FACULTY OF ENGINEERING & LIFE SCIENCES

BACHELOR IN TECHNOLOGY INDUSTRY

SEM FEB 2018

CORROSION FTS 2243

ASSIGNMENT 2
CASE STUDY (FLOWSERVE)

Prepared By:
Name: Mohamad Farid Asyraf Bin Ismail
Matric No: 4164003841

Submitted To:
Lecturer’s Name
DR Fredlina
FLOWSERVE

1.0 INTRODUCTION

Flowserve is one of the world’s largest manufacturers of valves, pumps, seals and components to
the process industries. The company produces metal seated ball valves for use in severe service
applications, including cyclic temperatures, highly abrasive and slurry environments.

Flowserve McCANNA cartridge ball valve, designed to help reduce maintenance costs and
increase productivity in hazardous or remote applications.

The new McCANNA cartridge ball valve is designed for high-cycle, long service life performance.
Should the valve require maintenance, the cartridge design simplifies repair for hazardous
containment or remote locations. Captive self-aligning bolting enables the internal cartridge
assembly to be robotically removed and replaced in one assembly. During an emergency, valve
components can be accessed or replaced in minutes.

“The McCANNA cartridge ball valve simplifies installation and maintenance while withstanding
high operating temperatures and hazardous process fluids.”

The valve’s design is based on proven McCANNA top-entry valve technology. The McCANNA
cartridge ball valve is available with a unique one-piece metal seat, which provides better wear
resistance and a higher operating temperature range compared to soft-seated designs. The full port
top-entry valve uses a single bonnet seal and live loaded stem seals for high seal integrity in
hazardous applications.

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2.0 REVIEW/COMMENT

After reviewing flowserve case study we know that currently Flowserve McCANNA was using
Stellite, a cobalt based nickel alloy, for its highly abrasive applications. But the solution was
expensive and, as a relatively soft material, had performance issues. Flowserve wanted to find a
cost effective alternative to solid metal alloy that would prevent galling (the primary concern with
metal to metal contact) as well as increase wear and corrosion resistance.

To counter this problem Flowserve McCANNA and Hardide Coatings worked together to design,
engineer and test the Hardide tungsten carbide-based CVD (chemical vapour deposition) coating
as an alternative to metal alloys in severe applications.

In the qualification process, Hardide coated balls and seats were still operational after more than
70,000 cycles in slurry, where Stellite failed in 29,000 cycles. The Hardide coating, due to its hard
non-porous composition, was proven to offer improved erosion and wear resistance over Stellite
at a lower cost in slurries and other metal seat applications.

Hardide is now the standard metal seated option on the Flowserve McCANNA seal top entry ball
valve on ½” to 4” ANSI 150-1500 and cryogenic to 800ºF applications. Leakage rates per MSS-
SP-61 equal between class IV and class V performance. Hardide has enabled Flowserve
McCANNA to offer its customers a lower cost, better performing alternative to Stellite for highly
abrasive metal seated ball valve applications.

Figure 1: Balls valves coated with Hardide

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The corrosion protective properties of the Hardide coating have been independently tested to
compare with hard chrome and other coatings via salt spray tests on Hardide coated mild steel
plates, commercially sourced hard chrome plating and HVOF coating. This is to prove that Hardide
coatings was much better than others.

The 480-hour tests were conducted in accordance with ASTM B117-07a standard. The images
below show samples of each of the three coatings after testing. The hard chrome plated samples
were badly corroded and had to be removed from test after just 288 hours exposure. HVOF coated
samples showed heavy rust stains and the coating cracked due to intensive corrosion of the steel
plate beneath. The Hardide coated samples showed only light staining.
Unlike various paints and soft anti-corrosion coatings, Hardide coatings offer the additional benefit
of enhanced wear and erosion resistance. The coatings can also be used at temperatures of up to
400°C where organic coatings and sealants cannot.

Figure 1: Samples of three different coatings after salt spray corrosion tests

HVOF Hard Chrome Hardide Coating

after 480 hours after 288 hours after 480 hours

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3.0 SOLUTIONS 1

One of the solutions to make the seats can withstand use beyond temperatures limits of common
materials is by making the seats using carbon and graphite. Flowserve offers seats in Carbon
Graphite 110 (a pure form of carbon graphite, without silicate fillers) to withstand the effects of
Paraxylene and the rigorous conditions in the oxidation reactor process, including any caustic
flushing applications that are introduced into the reactor to keep the PTA process clean.

McCANNASEAL PTA Ball Valves is capable of temperatures up to 1000 °F (538°C). The proven
wedge seat design of McCANNASEAL PTA ball valves permits the use of non-resilient seats for
services beyond the temperature limits of common materials. This design does not depend on seat
flexing or bending with nonresilient materials as it automatically compensates for pressure,
temperature and wear. For PTA applications a specific blend of carbon and graphite powders are
compressed in a confined die followed by baking in a non-oxidizing atmosphere producing the
desired carbon graphite seats.

Flowserve offers seats in Carbon Graphite 110 (a pure form of carbon graphite, without silicate
fillers) to withstand the effects of Paraxylene and the rigorous conditions in the oxidation reactor
process, including any caustic flushing applications that are introduced into the reactor to keep the
PTA process clean.

This seat material allows these valves to be used in temperatures as high as 1000°F (538°C). Metal
seats are also applicable to PTA applications when it is imperative to eliminate product
contamination. Waukesha 88 and Stellite have exceptional corrosion resistance and non-galling
properties and are capable of services between 650°F (343°C) and 1000°F (538°C). Extended
bonnets are recommended for valves equipped with carbon graphite seats. Grafoil stem seals and
spiral wound gaskets are available for PTA McCANNASEAL valves.

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 Figure 2: McCANNA Seal trunnion mounted ball valve and floating ball design

3.0 SOLUTIONS 2

Solutions to prevent corrosion is by using electroplating or mechanical plating.

Electroplating

A thin layer of metal (often Ni, Sn, Cr) is deposited on the substrate metal (generally steel) in an
electrolytic bath. The electrolyte usually consists of a water solutions containing salts of the
metal to be deposited.

Mechanical plating

Metal powder can be cold welded to a substrate metal by tumbling the part, along with the
powder and glass beads, in a treated aqueous solution. Mechanical pllating is often used to apply
zinc or cadmium to small metal parts.

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4.0 CONCLUSIONS

In the ends after reviewing the case study about flowserve all the solutions presented in this report
has its own advantages. For examples the solution presented by Flowserve McCANNA and
Hardide coating to come up with Hardide Tungsten carbide-based (chemical vapour deposition)
coating can minimize the cost and improve the quality of the product. It also increase the
performance of the product. Next is the McCANNASEAL PTA Ball Valves by making the seats
using carbon and graphite so the valves can withstand use beyond temperatures limits of common
materials is by making the seats using carbon and graphite. This valve is commonly used in
Purified Terephthalic Acid (PTA) Processes. Lastly all the solutions have its own advantage and
disadvantages.

5.0 REFERENCES

1. http://www.valveuser.com/1613-hardide-coating-advances-heap-and-partners-new-ball-
valve-technology.htm
2. https://www.hardide.com/documents/mst07.pdf
3. https://www.flowserve.com/sites/default/files/2016-07/mmenbr1015-e.pdf