1. Integral metal seat. With our proprietary HVOF RiTech® coating technology, the integral seat in ValvTechnologies’ valves is resistant to the attack of abrasive magnetite and ferrous oxides that may be seen in the steam flow.
2. Body seal ring. ValvTechnologies employs a field proven seal ring technology to ensure sealing under all operating conditions, up to 1400°F. The body seal ring is loaded at a pressure higher than 20,000 psi. In addition, valves sized three inch and above contain a secondary Grafoil seal to further guarantee reliability
3. Patented coating process. The sealing surfaces are overlaid with tungsten or chromium carbide using our exclusive HVOF RiTech® process. These surfaces have a hardness of 68 – 72 Rc to allow long periods of operation in the most severe conditions.
4. Live-loaded gland area. The V Series’ sealing design features a four stud, live-loaded assembly designed for heavy industrial applications. The sealing material is high purity Grafoil® surrounded by stainless steel wire mesh anti-extrusion rings. The six Belleville® springs (per stud) provide constant load pressure through extreme thermal shocks and prevent wear leaks in high-cycle service.
5. Blow-out proof stem design utilizes a one piece, hard-faced, blow-out proof stem that is inserted through the inside of the body cavity eliminating the possibility of blow-out through the gland area.

• Through conduit design: No tortuous flow path. When open it has the highest possible Cv’s. Minimized wear & tear. Benefit: Eliminated vibration, reduced maintenance
• Fixed position – quarter turn: No seating torques required. Benefit: Minimized stem wear, lower cost of ownership
• Hardened blowout proof stem: One piece, inserted through the body & shouldered. Eliminates the weak link of collared & pinned designs. Benefit: Improved safety
• Metallic body seal ring: Increases body integrity by eliminating external leakage. Benefit: Improved reliability, zero-leakage shutoff
• Live-loaded packing gland: Minimum four bolt configuration with shallow stuffing box. Ensures consistent torque at variable pressures & temperatures. Benefit: Increased reliability
• Hardcoated & mate lapped seats: High Velocity Oxygen Fuel (HVOF) RiTech® chrome carbide hardcoating with a Rockwell C of up to 72. Mate-lapped seats. Benefit: Wear & corrosion resistant, increased reliability, zero-leakage shutoff
• Seat designs: Hardcoated, both ball & integral downstream seat to the end-cap to eliminate a potential leak path. Benefit:Increased reliability
• Simplicity of design: Designed for ease of installation & maintenance. Benefit: Easily actuated, increased system reliability, increased efficiencies, ease of use, reeduced maintenance
• Stringent testing: Every valve is tested, documented & serialized. Benefit: Increased reliability, increased safety, total traceability

Case Study: V1-2 – Proven Track Record & Dependability

Product: V1-2 
Location: USA
Plant type: Fossil power
Application: Nitrogen purge/vent valve

Background: 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. Hundreds of thousands of dollars per day of lost revenue were at risk if the customer’s requirements, quick construction schedule and high performance expectations weren’t met.

Requirement: The customer required a nitrogen purge/vent valve system with intergrated gasification combined-cycle power generation IGCC units. This IGCC process recycles blast furnace coke, pulverizing and gasifying it to be burned in a heavy duty gas turbine. The power it generates can be used in the plant, and any excess can be sold to the public power grid.

An engineered valve solution was needed that could accommodate the process fluid of nitrogen with the interfacing fluids of syngas and air, as well as meet Class VI shutoff per the FCI 70-2 requirement. This would allow the customer to accomplish repeatable and reliable valve performance with on-time delivery.

Solution: The ValvTechnologies’ V1-2 metal-seated ball valve with bi-directional capability was identified as the best solution because it met the customer’s needs, including:

• Proven track record
• Superior performance
• Lower overall cost of ownership
• Fast delivery: 22 weeks as opposed to the competitor’s solution of 52 weeks

ValvTechnologies’ superior solution allowed the customer to meet their commitment to the end-user of increased plant efficiency and reduced emission rates compared to traditional integrated gasification combined-cycle power generation systems.

Case Study: V1-2 Innovative Solutions

Customer: NatureWorks, LLC of Blair, Nebraska

Plant type: NatureWorks is dedicated to meeting the world’s needs today without compromising the earth’s ability to meet the needs of tomorrow. NatureWorks is the first company to offer a family of commercially available, low-carbon-footprint Ingeo™ lactides and biopolymers derived from 100% annually renewable resources with performance and economics that compete with oil-based intermediates, plastics and fibers and provide brand owners new cradle-to-cradle options after the use of their products.

Industry: Downstream hydrocarbon
Application: Reactor control / block valve

Background: NatureWorks contracted Plant Services, Inc. of Spring, Texas which specializes in process engineering, to specify and locate a suitable solution for an existing control valve application. NatureWorks was experiencing ongoing problems with their existing valve which was installed in 2008 and failed to meet process application requirements due to galling on the ball and seats resulting in poor reliability.

Requirement: 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.

Donald Marek, an instrument and valve design specialist with Plant Services, researched numerous manufactures for a suitable valve for this extremely severe service application: ValvTechnologies was the only manufacturer that was willing to produce a valve to the specifications required.

The customer was impressed with ValvTechnologies’ coating technology and seating design of the V1-2 design as well as the QA/QC and stringent zero-leakage testing performed.

Solution: A 24” 300 lb metal-seated V1-2 valve was designed and manufactured by ValvTechnologies; a hydraulic Moog actuator, HPU system and automation was designed by Donald Marek and fabricated by Control Fluids, Inc. of Beaumont Texas. The EADS company, a ValvTechnologies’ distribution partner and integrator, provided the package as a complete system and facilitated the final product acceptance test prior to delivery to NatureWorks, LLC.

Bi-directional sealing
Special hard coatings
Various materials of construction
Sizes up to 36”
Elevated temperature options

301_V1-2 Cut Sheet_Aug.2023_V4.pdf

• Acid-resistant barrier coating
• Corrosion protection
• Resists 98% H2SO4 at a constant temperature of 300° C for more than 12 months.

• 3X the Performance at a fraction of the cost
• Greater Acid Resistance = Longer Life
• Extreme Hardness = Greater Durability
• Less Torque = Greater Efficiency

RiBlock® Product Brochure

• Seat supported ball valve with an integral downstream seat – extended wear life
• Traditional failure modes (slurry wear from passing and coating failure) eliminated
• Rhinoite® weld-applied carbide hard facing leads the industry for wear resistance – extended wear life
• Integral seat eliminates the traditional gap between the seat ring and the body pocket, which is a leak path
• Integral seat cannot move and will keep a continuous wiping action to maintain the sealing surfaces clean at all differential pressures
• The Rhinoite® process includes sealant which aids lapping/sealing and minimizes torque requirement

• Zero-leakage
• Certified fabrication process meets ASME Section II and PED standards
• Severe service rated for high-pressure leaching by acid or oxygen
• Long-wearing service life from high integrity components in class leading materials
• Bi-directionally sealing capability
• Designed for on-site repair and maintenance

ValvTechnologies’ HVOF RiTech® is a high velocity oxygen fuel coating process, with properties of high density and negligible porosity. A hot, high velocity gas jet sprays a coating of molten particles onto the ball and seat surfaces. An oxygen fuel mixture is forced through a spray gun nozzle and ignited. A mixture of powered materials (tungsten, carbide, nickel, chromium, etc.) are also forced through the spray gun nozzle. The ignited gas forms a circular flame surrounding the powder as it flows from the nozzle for uniform heating, melting and acceleration (5000-6000°F at >7000 fps).

• Improved quality
• Abrasion/corrosion protection
• Improved wear resistance
• Improved performance
• Ability for components to operate in higher and/or lower temperatures
• Ability to operate in the most severe service applications
• Improve efficiency

1. Carbide sealing surfaces. The sealing surfaces are overlaid with tungsten or chromium carbide using the ValvTechnologies-exclusive HVOF RiTech® coating process. These surfaces have a hardness of 68 – 72 Rc to allow long periods of operation in the most severe conditions.
2. High integrity seals. To prevent leaks around the seats, ValvTechnologies has developed an innovative double seal design for erosive services operation in high cycling applications. A secondary graphite seal is installed toward the body cavity.
3. Solids resistance. In addition to the carbide coatings which will allow the valve to function in highly abrasive applications, the individual valve parts have additional seals to prevent interference from solids in the system. This provides for outstanding service in severe-service isolation applications with high particle content from sand, elemental sulfur, hydrate, perforation shrapnel and pipe corrosion products.

• Guaranteed tight shut-off. Benefit: Enhanced process safety and repeatable sealing allows operation under process excursions
• True metal-to-metal sealing without using secondary elastomeric seals. Benefit: Inherent fire safety
• Solid-proofed by design. Benefit: Process reliability
• Exclusive HVOF RiTech™ coating technology. Benefit: Extended life
• Grafoil® fire-safe seals. Benefit: Reduced maintenance costs
• Double block-and-bleed capability. Benefit: Enhanced process safety
• High cycling capability. Benefit: Process reliability
• Bi-directional sealing by design. Benefit: Enhanced process safety, lower maintenance, less downtime
• Single-piece anti blow-out stem design. Benefit: Enhanced process safety
• Impervious to high thermal cycling. Benefit: Enhanced process safety
• Certified to use in SIL 3 loop. Benefit: Enhanced process safety
• Fire safe certification: API-607 / API 6FA. Benefit: Enhanced process safety
• Stem fugitive emissions per ISO 15848-1 Class B & TA-Luft. Benefit: Lower emissions, enhanced process safety

Case Study: HIPPS

Background: The customer placed a large order for High Integrity Pressure Production Systems (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.

Requirement: The traditional method to provide protection against over pressure is a safety relief valve (SRV). Per code, the SRV needs to have a capacity equal to the well capacity without any restriction in the choke. This can become impractically large. Protection with SRV-s numerous drawbacks, which include:

• Potentially impractical size or number of parallel SRV-s
• Potential continuous leakage if the set point and operating pressure are close, like in this application where that delta in the pressures is only 50 psi
• Capital cost of flare, possibly with burner
• Nuisance to the environment of flare noise and the visual effect of the burner flame
• Emission of methane and CO2. Both are greenhouse gases

Solution: HIPPS provide the same function as a relief valve, but instead of relieving the high pressure gas to atmosphere the HIPPS shuts in the pressure and contains the high pressure gas upstream of the lower pressure section of the piping.

The pressure transmitters forward the pressure signal to the logic solver. The program logic provides the set point and the voting rule. For example, the system may be based on closing the HIPPS if any two of the three pressure transmitters detect a pressure above the set point.

Upon closing of the HIPPS valves the down stream pressure is likely drop below the pressure safety threshold. Nevertheless, the HIPPS valves do not automatically re-open. Instead, a local, manual reset feature needs to be engaged forcing the operator to do a local, visual inspection and correction of the issue that caused the over pressure before allowing flow to restart. A key feature of HIPPS is the ‘spec break’, the transition from the high pressure piping to the lower pressure system. The spec break is indicated on the P&ID near the second HIPPS-valve.

Most importantly, a HIPPS is tightly regulated system, subject to regulatory oversight and stands alone to protect a piping system against over pressure and consequent potential for catastrophic failure, loss of life, loss of assets and damage to the environment.

• Purge connection
• Sealant injection
• Other options available – contact manufacturer for more information

HIPPS
ESD
Scraper receiver isolation
Molsieve switching
Manual isolation
Injection
Gas storage (withdrawal)
Gas transmission
Other gas treatment processes

1. Integral metal seat. With our proprietary HVOF RiTech® coating technology, the integral seat in ValvTechnologies’ valves is resistant to the attack of abrasive magnetite and ferrous oxides that may be seen in the steam flow.
2. Body seal ring. ValvTechnologies employs a field proven seal ring technology to ensure sealing under all operating conditions, up to 1400°F. The body seal ring is loaded at a pressure higher than 20,000 psi. In addition, valves sized three inch and above contain a secondary Grafoil® seal to further guarantee reliability.
3. Patented coating process. The sealing surfaces are overlaid with tungsten or chromium carbide using our exclusive HVOF RiTech® process. These surfaces have a hardness of 68 – 72 Rc to allow long periods of operation in the most severe conditions.
4. Live-loaded gland area. The V Series’ sealing design features a four stud, live-loaded assembly designed for heavy industrial applications. The sealing material is high purity Grafoil® surrounded by stainless steel wire mesh anti-extrusion rings. The six Belleville® springs (per stud) provide constant load pressure through extreme thermal shocks and prevent wear leaks in high-cycle service.
5. Blow-out proof stem design utilizes a one piece, hard-faced, blow-out proof stem that is inserted through the inside of the body cavity eliminating the possibility of blow-out through the gland area.

• Through conduit design: No tortuous flow path. When open it has the highest possible Cv’s. Minimized wear & tear. Benefit: Eliminated vibration, reduced maintenance
• Fixed position – quarter turn: No seating torques required. Benefit: Minimized stem wear, lower cost of ownership
• Hardened blowout proof stem: One piece, inserted through the body & shouldered. Eliminates the weak link of collared & pinned designs. Benefit: Improved safety
• Metallic body seal ring: Increases body integrity by eliminating external leakage. Benefit: Improved reliability, Zero-leakage shutoff
• Live-loaded packing gland: Minimum four bolt configuration with shallow stuffing box. Ensures consistent torque at variable pressures & temperatures. Benefit: Increased reliability
• Hardcoated & mate lapped seats: High Velocity Oxygen Fuel (HVOF) RiTech® chrome carbide hardcoating with a Rockwell C of up to 72. Mate-lapped seats. Benefit: Wear & corrosion resistant, increased reliability, zero-leakage shutoff
• Seat designs: Hardcoated, both ball & integral downstream seat to the end-cap to eliminate a potential leak path. Benefit: Increased reliability
• Simplicity of design: Designed for ease of installation & maintenance. Benefit: Easily actuated, increased system reliability, increased efficiencies, ease of use, reduced maintenance
• Stringent testing: Every valve is tested, documented & serialized. Benefit: Increased reliability, increased safety, total traceability

Case Study: Teamwork Builds Success

Location: Southeast United States
Plant type: Combined Cycle Power Plant
Industry: Power
Application: HP Steam

Background: During a scheduled weekend outage, a large combine cycle power plant discovered a valve that would not move. Upon further inspection, the customer found a damaged coupler on the valve’s mounting bracket. Assuming this damaged coupler was causing the valve to lock up, the customer decided against purchasing a new valve and instead simply replaced the damaged mounting bracket. Preparing to go back online, the customer found the valve would still not function.

Requirement: Immediate shipment of a V Series metal seated ball valve for main steam draining was required to avoid extended outage time.

Result: Receiving the emergency request on Saturday, ValvTechnologies quickly assembled a cross-functional team to provide the power plant with an immediate solution. Representatives from the Shipping, Warehouse and Service departments were called to the Houston office to solve the customer’s issue. The ValvTechnologies’ team was able to identify, assemble, test and ship a replacement zero-leakage valve by the end of day Saturday, the very same day the emergency request was received.

The customer received the valve Monday morning and immediately installed it. The new valve functioned perfectly and the customer was able to go back online, saving thousands of dollars in potential down time and revenue loss.

Oval hand wheel
Actuator mounting
Lock-out device

Standard ValvTechnologies’ four-year zero leakage warranty in steam and water applications.

302_V1-3 Cut Sheet_Aug.2023_V4

• Guaranteed tight shut-off
• True metal-to-metal sealing without using secondary elastomeric seals
• Two piece, split-body design
• HVOF RiTech® coating technology
• Grafoil^® seals
• Double block-and-bleed capability
• High-cycling capability
• Bi-directional sealing by design
• Single-piece anti blow-out stem design
• Impervious to high thermal cycling
• Live-load stem packing (four-bolt design)
• Stem fugitive emissions per ISO 15848-1 Class B
• Fire safe certification: API-607
• Meets ISO-15848-1 testing requirements for fugitive emissions
• Packing requires zero adjustment or maintenance
• Capable of 500,000+ cycles
• Durable packing solution for extremely fast cycle speeds of less than 0.5 seconds

These systems cycle many thousands of times per day. Conventional packing systems cannot handle the abuse of the fast cycle speed, combined with the high cycle count. ValvTechnologies’ EcoPack® solution was designed to address this challenge. The EcoPack® seal has been lab-tested at high pressure and line temperature to 450°F for over 500,000 cycles, requiring zero adjustments or maintenance. This equals longer plant operation between maintenance intervals, improved site safety and less emissions from the stem packing.

• Reduced emissions to comply with EPA fugitive emissions requirements
• Guaranteed tight shut-off. Benefit: Enhanced process safety and repeatable sealing allows operation under process excursions
• True metal-to-metal sealing without using secondary elastomeric seals. Benefit: Inherent fire safety
• Exclusive ValvTechnologies’ EcoPack® stem sealing technology. Benefit: Lower emissions and reduced maintenance
• Two piece, split-body design. Benefit: Increased safety and ease of maintenance
• HVOF RiTech® coating technology. Benefit: Extended life even in the most severe conditions, reduced maintenance costs, process reliability, enhanced process safety
• Grafoil® seals. Benefit: Reduced maintenance costs, less downtime
• Double block-and-bleed capability. Benefit: Enhanced process safety
• High-cycling capability. Benefit: Process reliability
• Bi-directional sealing by design. Benefit: Enhanced process safety, lower maintenance, less downtime
• Single-piece anti blow-out stem design. Benefit: Enhanced process safety
• Impervious to high thermal cycling. Benefit: Enhanced process safety
• Adjustment-free stem packing. Benefit: improved site safety and reduced maintenance
• Stem fugitive emissions per ISO 15848-1 Class B. Benefit: Lower emissions and enhanced process safety
• Fire safe certification: API-607. Benefit: Enhanced process safety
• Longer intervals of plant operation between maintenance schedules. Benefit: Increased safety and ease of maintenance
• Enhanced process safety and repeatable sealing. Benefit: Allows operation under process excursions
• Safer plant operation due to less exposure of plant personnel to valves requiring packing adjustment. Benefit: Increased safety
• Longer valve seal life. Benefit: Extended life even in the most severe conditions, reduced maintenance costs, process reliability, enhanced process safety

• Reductor
• Gasification of charcoal
• Gas cooling
• Phyrolysis of coal
• Combustor
• Combustion of coal/charcoal
• Melting of ash
• Discharge of ash as slag