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BY STEVE SPILKER

Can metal-seated ball valves provide effective long term, economical solutions for critical applications in steam-generating power plants? The answer lies in knowing the design limitations of the valve, in correctly identifying the application requirements and in proper installation techniques.

During the last 20 years, advances in machining, tooling, measuring and coating technology have led to ball valve designs that provide positive sealing solutions for the power industry. These new “power plant ball valves” can withstand temperatures and pressures that make them a viable solution for the industry.

THE HISTORY

Before these new designs, creating true and matching spherical sealing surfaces was limited so that one surface—the ball—typically was metal and highly polished. The second sealing surface—the seat—generally was a fluoropolymer or elastomeric compound. This combination works well in lower temperatures and pressures, and still is widely used today. However, it is not suited for the extremes seen in steam power generating stations.

Figure 1. Typical Y-pattern globe valveInstead, traditionally rising-stem globe valves have been the work horses for stop and isolation service in steam-generating power plants (Figure 1). These valves have massive stems, plugs and seats. They are top-entry valves and often have welded or pressure seal bonnets.

The sealing areas of the plug and seat are matched conical surfaces, which are well-suited for the high pressures, temperatures and velocities found in vent, drain and continuous process services. Operation of the valves is intuitive: If the stem is in the “up” position, the valve is open; if the stem is in the “down” position, the valve is closed.

METAL-SEATED BALL VALVES

Computer numerically controlled (CNC) machines with special tooling can now produce virtually perfect spherical metal-to-metal sealing surfaces—both concave, and convex for ball and seat—with almost infinite repeatability. Highly qualified and specialized coating contractors also can provide many varieties of flame-sprayed carbide coating compounds applied with exacting precision in laboratory conditions by CNC robotic machines. These coatings carry a toughness and hardness far exceeding that of the cobalt-based weld overlays traditionally used in rising stem globe valves, and the final coated surface exactly mirrors the machined contours of the underlying part. These technologies have lead to the emergence of the power plant ball valve, capable of withstanding temperatures in excess of 1050° F (566° C) and ­pressures in excess of 3000 psig.

CONSTRUCTION FEATURES

Many power plant ball valve manufacturers are machining valve bodies from forged bar stock materials with massive wall thicknesses far exceeding that of rising stem valves. Several use the same valve body design on 1.5-inch and smaller sizes for all pressures classes—so that an ASME Class 1500 valve may actually have an ASME Class 4500 body. This standardization reduces raw material inventory, streamlines machining, shortens production times and allows for virtually unlimited alloy material selection. Usage is restricted by the pressure and temperature rating stated on the original equipment manufacturer (OEM) tag and relevant American Society of Mechanical Engineers (ASME) and American National Standards Institute (ANSI) standards.

Figure 2. Two-piece end-entry design

Figure 3. One-piece end-entry design

Figure 4. Top-entry designValve manufacturers produce a ­variety of power plant ball valve body designs, including two-piece end entry (Figure 2), one-piece end entry (Figure 3) and bolted bonnet top entry (Figure 4). Different seat designs are produced: integral seat, pressed-in seat, welded seat and locked seat. All designs incorporate a downstream sealing seat, with an upstream ring used as a guiding, balancing and bearing surface.

Figure 5. Live-loading methodThese designs all include a large cross-section conical load spring (Belleville washer) behind the upstream bearing ring. The designs feature live-loaded stem packing, although several methods provide this live-loading (Figure 5). Some use one large central Belleville spring, while others use four, equally spaced spring sets. Packing design varies among manufacturers—some use a single die-formed ring with wire-braided backup while others use multiple die-formed rings, and still others use top- and bottom-braided rings with internal die-formed rings.

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BY GENILEE PARENTE

Valve and actuator end users are operating with tighter budgets and deadlines than ever before, which means increasing challenges in the distribution channels.

The last time a panel of distributors spoke before the Valve Manufacturers Association board (in 2005), the worldwide recession had not yet hit. However, the next few years were rough ones, and the need for tighter purse strings has since created a new set of challenges for distribution channels, according to a panel of experts from leading distributors who spoke at VMA’s annual meeting in October 2011.

The immediate effect of the economic recession was that “people pulled back—no one was stocking much,” explained Shelly White, division president of Baro Companies, a division of FCX Performance. When business picked back up, it was more difficult to fulfill orders. That situation will quickly right itself, but new pressures have arisen on the distribution channels that may stay around for awhile, panelists pointed out.

White, along with fellow panelists Andy Brown, president and owner of Mid States Supply, and his colleague, Ben Hurst, vice president for Mid States, as well as Gary Ittner, executive vice president for McJunkin Red Man Corporation (MRC), explained what their companies do today, how that has changed over the years, and the current challenges in the distribution field. (See sidebar, last page.)

DISTRIBUTOR AS BRIDGE

White said that one of the main trends she sees today in the distribution channel is that lead times “are really compressed.” The recession created a situation in which end-user customers have to do more with less resources, she pointed out.

These users remain under a lot more pressure, and as a result, they want distributors to do more of the work of finding the right product while taking on more of the risks inherent in that situation. At the same time, they have new sources of information such as what can be found on the Web.

Today, end-user customers “often pull out numbers for what they think a product should cost,” White said, which can be completely unrealistic or misunderstood.

End users also want a much wider range of products from a distributor than in the past.

“For example, a distributor may have just sold ball valves [in the past], but now the customer wants every possible thing that could go on that ball valve,” White says. More than ever before, end users also expect their distributors to be knowledgeable about the latest technology and to take responsibility for specifications and selecting the right equipment for applications while enabling those users to maintain a competitive edge.

Many users today require a distributor to manage the sub-vendors of the manufacturer such as foundries and companies that do the testing or provide machining, welding, assembly or packing.

Meanwhile, on the manufacturing side, a main trend is that the companies that make the products are increasingly asked for more severe service products, White said. This requires the distributors to keep up with what’s available.

FOR THE FUTURE

The calls for quicker delivery and reduced lead times are only going to increase going forward, according to White, and this situation will continue to be the main challenge for distribution channels.

Additional future challenges include:

• Competitive pressure from lower-end manufacturers will increase.
• Customers are getting more tech savvy, using e-sourcing and shopping online for products, which creates an uncertain situation for distributors of engineered, sourced products.
• Contract orders are getting larger and larger as big end users such as the giant oil companies want broader supply agreements.
• End users want to pass on more of the risk. “Whether it’s in the form of a letter of credit, performance guarantee or extended warranty through the startup period, the end user is applying more pressure on all sub vendors to perform until the plant starts up. There is more and more risk for suppliers with reduced reward. This has been happening for about five years, but it’s really coming to a head,” White said.
• There will be higher demands for response at all levels of the sales cycle, which is hampered by reductions in people and resources from within the manufacturing industry.

At Dahl’s second annual U.S. Rep of the Year awards, O & A Unique Solutions Inc. of Plainview, N.Y., took home top honors as the 2011 “U.S. Rep of the Year” for excellence in the company’s sales and service. In addition, Schroeder Sales Co. from Maple Grove, Minn., and Maple Sales West Inc. from Phoenix were named second and third prize winners, respectively.

Dahl, a family-owned manufacturer of plumbing and heating valves and specialties, recognized O & A Unique Solutions as the rep agency that demonstrated the greatest nominal unit sales increase, presenting the award at the company’s annual sales meeting. Accepting the award and prize of $5,000 was Amir Rosenfeld-Amir of O & A Unique Solutions (pictured right).

Enlarge this picture Jon Schroeder (left) from Schroeder Sales accepts the second prize of $2,500 from Dahl.

Jon Schroeder from Schroeder Sales attended to accept the second prize of $2,500 (pictured right), and Brannen Maples of Maple Sales West accepted $1,000 for third prize (pictured below). Presenting the awards from Dahl was Jannike Godfrey, Thomas Husebye, Patrice Bansa and Josh Jamieson.  

Enlarge this picture Brannen Maples (left) of Maple Sales West accepts $1,000 for third prize from Dahl.

“We’re so proud to have the support of our excellent sales agencies in growing the Dahl business,” said Thomas Husebye, Dahl’s vice president of sales. “It’s our pleasure to honor O & A Unique Solutions, Schroeder Sales and Maple Sales West as they continue to demonstrate their continued commitment to the success of both their business and ours.”

Source: Dahl

New World Stainless of Somerset, NJ, a manufacturer of precision-welded small-diameter stainless steel and nickel alloy tubing, has appointed Harry Stamateris as its director of business development.

Former Shell Oil Co. President John Hofmeister will address the PVF Roundtable at its dinner meeting Oct. 18 in Houston. He now heads the not-for-profit Citizens for Affordable Energy, which he founded in 2008 after he retired from Shell.

Hofmeister’s firm promotes sound U.S. energy security solutions, which include a range of affordable energy supplies, efficiency improvements, essential infrastructure, sustainable environmental policies and public education on energy issues. He is the author of “Why We Hate the Oil Companies: Straight Talk from an Energy Insider,” which was published last year.

As Shell’s president from 2005 to 2008, Hofmeister launched an extensive outreach program to discuss critical global energy challenges. The program included an 18-month, 50-city tour during which he led 250 other Shell leaders to meet with more than 15,000 business, community and civic leaders, policymakers and academics to discuss what must be done to ensure affordable, available energy for the future.

The PVF Roundtable is an organization of companies involved in the pipe, valve and fitting industry. These firms may be manufacturers, distributors, piping designers, engineering firms, construction companies or end-users.

For information on membership and next month’s meeting, visit www.pvf.org.

Art Shelton joined Houston-based master distributor Global Stainless Supply Aug. 16 as president and chief operating officer. He oversees GSS and its subsidiary companies: Forgings, Flanges & Fittings and Global Pipe Supply. Bill Bootz, former president and CEO, has left the company.

“Art brings to this position more than 30 years’ experience in the supply of products to the energy sector,” said John Howard, GSS director and interim CEO. “We believe his knowledge, expertise and professionalism will be cornerstones to our continued growth of the Global companies.”

Supply House Times featured GSS as its cover story in August 2010. Our article chronicled the growth of the company from its start in 2002 to its acquisition of master distributor Forgings, Flanges & Fittings in 2006. The majority owner of the company is Sumitomo Corp. of America. GSS sales in 2010 were $150 million. More information on the company can be found at www.onestoppvf.com.

The Federal Reserve Board of Governors reported Aug. 16 that industrial production advanced 0.9% in July with stronger manufacturing leading the way.  Manufacturing output rose 0.6% in July following gains of 0.2% in both May and June.

Capacity utilization for manufacturing in July was 75.0%, a rate 10.6 percentage points above its trough in June 2009. This level, however, still sits 4.0 percentage points below its long-run (1972-2010) average.

Automotive products posted a jump of 5.9% to lead the increase in durable goods, as motor vehicle output rebounded after the supply chain disruptions that resulted from the earthquake in Japan.

The output of construction supplies increased 0.3% in July, its second small monthly gain following a large jump in May, when it rose 1.3%. Over the past 12 months, the index for construction supplies has moved up 4.4%. Nevertheless, the index in July remained more than 20% below its average level during 2007.

Another notable gain during July included the output of utilities, which increased 2.8% as the extreme heat during the month boosted air conditioning usage in many parts of the country.

 At 94.2% of its 2007 average, total industrial production for July was 3.7 percentage points above July 2010. The capacity utilization rate for total industry climbed to 77.5%, a rate 2.2 percentage points above the rate from a year earlier but 2.9 percentage points below its long-run average.

MRC Global Inc., formerly McJunkin Red Man Holding Corp., announced it has filed a registration statement with the federal Securities and Exchange Commission for an initial public offering of stock.

The number of shares to be offered nor the stock price has been determined. However, the registration statement estimates the proposed maximum aggregate offering will be $100 million. The company said it will ask the New York Stock Exchange to list the stock under the symbol, "MRC."

MRC has more than 3,600 employees, including more than 380 in West Virginia. The company posted $4.6 billion in revenue over the past four quarters. MRC has more than 400 service locations and about $900 million of PVF stock strategically located around the globe.

Source: Charleston Daily Mail

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BY CARL TAYLOR

This segment of the chemical processing industry must deal with levels of cleanability and sterility that will ensure the safety of those who use or make the products.

As the world’s populations grow and age, developing countries expectations rise and new research brings new health solutions to the world, the biopharmaceutical (biopharm) industry flourishes. Like all chemical processing, biopharm has its own set of standards, special processing needs and challenges in materials and design.

At its most general level, one can define the chemical industry as the aggregate of entities engaged in processing raw materials using chemical reactions (often aided by pressure and/or forms of energy such as heat) to convert those materials into products. That general level has numerous subgroups, such as biopharmaceutical, organic/inorganic chemicals, industrial gases, petrochemicals, agrochemicals, polymers and paints. These subgroups are categorized further by the end-product goods and commodities such as dyes, acids, alcohols, fertilizers, hydrogen, nitrogen, herbicides, ammonia, soaps, detergents, hair sprays, enamels, varnishes and many more.

Commonly, the processes required to manufacture these products use constituents or conversion enablers that are toxic, or they result in products and byproducts that may be toxic themselves. The inputs and outputs to those processes can present additional challenges because of physical and chemical properties that can make media extremely corrosive or abrasive. Also, the media can be difficult to propagate and control throughout the process flow in situations where physical/chemical properties result in media that is semi-solid.

In each segment of the industry and in every subcategory of these segments, valves play a critical role. A variety of valves are appropriate for various applications and deployed for handling different types of media. Covering the entire industry is too great a task for one article. Therefore, the information that follows highlights where and how valves are used in chemical processing for the biopharm market.

THE MARKET

The biopharm industry can be divided into two segments: Pharmaceutical, which uses chemical processes to manufacture therapeutic and health-related products; and biotechnology (biotech), which uses living organisms and biological processes to create products used in many fields such as pharmacology, medicine, agriculture and many others. A primary example is therapeutic protein used for medical and therapeutic applications. Most biotech applications involve cell cultures of genetically modified organisms including yeasts, insect cells, bacteria cells or mammalian cells.

A full range of pumps, valves and instrumentation comparable to other processing systems can be used in the biopharm industry. However, stringent requirements regarding cleanability and materials of construction mean that some products that perform ordinary and useful flow control functions in other applications must either be used with great caution or not used at all. An example is check valves. Check valves are installed tentatively because even sanitary check valves allow formation of “dead areas,” despite the fact they are functioning according to specifications. Such areas potentially harbor contaminants or toxic agents.

BY JIM CAHILL

In earlier columns, I highlighted the value of online communities and their ability to connect people with similar expertise. The successful communities typically grow into the thousands and have many people actively participating by asking questions, providing answers and linking to interesting information available on the Web.

LinkedIn is a vibrant place for many of the professional groups, including those that deal with automation, which is one of the discussion areas that is a good source for Emerson Process Experts blog posts.

A quick check to see how many valve-related LinkedIn groups were active revealed a long list. At the time this article was written, the top five were Valve World Group with 3,052 members, Valve Network with 2,615 members, Valve Sales with 1,262 members, Valve Solutions with 995 members, and Valve Actuation Group with 759 members (see listings for these at the end of this column).

Together, that’s a lot of people sharing what they know on the subject of valves. A good way to see how useful the individual sites are is to look at a sampling of some of the discussions currently taking place.

The Valve World Group community is described as, “...a platform for valve professionals in the global process industries to exchange knowledge and offer networking opportunities.” Its discussions range from asking for suggestions for suppliers for specified valves, to suppliers sharing their recent white papers, to people new to the industry asking how to gain experience in the valve industry. The Valve Manufacturers Association and VMA.org website were highlighted by many respondents as an excellent resource for people new to process automation.

The rest of these groups require membership to see what’s available in the discussion threads. LinkedIn allows group owners the choice whether to have open groups or not. If open, anyone can view information about the group, but not participate unless he or she is a member. If the goal of these groups is to be broad based and easily findable through search queries, administrators are well served to open up their groups.

Each of the five groups mentioned above has a description that may help in deciding if they are valuable. For example, Valve Network is described as, “...a global networking platform for marketing, sales, development, design and manufacturing professionals dealing with valves and control valves.”

Valve Sales describes its purpose as, “...for sales professionals within the valve industry, to network and job search.” The Valve Solutions group shares its mission as, “...to offer a platform where piping & design engineers, flow professionals, process & operations personnel from various upstream & downstream manufacturing plants can interact with each other and seek flow solutions to various process applications.” Finally, the Valve Actuation Group, “...is for actuator, valve, control valve, instrumentation and automation experts in the global process industries. Through the group, members can develop their professional networks, transfer knowledge and share experiences.”

In just this small sampling of LinkedIn groups, you can see the focused communities for valve manufacturers, valve sales professionals, and project and plant engineers. If you are in one of these groups, it may be worth a look to join the community—it costs nothing except your time. You can configure your group settings to get a daily or weekly summary of the discussions sent to your work or personal email. I find these email summaries helpful so that I can view what’s being said on my own time and to get a quick sense for the conversations occurring in the community.

There is also no cost to start one of these communities, so if you have an area of specialization, you can easily become administrator for your own group. And the fact they can be open or closed to different degrees can be helpful in targeting the discussion. For example, if the knowledge you want to share is strictly for people inside your company, it makes sense to start this community inside your own firewall. Many enterprise software products also are adding their own capabilities for forums, status updates and other social forms of communication. In addition, open source software such as Wordpress and the BuddyPress provide a way to quickly enable knowledge-sharing sites inside your own firewall.

These online communities continue to grow in popularity because they are easily discovered through search engines. If you’re searching and land upon a thread that helps solve a problem, it’s possible you will end up joining the community to help you solve future problems.

Email most likely will remain a dominant form of business communication for the foreseeable future. But, as these online communities spring to life and add capabilities, their appeal will grow. Email is limited by who is already in your address book, and how easy it is to find information by digging through your archives. Online communities connect people with common knowledge and interests together from across the world. By and large, if the community is open, the content is fully indexed in the search engines and waiting to be discovered.

I hope you’ll give one of the mentioned valve communities a try to see whether or not it adds value. If it does, I encourage you to seek more value by getting your fellow experts to join.

JIM CAHILL leads Emerson Process Management’s social media efforts and writes the Emerson Process Experts blog: www.EmersonProcessXperts.com.

Links

Valve World Group

Valve Network

Valve Sales

Valve Solutions

Valve Actuation Group

VMA and Valve Magazine on the Web

As columnist Jim Cahill has noted, many in the industry are aware that the Valve Manufacturers Association has a website—www.VMA.org—that contains much useful information and resources. The same can be said of Valve Magazine’s website, www.ValveMagazine.com, in which we post Web-exclusive articles, new products, frequent news updates about valve manufacturing, end-user news and more.

We’d also like to remind readers that we have been posting digital editions of the magazine online since 2008 (www.ValveMagazine-digital.com). This can be a great way to find articles that include information you are seeking, using a keyword search.

Finally, we have plans to start our own group in LinkedIn, which will be active by the end of the year. Our focus will be on connecting U.S. and Canadian valve, actuator and control manufacturers with those who specify, purchase, maintain, operate, distribute and use these products.