All posts by Wyatt Link

Consolidated 1900 Series Restricted Lift Option*

The Consolidated 1900 Series Restricted Lift Option*

Do you have pressure relief valves with inlet pressure losses greater than 3% of the valve set pressure? Do you have over sized pressure relief valves causing valve chatter? Did you know a restricted lift pressure relief valve could solve these common problems?

API 526 Table 1 shows a 21% to 78% increase in effective orifice area from one selected orifice to the next lettered orifice. In some applications, the user may require an orifice somewhere in between so that the resulting rated capacity is lower. This reduction in rated capacity can be achieved by restricting the lift. A restricted lift pressure relief valve has a reduced flow area (reduced effective orifice area), resulting in a lower rated capacity for the valve. A lower rated capacity, based on the reduced lift, will lower the inlet and outlet piping pressure losses and reduce the acoustic effects. API 520 Part 2, Sixth Edition, paragraph 7.3.7.5 also recommends restricting the valve lift to address high inlet pressure losses.

Consolidated offers the 1900 Series API 526 pressure relief valve with a restricted lift option for orifices F-W under National Board capacity certification number 18223. This certification was granted by compliance to ASME B&PVC Section VIII, paragraph UG-131(e)(1). This option is available for all compressible media (gases and steam) applications for both new valves and repair valves.

ASME B&PVC Section VIII, paragraph UG-136(a)(11) gives the requirements that must be met for restricted lift applications which states valves shall not have their lifts restricted to a value less than 30% of full rated lift, or 0.080 in. (2 mm). Paragraph UG-133(h) states that when sizing and selecting valves, the restricted lift nameplate capacity shall be determined by multiplying the capacity at full rated lift as defines in UG-131(e)(3) by the ratio of the restricted lift to the full rated lift. Paragraph UG-136(c)(4)(b)(5) gives the requirements that an ASME Assembler must meet to supply restricted lift valves.

A VR stamp holder is not required by NB-23 (NBIC Part 3) to have ASME restricted lift capacity certification when performing lift restriction as part of a repair.

The nameplate on restricted lift relief devices shall be stamped to identify the reduced lift value and the rated capacity based on that reduced lift value.Restricted lift pressure relief valves may be specified by providing the manufacturer with a required restricted capacity. The manufacturer shall determine the lift that will provide a restricted rated capacity that meets the required capacity. Prior to making a final selection the purchaser shall confirm that the restricted lift relief device meets the design requirements. Note that valves restricted under a VR repair will have the rated restricted capacity and the restricted lift value listed on the repair nameplate.

SRVSpeQ has the restricted lift option included and requires the percentage restriction to be inputted. The valve configuration code will have an “RL” included at the end.
Lift restriction is accomplished by installing a limit washer between the guide and disc holder as shown in the figure. The limit washer is cut to the appropriate length based on the lift required.
1900-cutaway

Contact Setpoint Integrated Solutions,   1-800-256-7373 for all of your relief valve needs from Service to New Assembly.

*Adapted from Matt E Byers, Sr. Product Manager,                                                               Consolidated Valves, Baker Hughes, a GE company

Setpoint Integrated Solutions Expands Territory Agreement with Continental Disc Corporation, covering the Texas Gulf Coast

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Setpoint Integrated Solutions Expands Territory Agreement with Continental Disc Corporation, Covering the Texas Gulf Coast

FOR IMMEDIATE RELEASE

Setpoint Integrated Solutions expands territory agreement with Continental Disc Corporation (CDC). Click here for PDF.

Baton Rouge, LA (Feb. 19, 2018) – Setpoint Integrated Solutions (Setpoint I.S.) is pleased to announce that effective midnight Feb. 19 , 2018 Setpoint I.S. will acquire the sole exclusive Representative contract for Continental Rupture Discs for the Texas Gulf Coast Region. These offices consist of the Setpoint I.S. locations in Port Arthur, La Porte, Richwood, and Corpus Christi TX. Setpoint IS has and continues to be a value added business partner for the CDC and Groth product lines in the North TX ( Kilgore, TX ), Louisiana, Arkansas, Western TN and Mississippi Territories. Setpoint Integrated Solutions brings a vast array of both commercial and technical support.

“The addition of the Texas Gulf Coast Region to our existing exclusive distribution territory of Continental Disc gives us the ability to serve our customers across our entire footprint with a top-tier brand. Continental Disc Corporation has been an excellent OEM partner and we look forward to continuing to meet end-user needs together. ” said Jeff Kelley , Vice President of Sales and Marketing for Setpoint Integrated Solutions.

About Continental Disc Corporation

Established in 1965, Continental Disc Corporation is a leading manufacturer of rupture disc devices for a variety of process industries, including chemical, petrochemical, petroleum refining, pharmaceutical, food and beverage, aerospace, industrial gases, transportation, and other markets worldwide.

 

About Setpoint Integrated Solutions

Setpoint Integrated Solutions is the leader in the process control industry with 13 facilities across the Gulf Coast. Supporting the Power, Refining, and Chemical Industries with best in class valve repair services, delivering process solutions for control, relief, and automated valve requirements, along with industrial equipment including liquid level measurement, pressure gauges, PLC’s and more. Setpoint Integrated Solutions, headquartered in Baton Rouge, La., is a subsidiary of Pon Holdings B.V. of the Netherlands. Pon is an international trading and service organization with a workforce of 14,000 people spread over 450 locations in 32 countries. For more information, please visit www.setpointis.com and www.pon.com/en .

CONTACT:

Wyatt Link, Marketing Specialist Setpoint Integrated Solutions Phone: (225)-612-1167

wlink@SetpointIS.com

Setpoint Integrated Solutions Announces Jeff Birch as President & CEO

Setpoint Integrated Solutions Announces Jeff Birch as President & CEO

FOR IMMEDIATE RELEASE

 

Setpoint Integrated Solutions Announces Jeff Birch as President & CEO

 

Baton Rouge, LA (December 18, 2017) – Setpoint Integrated Solutions is pleased to announce today that Jeff Birch has been promoted to the position of President & CEO of Setpoint Integrated Solutions from his current role as Chief Operating Officer. Jeff has been with Setpoint Integrated Solutions for approximately 1.5 years.  During this time he has lead and contributed significantly to business improvements while also serving as the company’s CFO.  In his capacity as President and CEO, Jeff will be responsible for the operations, financial results, and strategic vision of the company moving forward.

 

The company has made a number of management and organizational changes over the last two years.  This represents the final significant change for Setpoint Integrated Solutions as part of that transition.  “We are very well positioned with a great team, strong OEM partners, and outstanding customer relationships as Setpoint Integrated Solutions enters 2018 and beyond”, said Jeff Birch when asked about his outlook on the company’s future.

 

Prior to joining the Setpoint Integrated Solutions team, Jeff was Vice President of Commercial Finance for the
Dr Pepper Snapple Group where he was based out of Northlake, Illinois.  Jeff earned a B.S. in Business Administration from the University of Louisiana at Lafayette, is a licensed C.P.A., and has a Master of Business Administration (MBA) from Northwestern University’s Kellogg School of Management.

 

Jeff and his wife Mary have four children. Jeff and Mary’s son (28) is active duty Navy based in San Diego. Their oldest daughter (23) is a military spouse currently stationed at Fort Hood near Killeen Texas.  They also have twin daughters (17) finishing the 12th grade. In their spare time Jeff and Mary enjoy traveling, playing tennis, cooking, and spending time with friends and family.

 

Setpoint Integrated Solutions is the leader in the process control industry with 13 facilities across the Gulf Coast. Supporting the Power, Refining, and Chemical Industries with best in class valve repair services, delivering process solutions for control, relief, and automated valve requirements, along with industrial equipment including liquid level measurement, pressure gauges, PLC’s and more. Setpoint Integrated Solutions, headquartered in Baton Rouge, La., is a subsidiary of Pon Holdings B.V. of the Netherlands. Pon is an international trading and service organization with a workforce of 14,000 people spread over 450 locations in 32 countries. For more information, please visit www.setpointis.com and www.pon.com/en .

PDF Found Here:  Setpoint-IS-Jeff-Birch-CEO-Announcement

CONTACT:

Wyatt Link, Marketing Specialist

Setpoint Integrated Solutions Phone: (225)-916-7893

wlink@SetpointIS.com

What Are Common Severe Service Applications

What Are Common Severe Service Applications?

Many process applications require specific materials and characteristics to meet industry standards for Severe Service. In this post we will review common severe service applications*.

 

Severe Service may cause corrosion

ASME’s Category M Service Dangerous fluid service is defined in ASME B31.3, Process Piping and is called Category M Service.

  •   A fluid service in which the potential for personal exposure is judged to be significant and in which a single exposure to a very small quantity of toxic fluid, caused by leakage, could produce irreversible harm to persons on breathing or bodily contact, even when prompt restorative measures are taken.

There are also other interpretations, as some end-users define dangerous fluids as:

  •  Toxic materials such as:
    • Phenol, Hydrogen Sulfide and Chlorine
  • Highly corrosive materials such as acids and caustic
    • Ex. HF Alkylation service is considered a critical service. It is an acid that vaporizes at 67 degrees F and is very corrosive. One drop can eat through your skin and the vapors will destroy your lungs.
  • Flammable materials, including light hydrocarbons
  • Boiler feed-water and steam requiring class 300 ratings and higher
  • Oxygen in concentrations greater than 35%

Other factors determining critical service are difficulty in the sealability of some medias, as well as high-temperature applications.  Includes mining and slurries  Very high temperature media are also considered critical service applications. Flue gas or catalyst injection.

Some common critical service applications:

  • Application: Nuclear                       Why Critical Service?: Oxygen
  • Application: Hydrogen                    Why Critical Service?: Highly Corrosive
  • Application: Hydrogen Sulfide     Why Critical Service? : Emergency Shutdown
  • Application: Chlorine                       Why Critical Service?: Flammable Fluids

Nuclear Applications

Nuclear electric generation plants are considered a critical service application due to the risk of equipment failure that could lead to exposure from radiation escaping containment. This application has very strict valve standards, codes and guidelines. Such as:

  • Near perfect casting requirements
  • Extremely tight quality requirements for nuclear valve manufacturers
  • Repair requiring ASME certification N – Stamp

Hydrogen Applications

Maintaining containment of gases, such as hydrogen, has an impact on materials and safety to keep personnel safe.

  • Very small molecule size of hydrogen requires forgings or high quality castings
  • Hydogren gas is highly inflammable
  • Hydrogren corrosion can be an issue
  • Governed by ASME B31.12-2008.

Hydrogen Sulfide Applications

Sour gas, or hydrogen sulfide is another application that can be hazardous to your health in certain concentrations. This sour gas can be found in some crude oils, from the well through the refining stages.

  • Prolonged low-level exposure destroys sense of smell
  • High ppm concentrations have no odor
  • Levels about 100 ppm are dangerous to life and health
  • H2S is highly corrosive
  • Valve Material specifications are covered by NACE international standards
    • MRO 175 Upstream applications
    • MRO 103 Downstream Refining applications

Chlorine Applications

Chlorine is another corrosive application where materials and proper equipment are crucial for public safety.

  • Lethal in concentrations of 35-50 ppm
  • Chlorine Institute issues guidelines for valves in chlorine service including those used on railroad tank cars

Oxygen Applications

Oxygen in itself is not dangerous, but when in service with other flammable material it can become dangerous.

  • Supports combustion
  • Makes any flammable material burn intensely
    • Can cause combustion hot enough to melt metals
  • Valves in Oxygen service must be completely free of all oils and grease
  • Oxygen Service Standards and Specifications are provided by:
    • Compressed Gas Association (CGA)
    • National Fire Protection Association (NFPA)
    • ASTM International

Highly Corrosive Media Applications

Primarily acids and caustics,  highly corrosive media presents its own challenges within applications. If the wrong material is chosen for corrosive service, some corrosives can eat though the base metal in a matter of hours. Therefore, proper material selection throughout the entire assembly is key. Valve Trims are often more susceptible to corrosion with the addition of velocity-based erosion.

Emergency Shutdown Valves (ESV)  or Emergency Isolation Valves (EIV)

Many critical pant applications utilize ESV or EIV valves. These valves must always work when required, and are usually a block valve that can be closed either by hand or automated.  ESVs are a requirement at all intervals in flammable service transport pipelines.

Flammable Fluid Applications 

All flammable fluids are normally considered a critical service applications. All hydrocarbons are flammable fluids. As a result the most common concern is leakage pasted a closed valve, sometimes do to corrosion or erosion. Research into flammable fluid control has led the way fro new valve designs.

With a variety of different packages to choose from, Setpoint Integrated Solutions has the appropriate specifications to meet your needs. Contact us today

*This post was adapted from content created by VMA at their Valve Basics Course, found here

What are the Characteristics of High Performance Butterfly Valves and Triple Offset Butterfly Valves?

What are the Characteristics of High Performance Butterfly Valves and Triple Offset Butterfly Valves ?

What Are the Characteristics of High Performance Butterfly  Valves and Triple Offset Butterfly Valves?*

Continuing to expound on the previous post on Resillient Seated Butterfly Valves ,this post will focus on the characteristics of  Double Offset , also called High Performance Butterfly Valves, and Triple Offset Butterfly Valves.

What is a High Performance or Double Offset Butterfly Valve?

High Performance Butterfly Valves use a disc offset from the seat center, hence the name Double Offset.

In this configuration, the disc is eccentric, or offset, from the valve seat. As the disc starts to rotate, it moves away from the seat instead of across it. This design actually uses the line pressure to help give it its seal. This feature allows the use of offset butterfly valves in high‐pressure applications such as ethanol or HVAC. It generally uses PTFE or plastic as its seat material, but metal seats are also available to meet fire‐testing specifications like API 607.

Offset Disc Butterfly Valves are comprised of the following components:

  • Body
  • Retainer Plate
  • Seat
  • Disc
  • Stem
  • Stem Seals

Standard double offset butterfly valves come with a polymer seat, usually PTFE, with a metal backup for fire safety. Metal‐to‐metal seats are also available and may provide a higher sealing quality, and allow slightly higher temperatures.

What is a Triple Offset Valve (TOV) ?

A triple offset valve is a torque‐seated valve. In addition to the standard components, the TOV has three offsets. Seats are made of a laminate of metal and graphite and are commonly field replaceable. This valve does not act like a normal butterfly valve that is seated by positioning the disc using a lever, gear or body stop. TOVs are similar to globe valves in that the disc acts like a cone being torqued into a circle seat. The only way to get a bubble‐tight zero leakage seal with a metal seat is to put a cone into a circle. Triple offset valves can be lug, wafer, flanged and butt‐weld. Class rated valves are available from various manufacturers and are manufactured in sizes up to 160 inches. TOVs are adaptable to a wide range of temperatures, from ‐420 to 1200 degrees F.

Because a triple offset valve has three offsets in the stem/disc alignment, its disc rotates 90 degrees with the last +/‐ 1 degree being a straightforward movement. The body seat of the valve is not a perfect cone; rather, it is “offset” and machined at an angle so the disc will match up with no rub when seating. A Stellite overlay ensures a hard seating surface. By tightening the handwheel the valve seats tighter into the seat, typically something only possible with gears. Unlike a gate, ball or high‐pressure butterfly valve, there is no drag across the seat when the disc contacts the seat.

As viewed from the top, the first offset is accomplished by positioning the stem off center to or behind the disc seating face. The second offset moves the stem off centerline of the pipe or valve opening. The third and final offset is the seat cone angle, which is machined into the valve body. When the valve disc is rotated there is no rubbing across the seat. These three offsets enable the TOV to accomplish zero leakage in a metal‐seated valve.

  • Main applications for TOVs
  •  Steam-distributed (600# & below)
  • Universities
  •  Hospitals
  •  Large buildings
  • Government facilities
  • Steam production plants
  • De-icing/heating for plants
  •  Petrochemicals
  • Coking
  •  Reformers
  • Tank switching
  • Ethylene
  • Butadiene
  • Isocyanates – plastics
  • Tank and terminal
  • Long pattern or gate valve replacement
  • Storage of hydrocarbons and chemicals
  • Upstream production
  • Process equipment
  • Separation
  • Switching
  • Floating production platforms
  • Manifolds
  • Slurry-tar sands

Setpoint Integrated Solutions offers a variety of high performance and triple offset butterfly valves that will suit any application. We are proud to partner with Flowserve Durco and Triac brands. Contact us today to find out what configuration works best for you.

*This post was adapted from content created by VMA at their Valve Basics Course, found here.

What are the Characteristics of a Quarter-Turn Isolation Butterfly Valve?

Setpoint Baton Rouge, LA - Resilient Seated Butterfly Valves

What are the Characteristics of Quarter-Turn Isolation Butterfly Valves?

Continuing with the previous posts regarding Quarter-Turn Isolation Valves with a post about the characteristics of Butterfly Valves.  Like the Plug and Ball, the Butterfly Valve  saves weight and is faster to open and close, but it also saves space. * This article will focus on Resilient Seated design. There are also Double Offset and Triple Offset Butterfly Valves, which will be explored in a forthcoming post.

Butterfly Valves are designed so that the fluid is controlled by a disc, rather than a plug or ball, which helps save space.  It can have a resilient seating design. This design incorporates a disc that is held in the center of the valve and rotates to control product flow. The disc is always in the media stream with minimal flow restriction. Resilient seated butterfly valves are not ANSI‐rated but fit between ANSI Class 125 & Class 150 flanges.

Most butterfly valves use the same basic stem configuration as a trunnion‐mounted ball valve with a stem on the top and bottom. However, in this case the stem is mainly incorporated to balance the disc. Many different types of seat materials are available, including Buna (NBR), EPDM, Viton (FKM), PTFE, natural rubber or neoprene.

The seat shown above is a cartridge type seat; it has a phenolic backing ring with the elastomeric seating material molded to it. Other types of seats are booted and molded.
Both the cartridge and booted type seats can be replaced along with other critical parts.
Elastomers are excellent for a broad range of services, except steam.

There are a variety of butterfly valve styles based on how they are mounted in a piping system. The wafer style fits between two flanges and bolts surround the valve. The lug style has protruding lugs with tapped bolt holes mating it to standard flanges. The lug style butterfly valve is commonly used in dead‐end service. Both wafer and lug style valves do not need gaskets when mounting them in the piping. Then there is the flanged style. It has two end flanges and is bolted up just like any other flanged end valve. Another type is the grooved end butterfly valve. The grooved end design has a longer face to face, like the flanged, but is much faster to install.

The basic elastomer‐seated butterfly incorporates an interference fit where the disc diameter is slightly larger than the seat, which provides a bubble‐tight seal. The shut‐off capability is solely a function of this interference and greatly affects the torque. The primary stem seal is also an interference fit. With the improvement in elastomer technology and the introduction of many new elastomers, the performance of butterfly valves has improved. These butterfly valves are well suited for on/off and throttling applications. They are available in 2‐inch through 72‐inch sizes.

There are many materials that can be used for the body, stems, disc and seats. Some options for the body include various irons, bronze and steels. Stems are often made from 316 or 416 SS, and Monel. Discs use aluminum bronze, ductile iron or alloy 20, to name a few. We previously mentioned the most common elastomers. Take care when selecting the seat material. The user should be familiar with temperature limitations and compatibility of the elastomers for the intended service.

  • Bodies:
    •  Ductile Iron
    • Cast Iron
    • Aluminum
    • Bronze
    • Carbon Steel
    • Aluminum
    • Stainless Steel
  • Stems
    • 416 SS
    • 316 SS
    • Monel
  • Discs
    •  316 SS
    • Monel
    • Aluminum
    • Bronze
    • Ductile Iron (NP)
    • Ductile Iron (PVF coated)
    • Alloy 20
    • Hastelloy C
  • Seats
    •  Buna-N
    • Black Neoprene
    • Hypalon
    • Viton
    • Peroxide cured EPT
    • natural rubber
    • White Neoprene
    • ETM-30230
    • Fluorosteam
    • Peroxide-cured food grade EPT
    • Peroxidecured Buna-N
    • Sulfur cured food grade EPT

 

Butterfly Valves can be utilized in a variety of applications. The HVAC industry is one of the biggest users of butterfly valves. Other industries include chemical, petrochemical, refining, irrigation, and oil and gas drilling. Butterfly valves are also commonly found in food and beverage applications, water and wastewater, power generation, mining and dry bulk handling.

Setpoint Integrated Solutions offers a variety of butterfly valves that will suit any application. We are proud to partner with Flowserve Durco and Triac brands. Contact us today to find out what configuration works best for you.

*This post was adapted from content created by VMA at their Valve Basics Course, found here.

What Are the Characteristics of Ball Valves?

What Are the Characteristics of Ball Valves?

What are the characteristics of Ball Valves? *

Ball Valves, like the previous post on Plug Valves, are a type of quarter turn isolation valve.

The most common design that is utilized features a ball that rotates between two circular seats which are usually made of some type of PTFE , co-polymer, or other resilient plastic material.  When this type of ball valve is in the open position, media flows through the opening in the ball, and when closed the flow is completely blocked. Ball valves are often used for On/Off service (isolation) and are suitable for Bi-Directional Flow.

There are two types of ball valves, Floating Ball Valves and Trunnion Mounted Ball Valves.

Floating Ball Valves

Floating Ball Valves feature a ball that floats between the two seats and uses line pressure to push the ball downstream for a positive closure.  Floating Ball Valve Characteristics include:

  • No lower stem, providing savings during constrution
  • Relatively small size range, typically from 1/2″ – 12″
  • Tight sealing ability via the ball on the seat
  • Low operating torque
  • Downstream sealing only

Floating ball valves will provide tight seating with low torque, while being well suited to multi-port applications.

A variety of ball valve configurations also exist, with one piece flanged, two piece flanged, two piece threaded, and three piece threaded options available.

Additionally, Floating Ball Valves have different seat designs and stem designs.

Trunnion-Mounted Ball Valves

A Trunnion-Mounted Ball Valve uses a Trunnion, or lower stem to support the ball within the valve body.  Characteristics of a Trunnion-Mounted Ball Valve are:

  • The ball is fixed, it does not float
  • The ball is centered by the stem at the top and trunnion at the bottom
  • The seal is formed by the seats moving toward the ball
  • More complex than floating ball valves

The Trunnion-Mounted Ball Valve is made up of the following basic components. Body, Ball, Seat/Seat Assemblies, Upper Stem, Trunnion and End Connections. These valves are often supplied with flanged or butt-weld ends.

The advantages of Trunnion-Mount Ball Valves are:

  • No size limit to the use of trunnion-mounted ball valves
  • Trunnion supports the weight of larger balls
  • May be used in higher pressure applications
  • Seat Moves to the Ball
  • Lower Torque and Actuation Costs
  • Ease of Operation
  • Double Block and Bleed Capabilities

The Trunnion seat design is manufactured in one operation that machines the metal seat holder / retainer to which the seat insert is added. In some configurations the seat insert is then locked into place by rolling the seat lip into the insert groove, resulting in an extremely reliable seal.

Applications

Ball Valves are used in a variety of applications including, but not limited to:

  • Turbine Skids
  • Compressor Skids
  • Generator Skids
  • Separator Skids
  • Field Gas Plants
  • Crude Oil Plants
  • Gas Feed Lines
  • Polymer Plants
  • Automated Process Applications
  • Industrial Gas Processing Plants
  • LNG Plants
  • Hydrocarbon Processing
  • Tank Farms
  • Oil Refinery Feed Stock Lines

Setpoint Integrated Solutions has a variety of both floating and trunnion-mounted ball valves available from top tier OEM partners. Contact us today.

*This post was adapted from content created by VMA at their Valve Basics Course, found here.

Setpoint Integrated Solutions Honored at Baton Rouge Business Report’s Top 100 Private Companies Luncheon

Setpoint Integrated Solutions Honored at Baton Rouge Business Report's Top 100 Private Companies Luncheon

Setpoint Integrated Solutions was honored Wednesday, October 11, 2017 at the Baton Rouge Business Report’s Top 100 Private Companies Luncheon.

Since its inception in 1982, the Greater Baton Rouge Business Report has been committed to delivering accurate, honest and in-depth coverage of the Baton Rouge business scene. After many years and hundreds of issues, this publication not only continues its mission, but also has exceeded expectations by becoming a true partner to business and the community.

Celebrating its 35th Anniversary this year and featuring a Setpoint Integrated Solutions full page ad in the commemorative anniversary issue below, the Baton Rouge Business Report hosts many events in the community. At the most recent event, the Top 100 Private Companies in Baton Rouge were all honored at a luncheon at the  Baton Rouge Crowne Plaza.

Setpoint I.S. was the 28th largest private company in Baton Rouge by 2016 revenue. 

At the luncheon,  report by Baton Rouge Business Report found here,  economist Dr. Loren Scott delivered his annual Louisiana Economic Outlook. Across the Setpoint Integrated Solutions footprint, the Industrial Boom continues.  Setpoint I.S. views this report as a positive indicator for growth and stands ready to meet our customer’s needs.

 

What Are the Characteristics of Quarter-Turn Isolation Plug Valves?

What Are the Characteristics of Quarter-Turn Isolation Plug Valves?

There are many choices of Quarter-Turn Isolation Valves within the industry, such as Plug Valves, Ball Valves, and Butterfly Valves.  This post will  focus on Plug Valves and their characteristics.*

• In the quarter-turn family, opens and closes with 90-degree rotary turn
• Used for on-off and regulating flow
• Lubricated and non-lubricated types
• Available in many different materials

Plug valves have been in use for quite some time, they are  the oldest design of the quarter-turn isolation valves. They contain three basic components, of a body, a plug, and a cover.  The plug can be round, rectangular, tapered, or cylindrical, features a passage through which the media can flow, and this media flow will be controlled by turning the plug 90°, hence the term Quarter-Turn.

The on-off rotary turns will allow for isolation  and for regulating flow.

While plug valves are useful in many applications, they are particularly easily adapted to multi-port construction. As a result, three and four way plug valves are commonly used in the chemical processing industry. An advantage of this is the elimination of fittings or multiple straightway valves with one multi-port valve.

Plug Valves can be classified into two types:
  • Lubricated
  • Non-Lubricated

QV mach 1 Flowserve

Lubricated Plug Valves

Lubricated Plug Valves allow lubrication to be injected in a fitting under pressure through grooves in the plug or body to prevent fluid leakage between the plug face, and the valve body.  The reduced friction from the lubricant also enhances easy and quick operation of the valve.  The lubricated plug valve seals only against the downstream seat, and when properly lubricated is often the most leak-free seal available. Temperature limits will be based on the lubricant used within the valve, and the pressure drop should be fairly low due to the flow path being streamlined.

Lubricated Plug Valves are often used in handling hydrocarbons, corrosive fluids, and slurries.

Non-Lubricated Plug Valves

Non-Lubricated Plug Valves have multiple different subgroups, comprised of Lift, Sleeved, Lined, Eccentric, and Offset Eccentric.

Lift type non-lubricated valves are designed so that the stem first lifts the plug off the seating surface and then rotates the plug into the open position. This is useful in extending the life of the plug as it is not being drawn against the seating surface during stroking. After rotating the plug to the closed position the handwheel will continue to need to be rotated until the plug is properly in position against the seat. The mechanical seal on both the upstream and downstream sides of the valve in the closed position allows this type of plug valve to be used as a double block and bleed.  This feature allows the center section to bleed or clear any debris within the valve if it is has been equipped with a bottom access plate.

Sleeve lined plug valves are similar to a conventional plug valve, but it uses a fluorocarbon sleeve locked in place surrounding the tapered plug maintaining a  continuous seal. THe sleeve supplies the lubricity needed to cycle the valve, giving it characteristics of quick open and close, maintenance free performance, non-stick, and an extended life.

A lined plug valve is the same as a sleeved plug except that the body and plug are completely plastic or teflon lined and this isolates the valve body from the media. Usually made with a body of Ductile Iron, which is sufficient due to low temperature and pressure used in chemical applications.  Having the valve body isolated offers a less expensive alternative to special alloys. The limits on a plastic lined or sleeved plug valve is that it has a limited operating temperature, usually no more than 400 degrees F.  These valves tend to be found in highly corrosive applications, pharmaceutical, and food / beverage applications.

Finally, the eccentric type of non-lubricated plug valves is similar to a conventional plug, with half of the plug being removed. As the plug  rotates it is moved away from the seat, so that the plug is completely out of the media flow path when fully open.

Setpoint Integrated Solutions has a variety of Plug Valves to choose from, as we are distribution partners of top tier OEM Flowserve Durco.

*This information was adapted from content created by the Valve Manufacturers Association for Valve Basics, details found here.

What Separates Valve Service Shops?

What Separates Valve Service Shops?

What Seven Factors Separate Valve Service Shops?*

  1. OEM Authorized
  2. Asset Management Tools
  3. Certified Technicians
  4. Diagnostic Capabilities
  5. Access to OEM Inventory
  6. Technological Expertise
  7. Facilities

Together these seven factors determine the quality of your valve service at the many options within the marketplace.  As companies increasingly turn to outside vendors, such as Setpoint Integrated Solutions, to manage their valve population, it is necessary to understand all the factors that can affect the quality of maintenance and repair.

Factor 1: OEM Authorized Repair

One territory can have dozens of firms that offer valve maintenance and repair services. All of these firms are not created equally.  Often times the experience can be described as:

” Valves coming back from the repair shop looked great. Testing, however, told a different story. Many of the valves have not been repaired correctly and are not performing to OEM requirements.”

This usually results in higher maintenance costs and/or lost production. It also can mean compromised product quality and unnecessary safety risks. In order to ensure repeatable quality and minimize these safety risks, working with OEM Authroized Repair Facilities is integral.

To diagnose control and line valves, the shop should have a unit that can compare current valve data to “Day One” baseline data.Most valve OEMs have a list of authorized service providers. No one is required to choose one of these providers, but the credential of being listed as authorized is one sign of a quality shop.

To become an authorized service provider, a shop must meet specific criteria the OEM sets in areas such as integrity, safety and environmental compliance. Plus, the team is required to complete the OEM’s training program. Usually, OEMs hold certified shops to high standards when it comes to facilities, equipment and personnel. Knowing that a service provider meets these criteria, however, gives companies added confidence that they are dealing with a reputable shop.

OEMs regularly audit their authorized service providers to ensure they are meeting the necessary performance standards. While ISO 9000 is a good standard to be followed, it is not a valve operating guideline. When it comes to valve assembly/testing and repair, the OEM is the body best equipped to conduct the detailed review necessary and is willing to share audit reports.

Additionally, OEM-authorized service providers have access to important details regarding the properties, construction and workings of a specific valve or part. This is because OEMs build their products to rigorous specifications. While it’s true that a valve or part can be re-engineered, only the OEM knows the original specs with certainty.

An OEM-authorized service provider also receives extensive product training from the OEM and can consult with the OEM’s engineers to diagnose problems. An authorized shop will use OEM parts, rather than re-engineered parts, helping to ensure that the valve performs as expected.

Finally, not using an OEM-authorized service provider may void the manufacturer’s warranty.

Setpoint Integrated Solutions is an OEM-authorized service provider. Specific certifications held across our branch locations are:  Masoneilan Authorized Repair Center (MARC), Consolidated Green Tag Center (GTC), Groth Authorized Repair Dealer (GARD), Flowserve Black Tie Authorized Repair House, Valve Automation and Control Repair Facility. Details found here.

Factor 2: Asset Management Tools

A significant differentiator between valve service shops today is the ability to provide asset management tools. These tools put valve records—including repair data, repair records, test documentation, wiring diagrams and “before” and “after” photos”—in a single, easy to use, accessible database. The customer owns the data and can access that information 24 hours a day.

This added capability can simplify record-keeping for inspections and make it easier to meet reporting requirements. But asset management tools can be so much more than just a document management tool—they can be a plant manager’s best friend. Some, for example, provide analysis features and can assist in detecting trends for repairs, some manage inventory for optimization, others provide features such as “turn-around management” clouds where one can drag and drop valves for planning a turnaround. Others help with diagnostics and provide recommended solutions for resolving issues.

Setpoint Integrated Solutions, in collaboration with Baker Hughes, a GE Company, utilizes ValvKeep for all the valves it touches. ValvKeep tracks each repair event for each valve that goes through our shops. This information is then used, similar to a medical record, to track the health of the valve throughout its lifetime. More information found here.

Factor 3: Certified Technicians

When a person chooses a physician, he or she is likely to consider degree of education, specialized training and other credentials. The same criteria should apply when choosing a valve service partner. Those choosing should ask to see a firm’s training certificates; and find out whether the technicians are trained in the latest OEM standards, as well as ­relevant standards from organizations such as the American Society of Mechanical Engineers. They also should ask whether the technicians’ certificates are up-to-date because training is not a one-time task, but a continuous process.

With more than 200 certified and nationally accredited technicians, Setpoint Integrated Solutions stands ready to serve your needs through process repair services. Setpoint I.S. is committed to the highest standard of safety and quality assurance.

Factor 4: Diagnostic Capability

To diagnose pressure relief valves, technicians should have electronic valve testers that can test a valve in-situ.Today, when your car has an odd noise, your mechanic uses computer-based tools to diagnose the problem. A solid valve service provider will have similar tools in its collection.

For example, a technician working with pressure-relief valves should have electronic valve testers that can test a valve in-line and in production (in-situ). For control and line valves, technicians should have a diagnostic unit that can compare current valve data to “Day One” baseline data. With a significant number of analog positioners still in use, such devices can help remove the guesswork from assessing valve health.

Setpoint Integrated Solutions Technicians are OEM certified and highly trained. Their use of diagnostic tools save you time and money by making the right repair the first time.

Factor 5: Access to OEM Inventory

A good service provider has OEM valves and parts in stock and can quickly configure, assemble and test a replacement valve.Even the best technician cannot get a process running again without the necessary parts, replacement valves and other devices. When something is needed to get that process going, the best providers of maintenance and repair services will simply pull from their well-stocked shelves the necessary OEM parts, valves, positioners, etc.

Certainly, it is impossible for a service provider to have every SKU in its warehouse. But affiliation with a network of service facilities can provide access to millions of dollars of inventory that can be on hand in days, and sometimes even hours. A prospective service provider needs to belong to such a network.

Setpoint Integrated Solutions carries significant inventory for all of the OEM partners that  it represents.

Factor 6: Technological Expertise

A growing number of facilities are adopting digital technologies such as wireless communication, valve diagnostics, the HART Protocol, the FOUNDATION fieldbus and PROFIBUS. A strong service provider will have a “digital champion” on staff or accessible who can guide users and who has the technical expertise to advise on when to upgrade to digital technology.

Setpoint Integrated Solutions focuses on providing best in class technological expertise through the aforementioned protocols as well as the use of other systems such as  ValvKeep, VavleAware, and Valve Vue.

Factor 7: The Facilities

Visit a prospective service provider’s facility. Take note of whether the shop is neat, clean and well-lit. Organization is strongly correlated to quality. This photo shows the DMC–Carter Chambers facility in LaPorte, Texas.A tour of a prospective service provider’s facility can reveal much. Such a tour should include stops at areas in the shop for sandblasting, machining, welding and painting. Take note of whether the shop is neat, clean and well-lit; organization of that shop is closely correlated to quality. After all, would anyone hire an accountant whose office was wall-to-wall stacks of paper? As an added benefit, some providers also have onsite facilities where they offer training for their customers.

State-of-the-Art Facilities: Setpoint I.S. features more than 400 employees and encompasses more than 425,000 sq. ft. of repair and distribution facilities across 13 strategic Gulf South locations. We’ve invested in the latest technologies and equipment to ensure our customers receive the best service available.

Choosing a valve service provider requires time and effort. But given the importance of valves to any process facility’s performance, the ­decision cannot be taken lightly. The key is: Do your homework; it will be time well spent.

Setpoint Integrated Solutions stands ready to assist in all your valve service and valve repair needs. Contact us today.

*This Content was adapted from an article by Gary Ostrowksi for Valvemagazine.com found here.