NEW APPOINTMENT – WORKSHOP SUPERVISOR VEREENIGING

We are very pleased to announce the appointment of Gideon Brown to the position of Workshop Supervisor Vereeniging Branch Valve Repairs. Gideon’s extensive experience will add value to both V&A and our valued clients.

Gideon,

  • Started his career at East Driefontein Gold Mine.
  • Worked in the Sasol Synfuels Valve Shop as a Control Valve Specialist for 5 years.
  • Has extensive experience with valve repairs arround the world having been a Supervisor and Control Valve Specialist for companies like Kentz, Sepam, B&W Energy Services managing projects located in Russia, Papau New Guinea, Saudi Arabia, Tunisia, Australia and Madagascar to name a few. He says he is on his 3rd passport due to the many customs stamps.
  • Is happily married to Madelain and they have 2 children.

Gideon brings his many years experience to supervising the valve repair workshop in Vereeniging. Gideon reports directly to Desmond Delport our National Sales Manager.

 

Gideon Brown

Workshop Supervisor (Vereeniging Valve Repairs)

Mobile No         : 082 412 9131

E-mail               : gideon.brown@alve.co.za

 

Johannesburg Office Gets a Facelift

Even though we have limited staff at the office and social distancing is still in force we have given our Johannebsurg office a facelift. New breakaway area with sofas as well as product banners, motivational pictures and pictures of various Sasol chemical plants.

We look forward to welcoming you for a cup of coffee when restrictions are lifted.

Actreg – Actlock Partial Stroke Testing (PST)

Emergency valves remain in their position and are actuated only in the case of emergencies. Often PST devices require complex software, a positioner with a PST function that requires special training and has fragile wiring and connections. The patented Actreg Actlock provides mechanical PST with a fully automated system reducing overall dimensions for the final control element compared with other solutions.

It is simple, integrated with the actuator and a 100% reliable mechanical solution. It offers a 3 in 1 option : Partial Stroke Testing, locking device and automatic stroke limiter.

Talk to our technical specialists today to see how we can help you protect your process plant.

To find out more watch the latest video or view the Actlock PST technical data.

The HX Story – Greater Demands Calls For Action

In 2011 Stafsjö was faced with a request from a well known international OEM supplier with a strong foundation within the Pulp and Paper Industry. They wanted a technically fast and reliable valve capable of operating within a broad range of pressures, pulp concentrations and temperatures. The develop ment team at Stafsjö got down to work and the story of the 20 bar rated HX valve began.

The production volume at pulp and paper mills across the globe are increased, new mills are being built capable of achieving new record production volumes and old plants are being converted or upgraded. As a knife gate valve supplier Stafsjö represents a part of the machinery equipment.

The Stafsjö HX knife gate valve ensures batch digester isolation during pulp stock production.

Read the story about HX severe service knife gate valve to see how it can help you improve production or find out more about the Stafsjö range of high pressure knife gate valves.

 

PMV-D30 Intelligent Valve Positioner

SA Instrumentation & Control Magazine – Front Cover Jan 2021.

While pumps and valves frequently get most of the attention, it is often the actuators and positioning solutions that are running the show.

Over the last few decades, the process plant instrument technician’s day in the plant has become busier. They see an increased work load in combination with increased pressure for plant uptime and reduced maintenance cost.

Their knowledge base must today span from mechanics to pneumatics, and hydraulics to data communication, i.e., system level interaction. They get less time to learn how to handle new instruments and to read IOM manuals. Knowledge on how to handle older design process instrumentation, based on springs, bellows, cams and manual calibration, is getting lost. With this in mind, PMV designed a simple to use yet very advanced modular digital positioner, which can be used on rotary or linear actuators, both single and double acting.

 

 

To find out more dowload the Jan 2021 magazine article, or view the PMV-D30 technical data.

 

 

 

 

New Storagetech Flame Arrestor Video

Storagetech Flame Arrestors are safety devices that are designed to inhibit flame propagation in a gas piping system as well as low pressure tanks that contain flammable liquids. Specifically designed to meet the high standards of the Oil & Gas, Chemical and Petrochemical industries, it has a flame barrier with a large number of defined passage gaps.

This new video shows you with exploded views how it is assembled and also where it should be installed and what it ultimately does to protect you and your plant. Watch the video. 

RICHTER – QMD™ MAGNETIC DRIVE PUMP

Richter Chemie-Technik Germany, a global leader in PFA lined pump and valve solutions, recently launched the QMD™ magnetic drive pump.

The Richter QMD series of magnetic drive pumps were designed to anticipate the fast growing Asian market. The main objective was to serve the local chemical market with a competitive pump with the typical Richter signature of high quality.

The pump series complies with the requirements of the local standard GB 5662. This can be equated with ISO 2858 and is designed for applications in the temperature range of -10°C to 100°C. The excellent chemical resistance provided by FEP lining and other high-quality materials like silicon carbide, allows for flawless operation in applications with a performance range up to 125 m3/h and 65 m head.

A total of 8 pump sizes are available from 40-25-125 to 80-50-200.

With the QMD series, you can count on the well-known product reliability of Richter Chemie-Technik GmbH.

To read more go to https://valve.co.za/products/product_category/lined-pumps-valves/

 

Zwick Tri-Shark Bares It’s Teeth

In the latest issue of MechChem Africa the leading industry magazine for mechanical and chemical equipment, Valve & Automation South Africa presents the features and advantages of the Zwick Tri-Shark control valve with Throttling Trim Cartridge, a valve that combines the advantages of leak-free triple-offset valves (TOVs) with high-performance control valves into a single valve solution.

To find out more, download the latest magazine article or view the Zwick Tri-Shark technical data.

 

 

 

More Zwick Triple Offset Valves for National Tank Farm

The Client & Application

Our client a leader in chemical and fuels required Triple Offset Valves (TOV) for their national tank farms to tie in to the Transnet Multi Product Pipeline. Their numerous other chemical plants throughout the world as well as their local refinery already use hundreds of Zwick Tri-Con valves, so they had a proven track record to draw on when making their final decision on what TOV to select for their tank farm tie ins.

Currently their local production plants use Zwick Tri-Con Triple Offset Valves up to 54”, so valves in 12” and 20” on final product (hydrocarbons) would give them a life time far longer than those on harsh production applications experienced in their chemical plants.

Rotork Electro Hydraulic actuator were fitted to the 12” and 20” Zwick B1 Tri-Con valves with gate valve face to face dimensions. This application for Zwick Tri-Con called for class V shutoff whereas Zwick can provide up to Zero leakage and as the product is final product, the valve will not be subjected to the harsh conditions like a high pressure and high temperature chemical plant.

Viresh Girdharie our Internal Sales Manager attended the FAT which was also attended by an end user senior quality control inspector with extensive experience. Pressure tests were done on all valves and the requirement was that the valve holds pressure at 22 bar for minimum 2 minutes. Viresh reports that everything was perfect and the shutoff class was exactly what clients have come to expect from Zwick.

Rotork Actuator Supervisor: “The Zwick valves seal so well, that I could easily leave these valves on pressure all night.”

 

 

 

 

 

 

 

Zwick Product Range

Zwick manufacture TOV‘s up to 88″ (DN2200) and PN100 / ANSI 900 as well the unique Tri-Shark rotary control valve which offers a rangeability of 100 : 1, ensuring control and Zero leakage all in one. Tri-Shark 100% Control / 100% Tight.

Talk to one of our skilled technical specialists today, to see how we can assist you with your Triple Offset Valves.

 

 

 

 

 

 

V&A WINS CHEMICAL PLANT UPGRADE

Our client a Global Leader with operations throughout the world chose Richter fully lined valves for the recent chemical plant upgrade based on the success they had with Richter and V&A over the last 30 years. The existing chemical plant which handles Chlorine Dioxide, Hydrochloric Acid and Brine needed to upgrade the Iron Exchange and Richter was the valve of choice for this project on isolation, on/off and control.

 

Prior to the chemical plant upgrade – Richter‘s increased reliability saved over R 1,400,000

This Global Leader, was having problems with unacceptable failure rates on lined butterfly control valves. The leaking valves resulted in ongoing losses due to their final product being inferior and rejected.

They were using a competitor’s fully lined butterfly valve to control Chlorine Dioxide flow. The valve had a Mean Time Between Failure (MTBF) of only 2 to 3 months. Each time they changed the valve it cost them R70,000 for the valve alone (excluding the costs of rigging, downtime, lost production and rejected product). When they replaced the valve, they required 2 riggers an instrument technician and a fire attendant. In the 2 ½ years we monitored this application they would have bought 10 competitor valves.

Instrument Technician : “We had ongoing leaks downstream and the valve never sealed. There is only so much Chlorine Dioxide that can go into the system before you have an inferior product that is rejected.”

Our technical specialist walked the plant looking at the installation and investigated the process conditions. V&A then supplied a Richter NK series lined butterfly valve as the solution that has now been in use for more than 2 ½ years and has not been taken out or maintained yet.

Instrument Foreman : “We have not looked at the valve in 2 ½ years and it just does what it is supposed to allowing us to focus on other plant issues.”

Valves Supplied for Chemical Plant Upgrade

Total valves supplied so far = 237 pieces / sizes DN25 (1″) to DN200 (8″)

Talk to one of our skilled technical specialists today to see how we can assist with your chemical plant.

Richter – MNK Magnetic Drive Pump

THE BIGGEST LINED MAG DRIVE PUMP GOT EVEN BETTER

Richter Chemie-Technik GmbH, a global leader in PFA lined pump and valve solutions, have introduced a new feature for the MNK 200-150-315 pump.

Richter Chemie-Technik Germany have developed the world’s largest fluoropolymer-lined, magnetically driven centrifugal pump. This pump made it possible to move flow rates up to 600 m3/h and achieve delivery heights up to 60 m.

Being able to control these operating conditions with this new product inevitably led to increased demand from international end-users. These ranged from the density of the conveyed product, temperature and flexible delivery rates from the partial load range to the overload range.

These increased demands, especially in the partial load range, require optimization of the impeller to control forces, vibration and noise emission.  The result is an impeller with five main blades and five additional “Splitter Blades.” Going forward the new “Impeller Hydraulics III” will be used as the standard in our MNK 200-150-315 pump.

Existing impellers can be easily replaced due to identical hydraulic performance against the previous “Standard Hydraulics II”.

This improvement makes the biggest lined magnetic pump in the world even more powerful and reliable in the most critical applications.

 

 

 

To learn more about the MNK Magnetic Drive Pump

 

 

ARCA delivers control valves for biomass heat and power plant

Kronospan, a global manufacturer of chipboards, MDF boards, OSB panels, laminated flooring and worktops have been working with the “Factory Of The Future “, EU’s project to reduce CO² emissions and environmental impacts of production plants substantially. To achieve this, a biomass heat and power plant was commissioned.

For the construction of the biomass power plant, CHP2, ARCA supplied almost all of the control valves and desuperheaters for the water-steam-condensate including all valves for the steam drum, boiler, feed water tank and condenser. Around the turbine, two steam Pressure Reducing and Steam Conditioning Stations (PRDS) were supplied, which redirect the steam in case of turbine failure. The high steam pressure is reduced in several controlled and fixed stages and at the same time the temperature is cooled with the integrated ARCA steam assisted nozzle placed in the centre of the pipeline. These valves are of great importance for the availability and safety of the plant. They can close within 2 seconds as well as open by means of a solenoid valve. The steam test unit for pressure monitoring after the bypass station also formed part of ARCA’s scope of delivery and safety concept.

The production of wooden products require a lot of energy and heating. This production process also creates wooden offcuts, the wooden offcuts are ideal energy sources for cogeneration. With this approach, wood that has come to the end of its utilization cycle, can be thermically recycled, thereby replacing fossil fuels with renewable energy.

ARCA Control Valves and Desuperheaters in use through South Africa in a wide range of process industries. Talk to one of our technical specialists to see how we can assist you with your control valves.

This is the kind of work we do. Well done Valve Repair Team

Jannie and his Valve Repair team have done us proud again. Make sure you look at the before pic first then see what is looks like when delivered yesterday.  The valve is a 14in (350mm) Piviviesse ball valve used by Sasol.

 

 

 

 

 

 

 

We have factory accredited facilities are available in both Vereeniging and Durban where skilled technicians with knowledge and extensive experience carry out the required valve repairs and reconditioning using OEM components. All final testing is done to appropriate industry and plant standards.

To find out more about our Valve Repair Centres.

Give one of our technical specialists a call to see how we can assist with your valve repairs.

SCHROEDER VALVES PROTECT PUMPS AT THYSSENKRUPP STEEL EUROPE

The Client

Thyssenkrupp Steel Europe AG has opted for Schroeder pump protection valves during the recent overhaul of Unit 4 of its power station, “Hermann Wenzel”, in Duisburg Germany.

These Pump Protection Valves are also known as Automatic Recirculation Valves.

The Previous Valves That Caused Problems

The valves that were installed previously, came from another supplier and repeatedly caused problems because the minimum flow control was carried out by two valves. This design often led to an increase in the drive power requirement and a drop in overall efficiency.

So Thyssenkrupp Steel looked out for a better solution. The required valves had to have a nominal size of 125 mm for the electric pumps and 200 mm for the turbopump and a nominal pressure of PN 630 bar.

The Schroeder Solution

Thyssenkrupp Steel decided on the automatic minimum flow system of the SMA Series manufactured by Schroeder Valves. These are high-pressure valves, which automatically protect centrifugal pumps against damage that may occur as a result of the partial evaporation of the pump content when the pumps are operated under low load. As soon as the main pump flow falls below a predetermined value, the valve opens the bypass and safely drains the minimum volume, even if the pumping volume in the main flow direction drops to zero.

The bypass is always completely opened or closed through its pilot-controlled valve piston. This “ON/OFF” control makes it possible to increase the load limit of the valves up to 630 bar (pumping pressure). The preferred utilization range is thus between PN 250 and PN 400 or ANSI CLASS 2500. The bypass amount may be up to 35% of the main pumping volume. The minimum quantity can be up to 10–12 percent of the full-load delivery rate.

The Schroeder SMA valve is a compact system that combines the performance formerly achieved by the two built-in valves so that a second valve is no longer necessary as with the previous supplier.

Thyssenkrupp Steel chose Schroeder Valves because of the proven track record of reliability, durability and extremely low maintenance in other plants. This is due to the construction and the high-quality materials used in the valves. In the event that maintenance should be necessary, Schroeder Valves has attached particular importance to the ease of maintenance: To replace wearing parts such as pistons and seat rings, it is not necessary to remove the minimum flow line or even the complete valve.

There are hundreds of Schroeder Valve installed in plants in Southern Africa with repairs and reconditioning provided by our Vereeniging and Durban Valve Repair Centres.

To learn more, view the SMA Series.

RICHTER EXPANDS VALVE PRODUCT RANGE TO INCLUDE QUARTER TURN PLUG VALVES

Richter – Your Safety Is Our Goal. Worldwide.

Richter Chemie-Technik GmbH, a global leader in fully lined pump and valve solutions for 60 years, has expanded its product range to include quarter turn fully PFA lined plug valves & non-lubricated PTFE sleeved plug valves.

With more than 600 Chlor-Alkali plants worldwide and a market share of more than 20%, in addition to the proven range of lined pumps and valves Richter can now offer both fully PFA lined and PTFE sleeved plug valves to these plants as well as other plants that handle aggressive chemicals and process media.

Since 1957, Richter Chemie-Technik have been designing and manufacturing products for use with difficult fluids, regardless of whether they are corrosive, hazardous, pure or even ultrapure.

Ever more complex processes, together with growing demands on plant flexibility and safety, require the use of highly advanced and universally resistant plant components. With a complete range of plastic-lined, chemical process and special pumps, shut-off, control and safety valves and now with the addition of quarter turn plug valves, Richter Chemie-Technik together with Valve & Automation, offers a product spectrum which satisfies these demands to a very high degree. Many years of experience enable us to also control additional difficulties, such as high and very low temperatures, solids contamination or the risk of dry-running.

Fully PFA Lined Plug Valve

Available initially from ½” to 6” in Class 150

Some features of the new lined plug valve:

  • In-Line adjustment, easy to access, stops media passing the plug and is independent of stem seals
  • Tapered plug is solid PFA encapsulated and moulded and provides positive in-line adjustment and sealing so there is no leakage past the plug
  • Stem seal is both static and dynamic as well as self-adjusting with reverse lip diaphragm eliminating leakage to atmosphere
  • PFA Lining is minimum 3mm thick using the high quality Richter German process proven over 60 years
  • Dovetailed locking of PFA lining to body in multiple places provides a perfect fit for severe service, cycling actions and vacuum

Non-Lubricated PTFE Sleeved Plug Valve

Available initially from ½” to 8” in Class 150 & 300

Some features of the new sleeved plug valve:

  • In-Line adjustment, easy to access, stops media passing the plug and is independent of stem seals
  • Tapered Plug, is pushed into the sleeve providing positive in-line adjustment and sealing so there is no leakage past the plug
  • Stem seal is both static and dynamic as well as self-adjusting with reverse lip diaphragm eliminating leakage to atmosphere
  • PTFE Sleeve has very large sealing area that provides positive shutoff and extended service life
  • Top, bottom and port seal ribs positively lock sleeve into body for better retention ensuring long lasting seal

Richter is renowned for its solutions in extremely demanding applications. Give one of our technical specialists a call today to see how we can assist you.

Stafsjö – MV Standard Knife Gate Valve

Do you want to try the MV performance?

This all-round valve with a proven global track record on dry solids or wet fluids… The MV valve’s ideal internal clearances lowers the friction and makes it easy for the bevel edge gate to cut through and seal tight on media such as pulp stock up to 7%, black liquor, white liquor, sludge, biomass, granules and water. When the gate reaches its final stage of closure it stops on the cast and precision machined body cams to avoid jamming on difficult media.

To learn more about this valve go to https://valve.co.za/product/stafsjo-mv-standard-knife-gate-valve/

ARCA Valves for Sustainable Energy Supply

ARCA recently received three orders for feed water and steam control valves as weld-in version, through its cooperation partner in Belgium.

After the initial proposal and numerous revisions, ARCA was awarded the fiercely contested tender. The control valves will be used in the process of lighting of boilers by biomass (sunflower seeds and hulls and coconut shells) for steam generation. The steam will be applied by means of a turbine for the power generation, the residual heat will be used as an energy source in further production processes.

ARCA control valves contribute to a sustainable energy supply.

To see the full range of ARCA products go to https://valve.co.za/products/brand/arca/ 

 

ARCA Celebrates 70 years

There has been great celebrations Tönisvorst: Seventy years ago Dr. Ing. Ludwig Kaspers founded the company ARCA after the war and started control valve production.

Today the company has grown to become a large group of companies with about 500 employees world-wide and offers innovative solutions in control and pumping technology in many areas. ARCA continually develops custom-fit solutions for its customers. On September 28th, the jubilee was celebrated with employees, their families and invited guests.

The managing director Johannes Fliegen welcomed all guests and reported on current developments within the company. There was music, food and drinks as well as an opportunity to get an insight into the manufacturing processes and the company in general.

The new processing station with three new state-of- the-art machining centres attracted special attention; this section was completed last year. The investment that ARCA has made has continued its path towards digitalization at production level. May ARCA continue successfully for many more years! To find out more about ARCA products see https://valve.co.za/products/brand/arca/

 

DAY 15 OF THE LOCKDOWN AND WE ARE STILL HERE FOR YOU

If you call to speak to one of our 35 staff located throughout South Africa, and in the background you hear a dog bark or a baby cry, do not be concerned as it’s us working from home. Do not worry, we are not asking staff to work on the Easter weekend, it’s just me reminding you that we are always here as we have been for the last 32 years. Have a blessed weekend with your families.

We are locked down at home supporting amazing clients like Sappi, Sasol, Mondi, Eskom to name just a few and this is where our ongoing investment in the best technology is paying off for us (and you),

  • Our Dell notebook computers with the fantastic Dell XPS 13 being used by our sales staff make sure we can support you with the best tools with us at all times.
  • Microsoft Office 365 ensures we have everything at our finger tips and on SharePoint for all of us to access from anywhere and on any device. We can get that document for you on our notebook computers or our cell phones quick and easy.
  • Microsoft Teams enables us to have video meetings with each other and with clients in South Africa as well as our suppliers throughout the world, making sure we never skip a beat. Training is still proceeding using video as are sales, management and director meetings and we can still run the company and provide service even if we are not in our business offices or in the same building together.
  • Yeastar Linkus Mobile Client VOIP software ensures that we can be contacted anywhere at any time if you call one of our 3 main telephone numbers. (0861 103 103 / 011 397 2833 / 031 579 2593)
  • Syspro ERP & CRM software which we have run for more than 15 years ensures we can process any orders, track the delivery and capture client information from anywhere at any time.

We still keep our stock in the Vereeniging & Durban warehouses and our suppliers in Europe manufacturing valves are still are operating while DSV and Kuehne + Nagel logistics and freight forwarding specialists are importing and clearing equipment so you can keep your plants running. One of our suppliers in Germany, Zwick, has 5000 castings in stock and can machine, assemble and dispatch faster than you may think possible.

Please remember we certified by CIPC as an essential service which means we have all the correct documents to travel so technical staff come to site to support you or supply valves, actuators and positioners from our warehouses.

Do not forget to keep your family and loved ones safe.

Give us a call, as the 35 of us are here to help.

ARCA – Sustainability by Packaging Reduction

There is probably no other term that has been used and interpreted in recent years in so many ways as the term ”sustainability “.

Originating from forestry, today the principle of sustainability is comprehensively explained by “meeting current needs without withdrawing from future generations.”

With these fundamental ideas in mind ARCA developed and produces their range of control valves.

With the process data and framework conditions supplied by customers, ARCA ‘s control valves are sized for the lifetime of the respective plants and beyond that, resource-saving without any negative impact on the product.

The responsibility for the control valves does not cease with the successfully completed pressure tests and final inspections but continues with the packaging and delivery, up to the initial operation.

Previously the packaging was never in focus as it is usually dictated in a packaging specification directive by the customer.

With ARCA’s ongoing goals to improve, we examined our packaging. Initially all the small parts, that were packaged wastefully in plastic bags. While researching we found a shrink hood machine that secures the small parts to corrugated paper and then holds it in place with a shrink-wrap foil. With this method we reduce about 75% of the plastic parts of the existing packaging and at the same time ARCA offers the customer a higher-quality and more robust packaging unit. As a positive benefit, the labelling and its readability have been improved. A win-win situation for the environment and the company and another contribution from ARCA for sustainability.

For more information on ARCA products see https://valve.co.za/products/brand/arca/

THE CIPC CERTIFIES V&A AS AN ESSENTIAL SERVICE

The CIPC  has cetified Valve & Automation (Pty) Ltd as an Essential Services Business and has permission to operate during the lockdown period as announced by the president of the Republic on 23 March 2020.

Please download the CIPC certificate here.

  • The Valve & Automation continuity plan is fully active covering the safety and health of all employees as well as the continuation of business in general.
  • All our staff will remain fully operational ensuring continued support to you through this difficult time as we all have been set up and are equipped to work remotely, having access to e-mails, phones, printers and scanners.
  • Should you require technical support on site, we are geared up for that as well.
  • All our e-mails and contact numbers remain the same.
  • Give us a call today, we are all here to support you.

Best Regards

Ron Nel

We Are Here For You

To all our valued clients,

  • The Valve & Automation continuity plan is fully active covering the safety and health of all employees as well as the continuation of business in general.
  • All our staff will remain fully operational ensuring continued support to you through this difficult time as we all have been set up and are equipped to work remotely, having access to e-mails, phones, printers and scanners.
  • Should you require technical support on site, we are geared up for that as well.
  • All our e-mails and contact numbers remain the same.
  • Talk to us, we will be there for you.
  • Best Regards Ron

Arca – Their new 2020 magazine is here

Sustainability is a major issue with ARCA Flow Group as you will read in our latest magazine. Sustainability has many faces. In our latest magazine we would like to introduce some of them from our everday life to you. Be it packaging reduction, be it measures for the long-term reduction of energy consumption or the increasing use of our products in biomass power plants for example. Download the latest magazine and read for yourself or visit the Arca Control Valve section to learn more.

 

ARCA – Around the Steam Turbine

At the heart of a power station are the steam turbines and Arca has the excperience. They serve as a generator or mechanical drive for pumps and compressors. For its operation a network of valves is built around the turbine. Steam inlet valves direct the steam flow into the turbine while extraction valves withdraw the steam from the different intermediate stages. Gland steam and leakage steam control valves provide the labyrinth seals in the hub areas with steam, that seal the turbine shaft towards the turbine housing. Drain valves drain accruing condensate from the steam pipeline to the condensate collector.

For the project Pingshan ARCA delivered the steam supply control valves, the seal steam control valves and the drain valves of the steam turbine. The supply control valve in DN 400 controls the steam flow from the reheater into the turbine. Equipped with a hydraulic actuator suitable for a hydraulic pressure of up to 140 bar, it has an actuating time during control operation of 20 seconds and for quick close and open it has a time of 2 seconds and 5 seconds respectively.

The actuator in the picture can provide a maximum actuating force of 44 kN. Silencer disks at the valve outlet ensure a low-noise operation. Turbine manufacturers world-wide count on the know-how and experience of ARCA for the design and delivery of these valves. Together with our customers we develop solutions for efficient turbines with valves suitable for temperatures up to 650°C and nominal pressure up to PN720/Class 4500. To find ut more visit https://valve.co.za/products/brand/arca/

New Stafsjö 3D Documents for knife gate valves added to website

Always “First In Knife Gate Valves”, Stafsjö have updated their 3D documents making it easier for design engineers who can download the files in .pdf or .stp. These have been updated for the following knife gate valves in each section of our website

Contact one of our technical specialists today, to see how we can assist you with reducing your life cycle costs.

Schroeder Introduces new SIP pump protection valve for peak loads in an energy grid

The new Schroeder SIP pump protection valve is the completion of the Schroeder portfolio and particularly developed to cover high pressure applications up to 250 bar with frequent plant operation at minimum flow conditions, i.e. with open bypass. Typical for this valve-type and the most relevant application is the boiler feed water cycle of combined cycle power plants (CCPP). In these power plants the bfw-pumps operate frequently at minimum flow conditions with pressures of 120–250 bar. The reason is the technical concept of a CCPP (e.g. gas turbine cooling with bfw.) as well as its purpose to cover load peaks in the energy grid.

To find out more contact one of our technical specialists or visit the technical page.

Valve & Automation Completes Advanced PMV Valve Positioner Training

Even after many years in business and numerous training courses on valve positioners, as part of our continuous development we recently completed advanced valve positioner training. After having been appointed exclusive agents for PMV valves positioners, Anders Ulne Global PMV Positioner Manager, recently visited South Africa to do training at our Johannesburg and Durban regional branches.

For many years PMV have manufactured valve positioners for companies like TYCO, KEYSTONE, DE-ZURICH, REVO, HITORQ, BETTIS and BABCOCK. If you see this logo below, you in fact have a PMV positioner and we can assist you wish all technical support.

PMV-D30

Training was done on the PMV-D30 robust intelligent valve positioner that provides optimum valve control. It has a very high air capacity, is designed to operate pneumatic rotary and linear valve actuators from control systems and electrical controllers with the analog control signal 4-20 mA, optionally superimposed by the HART communication signal. As an alternative, the digital operation by means of Profibus-PA and Foundation Fieldbus Is possible. The PMV-D30  positioner can also be integrated into system and application that support FDT/DTM concept according to the specification. For this purpose the required DTMs for HART and Profibus are available. The digital technology ensures the most accurate control and is the basis of the diagnostic tools using ValveSight Software. The features for predictive maintenance increase the availability of your process. The PMV-D30 positioner is also very easy and quick to configure and calibrate.

In the picture you can see our Johannesburg team on the day of the training from left to right

Hugo Terblanche (Technical Sales Specialist), Gawie Niewenhuis (Instrument Technician), Anders Ulne (Global Manager PMV Positioners, Johan van Zyl (Technical Sales Specialist), Desmond Delport (National Sales Manager), RJ Ferreira (Technical Sales Specialist), Gustav Coetzee (Internal Sales Manager), Jannie Janse van Rensburg (Valve Repair Manager), Johannes van Dyk, (Internal Sales).

To find out more about the PMV-D30 Valve Positioner visit the technical page. Or contact us to see how we can assist you.

Valve & Automation Opens in Johannesburg

As part of Valve & Automation’s focus on service to customers, we have opened our third facility in Bartlett, Johannesburg a few kilometres from OR Tambo International Airport. This branch will be known as our Johannesburg Branch and is located in the freight forwarding area where airfreighted imports are processed through customs. Having the new branch so close to major freight forwarders, enables us to expedite airfreighted goods as fast as possible and liaise with customs if required. The Johannesburg Branch is responsible for the entire Gauteng and Inland Region and has the Vereeniging Warehouse and Valve Repair Centre reporting into it.

With facilities in Johannesburg, Vereeniging and Durban as well as technical specialists in all major industrial areas we are able to support you from sizing and selection through to maintenance and valve repairs.

Contact Numbers:
SA: 0861 103 103
Tel: +27 11 397 2833

Physical Address:
Unit 32, Airborne Park,
11 Taljaard Road, Bartlett,
Boksburg North, Gauteng, 1459

Give one of our technical specialists a call today and see how we can help you.

Stafsjö close to attaining its 100 % on-time delivery vision

During 2019, Stafsjö focused on improving its delivery performance, 98 % of all orders received have been delivered on the confirmed delivery date. Stafsjö have set a new delivery standard.

The response from our customers has been fantastic. Stafsjö have a strong brand and recognized products, which are associated with high quality. In order to grow the brand it was necessary to improve our delivery performance. By doing this Stafsjö planned on retaining our existing customers and winning new ones. Stafsjö are focusing on delivering every order on time.

The company experienced strong growth during 2018 mainly due to large projects at the end of the year. In 2019, Stafsjö have had more versatile sales and it has been more evenly distributed over the year. During 2019 Stafsjö have focused on improving and securing the delivery precision. The manufacturing process plans are measured, not only at the end, but at every step from placing purchasing orders for material, through on-time delivery of incoming material, machining, assembly and delivery to customer.

When one job commences on time, other consecutive jobs in the process are able to do the same. If we lose time in an early stage we have to take measures to re-capture this lost time in the later stages. Stafsjö has daily meetings with all functional managers and planners where the status for all work orders of previous day is reported as well as reasons for late orders along with suggested actions to recapture. By having all managers’ present fast decisions can be taken when the information is shared. Deviations to processes or material failures are also reported for short and long term corrective actions to continuously improve the operations and products. During the next year reliability in delivery will become sustainable in the long run to ensure further growth and trust among the customers worldwide. To learn more about the range of products go to  https://valve.co.za/products/brand/stafsjo/

SA Instrumentation and Control – Jan 2020 Front Cover

ARCA: masters of innovation and variety in control valve solutions.

Dating back to 1918, ARCA Regler has earned global recognition for specialising in control valves, manufactured and marketed around the world primarily for the chemical, food, power, petrochemical, steel, pharmaceutical and oil and natural gas industries. ARCA’s Ecotrol control valves: committed to perfection in every detail ARCA’s Ecotrol range offers a wide variety of innovative solutions designed to fulfil all control task requirements. Whether housing, inner valves, valve seats, stem seals, actuators, or positioners, every detail benefits from the know-how of expert engineers with many years’ experience in a wide range of applications. Factors such as efficiency, control precision, price/performance ratio, weight, and lifecycle costs are all optimised to suit user requirements in order to deliver high control precision and lower………… Download the magazine editorial to read the complete magazine editorial.

The cover shows the very large valves supplied to Sasol. Take a look now! 

 

V&A Appointed Exclusive Agents For PMV Valve Positioners

PMV positioners are easily mounted to linear and rotary valves and quick to calibrate. For quick and easy valve positioner selection download our selection guide.

We have valve repair and automation centres in Vereeniging and Durban where we can fit a range of positioners to your globe control or rotary control valve and do complete function tests issuing a certificate.

Should you require an Explosion Proof positioner talk to one of our skilled technicians about the PMV-D3.

Call us today to see how we can help you with your positioner selection. 

Westlock Controls Second Generation Intelligent Valve Position Transmitter Digital EPIC-2

Westlock Controls second generation intelligent valve position transmitter EPIC-2, provides smart valve communication that enables plant operators to identify current operating conditions and verify valve health. It also allows plant personnel to carry out predictive maintenance before a failure occurs, keeping service interruptions to a minimum.

Automated valves are often used as critical safety components to protect vital plant infrastructure. They must be occasionally tested to make sure they are functional and maintain the safety integrity level (SIL) rating of the safety instrumented system (SIS). The Digital EPIC-2 enables the plant safety team to carry out partial stroke testing (PST), emergency shutdown (ESD) and full stroke testing (FST) with safety integrity level (SIL) 3.

Westlock’s Digital EPIC-2 provides detailed equipment analytics with information regarding the status and position of the valves. It captures valve performance data to identify if the equipment is operating within the safety configurations and how the valves respond under test. The device notifies the control room via alarm in case of any deviations from the measured parameters. In addition, its solenoid operated valve testing (SOVT) capability reduce the risk of an unplanned shutdown and disruption of the process by allowing plant operators to cycle only the solenoid valve and not the actuator. It de-energizes the SOV and monitors the drop in pressure without causing any valve movement.

The Digital EPIC-2 is easy to use and can be directly integrated with any control system. Its robust technology enables plant operators to perform accurate ESD valve diagnostics and identify valve automation maintenance in advance.

Westlocks’s extensive technical expertise and knowledge of valve actuation and control helps user’s lower risks and subsequent repair costs as well as increase plant service availability and safety level. Using Digital EPIC-2, customers can be more prepared for maintenance and resolve potential issues to prevent further damage to the plant and the environment.

Valve & Automation is the agent for Westlock products for more information go to https://valve.co.za/products/brand/westlock/ 

 

 

NAF receives the 2019 Industry Leader Award by the U.S. National Safety Council (NSC)

NAF is very proud to announce that they were awarded the 2019 Industry Leader Award in July 2019 from the U.S. National Safety Council (NSC). The award is given to the member companies that rank among the top 5% companies regarding occupational safety and health.

By continuously improving work environment safety NAF have now achieved 7 years without any down time due to accidents at work. Safety training every month, active preventive incident and observation work and annual external safety audits, are some parts of the NAF safety ethic.

To learn more about NAF see https://valve.co.za/products/brand/naf/

Stafsjö introduce FEPM seat for high temperatures and chemical services

Stafsjö are proud to announce the arrival of the new rubber valve seat compound FEPM for use on WB11WB14 and specifically to the full stainless steel high performance WB14E. Initially it has been released for sizes DN 80/3” – DN 300/12” (except for DN 125/5”)

The FEPM seat material has excellent resistance to wide range of aggressive chemicals, both acids and bases, and steam at high continuous service temperatures within -10 °C/14 °F up to 180°C/356 °F including short term peeks up to + 225 °C/437 °F. The compression set resistance at these high temperatures is superior to other standard rubber materials, but it is limited in low temperature applications. Function tests shows that the FEPM material can give the sealing system considerably longer life time compared to standard rubber compounds. This makes the FEPM seat suitable for severe applications where you need a long-lasting performance and a tight shut-off.

For more info see https://valve.co.za/products/brand/stafsjo/  

 

NAF D30 Valve Positioner – No Brackets or SS Piping Required

The NAF-D30 is an intelligent valve positioner designed to operate pneumatic rotary valve actuators from control systems and electrical controllers with the analog control signal 4-20 mA, optionally superimposed by the HART communication signal. It forms an integrated part in the NAF-TorexNAF-Setball and NAF-Duball control valve package with a unique direct mounting and does not require brackets. The air block between positioner and actuator means you no longer need to find SS fittings and bend SS tubing.

View the maintenance videos here.

Call one of our technicial specialists today to find out more!

Patent on the Artes Desuperheater with three stage pressure reduction

One of the most relevant products of the ARTES Range is the desuperheater.

Purpose & Advantages

The ARTES desuperheater is a control valve with which the temperature of vapour can be regulated by injecting cooling water. The ARTES desuperheater is frequently used in steam generators of power plants and other industrial systems. Special applications using other media have also been realised. By nature of its design and use of quarter-turn movement, the ARTES desuperheater offers many crucial advantages: The cooling water is always injected into the centre of the pipe, regardless of the quantity. The perfect combination of quarter-turn principle, nozzle design and subsequent nozzle opening ensures reliable and precise cooling in all load cases. Both its design and the use of high-grade materials prevent vibration fractures of the valve’s functional components and ensure a reliable operation without interruptions. With its high rangeability, the ARTES desuperheater offers an outstanding quality of control. The control performance is continuous across the entire control range. The valve is permanently leak-tight to the outside. The ARTES desuperheater can be actuated by means of electric, pneumatic or hydraulic actuators.

Function

In contrast to other valves that operate according to stroke principle, the ARTES desuperheater utilises a quarter-turn movement. The quantity of water to be injected is controlled by turning the valve stem by 90°. An additional control valve, as is necessary when using fix, uncontrolled nozzles, is not required here. As the valve stem is turned, the ball contour located directly behind the water connection opens and the flow to the desuperheater lance is enabled. Water flows through the hollow nozzle stem and reaches the various nozzles through openings in the nozzle stem. These openings are designed in such a way that there are no steps in the characteristic curve of the valve. Swirl inserts in the nozzles cause the water to rotate. As a result of the water rotation and nozzle geometry, the spray cone is uniform, with very fine atomisation of the cooling water. By using nozzles with different borehole diameters, any characteristic curve is possible – fine-tuned to the respective application. The perfect combination of quarter-turn movement, nozzle design and subsequent nozzle opening ensures reliable and precise cooling in all load cases. To achieve a very wide and fine water distribution, the maximum possible number of nozzles is always used. Here, the maximum number of nozzles is directly dependent on the inner diameter of the steam pipe.

Design

Depending on the pressure difference between cooling water and steam, the ARTES desuperheater is equipped with a single-, two- or three-stage pressure reduction. The version with single-stage pressure reduction is used in cases where the differential pressure between cooling water and steam is in a range of 5 to 30 bar. The entire differential pressure is effective at the nozzle systems, due to the very low pressure loss within the desuperheater. This guarantees the very fine atomisation of the water. The ball / seat ring system is only used for shutting off the water.

For higher pressure differences between 30 and 60 bar, the desuperheater reduces the pressure in two stages. In this version, the ball and seat ring additionally have a control and throttle function (control contour in the ball passage).

The three-stage version for pressure differences of more than 60 bar the desuperheater has additional internals at the ball stem area to reduce over-pressure. The ball / seat ring system is a pure metal-to-metal seat and works similar to a conventional ball valve.

To learn more go to https://valve.co.za/product/arca-artes-steam-atomising-desuperheater/

NEW APPOINTMENT – REGIONAL MANAGER KZN & COASTAL                      

We are very pleased to announce the appointment of Johan Jacobs to the position of Regional Manager KZN & Coastal. Johan’s extensive experience will add value to both V&A and our valued clients.

Johan,

  • Has a Diploma Business Management.
  • Spent 10 years with national pump company where he started as Operations Manager based in Pretoria leading teams that designed systems and supplied pumps & valves to the chemical, petroleum and mining industries.
  • He later relocated to Durban with them where he took on the role of KZN Regional Manager taking care of key clients in the region.
  • Worked in design and construction in the chemical industry prior to joining the national pump company.
  • Is happily married to Leandie and has a little daughter. He has just advised me the good news that his wife Leandie is expecting their 2nd child. We wish them health and happiness for the baby on the way.
  • Has varied interests from being in the bush with his family, to fishing and has recently taken up golf.

Johan will be responsible for all aspects of Management for the KZN & Coastal Region and will be supported by Desmond Delport our Nartional Sales Manager and Greg Woolfuth our Operations Director / Manager.

Johan Jacobs

Regional Manager KZN & Coastal

Mobile No         : 083 230 0649

E-mail               : johan.jacobs@valve.co.za

 

Structure Change

As part of our growth to ensure we improve operational support to our sales department and end users, Greg Woolfuth now hands over all of his Regional Manager responsibilities to Johan which will release him to focus his efforts nationally and drive operations to a higher level. Going forward Greg will be both Operations Director and Operations Manager.  This handover will take place during the remeinder of August 2019.

 

Greg Woolfuth

Operations Director / Manager

Mobile No         : 083 320 2549

E-mail               : greg.woolfuth@valve.co.za

 

V&A NOW WITH ADVANCED CONTROL VALVE SKILLS

Greg Woolfuth and RJ Ferreira recently attended a week long advanced control valve sizing and selection training course at ARCA Control Valves in Germany improving their skills significantly. ARCA now has 3 seperate factories in Germany with each one specialising in a different control valve range. Greg & RJ visited the factory that manufactures all the special designs and positioners as well as the factory that manufactures the high volume fast moving 1″ to 4″ Ecotrol® Globe Control Valve which can be assembled and despatched to you in a matter of days or weeks.

Advanced control valve training covered high pressure reduction valves for severe service as well as steam conditioning and desuperheaters. Inspection was also done on the oxygen cleaning facility.

The top pic is of ARCA’s ultra-modern head office and you can see them standing next to a 24″ Globe Control Valve.

Give one of them a call today!

ARCA – Full Steam Ahead

ARCA has delivered steam conditioning valves for the energy and process steam sector to a fertilizer plant in the Middle East. The entire project was handled as a turn-key project by a renowned Chinese plant manufacturer. The scope of delivery included four high pressure steam conditioning stations (Series 580) with nominal pressure rating PN 400 (nominal width between DN 100 and DN 250), two medium pressure steam conditioning stations (Series 518) and two desuperheaters of the ARTES Valve & Service GmbH, a member of the ARCA Flow Group. ARTES Valve & Service specialise in manufacturing control valves for the effective cooling of steam.

The provision of related spare parts for initial operations and two years of service have also been supplied, in order to guarantee smooth operation of the plant in the future.

To read more see https://valve.co.za/product/arca-500-prds-steam-conditioning-valve/

 

 

Zwick Triple Offset Valves New Company Video

For more than 30 years Zwick have been designing and manufacturing high standard triple offset valves. It is a family owned business that is still run by the Zwick family since it was founded. Zwick have state of the art production facilities in Germany where they have 5000 castings in stock ready for machining. The warehouse in Houston stocks 1000 completed triple offset valves ready for shipment at any time. There are thousands of Zwick Tri-Con valves in use in South Africa with companies like Sasol, Sappi, Mondi, Engen, Sapref and Eskom to name a few. There are more than 1000 pieces used at Eskom alone. Valve & Automation represent Zwick on an exclusive basis for Southern Africa. Watch the new video now.

Stafsjö introduce a new hydraulic cylinder to its modular actuator range

This hydraulic cylinder is supplied by the Swedish manufacturer Ceson. It is a 200 bar rated cylinder supplied with stroke length, piston rod and ISO 5210 attachment customized for Stafsjö’s knife gate valves. Any rebuild of existing Stafsjö valves can easily be performed in the field thanks to Stafsjö’s modular actuator concept.

The hydraulic cylinder can be supplied with Ø 32 mm up to 200 mm barrel with stroke lengths up to 1500 mm. It is coated in black RAL 9005 to fulfil the requirements of EN ISO 12944 class C3. It can operate in temperatures ranges from -20 °C to +80 °C.

Other colours, coating systems, materials and special editions on request. To learn more see https://valve.co.za/products/brand/stafsjo/

Stafsjö’s launches new FEPM seat for high temperatures and chemical services

Stafsjö have released their new rubber valve seat compound FEPM for knife gate valve series WB11, WB14 and specifically for the full stainless steel high performance WB14E. The new rubber compound is currently available for DN 80/3” – DN 300/12” except for DN 125/5”. 

The new FEPM seat material is an improved Viton/FKM based rubber compound that has superior function and strong resistance to high temperature steam and aggressive chemicals, both acids and bases. Pulp and paper and chemical industries are field of applications were the FEPM materials are well known and used on regular basis. FEPM rubber can be used as a direct replacement for the rubber trademark AFLAS which is a TFE/P FEPM material.

The seat is rated for max 180°C in continues service and short term peak up to 225°C. The compression set resistance at high temperatures is superior to other standard rubber materials, but it is limited in low temperature applications. Function tests shows that the FEPM material can give the sealing system considerably longer life time compared to standard rubber compounds. This makes the FEPM seat suitable for severe applications where you need a long-lasting performance and a tight shut-off. 

New guiding pad material to WB14E: PTFE
In parallel with introduction of the FEPM seat material we also introduce PTFE guiding pads to WB14E up to DN 300/12” to replace standard POM-C in applications where it is needed to fulfil FEPM temperature and chemical resistance. The guiding pads are located in the chest area to prevent galling and to support the gate at pressure loads. These can easily be replaced at any maintenance work as well. 

Contact one of our technical specialists today to see how we can help you extend the life of your knife gate valves, or download the WB14E brochure now.

STORAGETECH – BULK STORAGE TANK PROTECTION

With more than 30 years of experience in engineering and manufacturing of storage tank and pipeline equipment, Storagetech™ caters to a diverse range of of Internal Floating Roofs (IFRs)Flame Arresters & Storage Tank ValvesStorage Tank Equipment and Loading & Unloading Arm Systems for oil terminals and industrial plants. Manufacturing to international standards the Storagetech™ has exported to more than 60 countries worldwide and proved itself a global brand.

Storagetech™ applies an advanced quality system, which is accredited by ISO 9001:2000ISO 14001:2004 AND OHSAS 18001:1999 system and approved by TSEEx CertificateASME and CE/ATEX.

Storagetech is part of the Äager group based in Düsseldorf Germany and was founded in 1982. Their main 35,000m2 production facility located in Istanbul Turkey while they have branches in Istanbul Turkey, United Arab Emirates, Azerbaijan and Singapore.

Customers include Shell, OPET, BP, Total, Hess, Chevron, Abu Dhabi National Oil Companies, Qatar Petrol Companies, National Iraqi Oil Companies, Petronas, Petrofac, Schlumberger, Technicas Reunidas, Bechtel, L&T, Wood Group, Tekfen, Enka Six Construction, Alstom and many more.

Take a look at their latest company video now.

 

ARCA STEAM CONDITIONING VALVES

Steam Conditioning Valve Components tailored to meet any requirement:- 

Powerful actuator. Whether you want to use it for control or safety applications, the actuator for ARCA’s steam conditioning valves is designed with your plant in mind. This is made possible by our wide range of pneumatic, electric, and hydraulic actuators. The valve-closing force and stroking time of all actuators is sized according to your requirements.

Multi-functional positioner. The digital ARCAPRO® positioner allows the steam-conditioning valve to communicate with the controller or process control system via a multi-functional interface. The positioner is connected to the actuator either directly or using the NAMUR mounting method and ensures that the stroke feedback is always free from backlash for maximum precision control. The standard input is the standardized 4 to 20 mA analogue signal. HART®, Profibus®, and Foundation® fieldbus standards can also be used to establish a digital interface with bidirectional data exchange (including status messages). This means that the positioner can be parameterized in the field as well as remotely via the communication system. Optional accessories such as boosters, limit switches, and solenoid valves are available to customize the valve to suit your individual requirements.

Optimized static and dynamics sealing. ARCA have engineered a dynamic stem seal and static bonnet seal in the force bypass that are optimized in line with the pressure and temperature range of your application. The surface finish of the stem and the packing material are also taken into account here. The force bypass design used for the bonnet seal prevents assembly problems during service and maintenance. A self-sealing bonnet is used for high-pressure applications to ensure that the valve remains tight regardless of the torque applied to the bonnet screws. These design features also ensure that the valve seat and plug are not subjected to any lateral forces, thereby also minimizing internal leakage.

Versatile valve trims. These are the most crucial functional elements for controlling pressure and temperature. The perforated valve plug and seat ring are designed and manufactured to suit the prevailing flow conditions and the rangeability required. The type of water-injection selected is suited to the steam and cooling water temperature. For safety applications, a dirt strainer is inserted at the opening of the steam inlet. This prevents the ingress of contaminants and protects against defects. The patented retained seat ensures that maintenance is fast, simple, and cost-effective and does not require special tools.

To learn more go to   https://valve.co.za/product/arca-500-prds-steam-conditioning-valve/

STAFSJÖ KNIFE GATE VALVES USED WORLDWIDE TO PROTECT VALUABLE INSTALLATIONS FROM FIRES

Firefly, one of the world’s leading suppliers of spark detection and fire and dust explosion protection systems uses Stafsjö valves to protect installations worldwide.

 When it comes to industrial fire protection systems, reliability is essential. The system which is often on constant standby during long periods should be able to respond immediately and extinguish possible ignition sources to prevent fires and dust explosions. In the Firefly solution, Stafsjö’s valves have an important duty.

For more than 30 years, Firefly have been using Stafsjö’s valves in their fire protection systems. Stafsjö’s valves are robust, reliable, and deliver performance when required. It is a reliable product that provides the quality that our customers’ require. With a closed knife gate valve, fires and dust explosions can be prevented this therefore enhances levels of fire safety for our customers.

Stafsjö’s HG isolation valve has a through-going gate for reliable shut-off performance which is independent of pressure direction. Its ability to cut through static media columns also serve its purpose well. Superior flow characteristics enable it to act as a part of the pipe system without affecting the process flow. Stainless steel metal seats extend the service life and offers low friction to achieve ultra-fast isolation time. Sometimes the valve is also supported by a pressure tank to speed up the shut-off time.  To learn more go to https://valve.co.za/product/stafsjo-hl-and-hg-through-going/

 

If You Are Looking For BIG, Zwick Can Do It!

For more then 40 years Zwick have been leading the world in Triple Offset Valves. In South Africa it is no different. From 3″ (DN80) to the massive 88″ (DN2200), Valve & Automation together with Zwick can do them all.

Currently there are many hundeds of Zwick Triple Offset Valves installed throughout South Africa, in production plants owned by Sasol, Shell, Engen, Sappi and Mondi to name a few. Not to forget the more than 1,000 pieces installed at various Eskom Power Stations.

With repair & reconditioning facilities in both Vereeniging & Durban,  V&A can keep your valves running for many years bringing them back to new each time using original OEM spares. After reconditioning, we can also do the seat leakage tests, hydrostatic tests before they get returned to your plant. If you want us to fit actuators and calibrate the positioners and controls allowing you to witness the final tests before delivery to site, no problem.

With multiple factories in Germany and multiple warehouses in Germany and USA where short deliveries are managed as well as over 5,000 castings ready for machining are housed, V&A and Zwick meet all of your needs.

Remember, the Zwick Tri-Con valve is ZERO leakage, provides true cone in cone sealing, does not use pins to secure the disc to the shaft which means the disc is self-centering and ideal for applications where there are high temperatures or differential temperatures.

Give one of our technical specialists a call today to see how we can help you!

Zwick Triple Offset Valves for Molten Sulphur & Sulphur Tail Gas

Molten Sulphur or Sulphur Tail gas applications have many challenges. If you work with this media, please take time to read more.

Design engineers at Zwick in Germany have looked at solving on-going problems being experienced with valves on sulphur units.

Typical valve problems on large bore line sizes range from seizing of the packing to severe seat damage when valve need to be operated after long periods of time of inactivity. Valves should be specified as steam jacketed valves as this is a standard mandatory type of valve requirement.

Generally a standard valve may be suitable in an ideal line were there are never any shutdowns or upset conditions as once the valves body temperature has reached that of the hot sulphur or tail gas passing through it will not allow for any solidification, however in an upset condition were the valve body cools down with sulphur cooling also, then this will solidify in the bearing / shaft areas which will consequently generate a seizure of these elements.

Based on international experience, Zwick engineers recommend the use of steam jacketed valves as these would maintain the critical areas under a constant temperature, thus eliminating any potential seizure.

Zwick are capable of supplying valves in both wafer and double flanged style with steam jackets, and we can also apply a steam traced trim (stem and disc).

Zwick Tri-Con series valves come with bearing protectors, which reduce the ingress of the medium into the critical areas, which coupled with the bearing flush purge ports constitute a true cleansing and protection of these critical areas.

The following explanation highlights the technical differences between the Zwick Tri-Con valve and other manufacturers of valves ranging from double eccentric to unjacketed valves which will fail in this type of application.

The Zwick Tri-Con series valve is a specially designed process isolation, on/off and control valve, which has a wide range of application uses limited only by that of the actual materials used, in fact Zwick manufacture valves for applications which range from -196ºC up to +815ºC. Valves can be manufactured in any machinable form of alloy available on the market for specific client requirements.

The Zwick Tri-Con series valve is a triple offset valve with true cone in cone design which totally eliminates any rubbing of the seats, hence eliminates any wear and tear which would generate leakages across the seat, this is technically not possible for other typical high performance valves, which means it is limited to a double eccentric design, rubbing sealing in the last 15-18º which will generate leakage as the time goes by.

The other standard double eccentric are not designed for these severe applications therefore any attempt to use it for particular process applications may result in a problematic outcome.

Self Centering disc

With it’s unique self centering temperature compensating disc, the Zwick Tri-Con series construction guarantees the optimal position of the laminated seal against the seat. Jamming due to thermal expansion is therefore eliminated.

The torque transmission with keys

The disc is keyed to the shaft and not pinned, providing equal torque transmission and eliminating the danger of pins sheering off.

Ideal lamination and disc design

The strong disc with it’s elliptical supporting surface offers the best fixing of the lamination. The zero leakage is achieved by the special machining of thre lamination.

Supporting bearing bushing

The optimal position of the bearing reduces the bending of the shaft. This guarantees bi-directional tightness under maximum pressure.

General characteristics

  • Triple offset design
  • Metal seating
  • Zero leakage
  • Pressure classes
  • Full bi-directional shutoff tp API & DIN, ZERO Leakage
  • Temperature range -196ºC up to +815ºC
  • Size range 2” to 88” (DN50 to DN2200)
  • Friction free opening and closing
  • Vacuum tight
  • Laminated seal and seat made of stainless steel
  • Anti blow-out shaft to API 609
  • Steel casting, stainless steel and special alloys
  • Fire-safe acc. To BD 6755 and API 607 for both flow directions
  • Fugitive emission control acc. To “TA-Luft II”

To learn more visit the Zwick Tri-Jack page or download the flyer now.

ARCA – iNTEGREX Processing Machines Started Operation Successfully

During the last year Arca has upgraded its production in Tönisvorst with two new iNTEGREX processing machines. The 5-axis-machining centre Mazak INTEGREX i-400 – SmoothX 1500U, as well as the Mazak QUICK TURN 250MY SmoothG 1000U have been set up in the machine hall and successfully been put into operation. In January the planing for the new processing island, on which already the Mazak INTEGREX e-670 II has been started. The trio of new machines are designed in such a way, that the machines can support each other in a wide range of processing options and ensure shorter processing and lead times, as well as optimized process workflows.

Equipment that previously would have been produced on several machines, can now be completed on only one machine. Six employees were sent to Mazak for training and have put their skills to practical use in operating the machines.

The CAD/CAM connectivity as well as the complete infrastructure are implemented in a way that the new machining philosophy is reflected optimally in our processes from modelling up to the finished workpiece. With the new processing machines ARCA has taken its digitalisation to the next level. To learn more go to https://valve.co.za/products/brand/arca/

Arca Ecotrol® Control Valves for Cryogenic and Oxygen Service

Oxygen from Atmospheric Air

Control Valves for Cryogenic and Oxygen Service.

Technically, oxygen is produced from atmospheric air. During the complete cycle beginning with the production, the storage, the transportation, and finally the use of oxygen the gas passes different hazardous levels to material and to operation personnel. After the technical process the remaining oxygen is combined in oxides mostly as carbon dioxide and as steam. In the photosynthetic process of plants the oxides are transformed back into oxygen and the oxygen loop can start from the beginning.

Safety Standards

Even though safety standards in the gas processing industry are at a high level there are frequent accidents in the handling of oxygen. The existing safety regulations which are incorporated to the valve design and are applied during the manufacture, the assembly and the various tests, require an extremely reliable and skilled work force.

  • Safety Regulations and common rules, such as EIGA, Shell Engineering Practices and Air Liquide Standards require high alloy materials (Monel and Inconel) on the valve body and internals.
  • Material selection shall be strictly in accordance with IGC 13-02 „Oxygen Pipeline Systems“ in correspondence with the flow velocity
  • Supersonic flow must strictly be avoided

Typical Gases

Arca Ecotrol® Globe Control Valve for cryogenic gases like

Oxygen (O2) / Neon (Ne) / Nitrogen (N2) / Argon (Ar)

Arca Ecotrol® Control Valves for Oxygen

The Arca Ecotrol® Globe Control Valves are available in the following sizes, pressure classes and materials

Size Range

1” to 8” / 25mm to 200mm

Pressure Rating

ANSI 150 to 900 / PN 16 to PN 160

Materials

  • Valve body made of cast Monel 400 or Inconel 625
  • Trims made of Monel 400/500 or Inconel 625, on multistage trims kolsterized

High Pressure Oxygen

High Pressure Oxygen is used on various applications today:

  • Coal gasification plants
  • Coal-gas fired power plants (Shell and Krupp Koppers process)
  • H2/CO Plants (POX) by controlled burning of Natural Gas or Hydrocarbons

Production & Oxygen Cleaning

Control valves for Oxygen service

  • Must be free of dirt and grease under all circumstances. This requires a separate processing from other valves, in a room not connected to the factory.
  • After assembly and pressure and leakage testing, a reference leakage test with nitrogen is performed.
  • After this, the valve will be totally disassembled, cleaned in an ultrasonic bath and dried in a hot air furnace. The the valve will be reassembled in a separate fixture (only used on clean valves) with new gaskets and the reference measurement will be done again to verify correct assembly.

To learn more visit the Arca Ecotrol® page or download the Oxygen overview.

 

 

 

 

 

ARCA Valves receives prestigious award

For the year 2018 / 2019 ARCA has been awarded with the quality label “Innovative through Research “by the “Stifterverband für die Deutsche Wissenschaft“ (German Association for the Promotion of Science and Education). The award honours researching companies for taking responsibility for nation and society. With ARCA, research and development activities have a long tradition and are essential to stay innovative and be able to react to the continuous challenges of ever changing markets with new solutions.

To learn more on the ARCA range of products go to https://valve.co.za/products/brand/arca/

Zwick Valves – Expansion of factory facilities

Zwick Valves GmbH has recently increased its factory production capacity. It has added 2 500m2 to the existing area of approx. 20 000m2 at its headquarters and main factory in Ennepetal. The new space is being used to expand the production facilities, as well as for extra storage and additional testing capacity. This is the 6th expansion in the last decade.
This is a further step in line with the company strategic targets, “Made in Germany”, as well as a clear commitment to the current location and securing jobs in the region. To learn more about the Zwick range of valves go to https://valve.co.za/products/brand/zwick/ 

 

ARCA Anti-Surge Control Valves in Operation

Arca supplies its extensive range of valves to nearly all types of industry. An important part of the product range are valves for turbines and turbo compressors, especially anti- surge control valves. Arca manufactures its ECOTROL® series of valves Type 8C / 6N / 6H and 130, from DN50 / DN2“ to DN700 / DN28“ in pressure class PN10 / ANSI150 up to PN400 / ANSI2500.

Recently valves of a nominal width of 24“ have been delivered to several customers. In recent years the design of these valves has been further optimized in order to fulfil the requirements of the customer. Be it large valves for single-axle compressors or multistage high pressure valves for multistage gear box compressors, Arca have a valve for every application, including hot-gas compressors or cryogen plants, or even for acid gas and oxygen.

Arca not only manufacture all types of valves but also a wide range of pneumatic actuators for special requirements are being made. With extreme operating conditions the actuators of the series 811 / 812 / 814 and MA60 guarantee a steady control mode and, in case of an incident, move extremely fast into the safety position. By means of cleverly devised component parts, large valves can open fast regulated and on the other side close slow regulated, as appropriate to customer’s needs. A fast opening on a large valve is possible with an opening time of less than < 1 sec. The ECOTROL® valves with component parts that are suitable for assembly in exzone and in all climate zones. Special requirements are being placed on valves that are mounted in process gas plants where the process gas is used in food processing. To read more go to https://valve.co.za/product/arca-ecotrol-globe-control-valve/

ARCA – MAIN CONTROL VALVE VENDOR FOR BASF CHEMICALS

ARCA is now certified “Main Valve Vendor” of BASF Chemicals in Germany and one of only two global suppliers for automated process control valves.

The Main Valve Vendor Concept (MVV 3) is a selection process for suppliers developed by BASF Chemicals that is aimed at supplying standard valves for plant maintenance and projects with key suppliers.

Early in 2014 BASF started a concept for qualification of suppliers that has been divided into three phases and was decided using the criteria of quality, security and costs. The MVV 3 project was started in 2016, building on the already successful MVV 2 project, for standard manual valves and automated valves. The objective of the selection process included long time collaboration with suppliers, standardisation, planning reliability and global footprint all leading up to Total Cost of Ownership (TCO).

In future, small and medium-sized projects will be awarded directly to the MVV 3 suppliers without the need for tenders. For large projects the tender process will favour ARCA and one other control valve company both of whom are on the standard suppliers list.

With the qualification and acceptance to BASF Chemicals in Germany, ARCA once again proves its performance as a reliable control valve supplier. The award is sign of confidence that BASF places in ARCA. Visit ARCA control valves to find our more or contact one of our Technical Specialists who can assist you find a solution.

ARCA – Additive Manufacturing of Control Valve Components

Additive manufacturing, also known as 3D-printing, describes all production processes where the component produced is built up layer by layer from raw material (which can be a melt, a powder, a string or a wire). It is contrary to conventional production methods, where a cast or forged blank material is removed to get the desired component. The best known technique for additive manufacturing with metals is the selective laser melting (SLM), where metal powder is laid on in layers of typically 20-100 µm and is then melted by laser beams on those areas designed to become the product. Those areas will solidify to a compact mass with the properties of the base metal. Because production costs are about 70 times higher with this method than with conventional production methods, the additive manufacturing of larger components, as e.g. valve bodies, is still a dream of the future. The high specific costs limit use to relatively small components, where additive production can generate a measurable customer benefit. Especially the potential to produce inner contours with any shape and the direct production from CAD-data allowing individual solutions for applications where conventional constructions have reached their limits. Using the example of a multistage valve trim to prevent cavitation one recognizes easily that especially for these applications an additive produced throttling cartridge has several advantages as: a) The possibility of an individual sizing without significant extra costs, because the production can directly be transferred from the CAD-data b) The feature of building up inner contours allow a compact (one-piece) throttling cartridge c) The free arrangement of flow channels over the valve stroke which results in a more regular characteristic curve and better control d) The use of standard valve bodies even with more than six throttle stages; which results in comparable production costs for the complete valve.

Arca sees the next development step in throttling cartridges that are optimized for control valves with strong dependency of the differential pressure to the flow (and therewith the valve stroke). Such process conditions are typical for the control of feed water at spray-nozzles and steam conditioning. With smaller flow rate the entire pressure difference of the system lies at the control valve (with corresponding potential of cavitation), with huge flow rate at the nozzle. At the valve with full opening only a very small differential pressure and therewith no cavitation appears, however a rather large Kv -value is required. What could suggest itself more than to develop a throttling cartridge that holds in “lower” areas a high number of throttle levels and is in the higher area only single stage sized – optimized for a cavitation free control over the entire controlling range? Additive production makes (almost) everything possible! To learn more see https://valve.co.za/product/arca-ecotrol-globe-control-valve/

Arca quick delivery service. Control valves assembled in 48 hours.

Arca quick delivery service from Arca Control Valves Germany. Arca has a dedicated production line that builds control valves within 48 hours. The product range covers the Arca Ecotrol Globe Control valve from 1″ (DN25) to 4″ (DN100) from PN16-63 / ANSI150-600.

Download the Ecotrol Spect Sheet and see the items highlighted in blue that can be assembled within 48 hours Ex Works Germany and be shipped to South Africa within 2 weeks.

The Arca Ecotrol Globe Control Valve is a pressure control, pressure reducing and flow control valve that offers a wide range of innovative solutions designed to meet all your process control applications. These control valves are available with Class V or VI shutoff. It comes standard fitted with the Arcapro positioner for 4-20mA, HART and Profibus. Robust, high-precision valve trims are specially designed for the your specific process conditions of your plant. Our valve seats integrate the unique quick-exchange system and can be replaced without special tools.

Put us to the test and Contact Us Today!

Arca Control Valves New Company Video

Arca Control Valves in Germany is a family owned company now in its 3rd generation. Established more than 100 years ago, Arca now employs more than 500 hundred people in various countries. Arca has more than 100 patents registered showing that they lead the way in control valve technology. Arca and Valve & Automation have been partners in South Africa for more than 20 years. Take a look what Arca can do for you. Watch the new video now.

ARCA ECOTROL® 8C 4.0 – The Universal Process Control Valve

The ECOTROL® 8C Control Valve has proven itself in over 15 years of use in the process industry, whether in energy technology, in chemical and petrochemical processes or in water and environmental technology. With the unique clamping seat system that enables simple maintenance without special tools, the stainless steel stuffing box chamber – irrespective of the housing material – and the patented soft seal, the introduction of the ECOTROL® 8C control valve set new standards for industrial control valves. The associated actuator type 812 was also a trendsetting innovation with its innovative diaphragm clamping by secondary path of force, the direct attachment of ARCAPRO® positioners and the possibility of blanketing the spring chamber with instrument air (with air guidance through the actuator stem, i.e. without external piping).
Version W4 of the ECOTROL® 8C series, which resulted from a technical revision focused on product quality, flow capacity and life cycle costs, has been available since the beginning of 2015. It is characterized by the following technical improvements:
• All housings up to DN 100 (4”) in nominal pressure PN 16, PN 40 and ANSI Class 150 and 300 as well as the associated bonnets are manufactured in the standard materials 1.0619 (A216WCB) and 1.4408 (A351CF8M) as investment castings in the lost-wax process. This results in an improved surface finish. Beyond that, the wall thickness required for casting is thinner, especially with small nominal sizes, which leads to a considerable reduction in the weight of the valve.
• The standard material of stainless steel housings has been changed as a matter of principle to 1.4408 (A351CF8M); this enables the delivery of valves for the temperature range down to -196 °C at short notice.
• The trims have been optimised with regard to seat diameter, flow coefficient and characteristic; the valve plugs and stems are now manufactured from an inexpensive friction welding blank.
• The actuator yoke was changed from nodular cast iron GGG 40.3 to cast steel that is resistant to low temperatures. The actuator type 812 is thus usable in principle even where there are requirements for earthquake protection as well as at temperatures down to -40 °C.
In all of these technical changes the recognised technical advantages of the ECOTROL® 8C have been retained as a matter of principle and attention has been paid to ensuring extensive exchangeability of the usual spare and wearing parts.
ECOTROL® 8C valves remains a technically and economically impressive even after more than 15 years of production. To learn more 

ARCA AWARDED QUALITY LABEL “INNOVATIVE THROUGH RESEARCH”

For the year 2018 / 2019 Arca Control Valves was been awarded with the quality label „Innovative through Research“ by the „Stifterverband für die deutsche Wis-senschaft“ (German Association for the Promotion of Science and Education). The award honors researching companies for taking responsibility for nation and society. With Arca, continuing research and development activities have a long tradition. They are essential to stay innovative and be able to react to the continuous challenges of ever changing markets with new solutions. To find out more, download the magazine now.

For critical applications within the power industry you can rely on Westlock controls

Nations across the globe are struggling to meet the world’s growing power demand. The industry is constantly seeking ways to develop this precious resource faster, safer and more efficiently, with minimal impact on the environment.

Westlock’s experienced application teams deliver state-of-the-art solutions for our customers’ critical applications including high pressure and high temperature, severe service, isolation, over-pressure and control applications for actuated valves in:

Coal: controlling and monitoring valves to improve plant start up, performance and reliability for coal power stations around the world operating at temperatures as high as 720° C.

Natural Gas Combined Cycle: dedicated to optimizing and improving the reliability of our customers HRSG, Steam and Gas Turbine support systems.

Nuclear: optimizing the operation of valves on critical systems that serve this sophisticated, globalized market reliably regardless of code or reactor type.

Renewable Energies: whether solar, geothermal or biomass technologies.

Through the provision of robust, proven, integrated technologies, Westlock Controls’ products help customers across the power spectrum reduce downtime, optimize energy efficiency and produce safer working environments.

To learn more see https://valve.co.za/products/brand/westlock

V&A Appointed Exclusive Agents for Storagetech Pressure Vacuum Relief Valves and Flame Arrestors for Bulk Storage Tanks

To protect storage tanks during operating cycles, Storagetech have developed a full range of spring and weight-loaded pressure-vacuum relief valves (PVRValves), flames arrestors, gauge hatches and roof manholes. Replacing the open vents on a fixed roof vertical tank with a PVR Valve enables the internal tank pressure to remain equal to the external atmospheric pressure. This alone cuts the loss of valuable product to the atmosphere by 30% depending. These Pressure Vacuum Relief Valves  can be combined with a flame arrestor or have the discharged emission piped to a vapour collection tank or flared to atmosphere. Both are features that will enhance safety and improve the profitability of the storage terminal.

Since the company was founded in 1982, Storagetech has acquired extensive experience providing technically advanced emission control & safety equipment for bulk storage tanks, tanker vessels, and road tankers. World class companies like BP, Chevron, Petronas, Shell and Total to name a few use Storagetech Pressure Vacuum Relief Valves and Flame Arrestors to safeguard the integrrity of their  process plant and storage tanks. To find out more see https://valve.co.za/products/brand/storagetech/

ARCA: Comprehensive Solutions for all Processes of the Coal Gasification

Due to the availability of coal, coke and other refinery residues in almost all industrial and emerging countries, as well as the high efficiency and the excellent CO2 balance, the energy production in so called Integrated Gasification Combined Cycle (IGCC) power stations will in most countries show growth in the future.

In IGCC power stations, synthesis gas is burned in a gas turbine and the waste heat of the gas turbine can by way of heat reclamation be used for energy generation. During the gasification process the reaction parameters (medium property, pressure and temperature) make extremely high demands on all procedural components in the surroundings of the gasification reactor. The pre-product is extremely abrasive and has to be compressed to a reactor pressure of about 80 bar and then under this pressure be inserted into the reactor. The oxygen also has to be compressed to the reactor pressure and then (in most cases) preheated to 100-150°C to be injected through the control valves into the reactor.

With the expertise and technical skills of ARCA Regler GmbH in terms of development and production of control valves for abrasive media and for oxygen (including valves of nickel-base alloy like Monel and Inconel and also degreasing according to international approved standards), as well as steam and water valves for the whole circuit of the heat recovery, the ARCA Flow-Group offers comprehensive solutions for all processes of the coal gasification, the successive chemical processes and also for the energy generation from coal gas. To learn more

Stafsjö’s Double-acting pneumatic SC cylinder

Stafsjö’s standard double-acting pneumatic cylinder type SC is manufactured by Ebro Armaturen. It is a solid construction designed for tough knife gate applications available from 100 mm (4”) up to 320 mm (12.6”) bore diameter.

The SC cylinder has a hard anodized aluminium barrel with coated aluminium caps, hold together by stainless steel tie rods to enable a long-term linear operation independent of position. The SC also includes several internal and external precision supports to further guarantee the linear stroke. A piston rod wiper at the bottom end cap ensures that no material enters the cylinder.

The supply pressure for the cylinder should be max 10 bar and the compressed air should be dry or slightly oil misted. Temperature range for the actuator is -30 to +100 °C.

The SC cylinder is CE marked and also approved for use in EX areas according directive 2014/34/EU Group II category 2G/2D (zone 1 or 21).

To learn more see  https://valve.co.za/products/brand/stafsjo/ 

 

The Evolution of Partial Stroke Testing (PST): The Westlock Digital Control Transmitter

No operator ever wants to experience an Emergency Shutdown (ESD). Not only does that mean something went wrong on the line, but if the critical shutoff valves malfunction, it also could place personnel and the environment at risk, not to mention it could present a heavy financial burden on the company. The failure of these valves in crucial moments can be catastrophic, potentially rendering a Safety Instrumented System (SIS), put in place to reduce the possibility of an accident, useless.

Though static/dormant for long periods of time, these valves must work when the time comes and operators do not want to question the reliability of the installed control equipment. Therefore, it is important that some type of valve monitoring takes place within the processing plant on a consistent basis, and partial stroke testing (PST) has become the go-to method.

There are three PST techniques currently available, each offer different benefits, but all contribute to increased confidence in the equipment. Yet, which one is best for Emergency Shutdown? Thanks to continual advancement in smart technology, a new PST method has emerged as the most comprehensive solution for ESD applications. Representing an evolution in valve testing, digital control transmitters combine the features and benefits of other PST techniques to offer a broader diagnostic ability, an easier implementation, and a more cost-effective maintenance program. While not yet completely understood or adopted, their benefits offer solutions to key pain points in ESD which cannot truly be grasped without first reviewing PST in detail.

Partial Stroke Testing allows processing plants to test the installed base of valves without having to actually close the valve and shut down the plant, as is the case with Full Stroke Testing (FST). Through PST, the valve’s movement is checked via position control devices and only the most critical failure modes are tested.  During the PST, should a valve not move out of its end position within a specified period of time, the test is cancelled and an alarm is output, thus ensuring a blocked valve does not go unnoticed. Before PST was introduced, FST was the sole monitoring technique available. However, since this method required a complete plant shutdown, it was not only costly, but valves weren’t being tested as frequently, leading to more emergency shutdowns as a result of isolation valve failures. This testing method also did not offer any diagnostic insight into what was happening inside the valve, unlike the PST techniques of today. Now, certain PST methods, including those that utilize transmitters with pressure profiling, are able to provide valuable predictive maintenance data (i.e. the occurrence of valve friction) that can assist maintenance teams in prioritizing tasks and implementing corrective action before it becomes a problem. Thus, if repairs are needed, a scheduled, non-emergency shutdown can be implemented or the valve can be temporarily bypassed. By implementing a routine PST process, the SIS is protected and reliability of the isolation valve is improved, resulting in longer periods between required FSTs, and reduced maintenance costs.

For many years, there were two PST techniques available, each offering specific benefits for different uses.

Firstly, mechanical jammers are the simplest and least expensive option. They are highly reliable because of their ability to resist vibration, but they are also the most manual option, requiring the device be physically inserted into the valve assembly to prevent it from closing completely. This manual placement is subject to human error, placing the entire process in jeopardy of an accidental full stroke. This technique also poses a problem should an ESD occur during the PST process.

The second, more popular technique employs a modulating valve controller, or smart positioner. This is a more innovative technique that utilizes modern technology to automatically generate the PST function, either locally or remotely. Smart positioners monitor valve movement proportionally, measuring the speed of its response and its position. It is capable of cancelling the test should the response not occur within a specified period of time. They typically have a small flow factor making them appropriate for applications where valve movement is very small. That poses a problem in the ESD application because when a valve strokes during an emergency shutdown, it is generally required to move from a fully opened state to a fully closed one rather quickly. To compensate, solenoid valves (SOV) can be installed to achieve the required closing time, venting the actuator at a faster rate to close the valve. However, the SOV is not always tested during a positioner-based PST which poses the original problem of potential malfunction because problems are not identified before the ESD valve is needed. Additionally, smart positioners do have the ability to capture diagnostic data for use in maintenance, unlike mechanical jammers, although they will not capture the ESD event. To compensate for this, limit switches or additional transmitters can be utilized, thus requiring the installation of even more equipment.

The third and most comprehensive PST technique utilizes the solenoid valve. As the final element that is called upon to ensure the valve returns to a safe state, the SOV needed to be tested along with the valve/actuator combination which was not possible with the smart positioner-based PST method. When originally introduced to the industry, the SOV-based PST method involved an operator physically pressing and holding a switch to de-energize the SOV to relieve air from the actuator and allow for valve movement. It was the operator’s responsibility to visually monitor the movement of the valve and release the switch once the movement was confirmed. Though it allowed for SOV testing and did not require an expensive positioner, this labour-intensive technique had several drawbacks, including variability in operator decision making, the potential for holding the switch too long and causing a shutdown, and the risk of human error in the manual recording of the event. So over time the technique was improved upon, which brings us back to the digital control transmitter.

The digital control transmitter is an automated SOV-based PST technique that can functionally test the complete automated valve package, including the SOV as already described, either locally, remotely or on-schedule. Additionally, it has the ability to capture diagnostic information on the valves (including the ESD event), as well as the FST, solving problems posed by both mechanical jammers and discrete valve controllers (smart positioner). How it works: the digital control transmitter confirms the valve position prior to start and the SOV is de-energized through a solid state relay. The air is relieved from the actuator while the device’s electronics monitor the valve position changes. The SOV is re-energized at the correct moment to re-open the valve after a predetermined percentage open is achieved. This process reduces or eliminates the active labour requirement of the previous process, increases precision to the desired PST set point, decreases the potential for over travel and provides electronic reporting and feedback to control the system.

Digital control transmitters can be mounted to rotary and linear valves and are approved for use in hazardous areas. With only a few suppliers offering this solution, one in particular has been leading the way with advanced products that have expanded on these benefits and provide even more diagnostic features. Westlock Controls has an intelligent valve position transmitter called the Digital EPIC-1. This product offers discrete position control, as well as reliable, non-contact position feedback with digital communication via HART® protocol in an integrated package. Recently, the company launched its second generation Digital EPIC-2 product which introduces pressure profiling technology to monitor the supply and actuator pressure, confirming adequate supply pressure prior to initiating the PST. Unique in the added features it offers, the Digital EPIC-2 can record multiple variables, including the time and pressure required to break from the full open position, providing an early indication that there may be an issue with the valve/actuator integrity. The Digital EPIC-2 also has improved electronics and complies to the most current HART® 7 protocols.

The most interesting of the expanded features offered, and an approach unique to the Digital EPIC-2, is the ability to record valve signatures before and while the valve is functioning in the process line. Users can review maintenance and baseline signatures on their host system via DD/DTM technology to make determinations on valve health and schedule maintenance accordingly. Integrator and installation signatures are also available. When the valve is tested at an assembly shop prior to going on site at a plant, the integrator signature would be generated to ensure the whole package was tested and functioning when the digital control transmitter was integrated with the valve and actuator at the distributor location. The final installation signature is generated while installing the integrated valve package in line, assuring traceability of the entirety of the valve package commissioning process. To summarize, the digital controls transmitter is designed to combine continuous monitoring of valve travel with other valve control functions to keep the operator continuously informed. With more advanced product offerings, the level of diagnostics that can be captured has been elevated, enabling plant operators to make better assumptions and informed decisions regarding their ESD maintenance programs. Plant operators who have experienced problems with PST in the past, or who have not implemented it for various reasons will find digital control transmitters to be an effective and easy implementation compared to other techniques.

Being able to predict maintenance needs before they are required can save costs and enable plant operators to implement more efficient, proactive maintenance programs as opposed to reactive ones. To learn more see https://valve.co.za/products/brand/westlock

 

Stafsjö introduce LINAK electric actuator

Linak’s electric actuator is a compact maintenance free unit for on/off operations with a speed 7-11 mm/sec. It is available as standard in a 24 V DC version but it can also work on 230 V AC or 120 V AC if it is supplied with a control unit/transformer. The actuator unit features a solid stainless steel structure holding the actuator in exactly the correct position during operation. It can be supplied on Stafsjö’s  WB11, WB14, WB14E and MV knife gate valves from DN 50 (2”) up to DN 300 (12”).

Control units
The Linak actuator can be supplied with three different control units/transformers, all three can either be operated manually on the unit or remote operated via a cable of which two are available with push buttons for open/stop/close. An external battery back-up WCU-UPS can be connected to the WCU to ensure the valve unit is fully operational in case of a power failure. To learn more see https://valve.co.za/product/stafsjo-linak-electric-actuators/

 

Final Inspection In Spain For Major Refinery Order

Final inspection in Spain for major refinery in South Africa being done by Greg Woolfuth (Operations Director) and Gareth Taylor (Sales Manager). The initial shipment forms part of the 63 DBB Expanding Plug Valves for a major project. V&A’s management decided to do final inspection in Spain  due to the importance of the client and the criticality of the project. These DBB Exoanding Plug Vlves are used for fuel management , tank storage, bulk loading for ships, road and rail tankers, multi-product manifolds, metering stations and aviation & marine fueling stations. Greg and Gareth can be seen working with the VE production Manager and QC manager. Gate and ball valves have an inherent seat seal abrasion which shortens the ability to provide tight shutoff. The wedge and seat rings in a gate valve or ball and seats in a ball valve rub against each other with each valve operation or cycle reducing the ability to seal over time. When the seats and seals are damaged you will get contamination and product loss. To learn more, visit the product page https://valve.co.za/product/ve-double-block-bleed-expanding-plug-valves/

ARCA ECOTROL® DN 700 (28”) optimised for use as an anti-surge valve

ARCA DN700
ARCA DN 700

ARCA rounds off the proven series of ECOTROL® control valves at the high end with the new development of the nominal size DN 700 (28”). This valve has been specially optimised for use as an anti-surge valve on turbocompressors, but can also be used for all control applications involving liquid and gaseous media.
The requirement profile for the new development was:
• High flow coefficient KVS, which usually well exceeds the delivery capacity of the turbocompressor. The quantities of gas trapped inside the pipelines and heat ex-changers can therefore also be relaxed in a very short space of time upon safety shutdown of the compressor.
• Face to face dimension according to the specifications of EN 558.
• Mechanical resistance to the energy converted at the anti-surge valve and to mechanical forces due to pressure fluctuations or unfavourable pipeline layouts.
• Favourable acoustic characteristic values.
• Short actuating times – usually considerably less than 2 seconds for the complete 0 – 100% valve opening.
The overall length in accordance with EN 558 represents a particular constructive challenge in the case of globe style control valves, especially with large nominal sizes, since the ratio of seat diameter (ideally the same as the nominal size of the valve) to the overall length becomes increasingly unfavourable the larger the nominal size becomes. For this reason the parametric modelling technique using an upfront CAE tool was applied for the first time for the fluidic optimisation of the housing shape.
In this development process the component to be developed is defined (apart from fixed boundary conditions such as the process connections, the wall thicknesses and the trim) by a variable, parameter-controlled geometry. Beyond that, with reference to the target market as an anti-surge valve, the relaxation of an ideal gas with a pressure ratio x = (p1-p2)/p1 = 0.7 and the flow direction ‘flow to open’ were specified. In constant alternation between variation of the geometry and evaluation of the results (in the case of the valve housing the flow coefficient determined by means of CFD), the system converged after more than 60 variants to an optimum solution with a 25% higher coefficient of flow (in comparison with a conventional design).
In combination with the associated spring-return pneumatic piston actuator, which can be operated in both single-action mode and (for significant improvement of the control dynamics while maintaining a defined safety position in case of a failure of signals or power) double-action mode, this valve offers a technically and economically ideal solution for many applications. To learn more.

 

SCHROEDER SHP – A VALVE FOR HIGH PRESSURES AND ALL LOAD CONDITIONS

Schroeder Valves presented their latest innovation at ACHEMA: the Schroeder High Pressure Valve SHP. This automatic re-circulation valve was developed for high and extremely high pressures and also works reliably under highly fluctuating load conditions and long periods of operation under partial load conditions. This is achieved using a special fully automatic minimum flow control system that ensures that flow never falls below the required minimum specified by the pump. With this innovation, the specialist in protective pump fittings is responding to the requirements of its customers, primarily from the field of power plant and plant construction and the offshore industry.

The SHP builds on existing Schroeder Valve technology. The company already has years of operational experience with almost all of the effective principles and assemblies used. As such the SHP can be considered ‘Proven Equipment’. The individual system components have simply been modified and innovatively combined so that they enhance the dependable and low-wear area of application of the existing technology to meet the increased requirements. Thus, the new SHP-series automatic re-circulation valve enables and promotes the energy-efficient operation of modern power plant facilities.

The SHP takes the general development of higher pressures and temperatures and the increased energy-efficiency requirements into account, the changing way in which plants work was also considered in the development of the SHP. Special load sequence power plants, such as modern combined cycle power plants and coal-fired power plants, are operated at partial load for a large proportion of their operating time, on account of the increasing high proportion of regenerative energy generation and highly fluctuating load conditions.

Each Schroeder Valve undergoes a 100% pressure and functionality test prior to delivery. To ensure this with the SHP, the company is currently adding to their flow test centre a test stand for pressures up to 400 bar.

Read more at https://valve.co.za/product/schroeder-shp-eskom-power-generation-leak-off-valve/

Arca Series 190 – Forged Steel for your Safety

ARCA Regler completes the product range of control and shut-off valves for the steam turbine periphery and other applications with the new 190 series. Especially designed to meet high pressure and extreme temperature demands.

Due to the rapidly increasing technology requirements especially in power plants with higher steam or condensate temperatures as well as an increasing number of regular temperature changes, valves in such service normally suffer high stress. Inappropriate design or incorrect material selection, especially on casting components, could lead to early failure of the valves with impact to the productivity of the whole plant.

For this reason, when designing the new 190 series, the pressure containing parts (valve housing and bonnet) have been selected to be dye-forged parts. This manufacturing process guarantees a very homogeneous material structure without any discontinuities. Such microscopic defects, which are very difficult to prevent and to evaluate especially on cast materials, may lead to incipient cracks under hard mechanical or thermal alternating load and with this to early failure of the valve.

Additionally, most advanced CDF-technology was used to optimize the design of the valve body to avoid tension peaks resulting from sudden temperature changes.

The valve trims are correlating to the well-proven ECOTROL® – system:

  • Easy maintenance by exchangeable, clamped seat ring; means no seat thread requiring special tools.
  • Parabolic or perforated plugs in a wide range of rated flow coefficients; with equal-percentage or linear characteristic
  • Seat retainer optional in low-noise design
  • Metal seated, seat leakage either FIV Class IV or Class V

The valves are delivered with butt weld ends per EN 12627 or ASME B16.25; with the pipe outside diameter from 33,7 mm up to maximum 76,1 mm. Optionally, socket weld end or threaded connections are available.

The 190 series product scope are globe and angle style valves in standard materials as follows:

  • 0460 / A105
  • 7383 / A182F22 CL.3
  • 4903 / A182F91

Each of the materials has double-certification to EN and ANSI Standard, this means that valve housings from stock can be delivered into PED-range (up to PN 400) as well as into ASME/ANSI range (up to Class 2500; optionally available as “special class” valves with extended pressure/temperature range).

With this, a wide application range and a high availability can be guaranteed.

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RICHTER EXTENDS VALVE RANGE WITH STAINLESS STEEL BODY VALVES

Richter Stainless Steel Body Valve

RICHTER EXTENDS VALVE RANGE WITH STAINLESS STEEL BODY VALVES

Richter Chemie-Technik GmbH, a global leader in PFA lined pump and valve solutions, is expanding its range by introducing its ball- and diaphragm valves with a stainless steel body.

In production of food, pharmaceuticals and biotechnology products, cleanliness and sterility are critical. It starts with the production plant and ends with the final product which eventually will enter the human body. Hence, cleanliness throughout the production process is extremely important.

Typical painted cast iron valves will release paint chips which can enter the piping system with periodic maintenance procedures. Potential paint residues in the medium can be avoided by using high grade stainless steel (1.4408) eliminating the need to paint or coat the body to prevent corrosion. Stainless steel valves allows for fast, easy and thorough cleaning.

Our new series MV-S/F, KN-S/F and KNA-S/F with stainless steel bodies are based on valves which are well established in the chemical industry and have been continuously optimized for more than 30 years. The KN-S/F and KNA-S/F valves feature Richter’s Labyrinth seal and ENVIPACK stem seal technology, which adds to the total concept of a robust design combined with great performance. The bodies are made of precision cast stainless steel and available up to a size of DN 80.

Some key features of the new stainless steel body valves:

  • high resistance to corrosive environments
  • robust and proven technology
  • reduced contamination risk
  • low maintenance costs

In conclusion, PFA lined stainless steel valves fit perfectly in highly corrosive atmospheres and clean-room environments. Richter’s stainless steel valve series minimize the risk of contamination in the final product and contribute to a safe and reliable production process. /products/brand/richter

Arca Multi-Stage Trim for Blowdown of Fluids containing Solid Matters

The Arca Multi stage angle style control valve type 350 and 380 are proven under critical process conditions for a long time. If used in steam or process gas applications at high pressure and temperature, in cavitation-free relaxation of liquids at high pressure differential or in handling of forces fluids with high solid contents; the modular system of valve housings, bonnet and trim styles, in combination with a large range of materials, always offer an ideal solution.

The combination of high pressure ratio and solid-containing fluids is one of the most critical challenges for sizing, selection and design of a control valve.

Due to the high pressure ration multi-stage valves indispensable to avoid severe cavitation damages; however as soon as the fluid contains solid particles besides the normal fluid-dynamic sizing (determination of the number of throttling stages and their individual flow coefficient), the grain size of the particles has to be taken into account. The cross-section area of each flow channel in the valve must be that size and shape, which allow all particles in the fluid (assumed to be of spherical shape) to pass.

Since the cross section area if each throttling stage is explicit defined by the flow coefficient calculated form the fluid-dynamic valve sizing, only the shape of the flow channel remains to optimize.

It is obvious, that a circular shape is the optimum with regard to the permeability of spherical particles. The new-developed multistage trim MS4, which has only one flow channel each stage, milled as a spherical calotte into a rigid, multiple guided control rod, approximates this ideal shape in ideally way and is superior to any multistage parabolic plug in this point of view.

Another special feature of this trim style is the protection of the seating surface (which is the most sensible area in terms of erosion) by overstroke of the valve. With this, the control stages of the valve will open only as soon as a low pressure differential and with this a low small flow velocity at the seating surface is maintained.

The rigid multiple guidance of the control rod is an effective prevention of the valve against mechanical vibrations and the resulting wear, even at extremely high pressure differentials.

The multi stage angle style control valve Series 350 and 380 are available in sizes up to 10” (DN 250) and ratings up to Class 2500 (PN 400). Depending on the process conditions, MS4 trims can be delivered in valve sizes up to 4” (DN 100).

Contact one of our technical specialists today for a quote or download the brochure to learn more!

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