MINING & MINERALS

Autoclave Discharge Block Valve
Application: Autoclave discharge block valve, plot plant trial
Product: ANSI Class 300 AbrasoBlock® valve

ValvTechnologies' AbrasoBlock® valve was put to the test during an accelerated product trial in mining plant in Russia. Read this case study to find out how ValvTechnologies' valve performed and results from the trial.

POWER

IsoTech® - Proven Success in Single Isolation
Product: IsoTech®

One of the largest, cleanest and most efficient coal burning power station in the United Kingdom with capacity of 3,960 megawatts generates enough electricity to meet the needs of 7% of the UK. This plant, greatly concerned about the environment, focuses on a low-carbon economy, reducing emissions and saving money.

V1-2 Proven Track Record & Dependability 
Application: Nitrogen purge/vent valve
Product: V1-2 

A major global power company entrusted ValvTechnologies to help them identify the best possible solution to replace their existing triple offset butterfly valves in their nitrogen purge/vent valve application. 

ValvPerformance Testing™
Service: ValvPerformance Testing™

Learn how ValvTechnologies was able to assist the client in identifying leaking valves using ValvPerformance Testing™, as well as provision absolute zero-leakage drain valves saving the customer ~ $169,033 (€122,400) per year.

V1-1 Valves for Spray Water Applications
Application: Spray water control
Product: V1-1

This plant's globe valves were failing continuously, resulting in control loss of the spray water and decrease in plant efficiency. Additionally, the globe valves’ stem packing was tearing, causing high-pressure, high-temperature water to be sprayed around the malfunctioning valves, creating a dangerous environment for operating staff. Learn how ValvTechnologies solved this customer's problem.

Reducing TCO with ValvTechnologies' IsoTech®
Application: HP steam - main stop
Product: IsoTech® PSG

The plant had two main steam isolation PSG valves installed in this application. They were experiencing severe leakage when valves were required to isolate. From initial plant start-up, the frequency of valve maintenance of up to twice per year per valve. The cost of $40,000 per repair, was a particular concern for the plant. 

Lower Emission & Heat Rate Efficiency
Application: Combined Cycle
Product: V Series and IsoTech®

Severe service valve leakage significantly reduces a plant’s heat rate performance, because BTUs leak away, never reaching the turbine. By utilizing ValvTechologies’ V Series metal seated ball valves and IsoTech® parallel slide gate valves for vents and drains, steam and water leakage is eliminated, improving the plant’s thermal efficiency. 

V1-1 Lowest Total Cost-of-Ownership
Application: Attemperator block
Product: V1-1 with ValvXpress^® Automation

A major US combined cycle plant experienced significant seat leakage with a competitor’s valve that was installed in the attemperator block application of the plant. After just one year of service and multiple attempts to correct the issue, the faulty valve compromised the plants’ performance resulting in high maintenance
costs and poor reliability.

OEM Valve Specification Upgrades
Application: HRSG

ValvTechnologies met with an OEM’s HRSG design engineering team to inquire about issues they were experiencing with their plant’s globe valves. Learn how ValvTechnologies became their reliable partner and trusted advisor, and how they began the process of changing from traditional globe valves to modern advanced technology ball valve designs.

Significant Efficiency Increase
Application: HRSG HP evaporator system and drains/vents
Product: V1-1

A world-renowned OEM was experiencing difficulties brought on by 70 leaking globe valves in high-temperature, high-temperature severe service applications. ValvTechnologies addressed and resolved a number of the OEM's concerns with its innovative technology, optimizing the plant's performance, saving the customer time and money.

VirtualValv Support™
Application: Remote service, maintenance and repair
Product: VirtualValv Support™

While the whole world was in halt and majority of commercial flights grounded due to travel bans during the Covid-19 pandemic, OEM expertise remained high in demand. ValvTechnologies was tasked to find an innovative solution to reach its
customers remotely, safely and effectively.

Guaranteed Zero Leakage Improves Plant Efficiency
Application: HRSG and Steam Turbine
Product: V1-1

A power generation facility was using various valve types for isolation of high-pressure and/or high-temperature steam and water in their heat recovery steam generator and steam turbine systems, but persistent issues with these Y-Type globe, angle, butterfly, and gate valves were causing major efficiency losses that plagued the plant.

UPSTREAM OIL & GAS

Molecular Sieve Switching Valve Success
Application: Sour gas dehydration
Product: V1-4, NexTech®

Molecular sieves are often utilized in the petroleum industry, especially for the purification of gas streams. Valves leading into and out of molecular sieves cycle frequently and leakage in these critical areas can make it difficult or impossible to meet product purification requirements.

Emergency Shutdown Valves
Application: Emergency shutdown
Product: V1-2

ValvTechnologies and Portersville PRD are the trusted advisors and preferred suppliers of the industry-leading high-performance, zero-leakage isolation valves in critical applications for the engineering firm completing the design: the firm knew they could count on the superior expertise and global experience of ValvTechnologies and Portersville PRD.

Molecular Sieve Switching Valves Superior Design
Application: Sour gas molecular sieve
Product: V Series molesieve switching valve

Facing hundreds of millions of dollars in production losses annually, a major global oil company placed a multimillion dollar order with ValvTechnologies for molecular sieve switching valves to replace their existing rising stem ball valves.

High Pressure Protection Systems (HIPPS)
Product: HIPPS

The customer placed a large order for HIPPS trunnion valves, which were 8” class 2500. The scope was a total of 20 valves which were needed for the expansion of their gas field. Their excellent experience with ValvTechnologies’ on a previous order influenced them to choose our services again. 

Molecular Sieve Dehydration Unit Success Story
Application: Molesieve dehydration units
Product: V1-4

The customer switched to ValvTechnologies’ V1-4, solid Inconel 825 and the valves lasted for two years vs. the competitor’s 1-90 days and saved them millions of dollars of lost production. The customer has now standardized on ValvTechnologies’ valves in all their molecular sieve units. A second order was placed for 74 V Series valves, sizes 12” and 16” in solid Inconel.

Overcoming Resistance to Change
Application: Low pressure steam distillation control
Product: Xactrol® Mark I

The customer switched to ValvTechnologies’ V1-4, solid Inconel 825 and the valves lasted for two years vs. the competitor’s 1-90 days and saved them millions of dollars of lost production. The customer has now standardized on ValvTechnologies’ valves in all their molecular sieve units. A second order was placed for 74 V Series valves, sizes 12” and 16” in solid Inconel.

DOWNSTREAM & CHEMICAL PROCESSING

ValvTechnologies' Purge Design Saves More Than Half a Million Dollars
Location: Canada's Oil Sands
Plant: Upgrader
Application: Inlet feed coker valves

The client, a bitumen upgrader based in Canada’s Oils Sands, was experiencing heavy run-time and reliability issues due to coking up in their Inlet feed Coker valves, leading to significant damage and performance issues, and therefore rising costs due to unplanned downtime. ValvTechnologies high performance purge design solution performed beyond expectations and eliminated the need for costly servicing and replacement valves and over time increased production rates and overall plant operations. Learn more about the high-performance Coker valve purge design.

V1-2 Engineered Solutions
Application: Reactor block valve
Product: V1-2 with HVOF RiTech® coating

During a routine maintenance inspection at a petrochemical plant in the Texas Gulf Coast, technicians found a defective double ball valve that was installed in the reactor block valve application. Learn how ValvTechnologies utilized its unique zero-leakage valves with RiTech^® coating to engineer a cost effective and time saving solution.

TrunTech® Dosing Cup Valve
Product: TrunTech® trunnion dosing cup

A Texas polyethylene plant had valves grouped in a pair of fours with a drive system that could operate one or multiple valves as required. Instead of a traditional hole through the valve, these unique valves had a dosing cup that metered catalyst into the reactor, rotating 360° based on the drive system. Read more to learn how ValvTechnologies custom-engineered a first of its kind solution to meet the plant's unique needs.

Service Department - Customer Support
Product: Customer support, inspection & product servicing

One of our oldest customers is a large refinery in the Texas gulf area. They have several hundred ValvTechnologies’ valves installed: many of them are specially engineered designs and unique materials of construction for tough service applications in their refining units. A large number of these valves have been in service for more than 15 years. 

Turbine Isolation & IsoTech® Parallel Slide Gate Valves
Product: IsoTech®

A US chemical plant using wedge gate valves leaked so severely that steam passed through the valves and into the turbine making it impossible to perform turbine maintenance repair. The plant would have to be completely shut down so that the turbines could be accessed. With each occurrence, the cost associated with shutting down the plant was several million dollars per shut down.  

V1-2 Innovative Solutions
Product: V1-2
Application: Reactor control / block valve

NatureWorks required a valve that could be modulated to control back pressure and provide tight shut-off when closed. Their goal was to find a valve that would meet their specifications and provide tight shut-off. ValvTechnologies was the only manufacturer that was willing to produce a valve to the specifications required.

EPA Mandate on Coke Drum Venting
Application: Coker isolation valves
Product: Delayed coker valves

Implemented in 2016, the U.S. Environmental Protection Agency (EPA) issued a Risk and Technology Review (RTR) mandate on coke drum venting for petroleum refineries. To meet these standards, ValvTechnologies supplied refineries with severe service technology, extending the coker valve's isolation capabilities and saving operators thousands of dollars.

The Quality Certified Safety Solution
Application: Coker isolation valve
Product: V1-2

The refining industry confronts some of the most difficult valve application challenges in various process units. Companies are more and more focused on safety of the plant, their people and meeting production goals. As a means to provide worker safety in a delayed coker unit, one refinery in Southern California looked to install a safety process interlock system.

Hydrogen Isolation Valves
Application: Hydrogen isolation
Product: V1-1

A customer had a long standing history of using “Y” pattern globe valves for isolation valves in hydrogen isolation service. After reviewing the benefits of the ValvTechnologies’ zero-leakage design, the customer changed their specification to require ValvTechnologies’ zero-leakage, metal seated ball valves.

LC Finer Success Story
Application: LC finer
Product: V Series

ValvTechnologies’ replaced approximately 250 valves in the late 1990’s due to issues with the competitor’s valves. The facility ran for 14 years without needing to service ValvTechnologies’ products. ValvTechnologies’ products continue to perform exceptionally well, solving the plants problems, eliminating fires, leaks and equipment failures previously experienced with competitive products.

PulseJet Success Story
Product: ValvTechnologies' PulseJet

ValvTechnologies designed and manufactures a pulsejet valve to control the flow of syngas needed to disrupt the formation of the char cake. The valve satisfies the service conditions for operation of eight months or more, depending on the actual cycle time of the valve. To develop the most robust solution, ValvTechnologies designed the valve to meet the end user service requirements and agreed to some of the harshest requirements available. 

Coking - Heater Isolation Success Story
Application: Furnace heater isolation 
Product: V1-2

ValvTechnologies committed to the customer’s short lead time requirement based on their on-site delivery needs by offering expedite options with existing coker inventory/stock, changing out to forgings where able and working with valued suppliers to expedite materials with negligible impact on overall project cost. 

H-oil Unit Success Story
Application: Heavy oil
Product: V Series

ValvTechnologies' decades of engineering experience led to the design of its superior, severe service zero-leakage isolation valves that exceed industry standards. In this case, it also led to ValvTechnologies' largest ever h-oil project win and the displacement of a former firmly ingrained competitor.

Eliminates Maintenance Costs Success Story
Application: Resid hydration unit
Product: V Series

This customer saved $1.5 million per year that repairs were pushed off, saving a total of $4.5 million over three years. Additionally, the plant recognized repeatable, long-term, reliable tight shut off and longer run times with significantly reduced maintenance and lower total cost-of-ownership.

Instrumentation Isolation
Application: Instrumentation isolation
Product: V1-2

ValvTechnologies has successfully secured an order for a new coker unit in one of the largest crude oil refineries in North America. Learn how ValvTechnologies' proven track record at the facility and custom-engineered V1-2 valves satisfied the customers strict calibration requirements and specific material specifications.

PULP & PAPER

Twenty-Four Years of Exceeding Expectations
Application: Boiler drum vents
Product: V Series 2" Class 1500 metal seated ball valve

A leading producer of specialty paper products was experiencing significant steam leakage from their existing globe valves resulting in costly valve maintenance and unplanned shutdowns. Learn how ValvTechnologies provided a decades-long solution that saved the mill over $19,000 in annual labor costs and helped to recover the lost fuel producing steam.