For years, the Port Alberni Mill faced a boiler vent problem that never seemed to go away. Every annual outage and the occasional unplanned shutdown ended with the same task: replacing the boiler drum vent valve. The routine became so predictable that the process became accepted as part of normal operation.
But normal doesn’t always mean efficient. And in this case, “normal” was costing the mill far more than it realized.
The Boiler Vent Challenge: A Recurring Problem
Boiler drum vents remain closed through almost the entire operating cycle. They open only at the end of a shutdown to prevent vacuum formation and equalize pressure. Because they spend so much time closed under pressure, even a small amount of leakage can become erosive, gradually enlarging the path until the valve can no longer seal.
At Catalyst, the Y-Pattern Globe valves being used deteriorated quickly. With each outage, the seats would show more wear. By the end of the year, they would need to be replaced again.
The True Cost of a “Simple Replacement”
Replacing a valve isn’t just the cost of the valve:
- Annual valve price (~$800 each)
- Welding and labour
- Lost steam going to the atmosphere
- Lost chemicals needed to make pure water
- Penalties for leakage
- Time spent performing repeat maintenance
Across an entire year, this cycle drained time, money, and resources.
CGIS Recommends a Better Path Forward
In 1997, the assistant steam chief at Catalyst explored alternatives. CGIS recommended a ValvTechnologies 2″ Class 1500 socket-welded, manually operated steam isolation valve.
While the cost was higher, $1,699 compared to the $800 globe valves, the design offered superior sealing and long-term durability for high-pressure steam service.
A Confident Upgrade
CGIS reinforced the recommendation with a four-year guarantee against leakage, giving the mill confidence in the investment.
The decision was made, install the new valve and see if it could break the failure cycle.
The Results: A Single Valve That Lasted 24 Years
After installing the new valve, the impact became clear. The mill immediately broke its long-standing cycle of yearly replacements and saw results that far exceeded expectations.
| Before (Globe Valve) | After (ValvTechnologies Valve) |
|---|---|
| 1-year service life | 24-year service life |
| ~$800 per replacement | $1,699 once |
| Frequent maintenance | No replacements for decades |
| Steam & chemical losses | Eliminated leakage |
| Costly downtime | Continuous reliability |
The valve installed in 1997 was only replaced in 2021. In direct valve costs alone, the mill saved over $19,000, not counting avoided labour, chemical losses, fuel waste, and downtime.
A Clear Example of Total Cost of Ownership
When you add up the avoided yearly replacements, reduced operational losses, and eliminated leakage, the savings compound far beyond the initial purchase price.
This case shows the value of selecting a valve based on application not just upfront cost.
Key Takeaways for Steam and Process Facilities
This case highlights several important lessons for facilities facing similar valve challenges.
- Repeated valve failures are not “normal”; they’re a sign of a mismatch.
- A higher upfront cost can eliminate years of ongoing expense.
- Application-based valve selection dramatically improves reliability.
- For high-pressure or erosive service, severe service valves
offer better long-term performance - Partnering with specialists like CGIS helps identify the right solution from the start.
If your plant is dealing with recurring valve failures, leakage, or reliability issues, the right upgrade could save years of unnecessary maintenance.
Talk to a CGIS valve specialist today to find the best solution for your application.
If you’d like to see more real-world examples of how CGIS helps customers solve chronic valve problems, visit our full library of case studies and technical articles here.