We completed the replacement of an isolation / partial control valve with an EBRO Butterfly Valve for a potash company, where the abrasive solution was causing severe and frequent wear
The problem:
- Abrasive potash solution causing extreme wear
- Due to wear the original valve was no longer capable of flow control or isolation
- Maintenance staff needed down-time to effect a change-out which interfered with production
The plant had replaced the original valve with a rubber-lined plug valve in an effort to eliminate or at least reduce the MTBF. This did improve the MTBF to approx 6 months but the valve was expensive. In addition, due to the size of the new valve a change-out was a time-consuming exercise, taking two men a full day to complete, which added to production down time
The solution:
- we supplied the site with a 6″ Ebro Z011-A Butterfly Valve
- the valve was fitted with standard options of a polyurethane liner and a UHMW PE Disc
- both the liner and disc are designed for highly abrasive applications
- the butterfly valve has bubble-tight shut-off
As this has historically been the most problematic application on the site, we offered to supply the new butterfly valve on a trial basis to prove its benefits
The butterfly valve was installed over a year ago and on routine periodic inspection (every 3 months) it has been removed and inspected for wear. To date, none has been found
The benefits for the site are:
- extended MTBF of the valve
- a significant up front capital cost saving against the previously used plug valve
- cost saving in time – one man can complete all required tasks within a few hours
- as the valve is lighter, the maintenance fitter has less difficulty with manhandling
- increased production up time and reduced overall cost of ownership.
If your installation is suffering from poor valve performance due to abrasive applications send us a product enquiry or contact Brian Foley on Ireland: +353 21 4510900 or UK: +44 1633 877505