Severe abrasive service valves have become a critical component in the design and operation of varied industrial processing plants. Whether it be catalyst, harsh polymers, chemical slurries, waste materials in mining, or the transportation of mineral slurries at low and high pressure, all such applications need cutting edge technology compared to conventional liquid and vapour services. This paper examines how the application of severe abrasive service valves has become an important component in the successful design, construction and operations of processing plants throughout the world.
As the severity and diversity of industrial processes increases, Severe Service Valves (SSVs) play an increasingly important role in isolating and controlling the various fluids used within them. Valves can be constructed with cast, wrought or forged components, but for cost efficiency, especially in large valves, castings are the most commonly used form of metal for valve bodies. This paper looks at best practices for pouring and casting near net-shape body parts in high alloys defined here as those in ASME B16.34 for Group 2.8 (Duplex Grades) and higher, above common castings like Carbon and Stainless Steels.
This paper provides information about the selection of SSVs in all industries but focusses on metallurgical processes and applications and offers examples to illustrate the successful and unsuccessful use of these valves. All of this with the purpose of raising the awareness of the industry on all sides, from the suppliers and manufacturers, specifiers and to the users and owners of them. It also supplies tools to understand where and why to separate SSVs from general purpose or commodity valves (GPVs).
The technology behind industrial applications such as Hydrometallurgy continues to evolve, as do the corresponding regulations and specifications that ensure the safety of workers and the environment. Valves make up key aspects of this technology, and often represent the single point of failure for entire operations. This article reviews what the minimum requirements are for SSVs in Hydrometallurgy applications.
In the case of knife gate valves used in hydrometallurgical facilities, the author has seen first-hand, numerous examples of technical reviews that allowed knife gate valves to be used in applications that quickly proved to be detrimental to the normal operations, safety, and OPEX of the facilities once they start running. While our initial capital cost may be higher than some competitors, we continue to see concrete proof that by selecting the right valve for the application, our customers obtain the lowest cost of ownership. Download this article to find out more.
LNG plants typically consist of liquefaction and gas treating areas to condition the gas to be converted into liquid form for mass transportation across great distances. The process and applications within these facilities are demanding for valves; proper review of the conditions occurring when the valve is operating should be completed before a selection is made. In this article, we will look at an application solution along with valve design to address challenges faced in process industries.
No clear or universal industry definition or mechanism exists to describe and accurately define Severe Service Valves (SSVs) from general purpose valves, yet such a definition would allow clients to benefit from improved process performance, increased profitability, safety and environmental protection. This high level paper looks to offer an objective definition suggestion for better communication between users, specifiers and suppliers. To learn more, download the article.
PotashCorp needed to automate a positive displacement pumping system which would require a control valve to operate at a continuous high pressure differential. The discharge piping in their mine rises over 1000 meters to the surface, so the operating pressure can vary significantly based on the density of the liquid pumped. CGIS recommended a Flowserve Multi-Z control valve with a three stage trim design. By fully understanding the process, well before a dollar was spent, CGIS was able to provide the right valve for PotashCorp.
CGIS bid on and won the severe service knife gate package with Guided Shear Gates. Mistakenly, CGIS did not bid on the general purpose knife gate package which was eventually won by ITT Fabri. The Fabri knife gates were not as trouble free. One of the big problems that soon appeared was the Fabri cylinder rods that began to rust very quickly in the Australian climate and local atmosphere. Download this case study to discover choosing the correct SSV for your application can take your project from unsuccessful to successful.
Syncrude Canada has an ammonium sulphate plant owned and operated by Marsulex. It was designed and constructed with two types of knife gate valves: Clarkson KGD push-through type and Series 150 ASME Class 150 rated Guided Shear Gates. In general mining slurries having these valves discharge to atmosphere is a non-issue. When the application is not benign this can affect other piping components. This case study explores how CGIS was able to mitigate the problem at the Marsulex Alberta Ammonium Sulphate Plant.
Currently in Australia there are three companies that produce coal seam gas (CSG), purify it and export liquefied natural gas (LNG). They are QCLNG (Queensland Gas Company), GLNG (a joint venture between Santos, Petronas, Total and Kogas), and APLNG (a joint venture between Origin Energy, Sinopec and Conoco Phillips). All three operations use the same process to extract the coal seam gas from the ground and send it to a common LNG processing plant for purification. This case study details a common failure point in the CSG extraction process and how CGIS can show a significant reduction in well asset cost for the duration of production.
Greenlane Biogas designs biogas upgrading plants. The company uses a water scrubbing and pressure / temperature absorption gas cleaning process to produce renewable natural gas (RNG) from biogas and landfill gas. This featured incorrectly sized check valves resulting in downtime and maintenance repair. You can read more about how CGIS analyzed and presented a solution to the problem and successfully mitiaged the problem here.
The El Teniente lime plant presents harsh conditions for isolation valves to operate under. Not only does lime solidify internally it also cakes on every external surface available causing moving parts to seize. The challenge was to provide a valve that could isolate without requiring constant replacement or repairs. CGIS successfully analyzed the situation and recommended a valve change that saved the El Teniente plant time and money. Learn more about the case here.
Collahuasi shipped 492,727 tonnes of copper concentrate in 2009. The concentrate is sent from the concentrators at the mine site 250km away high in the Andes via a high pressure slurry pipeline to the Filter Plant at Puerto Patache where it is loaded for shipment to several countries for refining. The Filter Plant Superintendent reported that the Clarkson KGD knife gates required new seats (boots) once a month or after 7,200 cycles. This case study outlines CGIS critical contribution to this project.
Alcoa World Alumina and Wagerup Refinery in Australia discovered the production of alumina using the Bayer process creates alumina hydrate solids that precipitate out of solution and coat the insides of pipes and valves. In order to continue production, facilities must regularly caustic wash to dissolve the scale build up. This case study outlines CGIS’s contribution to the solution to this problem.
Most check valves are selected by size and Class to match the size and Class of the pipe. While this is convenient and simple, it is not necessarily the best way to choose the correct check valve. This paper looks to examine the consequences of selecting check valves the way most currently are and offers a different method of selection, why it can lead to far higher and longer performance and the supporting formulas and fluid dynamics that one can use to prove it yourself.
In the world of valves it is very common for many to categorize valves and have the perception they are all created equal and/or share the same performance characteristics. The category of butterfly valves is a good example of this belief. The term butterfly valve has been applied to this design due to the similarity of the internal modifier, the disc, and the shaft which closely mirror a butterfly’s wings and body. This article reviews the features and benefits of Position Seated and Torque Seated Butterfly Valves.
Selecting valves for cryogenic applications in liquefaction plants can be quite tricky. Application expertise, along with a high quality valve, is needed in order for the valve to operate effectively and efficiently in these demanding facilities. This article presents the latest in control valve innovations for liquefaction plants.
This article is intended to identify some common misconceptions regarding industrial valves and valve purchasing. There is a big gap between the perceived value of valves as compared to the actual cost of ownership.