L&T to build two chemical plants in RJ
The Hydrocarbon Business of
INDIA & MIDDLE EAST
May 2023 – Issue 27
Inside
• S
 potlight on:
FLOVEL VALVES PVT LTD:
Unlocking the potential of
flow with precision for every
application p4
• Managing wear p18
• Pipeline valves p21
• Motorized valves p26
BHEL, NPCIL target NP
Nuclear Power Corporation of
India Limited (NPCIL) and Bharat
Heavy Electricals Limited (BHEL)
have entered into an MoU
to jointly pursue business
opportunities in the area of
nuclear power plants based on
pressurized heavy water reactor
(PHWR) technology.
Under the MoU, BHEL, and NPCIL
will jointly explore opportunities
for the development of Nuclear
Power Projects to reduce project
gestation time.
In the presence of Dr. V. K. Saraswat
(Member – NITI Aayog), Sh. K. N. Vyas
(Secretary – Department of
Atomic Energy & Chairman –
Atomic Energy Commission) and
Sh. Kamran Rizvi (Secretary –
Ministry of Heavy Industries), the
MoU was signed by Dr. Nalin
Shinghal, CMD - BHEL, and
Sh. Bhuwan Chandra Pathak, CMD
– NPCIL at NITI Aayog, New Delhi.
Larsen & Toubro has recently
secured an order under its
AdVENT (Advanced Value
Engineering and Technology)
business vertical. The order is for
license plus engineering,
procurement, and construction
of a Technical Ammonium
Nitrate (TAN) plant along with
Weak Nitric Acid (WNA) plant at
Gadepan, Kota, Rajasthan from
Chambal Fertilisers and
Chemicals Limited (CFCL), a
leading fertilizer company in
India.
The TAN and WNA plants, having
capacities of approximately
240,000 Metric Tons (MT) p.a.
and 2,10,000 MT p.a. respectively,
Methanol project taking shape in Egypt
Methanex Egypt and the Suez
Methanol Derivatives (SMD)
Company signed an
infrastructure development
agreement for the supply of
methanol from Methanex
Egypt’s plant to the
neighboring SMD project in
Damietta.
This agreement comes in light
of the memorandum of
Slurry valves for alumina refinery
AMPO POYAM VALVES is
currently supplying more than
4,000 slurry angle severe
service valves for the
expansion project of Lanjigarh
Alumina Refinery from an
existing capacity of 2 MTPA to
5 MTPA in Lanjigarh, Odisha,
India. The completion of this
project will place Lanjigarh
Alumina Refinery, owned by
will be built under a technology
license from CASALE S.A., a
privately owned Swiss Company
headquartered in Lugano,
Switzerland.
Organised under Offshore,
Onshore, Construction Services,
understanding signed by both
parties in 2018 to investigate
potential support for providing
utilities and methanol to the
SMD plant. A USD 120M
methanol and formaldehyde
derivatives plant in Damietta,
SMD is designed to produce
140 KTA of main products
including Urea Formaldehyde
Concentrate 85% (UFC-85),
Vedanta, as one of the largest
single-location alumina
refinery complex.
All valves are being
manufactured in AMPO INDIA,
which comprises an area of
approximately 15,000 square
meters in Coimbatore (Tamil
Nadu), India, and which includes
valve assembly, testing, painting,
and packing facilities.
Modular Fabrication, and
AdVENT & Asset Management
verticals, LTEH offers integrated
design-to-build solutions across
the hydrocarbon sector to
domestic and international
customers.
Urea Formaldehyde Resins,
Sulphonated Naphthalene
Formaldehyde (SNF), in
addition to the capability of
producing up to 42 KTA of
special UF resins for various
end-use applications.
The project is currently under
construction and is expected
to start operation in October
2024.
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Plot No. 123-124, Aira Estate, B/h Security Estate, Near Kashiram
Tex le Mill, NAROL, AHMEDABAD - 382 405.

Contact : +91 90994 77256

E Mail : mkt@airaindia.com / export@airaindia.com

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Website: www.calistotechnocast.com Email: info@calistotechnocast.com Phone: +91 90334 80393

Valve World India & Middle East | issue 27 | May 2023

colophon Contents
May 2023 edition – Issue 27
http://www.valve-world-india.com
This publication appears bi-monthly
Spotlight on: Flovel Valves 4-7 Case history 20
ISSN: 2666-2051 ISSN Digital: 2666-206X Indian valves for offshore projects
Publishing Director
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n.nagel@kci-world.com Safety 21-23
Tel.: +49 2821 71145 55
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David Sear
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Lucija Kozina
Sarah Bradley
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Umut Gül
u.guel@kci-world.com
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s.bhagat@kci-world.com
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r.rajan@kci-world.com
Unlocking the potential of flow with precision
Subscriptions (print & online)
Annette Speer
for every application
a.speer@kci-world.com
Advertising material collection India news 8-11
Ambir Heuvelmann How Aramco is safeguarding pipeline valves
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In part three of his column, Prof. A S Khanna
addresses functional and smart coatings
The Netherlands Office
KCI Publishing B.V., De Leeuwenbrug 95,
7411 TH Deventer,
The Netherlands Regional news 16
kci.deventer@kci-world.com
Tel.: +31 575 585 270
Find us on: Interview 17
Q-Tork´s Gautam Cair supplying motorized valves for Jal Jeevan
Shah discusses Mission
successful gearbox
The publishers and the authors state that this manufacturing Actuator technology 27-29
magazine has been compiled meticulously
and to the best of their knowledge, however,
the publisher and the authors can in no way
guarantee the accuracy or completeness of
the information. The publisher and authors
therefore do not accept any liability for any
damage resulting from actions or decision
based on the information in question. Users
of this magazine are strongly advised not to
use this information solely, but to rely on
their professional knowledge
experience, and to check the information to
and
Materials 18-19
be used. KCI Publishing cannot guarantee
the accuracy of information provided by
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delete and change sections. The publisher Benefits of ´Springless´ Vane Actuators
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Valve World India & Middle East is a trademark
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The Netherlands. Managing wear in severe services Oil companies, audits and certification
©2023 All rights reserved.

Valve World India & Middle East | issue 27 | May 2023 3

 spotlight
FLOVEL VALVES PVT LTD: Unlocking the potential
of flow with precision for every application
The Mehta Family has
continued the legacy of
Mr. Mafatlal Mehta
with a history of
determination, skill,
and triumph through
their entrepreneurial
and leadership
abilities. The MRM
Group encompasses a
variety of successful
ventures, including
Metal Tubes (India),
M.Metal Tubes India
Pvt Ltd, Metallica
Tubes (India), Wao Loc
Instrumentations,
Forxar Industries Pvt Ltd,
Valvola Corporation, and
Flovel Valves Pvt Ltd etc.

Text by Mr. Mukesh Mehta
– Chairman of Flovel Valves
Pvt Ltd
Flovel Valves, a leading
company in industrial check
valve manufacturing, is
recognized for its exceptional
quality and innovation under
the umbrella of the MRM
Group. Even after over thirty
years, the company’s
innovative beginnings remain
at the heart of its current
principles. When creating a
new valve design, Flovel often
starts with an industry
standard like API 594 or API
6D and considers the end
user’s desired valve
performance for a given
application and set of service
conditions, prioritizing factors
like safety, reliability,
manufacturability, cost of
production, and marketability.
However, one of the most
critical design parameters,
reparability, is often
overlooked. To address this,
the company ensures
operational spares for all
valves for up to twenty years
of their working life. Flovel’s
dedication to design and
delivery integrity
complements its
commitment to innovation,
striving to provide cutting-
edge flow control products
to various industries
worldwide.
Ever-expanding portfolio
Since its establishment in
198 4, Flovel Valves has been
committed to providing
end users with high-quality
non-return check valves. Flovel Valves designed and built
the world’s largest dual plate
The company expanded its check valve, boasting a 104”
product offerings in 1986 by diameter.

Mr. Mafatlal R Mehta (Head of the Family): Mr. Mukesh M Mehta (Chairman):
A diminutive individual hailing from a A pivotal figure within the group,
small locality, Mr. Mafatlal Mehta Mr. Mukesh Mehta shoulders all
embarked on his journey in 1978 with a responsibilities and is a core
modest enterprise operating out of an member of his family. His penchant
80-square-foot rental office. Today, for taking the lead has propelled
Mr. Mafatlal Mehta has created more him up the ranks, and his
than eight successful companies through unwavering commitment to
hard work, integrity, and excellence. He excellence has solidified his
has built a culture of innovation and standing as a vital contributor to
progress, making his manufacturing and the Group’s triumphs.
engineering businesses a dominant force
in the industry.

4 Valve
Valve World
World India
India &
& Middle
Middle East
East || issue
issue 27
27 || MAy
MAy 2023
2023

Utilizing high-end software, the
company adds further value
to its existing portfolio and
provides a comprehensive flow
solution
creating and manufacturing
its own single disc check
valve. By 1988, Flovel had
incorporated a range of
dual plate check valve
options, and over time, the
company has developed
sizes ranging from two
inches to 104 inches, with
different classes ranging
from #150 to #2500,
capable of handling
pressures up to 30,000 P SI.
In response to market
growth and accuracy
requirements, Flovel has
also developed a range of
non-slamming axial flow
nozzle check valves, which
were introduced in 2006.
Under the guidance of its
Chairman, Sri Mukesh Mehta
and Managing Director, Shri
spotlight
Naresh Mehta, Flovel’s
Research and Development
team utilizes high-end
software such as SC Flow
and Solid Works to design,
analyse, and develop a new
range of bellow seal and
butterfly valves, adding
further value to its existing
portfolio and providing a
comprehensive flow
solution. Flovel’s product
designs adhere to major
international standards
such as ASME , API, BS, EN,
and ISO. The company is
currently working to extend
the lifespan of its valves by
improving the flow profile,
eliminating cavitation areas,
and reducing turbulence,
which will significantly
reduce energy losses,
contributing to a
sustainable future.
Cutting edge manufacturing
Flovel has several facilities that
house advanced equipment,
including seven automatic
vertical turning lathes, one of
which is three meters in size,
six automatic vertical
machining centres, one of
which is three meters in size,
ten conventional lathes, and
four welding machines,
including one automated
welding machine. With
forty-plus engineers having an
average of ten to twenty five
years of experience in the
industry, Flovel is capable of
manufacturing high-quality
valves of various sizes and
pressure classes.
Flovel Valves’ extensive
portfolio, which is built on
decades of experience, has
made it a specialist in
designing and
manufacturing check valves
for extremely sour, highly
corrosive, and severe
environments using
technological
advancements that carry
out corrosion resistant alloy
(CRA) and hard facing
overlays in a controlled
environment. As a self-
sustaining organization,
Flovel has an in-house
testing facility that
conducts various tests, such
as hydrostatic, pneumatic,
fugitive emission, high-
pressure gas, cryogenic,
high & low temperature,
type acceptance test, cycle
test, vacuum, fire-safe, and
all painting-related tests.
Key tests such as hydrostatic, pneumatic, fugitive emission, high-pressure
gas, cryogenic, high & low temperature, etc etc can all be performed
in-house
Quality is one of the most
important aspects of the
overall manufacturing
process, and Flovel has
invested in top-notch
quality control equipment,
such as spectrometers,
hardness testers, ultrasonic
testing machines, PMI,
impact & tensile testing
machines, and eight quality
inspectors with NDT LV 2 or
3 to ensure in-process
quality of the product.
Flovel Valves Pvt. Ltd.
boasts a team of forty-plus
highly experienced
mechanical engineers, each
with more than fifteen
years of experience in the
company, providing
consistent support to
customers throughout the
valve type and material
selection process to ensure
that the products meet

Mr. Satish M Mehta (Director): Mr. Ashok M Mehta (Shareholder):

A skilled entrepreneur who serves as An exemplary learner and a
the backbone of his family. He motivational force within his
consistently gives 200% effort to fulfil family. His contributions to his
his roles and responsibilities, executing family have been substantial,
them calmly and with unwavering and his accomplishments serve
dedication. He attributes his successful as an inspiration to individuals
endeavours and achievements to his aspiring to become successful
father and acknowledges his entrepreneurs.
contributions.

Valve World India & Middle East | issue 27 | MAy 2023 5


Flovel has invested in top-notch quality control equipment to ensure
in-process quality of all products
their performance
requirements.
The company’s objective is
to achieve a revenue of 150
Crores by 2025, and it plans
to achieve this using
cutting-edge technology, a
dedicated team, and
extensive experience. To
ensure the quality of its
products, Flovel strictly
controls every aspect of the
manufacturing process,
including design, through
total quality management.
With a manufacturing and
testing facility spanning
over 7000 sqmtr, Flovel is
capable of designing,
engineering, prototyping,
testing, and manufacturing
all under one roof. The
company’s continuous
investment in expanding its
manufacturing and testing
equipment has made it an
asset to clients globally.
spotlight
Global presence
Flovel’s extensive clientele
includes companies from
various industries such as
oil & gas, chemical,
petrochemical, energy,
offshore-onshore, district
heating, boiler service,
compressor & gas
industries. Moreover, the
company’s manufacturing
setup is highly regarded
and has been visited and
approved by EPCs
(engineering, procurement
& contracting companies).
See box on page 7.
To ensure clients’ needs
are properly met, Flovel
provides services to local
agents for maintenance,
repairs and operations
(MRO), enabling them to
serve their clients in full
capacity. The company is
recognized globally for its
ability to deliver products
on time and in compliance
with stringent technical
requirements and strict
quality tests.
Customer-centric
With a presence in over
65 countries, Flovel is a
competitive and successful
player in a fast-paced
industry that has urgent
needs to be met worldwide.
The company continues to
invest in growing its reach
by establishing local agents
to support sales throughout
Asia and to improve sales
and service in the Middle
East. This demonstrates the
company’s recognition of
the importance of a global
infrastructure in support
of its business, and its
commitment to better
serving the customer and
striving to be the best
solutions-provider for its
The company has an extensive clientele in multiple industries
clients. Flovel’s dedication
to expanding its reach is
exemplified by its efforts to
establish a global presence
and expand its reach to the
American and African
continents. Through this
expansion, the company
hopes to cater to huge
opportunities and increase
the overall export by 30%
in the region.
Most companies in the oil
and gas industry are
concerned about their
environmental impact and
are moving towards clean
energy. Flovel shares this
concern and is focused
on researching and
implementing solutions
that are environmentally
sustainable. Green
hydrogen and LNG are
some of the first steps that
the company is taking, and
it hopes to eventually
adopt more green

Mr. Naresh M Mehta (Managing Mr. Nirmal M Mehta

Director): (Shareholder):
He is the intellectual center of his A torchbearer who has
family, with a clear vision of demonstrated exceptional
making his company a world salesmanship through his
leader in manufacturing through dedicated and hardworking
advanced technologies and approach. He can serve as a
knowledge. He possesses model for future generations,
excellent leadership qualities and his accomplishments serve
and astute business acumen that as a source of inspiration.
can drive his company to
unprecedented heights of
success.

6 Valve
Valve World
World India
India &
& Middle
Middle East
East || issue
issue 27
27 || MAy
MAy 2023
2023
 spotlight
Global approvals
Flovel Valves has earned the approval of end user and
EPC companies such as:

• ADMA • NRL
• ADNOC • ONGC
• ADNOC Onshore • ONGC
• ADWEA • PDO Oman
• BG Exploration • Petrofac
• Bhel • PETRONAS
• Borogue • Qatar Gas
• BPCL • Qatar Petroleum
• CAIRN Energy • Reliance
• CPECC • Saipem
• Descon • SBM Offshore
With a presence in over 65 countries, Flovel is a competitive and • EIL • SBM Offshore,
successful player in a fast-paced industry • EIL-India • Takreer
• Essar Oil • Tata Project
technology. In the midst effectiveness in order to • Farabi • Technip
of the energy transition, better serve its customers.
• GASCO • Tecnicas Reunidas
Flovel’s goal is to support Through taking calculated
its customers with required risks and making strategic
• HPCL • Tecnimont

valves for both their investments, Flovel aspires

• IOCL • Thyssenkrupp
existing and emerging fields to earn the loyalty of its • Jacobs • TOYO
of clean energy, as this customers and position • Linde • UHDE
presents both challenges themselves as the top choice • MRPL • Worley
and opportunities. for any and all of their needs.
Flovel has always been
committed to providing the
best solutions for its
customers, and this
commitment has been a
driving factor in all the
company’s developments,
investments, and efforts.
Flovel firmly believes that
the customer is of utmost
importance, and this
principle guides every aspect
of its business. The
company’s goal is not just to
pay lip service to this
philosophy, but to actively
invest in improving its Sharing concerns about our planet, Flovel is researching and implementing solutions that are
service, quality, and cost- environmentally sustainable

Mr. Suraj M Mehta (Upcoming Mr. Jainam S Mehta (Upcoming Youth

Youth – Marketing & Sales): – Technical & Design):
He is regarded as the future of A valuable addition to his family’s
his family, currently in the business, currently in the learning stage.
process of absorbing knowledge He has a passion for keeping up with
and gaining valuable experience. the latest technologies and is a fast
He is a diligent and hardworking learner. He is a hardworking individual
individual, pursuing higher who has completed his studies and is
studies in London. His passion now pursuing higher education in
and determination are expected London. With his determination to learn
to enable him to create a legacy and succeed, he is sure to make a
and successfully achieve his significant contribution to his
company’s vision and mission. company’s vision and mission.

Valve World India & Middle East | issue 27 | MAy 2023 7


Proudly made in
India
A few weeks ago, a press
conference was held to celebrate
progress on the Chenab Railway
Bridge in the north of India. Once
operational (planned: December
2023/January 2024) the line will
provide faster connections for
passengers, encourage tourism
and speed up the flow of goods
to and from the region.
Looking at images, it is easy to
believe the bridge has been
hailed an engineering marvel.
With a total length of over 4,300
feet, the steel construction
elegantly spans the River
Chenab. According to reports, it
can withstand earthquakes
measuring 8 on the Richter Scale
and should still be going strong
120 years from now.
As an individual who can
appreciate the vision,
engineering skills and
determination of others, I salute
all involved in this mega-project.
In a similar vein, there are
plenty of folk who merit
acknowledgement in this
magazine. Take individuals such
as Dr. A S Khanna, Mr Jussi Hellman
and Mr Mohanned Tarabzouni,
who have a deep expertise of
issues such as coatings, valve
wear, and reliability management
programmes, respectively.
Others deserve acclaim for
developing businesses: the
Mehta family who have
positioned Flovel Valves as a top-
notch manufacturer of valves as
well as Mr Gautam Shah who has
helped shape Q-Tork as a
trusted source for gearboxes.
And to finish on another high
note, my congratulations to all at
MAGWEN for their ongoing
successes as an exporter. Not just
of valves, but of valves ‘proudly
made in India’.
David Sear
8 Valve
india news
Nagmur’s biogas plans
Nagpur Municipal Corporation
(NMC) has signed a memorandum
of understanding with
The Netherlands’ Sustainable
Business Development company.
This will make Nagpur the first city
in the country to produce
27 mcm of compound biogas
every year.
Work begins on India’s cryogenic facility
Work has begun on India’s
cryogenic manufacturing
facility in Savli in Vadodara,
Gujarat. INOXCVA Director,
Siddharth Jain presided over
the ceremony following the
signing of a Memorandum of
ONGC’s USD 7bn drive to boost output
Oil and Natural Gas Corporation
(ONGC) is stepping up a USD 7bn
investment over the next three-
four years to reverse years of
decline in oil and gas production,
the company’s director for
production Pankaj Kumar said.
Up to 24 field development,
enhanced oil recovery (EOR),
and improved oil recovery (IOR)
projects are currently in progress
that will further help reverse the
Valve World
World India
India &
& Middle
Middle East
East || issue
issue 27
A Rs 300 crore plant will
process 1,200 tonne of
municipal solid waste and
convert it into high-quality
compost, compressed biomass,
and recyclables daily. The
development will be on
30 acres of land allocated for
the plant at Bhandewadi.
Understanding with the
Government of Gujarat.
The project is to be constructed
on a green field site spanning 30
acres and will be India’s largest
manufacturing facility, with the
ability to fabricate over 20,000
MT per year of stainless-steel
equipment.
The new facility represents
an investment of INR 2bn
and will double the
manufacturing capability of
declining trend in oil and gas
production.
“Most of our fields are old where
the natural decline has set in. But
we are heavily investing in
technology to raise recovery as
well as tap isolated reservoirs,”
he told PTI. ONGC is investing
USD 5bn-plus in the development
of the Cluster-II region of its
flagship KG-DWN-98/2 asset in
the Krishna Godavari basin
27 || May
May 2023
2023
The company will undertake
the project through a local
partner and the solid waste will
be processed using the latest
global technology. It is expected
to significantly reduce the
emission of toxic gases into the
environment.
NMC and the company will hold
an equal share in the carbon
credit after processing the
waste. The agreement has been
prepared for 15 years, and there
will be a performance review
every five years, and further on,
it can be extended to 30 years.
the countr y’s entire
cr yogenic industr y.
It is expected to enhance the
manufacturing capacity of
storage and transportation
solutions for cryogenic gases like
liquid nitrogen, liquid argon,
liquid carbon dioxide, and liquid
medical oxygen, greatly
strengthening India’s medical
infrastructure. It will also have
numerous green fuel applications
for Liquid Hydrogen and LNG.
offshore India’s eastern coast. It
also has multiple field
developments in the west coast
region, including a planned fifth
phase of the redevelopment of
Mumbai High along with the
development of neighbouring
fields like Daman, he said, adding
these ongoing projects involve
an investment of Rs 60,000 crore
(more than USD 7bn) over the
next three-four years.
“We are investing in multiple
enhanced oil recovery (EOR)
and improved oil recovery (IOR)
projects,” he said. “In the fiscal
year ending March 31, we
managed to arrest the decline
in output after five years, and
from the current fiscal we will
see production rising.”

Dalmia Bharat progresses cement expansion
Cement manufacturer Dalmia
Bharat Ltd., which is currently
executing an expansion plan, is
working on its next phase of
expansion that will take its
capacity to 75 million tonnes
per annum (mtpa) by 2027 and
set it on its course to be a pan-
India player.
Under its current expansion
plan, it will be reaching an
india news
annual capacity of 54 mtpa by
the end of FY24, from its current
capacity of 39 mtpa.
In a recent meeting with
select analysts, the company’s
management said that it was
firm on allocating capital for
its core businesses while it
would be divesting non-core
holdings such as its stake in
India Energy Exchange to
focus on its growth. It has sold
about a 5% stake in the
energy exchange and still
holds about a 15% stake in it.
Over this financial year and
the next, the company’s
Capex of about Rs 10,200
crore will be partly met
through operating cash flows
of Rs 6,400 crore.
Dalmia Bharat’s management
expects cement demand to
grow faster than the country’s
GDP and the expansion plans
that have been set in motion
will equip it to meet that
demand and aid it in its
goal of becoming a pan-India
player. Through its expansion,
the company aims to
reduce its exposure to the
east-south region of the
country and by the end of
2024 to be present in the
western, mid, and northern
regions as well.
Nod for BPLC refinery exp.
Indian state-owned oil marketing
company Bharat Petroleum
Corporation Ltd has received
approval from the Madhya Pradesh
state government for expanding its
Bina refinery and setting up a
petrochemical project.
Bharat Petroleum will invest Rs
430bn (USD 5.27bn) to Rs 500bn
for the two projects, adding that
the petrochemical project
would start production by the
fiscal year 2027-28.
Billets and bars from MH
Ved Steels & Alloys is planning
to set up mild steel billets and
TMT bars manufacturing unit at
additional MIDC, Jalna in the
Jalna district of Maharashtra.
The proposed unit will spread
over 5.34 ha of the land parcel
and comprises the installation
of a 2x40 T induction furnace
to produce mild steel billets of
3,96,000 tpa and rolling mill
for 3,88,080 tpa TMT Bars by
hot rolled process, and 1,06,920
tpa by reheating furnace.

• Explosion-proof protection type Ex IIC T4

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installations
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• Large operating temperature range -65 - +75 Deg C

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• C5-M/C5-I or C5/CX Premium corrosion protection

Contact for business enquiries: Mr. Sanjay Kale

Email: sanjay.kale@auma.co.in Ph: +91 9763728625

Valve World India & Middle East | issue 27 | May 2023 9


L&T’s offshore deal
The Hydrocarbon Business of
Larsen & Toubro (L&T) has
recently secured multiple
offshore packages from a
prestigious client in the Middle
East. The scope of work
comprises engineering,
procurement, construction &
installation for various new
offshore facilities, and integration
with existing installations.
2200 mm goggle valve
india news
Asia will lead global midstream projects
Asia is set to witness the start of
operations of 402 midstream
oil and gas projects, accounting
for 31% of global upcoming
midstream oil and gas projects
starting during 2023 and 2027,
says GlobalData, a data and
analytics company.
GlobalData’s latest report, ‘Oil
and Gas Midstream New Build
and Expansion Projects
Analysis by Type, Development
Stage, Key Countries, Region
and Forecasts, 2023-2027’
highlights that the trunk/
transmission pipelines
segment dominates with 155 region during 2023 -2027. LNG
projects in Asia, accounting for regasification and oil storage
39% of the total upcoming segments follow with 115 and
midstream project starts in the 113, respectively.

Chemtech Industrial Valves has

successfully manufactured and
supplied a DN 2200 mm goggle
valve to a copper plant in West
India.
This critical supply is a continuous
testimony to the goodwill which
the company enjoys with its
customers for critical man-safe
isolation solutions such as goggle
valves. This goggle valve was
supplied within a record time of
four months. The valve measures
30 feet in length, is 6 feet wide
and 11 feet in height. Further,
the valve weighs a staggering
12 metric tonnes.
Chennai awards desalination plant DBO
Va Tech Wabag has won a
design, build, operate order
from Chennai Metropolitan
Water Supply and Sewerage
Board (CMWSSB) for building
400 million litres per day sea
water reverse osmosis
desalination plant at a total
cost of about Rs 4,400 crore.
The project has been funded by
Japan International Cooperation
Agency (JICA) and seeks to
improve Chennai’s water
security through a stable source
of drinking water in the form of
desalination.
The project will be executed by
WABAG in a joint venture with
Metito Overseas Ltd. Once
completed, the project will be
the largest desalination plant in
the South East Asian Region.
The contract includes design,
engineering, procurement,
construction, installation, testing,
and commissioning of the
desalination plant and the
associated sea water intake system
over 42 months followed by twenty
years of operation & maintenance,
according to a statement.

10 Valve
Valve World
World India
India &
& Middle
Middle East
East || issue
issue 27
27 || May
May 2023
2023

Fuel cell facility planned in Gujarat
Advait Infratech said it has
signed a memorandum of
india news
understanding with China’s
Jiangsu HuaDe Hydrogen Energy
Technology Co for setting up a
fuel cell manufacturing facility
in Gujarat. The design will be
developed by the HuaDE with
technology vested with it.
Advait will manufacture the fuel
cell systems in India, the
Ahmedabad-based company
said in a statement.
The fuel cell manufacturing facility
in Gujarat will use the latest
technology and equipment.
Advait’s strong presence in India’s
infrastructure sector and HuaDe’s
expertise in fuel cell technology
are expected to create a winning
combination driving growth.
This partnership is in line with
Advait’s commitment to building
sustainable infrastructure in India.
The fuel cell manufacturing
facility is expected to create new
jobs and contribute to economic
growth. Recently, the company
had also been awarded a green
hydrogen project by the state-run
THDC India. The pilot project is
aimed at demonstrating the
feasibility of using hydrogen as a
medium for storing renewable
electricity.

2000 cr expansion for Tinplate Company

Tinplate Company of India
Limited (TCIL), a Tata Steel
subsidiary, kicked off a Rs 2,000
crore expansion project capacity to 7 15,000 tonnes R N Murthy, managing director,
recently with Hemant Soren, by 2 026. TCIL , said the expansion was a
Chief Minister of Jharkhand, According to a company significant milestone in the
performing the groundbreaking statement, the upcoming company’s growth and
ceremony. facilities would have state-of- commitment to the state.
T CIL’s current capacity is the-art technology and higher “We are committed to
415,000 tonnes and the first levels of automation to cater to partnering with the
phase of expansion, which domestic and export markets, Jharkhand government and
involves an investment of minimise man-machine local communities to
around Rs 2,000 crore, interface, enhance safety promote the economic and
would add another 300,000 aspects, and designed to meet social development of the
tonnes, taking the total the EU environmental norms. region.”

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Valve World India & Middle East | issue 27 | May 2023 11


Functional and smart coatings
In the third of his series of six articles on coatings, Prof.
A S Khanna, Retd. IIT Bombay, Chairman SSPC India,
addresses functional and smart coatings. Functional
coatings correctly describe its utility for a particular
paint application. It is also possible to manufacture a
coating based upon the function required for a
particular substrate or surface.
Introduction
From the basic definition of
paint coatings, they are
generally used to improve
the aesthetics of a surface,
or its corrosion protection.
However, there are several
examples in industry, where
the requirements cannot be
met by these two simple
nomenclature. So the term
functional coating has been
introduced which not only
covers these two basic
functions but also performs
an additional specific
function. In fact, the best
way to explain a functional
coating is that it enhances
the functional capability of
a paint coating. Thus, a
functional coating, as the
name suggests, is designed
and used to solve a
particular functional
issue of a substrate.
There are several examples
to illustrate various
functions:
• Resistance from some
strong chemicals
• Water repellency –
hydrophobic surface
• Scratch and abrasion
resistance
• Anti-reflection coatings
• Solar heat reflection
coatings
• Making the surface
conductive
• Anti-glare and anti-fog
coatings
• Water proofing of a
surface
• Anti-graffiti property in
the coating
12
Coatings
• Anti dust pickup
• Anti-microbial and anti
fouling coatings
Functional coatings are a
type of materials that can
be specifically designed for
a variety of applications in
which they must be able to
carry out a defined function
or range of functions. They
can be organic, inorganic,
or hybrid. In countless
applications that are
part of our daily lives, there
are numerous functional
coatings. Functional
coatings are used on a
variety of products,
including household
furnishings, automobiles,
laptops, mobile phones,
solar panels, and more
complex items like
orthopaedic implants
and medical equipment,
invisible paints, radars, and
satellites. More recently, the
term “smart coating” has
been used to describe
functional coatings that can
react to specific stimuli
brought on by either
intrinsic or external events.
It is also possible to
combine some of these
functions to carry out more
than one function in a
coating [1-3]
Science and technology
of functional coating
How functional coatings
differ from the so-called
conventional coatings? Are
they altogether different
coatings with different
Valve
Valve World
World India
India &
& Middle
Middle East
East || issue
Fig. 1: Technical Data Sheet of an epoxy based nano coating whose
function is to resist a steel surface from highly acidic or alkaline
environment
composition, including
polymers, pigments or
additives or they use
different concept of
synthesis and formulation
technology? Answer is both.
In some cases, the base
polymer needs to be very
rugged and robust, in
other cases, a specific
combination of pigments
and additives works, while
in a few cases, special
concept of surface
properties is undertaken.
For example, a highly
corrosion resistant coating
with long durability can be
created by just changing a
basic epoxy with a phenolic
epoxy which resists
corrosion and enhances
durability due to better
cross-linking and rigidity.
Another method of
enhancing corrosion
resistance is to add special
pigments such as MIO, or
glassflakes in epoxy, which
enhance the permeability
resistance of the coating.
issue 27
27 || May
May 2023
2023
Another very recent
method is to add nano-
particles which enhance
corrosion resistance and
mechanical properties to an
extreme level. Very recently,
we made an acid resistant
coating from a basic epoxy
by adding very special
nano-particles which
provided us a coating which
can resist any acid
(sulphuric, hydrochloric or
nitric), any alkali or solvent.
It passed almost seven days
continuous immersion test
in each, 50% sulphuric acid,
10% hydrochloric and 10%
nitric acid, 10% sodium
hydroxide etc. and 4000h
of salt spray test. Also, its
temperature resistance
increased from a normal
110°C to 250°C. Figure 1
shows the Technical Data
Sheet of this coating. Its
functionality suits especially
for battery pit in ships and
submarines or for pickling
plants and for refineries and
petrochemical plants [4].
 Coatings

Fig. 2a: Formation of epoxy precursor using Sol-gel process followed Fig. 2b: Hydrophobicity on glass, cloth, wood and paper substrate [5]
by reaction with a fluro-based resin to give saturated coating

Hydrophobic coating
Let us now illustrate the
example of a functional
coating which is the base
for several important
functions in paint coatings,
such as water repellence,
self-cleaning, anti-glow
coatings etc. The first step is
to develop a hydrophobic
coating. The hydrophobic
coatings are defined as
those in which a water drop
makes a minimum contact
with the surface, which is
determined by the angle of
contact the water drop
makes with the surface. If
the contact angle is more
than 90°, it is called a
hydrophobic coating.
Coatings with contact angle
lower than 90° are classified
as hydrophilic coatings
while those having contact
angle more than 150° are
called super- hydrophobic
or oelo-phobic coatings.
The first step in making a
hydrophobic coating is to
create a low energy coating,
also called a well saturated
coating surface having
minimum reactivity to the
environment. For this, the
resin must have a C-F bond.
A demonstration of the
synthesis of such a coating
using Sol-gel process is
given in Figure. 2a.
An epoxy base precursor is
formed using a Si-based sol
(MTMS) which is allowed to drops slide over the surface
react with an epoxy resin resulting in self-cleaning. A
having at least one OH very interesting self-
group in the chain. This is cleaning coating, effective
then reacted with an amine on glass, cloth, plastic,
to create good cross- wood or concrete surface
linking, followed by was made successfully [5].
reaction with a fluro-based
resin. Such a coating results Self-healing coating
with hydrophobic The next example is the
properties as shown in development of self-healing
Figure 2b. However, to make coatings. Many coatings
this coating self-cleaning, even having a long design
the surface roughness of life, crack with time due to
the coating needs to be excessive weathering
reduced as well as to conditions such as extreme
create a lower sliding angle. sunlight, rain or snow or
This is achieved by reacting natural climate change
it with nano-particles such during hurricanes and
nano-ZnO or nano-Silica, strong wind conditions.
which makes these water These small cracks further

Halloysite nanotube (HNT’s)

Coating system A Coating system B Coating system C

@ pH=6
Inh-
0h

Loading

Inhibitor (Inh-) Washing and

Drying
40
Acidic Inh- release
Surface Potential in mV

30
20
mechanism
10
0
@ pH=10
2 4 6 8 10 12
24 h

-10
-20
pH
-30 Alumina
-40
-50
-60
Halloysite Inhibitor loaded HNT’s
Silica
-70
Alkaline

Fig. 3a: Example of self-healing coating in which the paint system Fig. 3b: Example of self healing being controlled by Halloysite
was modified by the addition of micro-spheres containing healing nanotube containing inhibitors which release on change in pH
material (linseed oil) in two different concentration resulting in during cracking and heal the crack [6]
varying time for healing for the scratch made

Valve World India & Middle East | issue 27 | May 2023 13


Fig. 4a: Lightning which can destroy an aeroplane part where it falls
damage the coating leading
to re-application of coating.
Self–healing helps to bridge
the small cracks thus
formed, leading to the
repair of such damages. This
exactly works on a similar
principle of crack or cut
formed on our skin due to
some bruise or cut, which
automatically cures due to
the presence of curing cells
in our blood. Method of
self-healing is basically
similar, if the equivalent
of natural cells in blood
are added in the paint
formulation right in
the beginning of its
manufacturing. There are
two important methods of
creating such cells, which
hold the anti-corrosion or
healing material which has
tendency to heal the crack.
It is possible to make the
anti-corrosive material
enclosed in small
microspheres using the
anti-corrosive material,
being exposed in a rotating
system which allows the
anti-corrosive material
stored in these spheres
acting as the healing
material and reach
immediately to the broken
or cut paint area and heal it
immediately. In the second
approach, Halloysite
nano-tubes, were used to
14
Coatings
hold the healing material.
These nano-tubes hold
them at a particular pH and
release them if this pH
changes. So when a paint
coating is damaged due to
some abrasion or scratch,
the pH at this point
changes, resulting in the
release of healing material
at the spot, leading to the
cure of the crack. Such
coatings were developed by
us and an example of
healing process is shown in
Figure 3a and Figure 3b.
Conductive coating
Another important example
of a functional coating is to
make a conductive coating.
Usually organic coatings are
insulating coatings which
are responsible to cut the
flow of electrons and
thereby reduce the
corrosion of metal
substrate. However, there
are several examples where
a partial conductivity is
needed on the coated
surface, such as for anti-
static coatings or coatings
which spread the electrical
charge very quickly over the
whole component surface.
A very special application is
the development of a
conductive coating for
aeroplane skin to counter
the damage due
Valve
Valve World
World India
India &
& Middle
Middle East
East || issue
12
10
Conductivity (S/cm)
8
0 10
2 4 6 8
% Weight of Graphene & Carbon Fibre
Fig. 4b: Results of the conductive coating developed by optimizing
the graphene, carbon fiber and carbon nanotubes
to lightning during polythiophene, which
thunderstorm (Figure 4a). provide adequate
For such applications, a conductivity and protection
conductivity of more than against corrosion for
5S/cm is required. There are aluminum alloys [7]. One
many formulations, which major drawback with these
use conducting polymers conducting polymer
like polyaniline (Pani), materials is their low
polypyrrole (PPy), solubility and fast
About the Author
Dr. A S Khanna, a retired
Professor from Indian
Institute of Technology,
Bombay, after 27 years of
teaching and research,
guiding 27 Ph.D’s, 125
Masters and creating
research expertise in High
Temperature Corrosion,
Coatings, Surface
Engineering, Corrosion of concrete structures and
nano-coatings. He has won several International
Awards such as Humboldt Fellowship from Germany,
Royal Norwegian Fellowship from Norway, Fellow of
Japan Key Centre and worked as visiting Professor in
Germany and France. He has written three books and
edited four books. He has published more than 300
papers in several International and National Journals
with more than 4500 citations. He is a coating expert
and is associated with Hindustan Zinc for several
assignments related to galvanization and its
applications, Sterling & Wilson for selection of sites
for solar power plants, oil & gas industry for
consolation on coatings for underground pipelines
and offshore structures.
He can be reached on: Anandkh52@gmail.com
issue 27
27 || May
May 2023
2023

disintegration. A very recent
method of making
conductive coating is by the
addition of graphene. The
unique 2D structure of
graphene combined with
the free pi electrons of C
atoms; make graphene a
highly electrically conductive
material (more than copper).
Other carbon allotropes like
carbon nano-tubes (CNT) also
possess high conductivity. We
made such kind of coating for
Boeing aeroplane. The coating
was made using 5% of
graphene, 5% of carbon fibers
and 2% C nano-tubes (Figure
4b). The coating formed
showed a conductivity of 3S/
cm [8] but did not possess
good mechanical properties.
In the same way one very
important coating made was
to create the anti-glare and
anti-fog function to avoid
accidents during driving due
to glare from vehicles coming
Coatings
from opposite side. In the
same way anti-fog function
helped in avoiding fog on
spectacles. Detailed
information is available in the
patent [9].
Conclusions
Functional coatings
correctly describe its utility
for a particular paint
application. It is also
possible to manufacture a
coating based upon the
function required for a
particular substrate or
surface. The paper describes
a few important functional
coatings. The manufacturing
of functional coatings can
depend upon the type of
resin to be used, a
combination of different
pigments and additives or
by using nano-additives.
This description helps to
understand the proper
utility of protective coatings.
References
[1] M
 .F. Montemor, Functional and smart coatings for
corrosion protection, Surface and Coatings
Technology, 258 (2014) p17-37
[2] https://www.paint.org/coatingstech-magazine/
coatingstech-topics/technologies/functional-
coatings/
[3] F unctional Coatings, https://encyclopedia.pub/
entry/27351
[4] M .Tech Thesis, Banti Kumar Singh, IIT Bombay
2017-18
[5] G arima Verma and A .S.Khanna, International
Journal of Scientific Engineering and Technology, 2
(4), 2013 p192-200
[6] K aran Thanawala, A .S. Khanna, Development of
Self-Healing Coatings Based on Linseed Oil as
Autonomous Repairing Agent for Corrosion
Resistance, Materials 2014, 7, 7324-7338;
[7] G unjan Gupta and A S Khanna, Int. J. Electrochem.
Sci., 8 (2013) 3132 - 3149
[8] K aran Thanawala, Thesis Boeing Report, IIT Bombay,
2018
[9] P atent No. 407897, 28.9.22, Anti-glare, hydrophobic,
scratch resistant and anti-fog coating.

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Valve World India & Middle East | issue 27 | May 2023 15

 Regional news
Kazakhstan butadiene plant award
Lummus Technology, a global provider of produce 85,000 MTA of isobutylene,
process technologies and value-driven energy 120,000 MTA of butadiene, and 40,000 MTA
solutions, announced Butadiene LLP has of methyl tert-butyl ether (MTBE). These
selected its iC4 CATOFIN®, CATADIENE®, products will feed Butadiene LLP’s new
CDMtbe® technologies, and BASF’s butadiene synthetic rubber production facility and
extraction technology for units at Butadiene supply the local Kazakhstan transportation
LLP’s new petrochemical plant in Atyrau, fuels market.
Kazakhstan. In addition to the licensed technologies,
The scope of this award includes the Butadiene LLP will have access to Lummus’
technology license and basic engineering portfolio of lifecycle services during the training simulators, extended
for four process units. Once complete, the implementation and operation stages of technical support, and digitalization
units will upgrade a mixed butanes feed to this project, such as advanced operator services.

‘Green’ metallics
plant for Oman

Oman’s Public Authority for Special

Economic Zones and Free Zones
(Opaz) has signed an agreement with
Kobe Steel, a leading Japanese steel
manufacturer, and Mitsui & Company,
a global trading investment company
for setting up a low CO2 iron
metallics project in the special
economic zone at Duqm.
As per the deal, the duo will
commercialise the manufacture and
sale of direct reduced iron (DRI)
produced through Kobe Steel’s
Midrex Process in coordination with
Opaz. Under this Midrex Process, the
iron oxide gets converted into DRI
inside the shaft furnace using
hydrogen-rich gas coming from
natural gas or hydrogen as a reducing
agent. Over 90 such Midrex plants are
in operation across the globe.
Kobe Steel said it has, along with
Mitsui, sealed a land reservation
agreement with the Port of Duqm
Company (PODC), the entity that
operates the Omani port. The
Japanese groups also held discussions
with Oman’s Ministry of Energy and
Minerals on detailed conditions for
natural gas supply. Having confirmed
the site and cooperative framework in
Sezad, Kobe Steel and Mitsui will now
move the feasibility study forward, it
added.

16 Valve
Valve World
World India
India &
& Middle
Middle East
East || issue
issue 27
27 || May
May 2023
2023
 Interview
From components to gearbox
in 90 seconds
Since moving into the gearbox manufacturing business

just nine years ago, Q-Tork Automation has established

itself as a supplier of choice to valve manufacturers and

end users in India and overseas. CEO Gautam Shah was

kind enough to discuss what it takes to achieve success

in this sector.

By David Sear The optimum gearbox

Setting up a business is
relatively easy. What comes
next – sustaining and
growing that business – is
the hard part. Fortunately,
Mr Gautam Shah and his
colleagues at Q-Tork
immediately had a clear
vision on how they wished to
conduct their operations.
“From the start, we focussed
on being very responsive to
customers’ needs. Our
development and
production processes are
therefore able to adapt
quickly. For example, with
our efficient manufacturing
set up we can produce a
single, standard gearbox
within 90 seconds via
channel assembly. This
flexibility has helped us to
gain market share amongst
valve manufacturers in India
and abroad.”
Speaking of customers,
Mr Shah notes the importance
of honesty and transparency,
especially when dealing with
complaints. “In fact, I would
say we appreciate criticism
from clients as honest
feedback is the best way to
learn. Equally important, it
gives us the opportunity to
put matters right.”
This approach has clearly
paid off, as today Q-Tork
boasts 65+ people working
in its gearbox factory.
At face value gearboxes
might appear to be very
simply – they are
uncomplicated mechanical
devices which transmit
power from an actuator to a
valve. However, Mr Shah says
their role must never be
underestimated. Mr Shah:
“The gearbox could for
example represent just five
per cent of the total cost of a
complete valve yet that
gearbox needs to work
perfectly each and every
time. After all, if the gearbox
fails, then the valve may not
cycle as expected or may fail
to operate at all! Therefore,
gearbox selection should
never be overlooked. The
person responsible for
selection must be familiar
with how forces work and
also understand the subtle
differences in gearbox
designs in order to ensure
the valve will operate as per
the customer’s needs.”
Q-Tork staff are of course
always willing to help clients
identify the optimum
gearbox for each specific
application. However,
Mr Shah says customers
could help by ensuring they
have key details at hand. “We
have gearboxes for valves
designed for quarter-turn or
multi-turn operation.
Therefore, having data such
as the valve specifications,
the pitch circle diameter,
the valve torque or thrust,
etc, is essential. Even for
repeat clients we check to
ensure the gearbox they
have in mind will deliver the
expected functionality.”
As a parting comment, also critical for gearboxes. In
Mr Shah notes that all fact, I would also advise
materials have to meet anyone looking to source
demanding quality gearboxes to first ask
requirements given the whether their prospective
forces gearboxes can have to supplier simply replies on a
handle. “We have a very one-time validation - which
strong inward quality checks may have taken place years
to ensure all raw materials previously - or conducts a
and components are up to thorough quality check on
standard. Final inspection is each and every batch.”
Three questions for Mr Shah
How do you relax after work?
I enjoy family time – I have three children – and also
practise yoga for the physical and mental benefits.
What is your management style?
I empower staff and let them get on with their jobs, only
becoming involved if really needed. I believe in giving
people the freedom to make mistakes and to learn from
those mistakes.
How have you enjoyed the past nine years?
Starting a business is inevitably a challenging experience
and of course from time to time there may be concerns
about whether everyone’s hard work will pay off. But I
have always found my role to be very rewarding and am
delighted to say that Q-Tork is on a solid footing.

Valve World India & Middle East | issue 27 | May 2023 17


Managing wear in severe services
Wear in valves is surely
an important concern
for plant owners and
operators. Eroded
valve internals can
have a long-term effect
on the functioning and
profitability of process
facilities. Materials
such as ceramic
reinforced metals can
be a good solution to
increase component
lifetimes in industries
such as oil and gas, says
Valmet’s Mr Jussi
Hellman.
By David Sear
Mr Hellman is a man with a
mission. His goal is to help
people like refinery owners
to boost plant availability by
increasing the lifetime of
valve components. He does
this be deploying Valmet’s
deep knowledge of applying
a whole range of materials in
severe applications.
Recently, for example, he
spoke to this magazine about
how to manage valve wear in
fluid catalytic cracking (FCC)
slurry oil service (see Figure 1).
“FCC units are used in a
refinery to convert heavy
Fig. 1: Representation of the fluid catalytic cracking process, with the fractionator bottom slurry valves
highlighted. NB: This diagram was originally published in Valmet’s Fluid Catalytic Cracking application
report and should not be viewed as an actual process flow diagram
18
Materials
A ball valve for FCC bottom slurry control service: trim and changeable flowport liners made of solid
MMC material.
feedstock into lighter, more
valuable products. Such units
are especially valuable in
refineries trying to maximize
gasoline production over
residual fuel oil. However, the
catalysts required in this
conversion process can cause
problems as they have a
tendency to accumulate in
the bottom slurry, despite the
use of settling tanks and/or
filters. Such catalysts are
erosive, causing challenges
for items such as valves,
pumps and piping,”
commences Mr Hellman.
Mr Hellman therefore works
with refineries to find the
Valve
Valve World
World India
India &
& Middle
Middle East
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optimum materials solution.
“Complete elimination of
wear is not always a realistic
objective. Therefore, what
happens when a worn valve
is identified for replacement
depends on the operating
strategy of the plant owners
as they look to increase
availability targets. I
therefore help them to
assess tolerable wear rates,
taking into consideration
factors such as the
expected future lifetime
of the system, the cost
of system repair or
replacement, the costs of
future interruptions in plant
issue 27
27 || May
May 2023
2023
uptimes, the likelihood of
valve jamming, etc.”
Materials options that
Mr Hellman can bring to the
table include thermal spray
coating, weld overlays,
ceramic reinforced metal
matrix composites (MMC),
metal reinforced ceramic
matrix composites (CMC)
and ceramics – see Table 1
and Figure 2. Each material
has its own list of
advantages and
disadvantages, he notes.
These include the wear
resistance but also other
technical issues such as
bond strength, robustness,
Jussi Hellman is Materials
Engineering Manager in Flow
Control BL, Valmet
 Materials
Table 1: Valve configuration materials

Thermal spray
Weld overlay MMC armoring MMC inserts Ceramic inserts
coating
Thickness 0.1 – 0.3 mm 1 – 3 mm 3- 15 mm Solid MMC Solid ceramic
Wear resistance ++++ ++ ++++ ++++ +++++
Closing members Closing members Flowports (+trim Closing members, Closing members,
Feasibility
(+ flowports) (+ flowports) bores) flowport liners flowport liners
More is more, changeability, Changeability,
Benefits cost Bond strength
robustness shock resistance uniformly hard
Wear allowance, Limited materials Softer than solid Crack sensitivity,
Drawbacks/ risks Increased cost
detatchment options ceramic limited ATEX

shock resistance, uniformity, as the oil and gas sector.

crack sensitivity, use as
inserts and/or closing
members, etc. “Of the two
composite forms it is the
MMC type that has
particular merit for valves
destined for severe
applications such as slurry
oil. That’s because MMC
items are mechanically very
reliable, which is a key
priority for the valve sector,”
comments Mr Hellman.
Life cycle cost analysis
Ceramic reinforced
composite materials may
sound new to many in the
valve industry but the
materials themselves were
invented in the 1920s.
Moreover, these materials
have since proven their
effectiveness in a range of
applications. “Valmet’s
history of deploying MMC
materials into products
dates back to the 1990s, with
parts destined for use in
minerals processing as well
Ceramic reinforced metal matrix composites
(MMC)
Fig. 2: Representation of the relative composition of MMC and CMC materials
These early success stories
lead to the use of MMC
materials in other Valmet
products such as valves from
around 2010 onwards,” states
Mr Hellman.
“Having a track record was a
major help when talking to
the first potential valve
customers in conservative
industries such as oil and
gas. We were able to
demonstrate that MMC
materials are both effective
and safe. And over the years
we have amassed a vast
number of references and
images which clearly show
how well MMC materials
perform over time.”
Interestingly, companies
wishing to use such advanced
materials in their products
cannot simply go out and buy
MMC ‘off the shelf’ as it were.
Instead, manufacturers
purchase the raw materials
from which they create the
ceramic-metal composites
themselves. Fortunately, from
Metal reinforced ceramic matrix composites
Catalysts used in fluid catalytic cracking processes can cause severe
wear in metallic construction materials (left), but also in ceramics
(right) when the process must run for years without interruptions.
an end-user perspective this
step is not a hurdle.
Be that as it may, materials
such as MMC will inevitably
cost more than less exotic
options. However, Mr
Hellman stresses that they
can in fact quickly work out
to be less expensive for
purchasers. “Ceramic
reinforced materials are by
no means cheap so the
initial investment will likely
be higher than standard
options. However, when
applied in highly
engineered products,
(CMC)
ceramic composites can be
incredibly cost effective. By
limiting valve wear,
advanced materials can
significantly reduce
spending on both planned
and unplanned downtimes,
bringing significant savings.”
Mr Hellman therefore sees
great potential for the use
of ceramic reinforced
composites in the wider oil
and gas industries as well as
other sectors such as mining
and metals. “If you have
valve challenges caused by
erosive or corrosive media
then maybe it is time to talk
to us about ceramics and
composite materials. And
installing a long-lasting
valve wont just increase
your process availability, it
will also help promote
energy efficiency. That is an
issue we are surely all
interested in and is yet
another reason why I derive
so much satisfaction from
being able to bring
advanced material solutions
to the market.”

Valve World India & Middle East | issue 27 | May 2023 19


Indian valves for offshore projects
MAGWEN recently shipped various non-slam nozzle
check valves, intended for hydrocarbon applications in
South-East Asia.
By Lucija Kozina
Asked about the order,
MAGWEN’s Managing Director
Mr Bhowmick Shah said there
were in fact two separate
contracts. Both were from the
same contractor but for
different end users. One
shipment was intended for an
FPSO and the other for
offshore production platforms
in South-East Asia. Giving
specifics, Mr Shah noted that
the orders were for non-slam
nozzle check valves for
hydrocarbon application on
lines ranging from 4” bore up
to 10” bore. The valves were
rated at #150 up to #900 and
they are all metal to metal
20
Case history
sealed with high quality
hardfacing. The #900 valves
were made from super duplex
steel in order to enable sour
gas service which also
confirms their top-quality.
Mr. Shah is proud to say the
company have once again
proven their capability for
taking on new challenges.
“For example, the #900
valves were gas tested from As stated by Mr Shah, these segment of the oil & gas
20 to 160 bar, metal to metal orders may not have been industry. “MAGWEN can
seat with zero leakage. But I large but will surely prove to proudly say that we have
believe the most important be significant in the future once again confirmed our
criteria in the client´s and provide more slogan “Born in Germany,
decision to choose these opportunities to work with proudly made in India” seeing
valves was the fact that the old and new contractors in as these valves were
fast action nozzle check valve South-East Asia, especially completely made in India
comes with anti-surge when it comes to offshore from design to delivery,”
properties.” application in the upstream concluded Mr Shah.
Valve
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 Safety
How Aramco is safeguarding
pipeline valves
In the oil and gas
industry, safety of
plants, personnel and
the environment are
always a top priority.
This article first
introduces Aramco’s
pipelines in general,
then provides an
overview of valves
typically used in
pipelines, before going
deep into the
company’s Valve
Reliability Management
Program.

By Mohanned Tarabzouni
and Saleh Humidi
Introduction
One of Aramco’s missions
when it comes to
hydrocarbon pipelines is
to transport the Kingdom’s
hydrocarbons with the
highest standards of safety,
reliability and efficiency
by empowering competent
teams to apply innovative
methods and state of the
art technologies. Aramco
uses these pipelines
to transport several
hydrocarbon products
such as oil, gas and
refined products from its
Targetting critical valves, Saudi Aramco’s “Valve Reliability
Management Program” is designed, amongst others, to improve
valve performance by addressing major causes of failures
origin to all across the
kingdom.
Pipeline valves overview
Pipeline valves are governed
by API 6D which includes ball,
gate, plug and other types of
valves. The most common
types found in pipeline
networks are ball, gate and
plug.
Ball valves
A ball valve is an on-off or a
shut-off valve. It is a
quarter turn valve and is
used where quick and
frequent operation is
essential. Full bore valves
are used in pipelines which
are often subject to scraping
operations and require the
bore of the ball valve to
match the internal diameter
of the pipeline. See Figure 1.
Gate valves
A gate valve is a valve
which opens by lifting a
gate out of the path of the
fluid. These valves require
little space along the pipe
axis and hardly restrict the
flow of fluid when the gate
is fully opened. Gate valves
are mostly used with larger
pipe diameters since they
are less complex to
construct than other types
of valves in large sizes. See
Figure 2.
Plug valves
A plug valve is shaped like a
cylinder or cone and can be
rotated inside the valve body
to control flow of fluids. Plug
valves have one or more
hollow passageways often
placed horizontally to allow
ease of flow through the valve
when open. See Figure 3.
Program objective
The “Valve Reliability
Management Program”
targets critical valves, which
provide safe isolation in
pipelines during emergencies
and major operational
shutdowns.
The program will capitalize
on assessing critical valves in
the field of integrity and
reliability, enhance current
procedures and practices as
well as elevating the work
force skills, knowledge and
competencies. As part of this
program, a team was formed
consisting of several entities
to evaluate and improve the
current pipelines critical
valves performance,
reliability, integrity including
life cycle. The collaboration
helped achieve the
following:
• Improve valve performance
by addressing major causes
of failures
• Enhance maintenance
response both for
preventive & corrective
maintenance
• Adapt from reactive to

proactive maintenance
strategy
• Reduce major incident

hazards and their impact
on people, assets &
environment.

Valve World India & Middle East | issue 27 | May 2023 21


Fig. 1: Typical designs of ball valves
Scope
The scope of work for this
study include the following
tasks:
1. Critical Valves Data Base
Development
• List all critical valves
across the facility’s
pipeline systems and
stations
• Identify bad acting and
 troubleshooting. A total
frequently failing valves
• Review the maintenance,
 identified and listed.
repair history and
equipment data.
2. Reliability Analysis for
Critical Valves
• Conduct critical
assessment of commonly
failing valves
• Identify and analyze
 important and will be a
reported failure modes.
The program structure
consisted of two main phases
which included data
collection, development and
detailed analysis.
Phase 1 critical valves data
base development
As the base line of the
program, the first step resulted
in establishing a data bank
that includes listing all critical
valves across each operational
area such as critical
equipment isolation valves,
main isolation valves in pump
stations and other identified
critical valve functions. This
task included extensive review
of all reviewed valves across
the area’s facilities and
stations. Developing this list
included collecting all valve
related information such as
22
Safety
design, operator mode,
pipeline service, failure history,
repair orders and several
others. This is also included
reviewing the annual
maintenance history and
identifying failure modes as
well as the man-hours count
for each repair job of any valve
that experienced
number of 614 valves were
Phase 2 critical valves
asset management study
As valves are one of the main
components for any industry
pipeline network, reviewing
reliability for valves is very Fig. 2: Some typical gate valves
useful tool to improve the
overall pipeline network
performance and safety. To
minimize the impact of valve
failures, it is crucial to identify
those valves and the most
severe consequences in
terms of safety and
performance on the system.
In this section, the critical
Fig. 3: Some typical designs of plug valves
valves data bank developed in
phase 1 will be evaluated
based on the maintenance remediation approaches. pipelines network. The
history and failure frequency Finally, phase 2 will be assessment also showed that
for valves and analyze existing concluded with the selected operational area
related SAP data including but recommendations to ensure has a total of 219 top critical
not limited to, specifications, bad acting valves are valves, classified as per Table 1.
operator type, class, service, addressed. In this assessment, the
repair orders and failure The conducted valve average Mean Time Between
reports. criticality assessment Failures (MTBF) and Mean
Additionally, all frequently identified critical isolation Time to Repair (MTTR) was
failing valves will be classified valves of stations, major estimated for all the selected
as bad actors and that will be equipment and crossing as top critical valves (219 valves)
followed by a detailed analysis well as sensitive locations as based on 73 failed valves
highlighting failure causes and the most critical in the between 2015-2022.
Valve
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 Safety
Major findings 73 critical valves is around Table 3: Valve failures classified per operating mode
This analysis identified the 35 months calculated Operating mode Total Failed % of total
following major findings: based on the MTBF for failed valves
• 73 valves out of the total each valve and its mean GOV (gas operated valve) 48 11 15%
219 failed time to repair is 2 months
HOV (hydraulic operated valve) 18 6 8%
• 
These valves are • All failure modes have
distributed in four areas as been considered with the MOV (motor operated valve) 151 55 75%
shown in Table 2. same impact on valves but Manual 2 1 1%
Based on area location, it was a different period of repair
Total 219 73
found that Areas I and II was considered including
represent 41% of total valves 8 hours for annual
Table 4: Target valves classified per criticality class
while these represent 62% of maintenance
total top critical valve failures. • The total operating time Classification Total Failed % of total
In general, 50% of Area I & II for all critical valves is failed valves
valves experienced failures. around 12,000 months. It Critical 72 20 27%
These valves are distributed means that the MTBF for
based on three operating 219 critical valves is 160 Non-critical 40 26 36%
modes, as shown in Table 3. months based on 73 Isolation 80 16 22%
Based on operator type, it was failures
Others 27 11 15%
found that motor operated • From the above findings, it

valves (MOV) represent 69% is observed that MOV Total 219 73
of total valves while these valves have the most
represent 75% of total top failures compared with • Repair reported bad acting • Conduct a campaign to
critical valve failures. other operating modes valves in all four areas resolve all internally
The target valves are distributed • was also found that the
It • 
Keep the critical spare passing valves.
based on four criticality classes, majority of failures are ball parts available in closest
as shown in Table 4. valves of all failed valves facility store Conclusion
Based on classification, it was which accounts to 42 • Add all critical valves to
 The Valve Reliability
found that non-critical valves valves the annual inspection and Management Program was
represent 36% of the total • In Areas III and IV, the
 maintenance program conducted within Aramco,
selected valve failures. Based on majority of failures are • Report any new findings
 Saudi Arabia covering the
size, it was found that the gate valves. during preventative period from 2016-2022 and
majority are 48” valves (82 valves). maintenance as a different was only made possible with
This number represents 38% Recommendations seperate notification to thanks to the efforts of many
of total critical valve failures. • Repair all previously failed enhance data logging and individuals, teams and
MOV valves for all areas in support future reliability departments within the
Asset management analysis order to avoid analysis for critical valves company. The
• The average mean time unnecessary reactive • Adapt new predicative
 recommendations as listed
between failures over the maintenance cost maintenance strategies to above will help to further raise
predict failures and our standards for overall plants
Table 1: The top critical valves, classified per operation sector troubleshoot valve and production productivity,
problems reliability and safety.
Operational Area Total # of valves

I 54 About the Authors

II 36 Mr. Tarabzouni, who is a piping and valves
engineer, holds a BSc in Mechanical
III 93
Engineering, an MSc in Pipelines
IV 36 Engineering and is CMRP certified. He
Total 219 works for the Projects & Technical Support
Department at Saudi Aramco.
mohanned.tarabzouni@aramco.com
Table 2: Incidence of valve failures amongst the 219 top critical valves

Ops. Area Total Failed % of total failed valves Mr. Humidi, who is a mechanical
engineer, holds a BSc in Mechanical
I 54 27 37% Engineering from the University of
New Haven, USA. He works for Projects
II 36 18 25% & Technical Support Department at
III 93 19 26% Saudi Aramco.
IV 36 9 12% saleh.humidi@aramco.com

Total 219 73

Valve World India & Middle East | issue 27 | May 2023 23

 Meeting Point
Valve World Americas plans 7th edition
The Valve World Americas Expo & Conference 2023

will welcome end users, manufacturers and other

members of the valve supply chain to share industry

knowledge and expertise at the George R. Brown

Convention Center, Houston, TX, USA on June 7 and

8 2023. Among those set to take part are five

suppliers from India and Turkey, which are profiled

below.

Serving as the meeting point
for the valve industry, the
Valve World Americas Expo &
Conference will again give
professionals the perfect
opportunity to network and
gain experience, and
ultimately make valve
equipment a priority.
Given the previous successful
shows, it is no surprise to hear
that companies from India and
Turkey will be taking part. They
will be presenting a wide range
of highly relevant components
and finished products for the
flow control sector, as the brief
descriptions below will
demonstrate (companies
listed in alphabetical order; list
complete as of early April
2023).
• Based in Rajkot, India, Inova
Cast has developed
a global presence by offering
premium investment castings
in accordance with ethical
business standards. With
modern equipment available
for wax injection, wax
assembly, ceramic coating,
dewaxing, melting, pouring,
fettling and heat treatment,
as well as CNC machining
(including vertical milling
centres turn mills and tool
design), the company’s
technical team are always
focussed on delivering 100
per cent customer
satisfaction. The valve industry
constitutes a cornerstone of
Inova Cast’s clientele, who
appreciate the high quality,

24 Valve
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2023

reliability, ruggedness,
corrosion resistance and
long-life performance of its
products.
• From Turkey, Pnösan
Pnomatik is a renowned
source for a whole host of
steam and flow control
equipment. For example, the
company offers multiple
designs for steam traps, air
eliminators, sight flow
indicators, butterfly valves,
pressure reducing valves,
globe valves, ball valves, check
valves, safety valves, knife-
gate valves, angle-seat valves,
control valves, strainers,
expansion joints, etc. The
company states that: “Pnosan
Group is aiming to invest in
future with its ‘NST-
Nordsteam’ brand. Our Group
has steam armatures made in
Turkey with CE certificate as
https://valveworldexpoamericas.com/
Meeting Point
well as installation equipment
and all kinds of technical
materials available in stock.”
• Boasting numerous foundry
approvals, Rajan
Techno Cast delivers more
than 6500 different types of
components for various
industries. Zooming in on
items destined for the valve
sector, parts delivered include
valve bodies, butterfly discs,
multi-port bodies, knife-gate
bodies, swing-disc check valve
components, bonnets, stems,
balls, etc. Interested parties
are almost guaranteed to be
able to source the required
items, as the company casts a
whole range of materials, from
carbon steel ad low alloy
steel through to super duplex
stainless steel and nickel
super alloys. Moreover,
components can range from
Valve World India & Middle East | issue 27 | May 2023
50 grams to 15,000 kilograms
per item.
• Shree Hans Alloys -
founded in 1984 and
located in Dholka, India - is
recognized as a leader in
manufacturing steel and
stainless steel sand castings by
semi-automated no-bake
Alpha Set molding (alkaline
phenolic) process. The
company’s range includes
products for valves and
pumps, marine and dredging,
hydro turbines, mining, power
plants etc. Naturally Shree
Hans Alloys confirms to various
IS, ASTM, DIN & BS standards.
The company regularly invests
in equipment from top global
suppliers. For example, two
continuous mixers delivering
chemically bonded sand for
molding were the latest items
to arrive from Italy.
• Founded in India in 1996,
Superlite Jointings today
boasts seven production lines
producing non-asbestos
jointing sheets. A dedicated
team of R & D engineers
ensures that products not
only meet customer
requirements but also
develop new grades to meet
evolving challenges. For
example, in 2016 Superlite
Jointings launched a product
called Spiral Wound Gasket,
which further cemented the
company’s reputation
worldwide. Today, customers
can be found amongst
industries such as
manufacturing, infrastructure,
automotive, marine, oil & gas,
the chemical industry, pulp &
paper, the energy sector, food
& beverage and the
pharmaceutical industry.
25
 Water & wastewater
Cair is proud to supply motorized
valves for Jal Jeevan Mission
Jal Jeevan Mission is a flagship program launched by
the Government of India in 2019 to provide safe and
adequate drinking water to every rural household in
the country by 2024. The program aims to provide
functional household tap connections (FHTCs) to every
rural household, ensuring potable water supply on a
regular and long-term basis. Cair Euromatic
Automation Pvt. Ltd. is proud to supply motorized
valves for this worthy cause.

The Jal Jeevan Mission has
set a target to provide piped
water supply to 55% of rural
households by 2022 and
100% by 2024. The program
is implemented in a
decentralized manner, with
the involvement of local
communities, gram
panchayats, and other
stakeholders.
CAIR, a well-known
manufacturer of electrical
actuator and industrial
valves, recently took on the
order for the UP Jal Jeevan
Mission project, which is
under the supervision of UP
Jal Nigam. The project is
based in Ayodhya, a city
located in the Indian state
of Uttar Pradesh.
As part of the project, CAIR
was tasked with supplying
various types of motorized
valves, including motorized
CAIR is supplying various types of motorized valves, including
motorized sluice valves and air valves with isolation ball valves
and sluice valves, to the Jal Jeevan Mission
sluice valves and air valves
with isolation ball valves and
sluice valves. The company
provided 1-φ (single phase)
electrical actuator operated
387 sluice valves, 391 air
valves with isolation ball
valves, and air valve with
isolation sluice valve. These
motorized valves are used
to control the flow of water
in the system and to ensure
that the system operates
efficiently.
One of the most impressive
aspects of CAIR’s work on
this project was its ability to
complete the manufacturing
process within the
stipulated timeline. This was
no small feat, as the
company had to co-ordinate
with various stakeholders,
including the contractor, JJM
Engineers, and Third-Party
Inspection Agencies. Despite
Schematic for CAIR MOV operation
these challenges, CAIR was
able to execute the project
flawlessly and deliver the
required products on time.
To ensure that the valves
with electrical actuators
supplied by CAIR met the
required quality standards,
the company carried out a
third-party inspection in the
presence of JJM Engineers.
The inspection was
conducted by Crown Agents,
An independent agency that
specializes in the inspection
of industrial equipment.
This ensured that the valves
met the required
specifications and were fit
for use in the project.
The project is powered by
solar energy, as the site does
not have access to grid
power due to its remote
location. This presented a
unique set of challenges for
CAIR, as it had to ensure
that the valves supplied
were compatible with the
solar-powered system.
Despite these challenges,
CAIR was able to execute
the project successfully and
deliver high-quality
motorized valves (valves
operated by an electrical
actuators) that met the
project’s requirements.
CAIR, an Indian electrical
actuators and industrial
valves manufacturing
company, has an advantage
of giving motorized valves
solution as it manufactures
electrical actuators and
industrial valves
indigenously, making it one
of the rarest industry of
such kind in India.
Generally, electrical
actuators are best suited for
grid power supply, but solar
power has more fluctuation,
which can in turn
malfunction the actuators.
Seeing this as a major issue,
CAIR designed the PCB
board of its electrical
actuator such that it can
sustain the fluctuations of
solar power. This could be
achieved because of its
control on all the electrical
actuator’s components,
from electronics to
mechanical, to rubber
mouldings.
The working of CAIR
electrical actuators will be
such that the power coming
from solar panels will be
transmitted to various VFDs
(variable frequency drive).
One of those VFDs operate
CAIR electrical actuators
though a PLC system.

26 Valve
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 Actuator Technology
Benefits of ‘Springless’ Vane Actuators
The challenge with
fail-safe processes
within air reservoirs
can be boiled down to
the lack of
standardization that
results in complicated
and costly assemblies.
Standardizing these
processes can make all
the difference and be
immensely beneficial.
Lack of standardization in fail-safes within air reservoirs.

By Bob Donnelly
The Challenge
Due to the complication and
cost of integrating a fail-safe
in an air reservoir, the
decision to use air reservoirs
over springs is determined
based on the projected
return on time and
investment (ROI). Historically,
the ROI for air reservoirs has
only been worthwhile on
large actuators or on vane
actuators. Setting up air
reservoirs for fail-safe is
equally as complicated on a
large actuator as on a small
actuator. The difference in
cost of a large spring return
more than absorbs the
necessary fixed cost to set up
an air reservoir system. For
vane actuators, the clock
spring adds significant weight,
cost, and complexity of
manufacturing.
However, the basic premise
of how fail-safe within air
reservoirs work is as simple
as understanding how
double-acting actuators
work. When the main air
supply is normal, the open
and close motion of the
double-acting actuator is
powered by the main air
supply, see Figure 1. When
the main air supply is
abnormal, the open or close
motion to drive the actuator
to the fail position is Rather than treating the system and check valve with
powered by a secondary air actuator and the secondary either a solenoid valve, pilot
supply. The secondary air air supply as independent valve, or positioner into one
supply could be thought of components, it is control system. See Figure 5.
as a separate supply airline, recommended that the two When the actuator and the
or an air reservoir separated pressure vessels be unified control system (trip system
from the main air supply with under one body. See Figures and check valve with either a
a check valve, see Figure 2. 4a and 4b. pilot valve, solenoid, or
While simple in concept, the In addition, it is suggested positioner) are unified,
historical market failure of that the user unify the trip integrating the actuator
fail-safes within air reservoirs
has been in the complexity of
integrating all the various
components (main air supply,
secondary air supply, trip
system with pilot valve,
solenoid, or positioner with
the actuator). Each individual
component and connection
between the components are Fig. 1: Normal main air supply.
custom, making it a high-
costing and time-consuming
expenditure. See Figures 3a
and 3b.
The Solution
A solution to the complexity
and cost of fail-safes within
air reservoirs is to unify and
standardize the components. Fig. 2: Abnormal main air supply.
Figs 3a and 3b: Using individual components drives up the cost of a fail-safe within air reservoirs system.
NB: Each colour on the flow diagram and the actual photo represents a unique component.

Valve World India & Middle East | issue 27 | May 2023 27

 Actuator Technology
Figs 4a and 4b: Example of an actuator and secondary air supply
unified in a single body
Fig. 5: Integrated trip system options
Figs 6a and 6b: Fail-safe setup with solenoid valve, pilot valve, positioner.
Fig. 7: Normal air supply.
Fig. 8: Abnormal air supply.
28
becomes far simpler, much
like integrating two
standardized components or
assembling a solenoid valve
on an actuator (two bolts). The
cost of integrating a fail-safe
air reservoir approaches zero.
Figures 6a and 6b show how a
fail-safe with an air reservoir
package would look.
The airflow is the same as
traditional fail-safe within air
reservoirs. When the main air
supply is normal, the open and
close motion of the double-
acting actuator is powered by
the main air supply, see Figure 7.
When the main air supply is
abnormal, the failure to open or
failure to close motion is
powered by a secondary air
supply, see Figure 8.
Valve World India & Middle East | issue 27 | May 2023
Result and Savings
By unifying and standardizing
disparate components, the
cost of utilizing an air reservoir
for fail-safe approaches zero.
As a result, the operational
and financial calculus
between using air reservoirs
versus springs for fail-safe
fundamentally changes across
both small and large
actuators. The implication is
improved safety, as well as
more solutions and benefits
for the end-user.
Construction simplicity
Converting a double-acting
actuator into a spring-return
actuator system requires many
new components. Specifically,
adding many springs in the
actuator and changing double-
acting 5/2 solenoid valve to a
single-acting 3/2 solenoid valve.
On the other hand, with a
comprehensive smart air-
reservoir fail-safe system,
converting between double-
acting to fail-safe can be as
simple as deciding whether or
not to incorporate a check
valve inside the same solenoid
valve. In effect, it exchanges the
complexity of adding multiple
moving springs into actuators
to only adding a singular check
valve. From a failure mode and
effects analysis, this greatly
reduces the potential failure
points in a system.
Furthermore, springs in
spring-return actuators will see
environmental air that could
be corrosive, the check valve
will only see instrument air. See
Figure 9.
Indirect cost
A smart air-reservoir fail-safe
system not only allows the
quick and easy conversion
between double-acting and
fail-safe (can be as easy as
incorporating a check valve or
not) but converting an actuator
between fail-close and fail-
open is as easy as reversing the
air supply to the actuator. This is
as easy as mounting the control
 Actuator Technology
Fig. 9: Actuator conversion options
system, such as the solenoid
valve, upside down. See Figure
10. With spring-return actuators,
everything inside the actuator
has to be reinstalled in reverse.
The simplicity of converting
between double-acting,
fail-close or fail-open reduces
the necessary inventory
required to cover all actuation
requirements and drastically
reduces the labor time
necessary for such conversion
(less than two minutes).
Direct cost
Air reservoirs have generally
been used as an economical
solution over large spring-
return actuators for the simple
reason that actuators do not
have to be an extra-large size
to generate the torque to
overcome the spring and the
valve. Springs eat up more
than half (typically 65%) the
torque of what actuators can
generate, meaning the
actuator has less than half
Fig. 10: Fail-close versus fail-open installation.
(usually 35%) of the torque spring-return actuators is
available to the valve. Air already high in both small and
reservoirs do not have to large model sizes.
contend with springs, so only a
smaller size upgrade (less About the Author
costly) is necessary. With the Bob Donnelly
cost of incorporating air is Vice
reservoirs approaching zero, President of
this highly economical Business
Development
solution is now available to
for FloTite Valves &
both small and large actuators.
Controls. He has over 30
Most noticeably, this benefit is years of process control
evident in the vane actuator automation experience.
market where the cost of
 Regional news
Rabigh 4 water plant
project signed
The Minister of Environment,
Water and Agriculture and
Chairman of the Board of
Directors of the Saudi Water
Partnership Company, Eng.
Abdulrahman bin Abdul
Mohsen Al-Fadhli, at the
Ministry’s headquarters signed
the project agreements of
Rabigh 4 Independent Water
Plant, which will be established
in Rabigh governorate in
Makkah region, with the
potable water production
capacity of 600,000 m3/d of
desalinated water.
ABB India automates cross-
border oil pipeline
ABB India, a unit of Swedish-
Swiss engineering and
technology major ABB Ltd, will
secure the 130 km Indo-Bangla
Friendship Pipeline (IBFPL),
through integrated automation
and control solutions, the
company said.
The cross-border pipeline was
jointly inaugurated by Indian
Prime Minister Narendra Modi
and Bangladesh Prime Minister
Sheikh Hasina on March 18. It
30 Valve World India & Middle East | issue 27 | May 2023
Eng. Al-Fadhli explained
that these agreements will
help in achieving the goals
and plans of the Ministr y, to
showcase water production
projects in the various
regions of the Kingdom. In
addition, it is a continuation
of previously signed projects
to further enhance the
active participation of the
private sector in developing
this vital water sector and
increasing its contribution
to the Kingdom’s
development.
will carry diesel from India to
Bangladesh.
“ABB’s SCAD Avantage, Remote
Terminal Units (RTUs), and leak
detection system will allow
Numaligarh Refinery Ltd (NRL)
to remotely monitor and
control vital pipeline
parameters such as flow,
pressure, and temperature, as
well as detect leaks,” said G
Balaji, SVP, Head of Energy
Industries, ABB India.

IVAMA Association plans another
Customer Focussed Event
Indian Valve and Actuator
Manufacturers Association
(IVAMA Association)
successfully organized
Annual Conference 2022, a
customer focused event in
New Delhi in July 2022 to
provide opportunities to our
members to interact with the
customers and EPCs. The
theme of the conference was
“Make in India for the World”.
Based on success of this
conference, it was decided to
organize similar Annual
Conference on September
15th, 2023 in Mumbai.
To effectively arrange the
conference, an organizing
team has been formed to
organize the event in a
grand manner. They will help
select apt current theme
for the event, session topics
and identify predominant
speakers for each topic. The
presentations and addresses
of speakers will give
participants an overall
picture of the industry
and will be helpful to
understand customers’
requirements better. Senior
executives of Oil & Gas
majors, EPC Contractors,
PSUs and Government
officials shall be invited for
the conference.
Mr Amit Shah
CEO of Rotex
IVAMA Column
More than 150 participants
are expected to attend the
conference. There shall be
an exhibition area for the
sponsors to showcase their
new products and services.
There shall be a networking
dinner which will provide
abundant opportunities for
face-to-face interactions and
discussions between
members and customers.
Industry report
IVAMA compiled ‘First Report
on the Status of Indian
Industrial Valves and Actuators
Industry’ in Oct 2021. It was
well received by the members
and the industry and became
a good reference for the valve
market analysis. It has been
decided that this report shall
be reviewed and updated with
the help of Amrita School of
Business and a prominent
market analysis consultant. It
is targeted to release the
updated report during the
annual conference for the
benefit of members
as well as the industry.
On September 16 th, 2023,
CEO Meet of member
companies is planned
wherein the current issues
and opportunities will be
deliberated. A board
Mr Vinayak Lokur
MD of Expert Valves
Valve World India & Middle East | issue 27 | May 2023
meeting and fourth Annual
General Body Meeting are
also planned during the
conference.
IVAMA would like to conduct
cluster meetings of members
at hubs where there are many
valves and actuators
manufacturers. So, this time,
Hubli is selected to conduct a
members’ meet on May 20th,
2023. Current topics of interest
are planned to be presented
by eminent speakers.
New directors and
members
IVAMA Board decided to
increase the strength of
members. The objective was
to keep the leadership
diverse and dynamic with
participation from the
leaders willing to contribute.
Following well laid out
criteria and process,
Mr Amit Shah, CEO of Rotex
and Mr Vinayak Lokur, MD of
Expert Valves are shortlisted.
They were approved in the
fourteenth board meeting
held on 9th March 2023 and
appointed as additional
directors. After rectification
in the next AGM, they will be
appointed as Directors.
IVAMA is pleased to welcome
them on board.
IVAMA Association is very
pleased to inform the
following companies have
become members of the
association recently –
CIRCOR Flow Technologies
India Pvt Ltd, Coimbatore as
Manufacturer Member and
Flexatherm Expanllow Private
Limited, Vadodara, Janatics
Industrial Automation Private
Limited, Coimbatore and
Malnad Alloy Castings Private
Limited, Shimoga as Associate
Members.
We look forward to
enthusiastic participation of
all members in the activities
of IVAMA Association,
particularly in above Annual
Conference and CEO Meet.
Membership is also available
to valve and actuator
manufacturers, supply chain
companies and engineering
back offices. Interested
companies may register for
membership by logging on
the website (https://www.
ivama.in/register).
R Muruganantham, Director
General, IVAMA Association,
www.ivama.in; Admin@ivama.
in, +91 9841289271.
31

Oil companies, audits and certification
It is common knowledge that
oil companies are keen on
purchasing products from
quality suppliers who strictly
adhere to relevant
manufacturing certificates.
However, the same interest is
clearly getting diluted once it
comes to repair and servicing.
Notably valve manufacturers
are not doing servicing of
valves after warranty. Servicing
is instead handed over to
‘service shops’ who are not
connected to valve
manufacturing or OEMs.
Most of the service shops are
not qualified to work
according to applicable
quality certification. A classic
example being valves made
according to API 600, API 6D,
API 6A etc design standards
that are given to non-certified
India’s Largest Processor of
FLUOROPOLYMERS
32
column
valve service shops for shut
down maintenance, general
servicing, annual maintenance
contract, etc.
Based on several decades of
working with valves in refinery
applications, I can state quite
clearly that it is most
important for an API valve to
Are you buying a valve from API certified
source? Then do servicing with API
certified shops!
be serviced at an API certified
workshop. There is a technical
point to this; API guidelines
are very strong on how to
rectify a job or how to view a
challenge in valves. Such
guidelines must be followed.
Oil companies must identify
Valves qualified ISO 15848-Part 1.
Pipework qualified ASTM F 1545
Valve World India & Middle East | issue 27 | May 2023
the importance behind
servicing a valve at API
certified workshop because
the valve was bought
originally from API certified
valve manufacturing company.
Accidents cannot be ruled out
and nor can they be eradicated
via preventive maintenance Meet Mr. N.S. Rao
Mr. N.S. Rao
has spent
over
thirty-five
years in the
valve sector
and is experienced in
and/or predictive maintenance. valve design,
manufacturing, vendor
There are all chances of failure
development, foundry
while in line. So instead of
development, quality,
seeing their plants turning to approvals, presentation,
ashes, oil companies are and marketing. He can
strongly recommended to have be reached on:
valve servicing performed at valvemen@gmail.com
API certified workshops only.
www.horizonpolymer.com
H O R I Z O N P O LY M E R
E N G I N E E R I N G P V T. LT D . :
EMAIL: vp@horizonpolymers.com
ADDRESS: 204, Sumer Kendra,
Pandurang Bhudhkar Marg, Worli,
Mumbai - 400018. India
CALL: +91 22 24965031 - 36
FAX: +91 22 24961073
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