in chain conveyor

Your benefits

• Easyvisualleakdetection

• Simpletechnology

• Onlyoneoperatorisrequired

• Minimummaintenancecosts

Your possibilities

• Bathsforcontinuousflow,forcamp-ing cylinders or domestic cylinders

• Bathswithtiltablecylinderracksandmanual,semiautomaticorfullyautomaticcylinderhandling(for4,8or 10 domestic cylinders and for 2 or 4 industrial cylinders)

Your safety

• AllleaktestingbathsareEUap-proved and designed in accordance withcurrentEUdirectives,incl.theATEXDirective(94/9/EC)

• Allleaktestingbathsaredesignedfor use in hazardous areas classified

as Zone 1 according to IEC 79-10 andClassI,Division1accordingtoNEC(USA),article500



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wEIGHT CORRECTION mACHINES

Kosan Crisplant’s weight cor-rection machines are designed to perform safe and accurate weight correction of the LPG content in incorrectly filled cylinders. Weight correction is obtained by filling or evacuat-ing the LPG cylinder.

• Weightcorrectiononthespot

• Flexibleforallvalvestypes


• Automaticcheckweighingafterweight correction



• Independentunits


The weight correction machine is designed for incorporation in a roller conveyor. This basic model can be equipped with manual pneumatic filling heads for screw valves, and/or manual mechanical filling heads for centre valves. The weight correction machine is available in models for all cylinder types.

Your benefits

• Fastandcorrectweightcorrection

• Noaccumulationofincorrectlyfilledcylinders

• Minimumtimespentonincorrectlyfilled cylinders

• Highsafetyduetointrinsicallysafenetwork




Your possibilities

• Tiltableevacuationrackfordomes-tic cylinders

• Stand-alonetiltableevacuationrackfor industrial cylinders

• Manualorautomaticheadforfillingand evacuation

• Onemachinecanbeequippedwithvarious heads for filling and evacua-tion

• Stand-alonemachineorincorporat-ed in roller conveyor

Your safety

• AllweightcorrectionmachinesEUapproved and designed in accord-ance with current EU directives EN 50014,EN50020,EN50081,EN50082,EN55022,incl.theATEXDi-rective (94/9/EC)

• Allweightcorrectionmachinesaredesigned for use in hazardous areas classified as Zone 1 according to IEC 79-10andClassI,Division1accord-ingtoNEC(USA),article500

• Allweightcorrectionmachineshaveweighing Accuracy Classification C3 according to OIML R 76/EN45501

• National/localapprovalsThe tiltable evacuation rack for industrial cylinders is designed for stationary installation. It can be equipped with manual pneumatic filling heads for screw valves and/or manual mechanical filling heads for centre valves.

The weight correction machine with tiltable evacuation rack for

domestic cylinders is designed for incorporation in a roller conveyor.

It can be equipped with manual pneumatic filling heads for screw valves, manual mechanical filling

heads for centre valves and/or automatic filling heads for centre

valves.

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EvACUATION SySTEmS

The MS-U evacuation head is especial-ly designed for evacuation of LPG cyl-inders with screw valves with external thread

Almost all Kosan Crisplant’s filling heads can also be used as evacuation heads

M-4 evacuation rack with ES-HP evacuation pump

Kosan Crisplant’s evacuation systems are designed for easy and safe evacuation of LPG cylinders before repair as well as for evacuation of overfilled and leaky LPG cylinders.

• Solutionsforanyevacuationre-quirement

• Allsystemshavethoroughlytesteddesigns

• Completemodularsystems

• Minimumcylinderhandling

• Meanstoavoidaccumulationofleaky and incorrectly filled cylinders

• Ex-proofdesignforinstallationdi-rectly in filling hall

Your benefits

• Modularsolutionswithbuffertanks,pump,compressorandevacuationracks

• Highsafetylevelthankstofasthan-dling of leaky and incorrectly filled cylinders

• Nobottlenecks-thetotalevacua-tion system including piping is de-signed by Kosan Crisplant

• Differentevacuationheadsmountedon the same evacuation rack

The tiltable evacuation rack for industrial cylinders is de-signed for stationary installation. It can be equipped with manual pneumatic filling heads for screw valves and/or man-ual mechanical filling heads for centre valves.

The ES-M evacuation system is designed for stationary installation on floorA Connection to evacuation rackB Connection to storage tank1-2 Tanks3-4 Four-way valves

In-line ERI evacuation system integrated in chain conveyor

Your possibilities

• Manualorautomaticoperation

• Manualorautomatic,tiltablestand-alone evacuation racks for industrial cylinders

• Stationaryevacuationracksfor1to12 domestic cylinders

• Tiltableevacuationracksfor4to8domestic cylinders

• In-lineorstand-aloneevacuationracks for domestic cylinders

• In-linesystemsaresuppliedwithchain conveyor for control of cylin-der flow

• Air-drivencompressorforsmallca-pacities

• Compressor/pumpsolutionsforhighcapacities

• Evacuationheadsforcentrevalvesand screw valves

Your safety

• AllevacuationsystemsareEUap-proved and designed in accordance withcurrentEUdirectives,incl.theATEXDirective(94/9/EC)andthePressure Equipment Directive (97/23/EC)

• Allevacuationsystemsaredesignedfor use in hazardous areas classified as Zone 1 according to IEC 79-10 andClassI,Division1accordingtoNEC(USA),article500


5 Handle6 Gas compressor7 Electrical motor


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vALvE ORIENTATION mACHINE

Kosan Crisplant’s valve orien-tation machine is designed to perform a help function in con-nection with manual or auto-matic filling of cylinders with screw valves. The valve orien-tation machine ensures that the LPG cylinder is turned with the socket of the cylinder valve in the right direction for processing.

• Fullyautomaticorientationofscrewvalves

• Capacityincrease


• Flexibleforcylinderswithorwithoutshroud



The VOS valve orientation machine is de-signed to be incorporated in-line in a chain

conveyor. It is used for automatic orienta-tion of screw valves on gas cylinders, prior to various automatic processes as e.g. fill-

ing or application of caps.

In connection with fully automatic filling on carrousel, the machine is placed before

the introduction unit in order to ensure correct orientation of the cylinder valve before introduction of the cylinder onto

the filling machine.

The rollers on both the centring unit (green) and the rotation unit (red) are made of polyurethane (PUR), an extremely durable material, which ensures a good grip of the cylinder

Main components of the valve orienta-tion machine: orientation head (1), cyl-inder rotation unit (2), cylinder centring unit (3), cylinder stop (4), and cylinder lifting unit (5)

The orientation head is lowered upon the valve and the cylin-der is rotated. When the valve is in the right position inside the orientation head, a fibre optic beam (on the picture shown as a read beam) is cut off, and the cylinder stops rotating.

Your benefits

• Fastanduniformorientationofscrew valves

• Minimizednumberofbreakdowns

• Cylinderscanbeprocessedauto-matically after orientation

• Capacityincreasethankstooptimi-sation of manual processes

• Optimisedergonomicsduetoelimi-nation of one-sided repeated work

• Easytosetup:allnecessarysoft-ware is installed in the HMI/CUC controller

• Readyforintegrationinfullyauto-matic filling system


• Lowpowerconsumption Your possibilities

• Goodforinstallationbeforeallin-line process machines demanding uniform orientation of screw valves

• Possibilityforcommunicationwiththe following system-integrated ma-chine

• Heightadjustablemodelavailable

• Stand-alonemodelavailable

Your safety

• AllvalveorientationmachinesareEU approved and designed in ac-cordance with current EU directives EN50014,EN50020,EN50081,EN50082,EN55022,incl.theATEXDi-rective (94/9/EC)

• Allvalveorientationmachinesaredesigned for use in hazardous areas classified as Zone 1 according to IEC 79-10andClassI,Division1accord-ingtoNEC(USA),article500



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vALvE OPENER AND CLOSER

Kosan Crisplant’s valve opener and closer is designed for opening or closing of screw valves by means of a preset opening or closing torque. The valve opener and closer is used in connection with filling of LPG cylinders with screw valve and leak test of screw valves with open valves.

• Avoidone-sidedrepeatedwork

• Obtainhomogenousandsufficientvalve closing torque

• Avoidlockedhandwheels


• Flexibleforalltypesofscrewvalves

• Minimalspacerequirements


Your benefits

• Reliableequipment

• Savingsonmanpower

• Screwvalveslastlonger

• Easyadjustmentofopeningorclos-ing torque

• Novalvesarelockedwhenopened

• Automaticin-linevalveopenerhasabuilt-in revolution counter

Your possibilities

• Manualvalveopenerandcloser

• Automaticvalveopenerforin-lineinstallation

• Automaticvalvecloserforin-linein-stallation

• Allmodelsareavailablewithmanu-ally operated height adjustment de-vice

• Additionalfrictionrubberspannersfor other screw valve types

• Valveopenercanbesuppliedwithsafe closing of valve before opening it by a preset number of rotations

Your safety

• AllvalveopenersandclosersareEUapproved and designed in accord-ancewithcurrentEUdirectives,incl.theATEXDirective(94/9/EC)

• Allvalveopenersandclosersde-signed for use in hazardous areas classified as Zone 1 according to IEC 79-10andClassI,Division1accord-ingtoNEC(USA),article500


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THERmOSEALING mACHINES

The fully automatic SMS thermosealing machine, which shrinks seals by means of water steam, is designed for installation in a chain conveyor

The pneumatic manually operated SMS thermosealing ma-chine, which shrinks seals by means of water steam, is de-signed for stationary installation on floor by e.g. a chain con-veyor or a roller conveyorThe fully automatic SMA thermosealing machine, which shrinks seals by means of

hot air, is designed for installation in a chain conveyor

Kosan Crisplant’s thermoseal-ing machines are designed for safe and efficient shrinking of thermoplast caps or sleeves around LPG cylinder valves.

• Sealedvalvesareprotectedandsafe valves

• Logocanbeprintedontheseal

• Sealedvalvesareaguaranteeforcorrect cylinder net weight

• Cylinderswithsealedvalvesarefilled by authorised fillers

Your benefits

• Satisfiedend-usersduetosafeandcorrectly filled cylinders

• Imagebuildingasregardsqualityand safety

• Visualdifferencebetweenemptyand filled cylinders

• Sealingofmostvalveandcylindertypes

• Electricitysavings;automaticsen-sure limited use of full power

• Integratedautomaticsprotectagainst overheating

Your possibilities

• Shrinkagebymeansofwatersteamor hot air

• Manual,semiautomaticorautomat-ic solution

• Installationasstand-aloneunitorin-line in conveyor

• Within-lineconveyortheprocesscan be fully automatic

• Forfixedcylinderheightormanuallyheight adjustable

• Sealingofvalveswithhardcaps

• Ex-proofsteamgeneratorforinstal-lation in hazardous area when shrinking with water steam

• Separatesealapplicationsystemformanual or automatic application of shrinkable caps or sleeves

Your safety

• AllthermosealingmachinesareEUapproved and designed in accord-ancewithcurrentEUdirectives,incl.theATEXDirective(94/9/EC)

• Allthermosealingmachinesarede-signed for use in hazardous areas classified as Zone 1 according to IEC 79-10andClassI,Division1accord-ingtoNEC(USA),article500



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SEAL APPLICATION SySTEmS

Examples of shrinkable caps

Fully automatic cap applicator

• Integratedcontrolandsupervisionunit initiates stop when buffer stor-age is empty

• Uniformapplicationofshrinkableseals

• Nohumanerrors

Your possibilities

• In-lineinstallationinstandardchainconveyor systems

• Supplyofhardcapswithgas-tightsealing

• Installationofthermosealingma-chine right after seal application system

• Supplyofshrinkablesleevesinrollswith automatic cut off

• Supplyofshrinkablecapsinsticks

• Supplyofhardcapsinbulk

Your safety

• AllsealapplicationsystemsareEUapproved and designed in accord-ancewithcurrentEUdirectives,incl.theATEXDirective(94/9/EC)

• Allsealapplicationsystemsarede-signed for use in hazardous areas classified as Zone 1 according to IEC 79-10andClassI,Division1accord-ingtoNEC(USA),article500


Kosan Crisplant’s seal applica-tion systems are designed for application of all kinds of shrinkable seals on LPG cylin-der valves.

• Sealingofbothcentrevalvesandscrew valves

• Sealedvalvesareprotectedandsafe valves

• Automaticapplicationofshrinkableseals or caps

• Highcapacity


Your benefits

• Savingsonmanpower

• Avoidone-sidedrepeatedwork

• Automaticfeedingofshrinkableseals from buffer storage

Fully automatic sleeve applicator

Fully automatic cap applicator


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wASHING SySTEmS

The integrated heating elements ensure that the soap water has the right temperature

All filters in the washing system are easily accessible and can be cleaned easily and rapidly Ex-proof motor for water pump

The above series of pictures illustrates cylinders, which have been washed one time in a standard washing system

In case of particularly dirty cylinders a soap application section can be installed (1) before the washing section. The X distance depends on the time necessary for the soap mixture to dissolve the dirt on the cylinders before rinsing in the washing section (2).

Kosan Crisplant’s standard washing systems consist of a washing section (2) for washing and rinsing of cylinders by means of temperate soapy water, as well as a blow-off section (3) for blowing off excess water of cylinders

A piping system with fitted nozzles is installed on the inner side of the washing tunnel. The piping system as well as the placement of the nozzles is adapted to the relevant cylinder type(s), which ensures an optimal washing result.

Example of Kosan Crisplant’s stainless washing system with washing section and blow-off section

Kosan Crisplant’s washing sys-tems specially designed for LPG cylinders are developed in cooperation with leading sup-pliers of industrial washing machines. The washing sys-tems are highly efficient and ensure optimal cleaning of the cylinders.

• Themostefficientwashingsystemson the market

• Hotwaterwashingwithsoap

• Extensionofthecylinders’lifecycle

• Endusersperceivecleancylindersas safe cylinders

• Cleancylindersleadtoincreasedsales

Your benefits

• Allkindsofdirtandgreaseisre-moved from the cylinders

• Thoroughwashingofcylindersdueto optimal location of nozzles and rotation of cylinders

• Cylindersaredriedimmediatelyaf-ter washing thanks to a surface-ac-tive agent and efficient water blow-off

• Minimumwaterconsumptionthanksto recirculation of water and optimal water blow-off

• Minimizecorrosiveactiononthecylinder surface

• Easycleaningoffilters

Your possibilities

• Modularwashingtunnelwithvari-ous processes

• Watertankswithheatingelements

• Watertankswithfilters

• Rinsingsection

• Blow-offsection

• Machinesforvariouscylinderheights

Your safety

• AllwashingsystemsareEUap-proved and designed in accordance withcurrentEUdirectives,incl.theATEXDirective(94/9/EC)

• Allwashingsystemsaredesignedfor use in hazardous areas classified as Zone 1 according to IEC 79-10 andClassI,Division1accordingtoNEC(USA),article500


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LPG PIPING SySTEmS

Kosan Crisplant’s LPG piping systems are designed for sup-ply of LPG to both filling ma-chines and evacuation sys-tems.

• 50years’experiencewithdesignofLPG piping systems

• Dimensioningandsupplyofcom-plete LPG piping systems

• Weonlyuseinternationallyac-knowledged suppliers of compo-nents

• Maximumsafety

• Competitiveprices

• Future-orientedsolutionswithpos-sibilities of expansion

Your benefits

• Clearvendor/clientinterface

• Constantfillingpressureensured

• Homogenousbasisfordimensioningand design

• Unambiguouscolourcodeonpipes

• Fullsupplyincludingallnecessarypipefittings,boltsandgaskets

• Longlifecycle


Your possibilities

• Engineering,projectinganddocu-mentation

• Differentialpressurevalves

• Pressurereliefvalves

• Connectionsbymeansofflangesorwelded pipes

• LPGpumps

• LPGcompressors

• LPGfilters

• Manometers

• Gasstopvalves

• Blow-offvalves

• Ballvalves

• Hydraulicquick-closingvalves

• Protectionagainstdryrunning

• Y-strainers

• By-passvalves

• Non-returnvalves

• Loadingandunloadinghoses

• Hosecouplings

• Massflowmeters

• FlowmetersYour safety

• LPGpipeengineeringaccordingtoall known international norms

• AllLPGpipingsystemsaredesignedfor use in hazardous areas classified as Zone 1 according to IEC 79-10 andClassI,Division1accordingtoNEC(USA),article500


Example of a pressure regulation arrangement used to maintain the desired constant filling

pressure in an LPG filling system

Supply line from LPG pump (1)Return line to storage tank (2)

Supply line to filling system (3)

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TANK yARD EqUIPmENT

Kosan Crisplant’s tank supervision system gives complete overview of the tank yard and can be adapted to any need. The valve overview indicates present status for all valves and the tank overview lists all information about pressure, tem-perature and filling degree for each tank.

ISO tank 20”

LPG pump installation

Mounded tank

Road tanker loading and unloading point

Spherical tank

Cylindrical tanksKosan Crisplant’s tank yard equipment is an optimal solu-tion for LPG storage. We supply complete systems dimensioned according to any recognized international standard.

• 50years’experiencewithsupplyoftank yard equipment

• Maximumsafety


• Future-orientedsolutionswithpos-sibilities of expansion

• Weonlyuseinternationallyrecog-nized suppliers of components

Your benefits

• Completeequipmentfortankyardsincludingsafetyequipment,measur-ing and control equipment as well as operating equipment and shut-off valves

• Equipmentwithlonglifecycle



• Clearsupplyinterface

Your possibilities

• Sphericaltanks

• Cylindricaltanks

• Moundedtanks

• Tanksupervisionsystems

• Pumpandcompressorequipment

• Loadingandunloadingpointsforroadtankers,railtankwagonsandships

Your safety

• AlltankyardequipmentisEUap-proved and designed in accordance withcurrentEUdirectives,incl.theATEXDirective(94/9/EC)

• Alltankyardequipmentisdesignedfor use in hazardous areas classified as Zone 1 according to IEC 79-10 andClassI,Division1accordingtoNEC(USA),article500


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fIRE wATER SySTEmS

Kosan Crisplant supplies com-plete and efficient fire water systems for LPG filling plants, dimensioned according to in-ternational standards.

• 50years’experienceindesignoffire water systems

• Maximumsafety


• Weonlyuseinternationallyrecog-nized suppliers of components

Your benefits

• Firewatersystemswithlonglifecy-cle



• Futureorientedsolutionswithpossi-bilities of expansion

• Clearsupplyinterface

Fire water pump system

Test of fire water system on spherical LPG storage tank

Fire water system on cylindrical LPG storage tank

Your possibilities

• Electricallydrivenordiesel-poweredfire water pump systems

• Jockeypumps

• Firewatertanks

• Sprinklersystemsforfillingplants,tanks,loadingpoints,pumpingsta-tions etc.

• Sprinklersystemsforwatercurtainsor for coverage of total areas

• Coolingsystemsforsphericaltanks

• Delugesets

• Drychemicalextinguishersandoth-er equipment

• Integrationwithalarmsystemsanddirect alarm to fire departments

Your safety

• AllfirewatersystemsareEUap-proved and designed in accordance withcurrentEUdirectives,incl.theATEXDirective(94/9/EC)

• Allfirewatersystemsaredesignedfor use in hazardous areas classified as Zone 1 according to IEC 79-10 andClassI,Division1accordingtoNEC(USA),article500


Diesel-powered fire water pump

Water canon test Fire water tank and fire pump house

Sprinkler system integrated in container filling plant Sprinkler system at road tanker loading and unloading point

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CUC POwER AND DATA NETwORK

Example of CUC configuration

Kosan Crisplant’s HMI/CUC controller

Kosan Crisplant’s CPI-Ex for supply of power and data to intrinsically safe network

Complete PC system including standard software and Kosan Crisplant software for collection and handling of data

Kosan Crisplant’s CUC power and data network is designed for intrinsically safe power supply to CUC controlled ma-chines and for data communi-cation between CUC controlled machines.

• 100%intrinsicallysafenetworkap-proved for hazardous area

• Networkcommunicationbetweenmachines without PC intervention

• Totalprotectionandisolationofin-trinsically safe network via CPI-Ex power supply

• Highsafetythankstointrinsicallysafenetwork,allcablescanbebro-ken without any risk

1 PC system (hardware and software)2 Ex-proof CPI-Ex power supply3 HMI/CUC controller for palletizer4 Slip ring5 Carrousel filling system6 HMI/CUC controller for UFM filling

machine installed on filling carrousel

7 HMI/CUC controller for introduction at filling carrousel

8 HMI/CUC controller for ejection at filling carrousel and for ECS check scale

9 HMI/CUC controller for leak detector

10 HMI/CUC controller for stationary UFM filling machine

a Load cell moduleb Load cellc T-connectord Connection boxS Non-hazardous areaX Hazardousarea

Your benefits

• Lowinstallationscosts

• Simplecablesandconnections

• Easycabling-poweranddatainthesame cable

• EveryHMI/CUCcontrollercancon-trol any machine in the network

• Softwarefordifferentmachinefunc-tions is already installed on HMI/CUC controllers

• Fewcomponentstobekeptinstockthanks to uniform components

• Built-intransientprotectioninCPI-Ex power supply with protection against excess voltage

• VariationininputsignaltoCPI-Expower supply between 85 and 264 VAC/ 47 and 63 Hz

• Easyexpansionofandcommunica-tion between parallel network

Your possibilities

• CPI-Expowersupplyapprovedforinstallation in hazardous area

• ParalleluseofseveralCPI-Expowersupplies

• HMI/CUCcontrollersavailablewithdifferentI/Oconfigurations,upto16outputs and 32 inputs

• UPS(UninterruptiblePowerSupply)to the PC and the CPI-Ex power sup-ply in order to ensure correct close-down of PC and to secure data of ongoing filling

• InstallationofPCinnon-hazardousarea up to 500 meters from filling hall

• OnePCcancollectandhandledatafrom up to 10 carrousel systems si-multaneously

Your safety

• Allequipmentandmachinesinthenetwork are EU approved and de-signed in accordance with current EUdirectivesEN50014,EN50020,EN50081,EN50082,EN55022,in-cl.theATEXDirective(94/9/EC)

• Allequipmentandmachinesinthenetwork are designed for use in haz-ardous areas classified as Zone 1 accordingtoIEC79-10andClassI,Division1accordingtoNEC(USA),article 500



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PRODUCTION DATA mANAGEmENT SySTEm

Kosan Crisplant’s HMI/CUC controller

Graphic display of total filling capacity and filling accuracy

Complete PC system including standard software and Kosan Crisplant software

Various displays

Kosan Crisplant’s Production Data Management System col-lects data from filling process machines controlled by the HMI/CUC controller. The data is monitored and serves as a ba-sis for reports concerning the filling process.

• Automaticcollectionofallimportantproduction data

• Highsafetylevelduetoproductionsurveillance

• Effectivetoolsforviewingandana-lysing production data

• PCmonitoringofrealtimeproduc-tion status

• Reportstatisticsforfillinghallpro-duction overview

• Easyidentificationofmaintenanceand adjustments needs

• Readyfordirectconnectiontoexist-ing CUC network

Your benefits

• Analysisofbothsinglemachineca-pacity and filling plant capacity

• Overviewofproductioninterruptionsand of development in filling capaci-ty

• Analysisofsinglemachinefillingac-curacy and adjustment need

• Surveyoftotalproductionfillingac-curacy

• Reviewofcylindersrejectedatcheck scales and leak detectors

• Reportspercylindertypeandforgiven time periods

• On-linesupervisionofallHMI/CUCcontrollers including alarm log and status overview

• Elaborationofpresentationgraphson the basis of report data

• Efficientdatastorageandsearchindatabase

• Disasterrecoveryincl.quickre-in-stallation of PC in case of crashing

Your possibilities

• InstallationofPCinnon-hazardousarea up to 500 meters from filling hall

• OnePCcancollectandhandledatafrom up to 10 carrousel filling sys-tems simultaneously

• Updateofsoftwareviamodem

• Standardhigh-qualityPCwithDVD-RWdrive,keyboard,mouse,flatscreen,andcolourprinter

• Standardsoftware(e.g.MicrosoftWindows,SQLdatabase,etc.)

• KosanCrisplantsoftware(CUCMonitor,RCCReports)

Your safety

• Hardwareandsoftwareaccordingtointernational standards


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ELECTRICAL EqUIPmENT

Ex-proof power panel Power panel for non-hazardous area

Electrical installation (in non-hazardous area) for firewater pump system

The purpose of Kosan Crisplant’s range of electrical equipment is to obtain safe and optimal operation of complete filling plants.

• 50yearsexperiencewithelectricalengineering in hazardous areas

• Future-orientedelectricalsolutionscapable of improvement

• Ex-proofcomponentsaccordingtoEuropean norms

• Oursuppliersareallinternationallyapproved and certified


Your benefits

• KosanCrisplantcansupplyaninte-grated system solution including both filling equipment and electrical equipment

• Anintegratedsystemsolutionpro-videsyouwithasimpleinterface,optimal safety and easy-to-operate filling halls

• KosanCrisplantprovidesafter-salesservice on both filling equipment and electrical equipment

Pole with start/stop switches and emergency stop switch

Kosan Crisplant’s CPI-Ex for supply of power and data to intrinsically safe network Example of lighting

Ex-proof power panel including all switches (main switch, start/stop switch, lighting switch, emergency stop switch, etc.)

• Ex-proofcertificatessuppliedwithmachines for your safety

Your possibilities

• Engineering,projectinganddocu-mentation

• Mainswitchboardsandsecondaryswitchboards in non-hazardous area and hazardous area

• Ex-proofstart/stopswitches

• Emergencystopsystemsincludingswitches

• Localpowersupply(generator)

• Emergencypowerplant(generator)with manual or automatic switching on

• Earthingincludingequipotentialbonding and earthing rod

• Machineprotection

• Cabling,cables,cabletrays

• Lightinginbuildings

• Outdoorlighting,lamppolesintankyard,drivewaysetc.

• Sirens

• Lightningprotection

• Fire/gasalarmsystems

• Firewaterinstallation

Your safety

• Electricalengineeringaccordingtoallknowninternational norms

• Allex-proofelectricalequipmentisdesignedfor use in hazardous areas classified as Zone 1accordingtoIEC79-10andClassI,Division1accordingtoNEC(USA),article500


Ex-proof power panel for LPG pump unit


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fIRE AND GAS ALARm SySTEmS

Gas detector at loading and unloading point for rail tank wagons

Example of fire detector

Examples of gas monitors

Examples of gas detectors

1 Gate house

2 Parking area

3 Administration building

4 Parking area for trucks

5 Railroad

6 Loading points

7 Storage tanks

8 Pump house

9 Filling hall

10 Fire water tank

11 Pump house

12 Air compressor room

13 Workshop

14 Changing room for the personnel

15 Switchboard room

16 Emergency generator

17 Diesel tank

18 Storage for filled/empty cylinders

19 Kerbstone

20 Lighting pole

Gas detector

Fire detector

Control panel

Fire alarm sirene

Examples of fire zones

Basic layout for installation of a fire and gas alarm system in connection with an LPG filling plant

Kosan Crisplant’s fire and gas alarm systems are simple and efficient modular systems which provide maximum safety and meet any requirement for gas and fire detection.

• Remotecontrolpanel

• Audioand/orvisualalarm

• Visualalarmoverviewoncontrolpanel

• Minimalmaintenance

• Detectorsdesignedforharshindustrialenvironments

Your benefits

• Built-inbatteryback-up

• Easyintegrationwithexistingequip-ment

• Simpleandeasycalibration

• Detectorscanbecheckedfromcon-trol panel

Your possibilities

• Flexibleoutputoptions

• Directalarmtofiredepartmentsinthe event of fire

• Detectorscanbeplacedanywhereat the filling plant

• Presetactionsforalarmsituations,e.g. stop of LPG pumps

• Alarmscanbesetforrisingandfall-ing gas levels

Your safety

• AllfireandgasalarmsystemsareEU approved and designed in ac-cordancewithcurrentEUdirectives,incl.theATEXDirective(94/9/EC)

• Allfireandgasalarmsystemsaredesigned for use in hazardous areas classified as Zone 1 according to IEC 79-10andClassI,Division1accord-ingtoNEC(USA),article500


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SHROUD AND fOOT RING STRAIGHTENERS

Shroud straightener

Foot ring straightener

Hydraulic unit

Your safety

• Allshroudandfootringstraighten-ers are EU approved and designed in accordance with current EU direc-tives,incl.theATEXDirective(94/9/EC)

• Allshroudandfootringstraighten-ers are designed for use in hazard-ous areas classified as Zone 1 ac-cordingtoIEC79-10andClassI,Di-vision1accordingtoNEC(USA),ar-ticle 500


Your possibilities

• Shroudandfootringstraightenerscan be supplied as individual ma-chines or together

• Supplyoftailor-madestraighteningtools for any shroud and foot ring di-ameter

• Eachstraighteningtoolcanbeusedfor shrouds and foot rings with a 10 mm variation in diameter

• Supplyofextrastraighteningtools

• Hydraulicunitforoperationofonemachineatatime,orforoperationof both machines simultaneously

Kosan Crisplant’s shroud and foot ring straighteners are de-signed for rapid, precise and safe repair of damaged shrouds and foot rings on LPG cylin-ders.

• Obtainnice-lookingcylinderswithhigh market value

• Avoidaccumulationofdamagedcyl-inders in the filling hall

• Avoidproductionstopsandbreak-down because of damaged shrouds and foot rings

• Ex-proofequipmentforinstallationdirectly in filling hall

• Deliveredreadyforuse

Your benefits

• Easyoperation

• Semi-automaticprocess

• Integratedsafetydeviceformaxi-mum operator safety

• Completedeliveryincludinghydrau-lic unit

• Rapidandeasyreplacementofstraightening tools


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PRESSURE TESTING EqUIPmENT

PTU pressure testing unit for industrial cylinders

PTL-10 linear pressure testing rack for domestic cylinders

PTL-5 linear pressure testing rack for domestic cylinders

Left: Cylinder being pressure tested on a carrousel

Right: WT-2500 water tank for pressure testing carrousel

PTC pressure testing carrousel for domestic cylinders

Kosan Crisplant’s pressure testing equipment is designed for rapid and safe pressure testing of LPG cylinders. Pres-sure testing is a part of the general requalification and testing procedure.

• Pressuretestedcylindersaresafecylinders

• Flexiblesolutionswhichmeetanyrequirement

• Highcapacityupto450cylindersper hour

• Variabletestpressureupto45bar

Your benefits

• Stand-alonerackscanbeinstalleddirectly in the filling hall

• Visualinspectionofthetotalcylin-der surface

• Recirculationofwatermeanslowwater consumption

• Thetestperiodcanbevaried

• Highsafetythankstotheuseofwa-ter as pressure medium

• Highfilling/evacuationspeed

Your possibilities

• Carrouselsystemwithupto20pressure testing units for domestic cylinders

• Pressuretestingunitforcarrouselwith manual or automatic horizontal rotation

• Pressuretestingunitforcarrouselfor one cylinder size or manually height adjustable

• Stand-alonepressuretestingrackfor 5 or 10 domestic cylinders

• Stand-alonepressuretestingrackfor one cylinder size or manually height adjustable

• Stand-alonepressuretestingrackforonecylindersize,manuallyheightadjustable,forindustrialcyl-inders and domestic cylinders

• Pumpunit(lowpressure/highpres-sure pump) incl. water tank with a volumeof1,000or2,000litres

• Carrouselsolutionwithintegratedpump unit and water tank

• Pressuretestheadswithintegratedimmersion pipe

• Immersionspipesforallcylinderflange types

Your safety

• AllpressuretestingequipmentisEUapproved and designed in accord-ance with current EU directives



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PURGING SySTEmS

Fully automatic purging unit

Fully automatic purging: the purging head is lowered upon and fitted tightly to the cylinder flange. The subsequent purging process includes two steps: first all atmospheric air is sucked out of the cylinder (1) and afterwards a predetermined quantity of gas is filled into the cylinder (2). The gas is dosed according to the cylinder volume in a quantity which makes the gas vapour settle at approximately the same level as the cylinder flange. In this way the cylinder is protected against unnecessary gas leaks.

Manually operated purging unit, where the length X is adapted to the height of the cylinder(s) for purging

Manual purging: the operator inserts the purging unit into the cylinder all the way to the bottom. Afterwards, the operator fills a predetermined quantity of gas into the bottom of the cylinder, and the evaporated gas presses all atmospheric air out of the cylinder. The gas is dosed according to the cylinder volume in a quantity which makes the gas vapour settle at approximately the same level as the cylinder flange. In this way the cylinder is protected against unnecessary gas leaks.

Manual purging

Kosan Crisplant’s purging sys-tems are designed for quick and safe replacement of at-mospheric air in cylinders with LPG in vapour state. The pro-cess is applied on LPG cylin-ders without valves. Valves should be mounted right after the purging process.

• AvoiddangerousmixofLPGandat-mospheric air in cylinders

• Fillingspeedatmaximumlevel

• Avoidcapacityreduction

• Controlledprocess:nodangerousaeration of cylinders after filling

• Noaerationofcylinderswhenend-users start using them

Your benefits

• Highsafetyforend-users

• Easytousemanualpurgingunit

• Themanualpurgingunitrequiresminimum space


• Flexibletoallcylinderdiametersand heights


Your possibilities

• Manuel,semiautomaticorautomat-ic process

• Manualpurgingunitcanbeusedasstand-alone unit or together with conveyor

• Automaticpurgingisintegratedinchain conveyor

• DozingofvariablequantityofLPGdepending on cylinder size

• Vacuumsuctionand/orgasdosing

• Automaticsforcontrolofcylinderflow with manual purging unit in-line in chain conveyor

Your safety

• AllpurgingsystemsareEUap-proved and designed in accordance withcurrentEUdirectives,incl.theATEXDirective(94/9/EC)

• Allpurgingsystemsaredesignedforuse in hazardous areas classified as Zone 1 according to IEC 79-10 and ClassI,Division1accordingtoNEC(USA),article500



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vALvE CHANGING mACHINE

PVS valve changing machine for installation in chain conveyor

Kosan Crisplant’s valve chang-ing machine is designed for quick and safe change of LPG cylinder valves.

• Quickandefficientscrewingandun-screwing of valves

• Changeofbothcentrevalvesandscrew valves

• Specialkeysforallvalvetypes

• Meanstoavoidaccumulationofleaky and incorrectly filled cylinders

• Ex-proofdesignforinstallationdi-rectly in filling hall or maintenance hall

Your benefits

• Noneedforhandtools

• Minimumcylinderhandlingwithin-line chain conveyor

• Extramomentofrotationforposi-tioning of screw valves according to cylinder shroud

• Quickchangeofspecialkeywhenchanging valves

Your possibilities

• Manualmachineasstand-aloneunitor in-line in roller conveyor

• Semiautomaticmachinein-lineinchain conveyor

• Availableindifferentheights

• Availablewithmanualheightad-justment

• Ekstraequipmentfordosingofthread paste and for cleaning of thread

• Extracontrolboxforhandlingtallcylinders

Your safety

• AllvalvechangingmachinesareEUapproved and designed in accord-ancewithcurrentEUdirectives,incl.theATEXDirective(94/9/EC)

• Allvalvechangingmachinesarede-signed for use in hazardous areas classified as Zone 1 according to IEC 79-10andClassI,Division1accord-ingtoNEC(USA),article500


The valve changing machine is easy and safe to operate

PVS valve changing machine for stationary installation on floor

Each valve changing key can be fitted to the valve type in question (or possibly to the

valve types in question)


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EqUIPmENT fOR INTERNAL CLEANING AND INSPECTION Of LPG CyLINDERS

Equipment for internal inspection of LPG cylinders

Equipment for internal inspection of LPG cylinders installed in-line in chain conveyor

Equipment for internal cleaning of LPG cylinders installed in-line in chain conveyor

Combined machine for internal cleaning of LPG cylinders with steam and suction of residual water and dissolved dirt. The illustrated machine is to be installed in-line in chain conveyor and can handle two types of cylinders with different heights.

With Kosan Crisplant’s equip-ment for internal cleaning and inspection of LPG cylinders you can perform efficient cleaning of LPG cylinders as well as vis-ual control of the state of LPG cylinders after cleaning.

• InternalcleaningandinspectionofLPG cylinders is part of the requalifi-cation procedure

• RequalificationofLPGcylindersisimportant because of the cylinders’ high value

• InternalcleaningandinspectionofLPG cylinders is easy to perform while changing valve

• Internalcleaningofcylinderscon-tributes to high safety

• Cylinderswithlonglifecycle

Your benefits

• Whencylindersarecleanedinter-nally,thewaterusedduringthepressure testing process is clean

• Residueemptyingdeviceremovesbad smelling slurry from cylinders

• Efficienthighpressurecleaningwithrotating nozzle

• Onlylittlewaterisconsumedduringinternal cylinder cleaning process

• Collectionofslurryinclosedcon-tainer prevents obnoxious smells and environmental pollution

Your safety

• Allequipmentforinternalcleaningand inspection of LPG cylinders is EU approved and designed in ac-cordancewithcurrentEUdirectives,incl.theATEXDirective(94/9/EC)

• Allequipmentforinternalcleaningand inspection of LPG cylinders is designed for use in hazardous areas classified as Zone 1 according to IEC 79-10andClassI,Division1accord-ingtoNEC(USA),article500


Your possibilities

• Fullyautomaticcleaningequipmentfor installation in-line in chain con-veyor

• Cleaningequipmentcanbesuppliedwith pump unit and water tank

• Fullyautomaticwaterandslurryemptying device for installation in-line in chain conveyor

• Manualresidueemptyingdeviceforinstallation in-line in chain conveyor or as stand alone unit

• Cleaningequipmentandemptyingdevicewith1,000litrewatertankwith filter and pump unit

• Videoequipmentorsimpleinspec-tion equipment with light source for manual internal cylinder inspection. Bothsolutionsareavailableforin-stallation in-line in chain conveyor or as stand alone units


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mARKING Of LPG CyLINDERS

Example of ink-jet printed bar code

Example of cylinder spray painted through screen

Example of stickers on cylinders

9 & 10 – Examples of cylinder tagging with electronic data carriers

Example of plastic disc around cylinder valve

Example of ink-jet printed cylinder data as clear text

Full-bodied cylinder sleeve application equipment

Equipment for silk screen printing (serigraphy)

Example of cylinder data engraved directly into cylinder handle

Kosan Crisplant’s extensive pro-gramme of select equipment for marking of LPG cylinders offers all sorts of marking jobs includ-ing statutory safety instructions, commercial logos, guidelines for end-users and other promo-tion features. In addition, there is a series of options for indi-vidual marking of cylinders with data to be used in the fill-ing and control processes (tare marking, process date etc.).

• Markyourcylinderswithcodesforautomatic reading and automate the filling and control processes

• Observestatutorydemandsformarking of cylinders

• Useyourcylindersforpromotiondisplays

• Strongcompanyprofiling

• Safetyinstructionsandgeneralguidelines on your cylinders for end-users increase safety

Your benefits

• Equipmentcanbeinstalledinexist-ing plants

• Imagebuildingasregardsqualityand safety

• Clearmarkingofinspectiondatein-creases safety

• Cleartaremarkingreducesopera-tional stops and ensures correct fill-ing

• Automaticreadingofprocessdata(bar codes or electronic data carrier) increases capacity and reduces the number of human errors

Your possibilities

• Silkscreenprinting(serigraphy)orpad printing

• Brushorspraypaintingthroughscreen

• Applicationoflabelorsticker

• Ink-jetprintingofbarcodesand/orclear text

• Applicationofplasticorcardboarddisc around the cylinder valve

• Electronicdatacarrierintheshapeof a chip

• Engravingorstampingofcylinderdatadirectlyintofootring,shroudorvalve bung

• Plasticsleevearoundthecylinderbody

• Barcodesandelectronicdatacarri-ers can contain either individual da-ta or a unique serial number that re-fers to a central database

Your safety

• AllequipmentformarkingofLPGcylinders are EU approved and de-signed in accordance with current EUdirectives,incl.theATEXDirec-tive (94/9/EC)



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SURfACE TREATmENT Of LPG CyLINDERS

Shotblasting equipment with automatic loading and unloading of cylinders

Overhead conveyor system

Dry-filter booth for wet painting

Manually operated powder paint gun Spray booth for automatic application and recovery of powder paint

Fully automatic powder painting equipment

Automatic transfer of cylinders from chain conveyor system to overhead conveyor system

Spray booth for manual application of wet paint

Tunnel oven for drying after pre-treatment, curing/drying wet paint or curing powder paint

Kosan Crisplant’s vast product line of equipment for surface treatment of LPG cylinders is a means to obtain high cylinder quality and long cylinder life-time. Surface treatment, in-cluding cleaning and painting, is an important and natural part of the regular standard inspec-tion procedure.

• Nice-lookingcylindershavehighmarket value

• End-usersprefernewlypaintedcyl-inders

• Surfacetreatmentextendscylinderlifetime

• Distributorsandend-userstreatnewly painted cylinders with care

Your benefits

• Asmoothunbrokencylindersurfacecan be cleaned easily

• Surfacetreatmentprotectsagainstcorrosion

• KosanCrisplantonlyusesinterna-tionally recognized sub-suppliers

• Usemanpowerforcylindermainte-nance in quiet periods

• Reductioninprocurementofnewcylinders

Your possibilities

There are three main methods for sur-facetreatmentofLPGcylinders:

1 Make-up wet painting in filling hall (hazardous area)

•In-lineinchainconveyor•Dryingofcylindersonchaincon-

veyor•Operationcanbemanualorfully

automatic

2 Wet painting in non-hazardous area

•Cylinderssuspendedinoverheadconveyor

•Canbeusedincombinationwithshotblaster and drying oven

•Operationcanbemanual,semi-automatic or fully automatic

3 Powder painting in non-hazardous area

•Cylinderssuspendedinoverheadconveyor

•Mustbeusedincombinationwithshotblaster and drying oven

•Operationcanbemanual,semi-automatic or fully automatic

Whenusingtheabovemethods,thefollowingequipmentcanbeapplied:

• Stand-alonecabinsforshotblasting

• In-lineshotblastingwithautomaticloading onto or unloading from chain conveyor

• Ovensforburningoffoldpaintingbefore shotblasting for obtaining the best possible starting point for new surface treatment

• Manualspraybooths

• In-linewetpaintingbooths

• Fullyautomaticpowderpaintingplants with overhead conveyor sys-tem and loading onto or unloading from chain conveyor

Your safety

• Allequipmentforsurfacetreatmentof LPG cylinders is EU approved and designed in accordance with current EU directives



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HOT REPAIR Of LPG CyLINDERS

Semi-automatic surface welding equipment

Cutting equipment

Annealing furnace (630°C) including automatic loading/unloading system for cylinders and cooling section

Grinding tool for preparation of welding surfaces

Work place for straightening of dents by use of pressure, burner and hammer

Kosan Crisplant offers a com-plete product line for hot repair of LPG cylinders that cannot be repaired by Kosan Crisplant’s shroud or foot ring straighten-ers because of very deformed shrouds or foot rings. Kosan Crisplant’s equipment for hot repair includes accessories for cutting and surface welding of shrouds and foot rings as well as equipment for normalizing LPG cylinders.

• Obtainnicelookingcylinderswithhigh market value

• Avoidproductionstopsandbreak-down because of damaged shrouds and foot rings

• Considerablesavingsthankstolessneed of new cylinders

• Installationofcompleteworkingplaces for cutting and welding

Your benefits

• Minimumwasteofcylindersthanksto reuse of intact cylinder bodies

• Highfillinghallcapacityduetocon-tinuous production with no stops and breakdowns

• Minimumuseofspareparts

• Minimumrepairoffillinghallequip-ment

• Noaccumulationofdamagedcylin-ders in the filling hall

• Weonlyuseinternationallyrecog-nized subsuppliers

• Useofmanpowerforcylindermain-tenance in quiet periods

Your possibilities

• Vastproductlinefrommanualhandtools to automatic processing ma-chines

• Manualorsemi-automaticprocessfor cutting off shrouds and foot rings

• Variouspossibilitiesforcuttingpro-cess,e.g.plasmacutting,ordinaryflamecutting,hydraulicshearing-offor chiseling

• Grindingtoolforpreparationofwelding surfaces

• Manualorsemi-automaticsurfacewelding of new shrouds and foot rings

• Normalizingfurnaces(920ºC)oran-nealingfurnaces(630ºC)forin-linecontinuous operation or solutions for stand-alone manual or semi-au-tomatic operation

• Straighteningofdentsincylindersbyuseofpressure,burnerandham-mer

Your safety

• AllequipmentforhotrepairisEUapproved and designed in accord-ance with current EU directives


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OxyGEN AND NITROGEN PLANTS

Oxygen plant

Functional descriptionAn oxygen/nitrogen plant may be devided into the following three basic processes or steps. All processes are executed simultaneously and continuously.

Step 1: Production of clean compressed atmospheric airStep 2: Production of oxygen/nitrogenStep 3: Storage and filling into cylinders

Nitrogen plant

With Kosan Crisplant’s oxygen or nitrogen plants you can make money on the basis of at-mospheric air. Install an oxy-gen or a nitrogen cylinder fill-ing station and create a new business or secure your own supply of oxygen or nitrogen.

• Smallmobileandprefabricatedplants–plug&play

• Theindividualplantisforoneprod-uct only

• Capacityaccordingtocustomerneeds

• Expandyourbusiness

• Idealsolutionforfastentrytomar-kets

• Smallinitialinvestment


• Alreadyestablishednetworkcanbeused for distribution of oxygen and nitrogen cylinders

Your benefits

• Fastpay-backtime

• Securityofsupply

• Highqualityequipment

• Fastdailyproductionstart-up

• Easytooperate


• Skidmountedplantsforeasyinstal-lation

• Onlyelectricityisneededforopera-tion of the plant


• Minimumandsimplemaintenance


• Integratedsupervisionandalarmsystem

• Monitoringsystemgeneratespro-cess information

Your possibilities

Utilization areas for nitrogen:

• Coolingoffoodstuffs;liquidnitrogen(-196ºC)quicklycoolsdownfood-stuffs

• Fillingofpipeswithnitrogenbeforewelding

• Rinsinginordertoavoidoxidation

• Toavoidoxidationoffoodstuffs/bio-logical material during storage

• Toavoidrancidnessofoil

• Cooling/congelationofthesoildur-ing ground work/sanitary and heat-ing installations

• Pressureagentcreationofoverpres-sure in containers to avoid oxida-tion/corrosion

• Toavoidcarburization/annealingofsteel during production of metal

• Productionofglass–coolingofelectrodes

• Anticorrosive

• High-pressurecastingduringpro-duction of tyres

• Intheelectronicsindustry–tocre-ate a different atmosphere during productionoftransistors,diodesetc.

• Intheammoniaindustry–duringproduction of ammonia

• Intheoilindustry–forcreationofpressure during drilling to force crude oil to move upwards

• Fluorescenttubes–thetubeisfilledwith nitrogen

• Welding–usedasweldinggaswithother types of gases

Utilization areas for oxygen:

• Combustion-createshighertemper-atures than normal air

• Fermentationoffoodstuffs

• Preservestheredcolourofmeat

• Inhibitsmicro-organismsinfood-stuffs at a high concentration

• Toavoidrancidnessofoil

• Oxidationprocesses

• Productionofpaper

• pHcontrol

• Oxidationofwater-duringbreedingof fish

• Generationofozone(wastewater)

• Medicaluse

Your safety

• Alloxygenandnitrogenplantsaredesigned in accordance with current EUdirectives,incl.ThePressureEquipment Directive (97/23/EC)

• KosanCrisplanthas50years’expe-rience as a global supplier of turn-key projects to the gas industry

AIRCOMPRESSOR

AIRDRYER

OXYGEN/NITROGEN

PRODUCTION

HIGH PRESSURECOMPRESSOR

CYLINDER FILLINGAIR

RECEIVER

OXYGEN/NITROGENRECEIVER

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SERvICE AND TRAINING

At your service – 24 hours a day, 7 days a week

Kosan Crisplant service points

Kosan Crisplant offers tailor-made training courses for e.g. operators, maintenance staff, technicians and plant managers

Kosan Crisplant offers a wide range of service from many service points around the world. We can assist you with everything from machine repair to training of your personnel and how to expand your LPG business.

• Professionalassistancefromanex-perienced supplier with more than 50 years in the LPG business

• Equipmentmalfunctionsarelocatedandcorrected,oftenbeforetheybe-come critical

• Continuoustrainingofmanagement,maintenance personnel and opera-tors

• Thoroughstatuscheckoftheentireoperation

• Improvementsuggestionsgivenbyour experienced service supervisors

• Optimisationofthesparepartsstock

• Preventionofemergencybreak-downs

• Finetuningofthefillingequipment

Your benefits

• Onesupplierwhocanassistyouwith everything related to the LPG business

• Beresourcefulwithskilledpersonnel

• Avoidcostlyproductionstops

• Lesshumanerrors

• Increaseproductionoutput

• Reducesparepartsstock

• Improvedsafety

• Reducegasgiveaway

• Longservicelifeoftheequipment

Your possibilities

• Flexibleservice-servicewhenyouwant it and how you want it

• Servicecontracts,servicetourorservice on demand

• Warrantychecks

• Telephonehotlinearoundtheclock

• Trainingofmanagement,operatorsand maintenance personnel

• Serviceseminars

• ServiceonalltypesofLPGfillingequipment and cylinder requalifica-tion equipment

• StationingofKosanCrisplantadvisor

Your safety

• KosanCrisplanthasbeenintheLPGbusiness for more than 50 years and is most experienced in all aspects of this business

• Allservicepersonnelisskilledandprofessional


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ENGINEERING

Kosan Crisplant’s staff of ex-perts makes calculations and dimensioning within all fields related to installation, exten-sioning, upgrading and renova-tion of filling plants, LPG stor-age facilities, distribution cen-tres and maintenance plants. In addition our staff also elabo-rates market analyses, opera-tional analyses and efficiency tasks for customers all over the world.

• KosanCrisplanthasmorethan50years’ experience in engineering and analytic work

• MakeuseofKosanCrisplant’sex-tensive knowledge about the LPG business

• Tailor-madesolutions

• NojobistoosmallortoobigforKo-sanCrisplant–alljobsareexcitingjobs

Your benefits

• Allengineeringworkdeliveredbyone supplier

• Clearvendor/clientinterface



• Future-orientedsolutions

• Fullydocumentedengineeringjob

• Layoutsareelaboratedonthebasisof thorough logistical analyses

Your possibilities

• Generallayouts

• Layoutsforfillingplants

• Layoutsformaintenanceplants

• LPGpumpandpipinginstallations

• Firewaterinstallations,incl.elec-tric,dieselorgasdrivenpumps

• Compressedairinstallations

• Fireandgasalarmsystems

• CompletetankyardsforLPGstorage

• Engineeringofpowersupply

• Civilworks

• Foundationdrawings

• P&Idiagrammes(pipingandinstru-ments)

• Provisionofpressuretestcertifi-cates,materialcertificatesetc.

• Elaborationofmarketanalyses

• Elaborationofoperationalanalyses

• Elaborationofefficiencytasks

• Consultancy

Your safety

• Engineeringaccordingtoallknowninternational norms


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SUPERvISION Of INSTALLATION

Our team of supervisors has all the necessary qualifications to get the job done; an advanced professional background, a thorough knowledge of our products and systems, a high sense of responsibility, flexibility and creative approach, and the ability to adapt to different conditions and cultures

In full operation as agreed at the agreed time

Kosan Crisplant’s staff of highly qualified technical field super-visors ensures a quick, safe and efficient installation, com-missioning and handover of equipment and plant.

• Supervisionofinstallationofthesupplied equipment by local labour

• Technicalguidancetomeetcustom-er expectations the best way possi-ble

• Perfectcontroloftheinstallationwork ensures the shortest possible installation time

• EfficientcommunicationbetweenKosan Crisplant and the customer

• Avoiderrorsintheinstallationwork

Your benefits

• Relevantpracticalandtheoreticaltraining of the customer’s staff and interpretation of manuals and spare parts lists

• Elaborationofprogressreportsonthe installation work

• Efficientdecisionsonthespot

• KosanCrisplantspecifiesthenum-ber and required skills for local la-bour

• PerformanceTestinconnectionwithHandover

Your possibilities

• Possibleuseofsupervisorteamonlarge installation jobs

• Thoroughgoingthroughofexistingplant with recommendations regard-ing maintenance and safe operation of the equipment and plant

• KosanCrisplantcansupplyman-power for the installation works

• PerformanceTestandfinetuningofequipment

• Mechanicalerectionandcommis-sioning of all equipment within the fence

• Installationofelectricalequipment

• InstallationofPCsystemsfordatacollection and processing

• Installationandpurgingoftanksandpiping system

• Installationofcompressedairsys-tems

Your safety

• AllKosanCrisplantfieldsupervisorsfollow the guidelines laid down in the ”Kosan Crisplant’s Safety Regu-lations”-theBookonsafety

• Highestpossiblesafetylevelintheinstallation stage

• Supervisionofinstallationwillleadto safe functioning of equipment and plant


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SPARE PARTS

At your service – 24 hours a day, 7 days a week

Original Kosan Crisplant spare parts for filling equipment ensure long service life and continuous high production.

• Sparepartsincompliancewithoriginal equipment standards

• Scheduledreplacementofspareparts leads to high reliability in operation

• Sparepartsinstockensuresimmediate repair

• KosanCrisplant’sstockhandlingsystem provides full overview

Your benefits

• Costsavingthroughrepairing

• Minimizationofdowntime

• Increaseinproduction

• Regularmaintenancepreserveshighquality of the equipment

• Scheduledmaintenanceminimizesnumber of emergency breakdowns

Your safety

• Sparepartsofthesamehighqualityas the original equipment

• Youareassuredoftenyears’component supply at purchase of filling equipment

Your possibilities

• Replacementandrepairofexpensive and complicated components

• Sparepartkitsandoverhaulkitsavailable

• Orderingbyphone/fax/e-mail

• Identificationofitemnumbersbymeans of full technical documentation

• Keeponlyrecommendedsparepartsin stock

• KosanCrisplant’sstockhandlingsystem to control the spare parts stock

• Accesstoexperiencedtechnicians24 hours a day

8988 KC ServiShare • R01/03/2014 • www.kosancrisplant.com KC ServiShare • R01/03/2014 • www.kosancrisplant.com

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KC SERvISHARE

KC ServiShare is software de-signed to support management and operation of filling plants with regard to logistics, pro-duction and maintenance.

• DevelopedaccordingtocustomerneedsandKC'slifelongexperience

• Flexible,customizableaccordingtocustomer needs

• Easytouseandtomaintain

• Powerfulreportingtool

• Accessiblethroughtheinternet

• Smallinvestment

Your benefits

• Improvedproductivity

• Suppliesanup-to-dateknowledgebase

• Centralizesallinformation

• Createscommunicationchannelsbetween all entities

• Canbeintegratedwithotherappli-cations within the KC portfolio

• CanbeintegratedwithotherERPsystems

• Globalknowledgeexchange

Your possibilities

• Managecorrectiveandpreventivemaintenance procedures

• Generatedetailedmaintenance/ service reports–Correctiveandpreventivemainte-

nance activities–Manpowerallocation–Executionrates

• Managesparepartsstock–Trackandusespareparts–Forecastsparepartsconsumption–PlacesparepartsorderswithKC–Reportconsumptionandneeds

• Managelogisticsandproduction–Keeptrackofthevehiclesflowin

the filling station–Planandmanagethedailycylin-

der production–Managethecylinderstockwithin

the filling plant–Reportproductionfigures

Your safety

• SupportfromtheKCteam

• Encryptedandsecurewebaccess

• Dailybackupassured(nodataloss)


PROjECT mANAGEmENT ExPORT fINANCING PACKAGE

Binding quotationsubmitted

Project started& approved

Projectidentified

Contractnegotiations

Design

Procurement

Installation

Commissioning

Warranty

After sales& service

Contract signedSales Project

Design approved

Materials on site

Installationcompleted

Handover

End ofwarranty period

Kosan Crisplant’s Stage-Gate Plan

Kosan Crisplant is not only a supplier of equipment. Our experienced staff of project managers ensures the implementation of projects within the economical terms and the agreed time limit.

• Implementationofprojectsisafocus issue for Kosan Crisplant

• Weofferprofessionalprojectmanagement which is of vital importance for the success of a project carried out by professionals

• Preciseandstandardizedprojectmanagement model used for all projects

Kosan Crisplant offers attrac-tive unbinding financing pack-ages in collaboration with our bank and the Danish Export Credit Agency “Eksport Kredit Fonden” (EKF).

• Loansupto85%ofthecontractualamount

• Advantageousterms

• Minimumborrowingcosts

Your benefits

• Thecurrencyofborrowingisnotnecessarily the contract currency

• LenderisourbankNordeaBankDanmark A/S

• ExportcreditguaranteeissuedbyEKF

Your possibilities

• Floatingorfixedinterest

• LoaninEUR,USDorothercurrencyacceptedbyNordeaBankDanmarkA/S

• Normallyfiveyearsmaturity

• Maturityforhighloanamountsisnegotiable

Your safety

• Internationallyrecognizedlender

• Fixedinterest:CommercialInterestReference Rate (CIRR) fixed monthly by OECD

• Floatinginterestbasedonthesixmonth London Interbank offered rate (LIBOR)fortheloancurrencyplusabank margin to be agreed

• LoanagreementbasedonNordeaBankDanmark’sstandardformat

Your benefits

• Onepersonhasfullresponsibilityfor the project from quotation to handover

• Theprojectmanagerhastheauthor-ity to make decisions on the spot

• Constanteducationandtrainingofproject managers make Kosan Crisplant world champion within project implementation in the gas industry

• KosanCrisplantuseseffectiveandmodern IT tools for project manage-ment

• Allprojectcommunicationin:Eng-lish,German,FrenchorSpanish,ac-cording to your choice

Your safety: Kosan Crisplant’s Stage-Gate Plan

• Asetofcommonrules,whichleadsto an organized implementation of projects from start to finish

• Astronginstrument,whichensuresfocus on achievement of targets and results in due time

• Aninstrumenttodividecomplicatedprojectsintosmallerstages,eachwith a conclusion and a measurable result

• ForfurtherinformationaboutKosanCrisplant project management and ourStage-GatePlan,ourfolder”TheKosan Crisplant Project Manage-ment Model” is available upon re-quest

9392 KCP • R01/10/2014 • www.kosancrisplant.com KCP • R01/10/2014 • www.kosancrisplant.com

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KC PROSUPPLy

KC ProSupply is Kosan Crisplant's trading division which offers gas-related com-ponents and equipment as well as consultancy services to the gas industry worldwide.

• Oneplacetogoforanytypeofgascomponent

• Expertguidanceoncomponentchoice

• Collaborationwiththeleadingsup-pliers of gas components

• Hugestockandcollectedshipments

• Customizedengineeringandstock-ing solutions

• KosanCrisplantspecialistsavailableon-site

Your benefits

• Aminimumofworkbyusingaone-stop-shop

• Wewilltrackdowntherightcompo-nent at the right price for you

• Wehavethewidestthird-partyproduct range in the industry

• Ourproductrangeconsistsofhigh-quality products from leading suppli-ers


• Fastdelivery–decentralizedstockpolicy

• Wehavetheknow-howandexper-tise

Your possibilities

• ProductsfortheLPG,NH3 (ammo-nia) and cryogenic industries

• ComponentsforLNG(liquefiednatu-ral gas) and CNG (compressed natu-ral gas)

• Ourwideproductrangealsoin-cludes bobtails and semi-trailers

• Additionalproductsandconsuma-bles(e.g.valvesealingcaps,leakdetectionspray,etc)

• Requalification,inspectionandcali-bration of equipment

• AccesstoKosanCrisplantGroupspecialists and engineering capabili-ties

• KCProSupplycanassistyouwith:–Findingoutwhichcomponents

need replacing

–Findingoutwhattoreplacethemwith

–Researchingthemarketforsuita-ble suppliers

–Sendingoutinquiriestopotentialsuppliers

–Comparingoffers–Orderingdifferentcomponents

from different suppliers

• Whatevercomponentyouneed–we'llfinditforyou!

Your safety

• KCProSupplyispartoftheKosanCrisplant Group that has more than 60 years of experience in the gas in-dustry–know-howandengineeringcapabilities that ensure you always get the right product and solution

• Weworkexclusivelywithhigh-qual-ity products and components

9594 LAY • R01/12/2009 • www.kosancrisplant.com LAY • R01/12/2009 • www.kosancrisplant.com

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fILLING HALL PROCESS OvERvIEw

Manual filling line for industrial cylinders

1 Overhead conveyor for cylinder handling system

2 Cylinder handling system3 Roller conveyor4 Filling machines (in-line)5 Check scale6 Leak detector7 Filling machine (stationary)8 Valve changing machine9 Evacuation rack10 Lorry/truck

Automatic filling line for domestic cylinders

1 Palletizing system2 Chain conveyor system3 Telescopic conveyor4 Shroud and foot ring straightener5 Sorting point for cylinders to

reconditioning6 Pallet loader for cylinders to

reconditioning7 Sorting point for cylinders to

washing8 Washing system

9 Valve orientation machine (only for cylinders with screw valves)

10 Tare encoding/reading11 Carrousel filling system including

introduction/ejection units and filling machines

12 Check weighing system13 Weight correction machine14 Valve tester15 Leak detector16 Valve opener (only for cylinders

with screw valves)17 Leak testing bath18 Valve closer (only for cylinders

with screw valves)19 Seal applicator20 Thermosealing machine21 Seal detector22 Evacuation system

23 Evacuation rack24 Valve changing machine25 Cylinder storage area26 Fork-lift truck27 Lorry/truck28 Storage area for

palletized cylinders

9796 KCG • R02/03/2014 • www.kosancrisplant.com KCG • R02/03/2014 • www.kosancrisplant.com

THE KOSAN CRISPLANT GROUP

wherever you are, we are ...

P.O. Pedersens Vej 22DK-8200 Aarhus NDenmarkTel +45 8740 3000Fax +45 8740 [email protected]@kosancrisplant.comwww.kosancrisplant.com

INNOvATING THE LPG CyLINDER fILLING bUSINESS SINCE 1951

100% Kosan Crisplant

S I N C E 1 9 5 1

SAFETY THROUGH QUALITY

general product catalogue

Documents