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The oil and gas industry operates under some of the most hazardous conditions, where safety and reliability are paramount. From high-pressure pipelines to volatile hydrocarbons, the potential for catastrophic incidents is always present. In such environments, equipment that meets SIL 3 certification standards is not just a preference—it’s a necessity.

IPC Valves, with its SIL 3-certified Floating Ball Valves and Pneumatic Actuators, ensures safety and performance, offering peace of mind for operators handling critical systems. Here’s why SIL 3-certified valves are indispensable in the oil and gas industry.

3 Reasons Why SIL 3 Certification is Essential in Oil and Gas

1. Minimizing Risk of Catastrophic Failures

Oil and gas processes involve high pressures, extreme temperatures and flammable materials. A single failure in a safety-critical valve could lead to explosion, environmental disaster or loss of life.

SIL 3-certified valves, such as IPC’s Floating Ball Valves, are designed to perform reliably even in extreme conditions. Their certification ensures a failure probability of less than 0.1%, significantly reducing the risk of accidents.

2. Maximizing System Uptime and Operational Efficiency

Downtime in oil and gas operations can cost millions of dollars per day and disrupt supply chains. Ensuring that critical systems perform reliably is essential for maintaining smooth operations.

SIL 3-certified valves and actuators are built to deliver consistent performance with minimal failures. IPC’s Pneumatic Actuators, for example, are designed to withstand wear and tear, enabling uninterrupted functionality in demanding environments. By using SIL 3-certified equipment, operators can achieve higher system uptime and operational efficiency.

3. Supporting Emergency Shutdown Systems (ESD)

In oil and gas operations, emergency shutdown systems (ESD) are critical to halting operations safely during equipment malfunctions or hazardous events. A valve’s inability to close quickly and securely during an emergency could escalate a manageable situation into a disaster.

SIL 3-certified valves are specifically designed for such scenarios. IPC’s Floating Ball Valves and Pneumatic Actuators ensure reliable shut-off performance, enabling swift and effective responses during emergencies, thus protecting assets, personnel and the environment.

Why Choose IPC Valves?

IPC Valves stands as a trusted name in providing reliable solutions for safety-critical systems. Here’s what makes our SIL 3-certified products the ideal choice for the oil and gas industry:

1. Precision Engineering:Our Floating Ball Valves and Pneumatic Actuators are designed to handle the harshest conditions with superior performance as per SIL-3 requirements.
2. Rigorous Testing:Each product undergoes extensive testing to meet the exacting standards of SIL-3.
3. Proven Track Record:IPC Valves has a long-standing reputation for delivering safety and quality to the oil and gas sector.

IPC’S SIL 3 certified Ball Valves and Actuators in India

With IPC’s SIL 3-certified Floating Ball Valves and Pneumatic Actuators, you’re investing in safety and reliability.

Ready to secure your operations? Contact IPC Valves today to learn more about our SIL 3-certified solutions. 

When it comes to flow control across industries, high-quality soft seated ball valves offer unmatched reliability and performance. Soft seated floating ball valves, in particular, have become a go-to solution for a wide range of applications due to their simplicity, efficiency, and excellent sealing capabilities. Let’s take a closer look at the benefits and features of these trusted valves.

Soft Seated Floating Ball Valves

Soft seated floating ball valves are designed with a ball that is not physically restricted by any component within the valve body. This floating design allows the ball to move slightly and press against the sealing surface when the valve is closed, ensuring a tight seal. They come in both two- and three-piece configurations and are available in standard or customized designs, making them versatile for various industry needs.

These valves are ideal for economical automation, combining high performance with low maintenance. Their low torque design ensures they can be operated easily without requiring significant effort, making them a convenient choice for operators.

Key Benefits of Soft Seated Floating Ball Valves

1. Efficient Sealing: The floating ball design ensures the ball creates a tight seal against the valve seat, which prevents any leakage and guarantees reliable operation, especially in pressurized systems.
2. Versatile Materials of Construction: These ball valves are available in Carbon Steel (CS), various types of Stainless steels and duplex & super duplex steels, various alloy steels, which makes them suitable for various environments, including corrosive and high-temperature applications.
3. Easy Installation and Maintenance: Thanks to their sturdy construction and simple assembly, floating ball valves are easy to install and maintain, reducing downtime and labor costs.
4. Fire-Safe Design: In hazardous areas, fire-safe design offers additional protection. Antistatic devices are built into the valve stem to ensure electrical continuity between the ball, stem, and body, increasing safety during operation.

IPC’s offers Unique Features of High-Quality Soft Seated Ball Valves

• Superior Shut-Off Capabilities: The soft seat and high sphericity of the ball provide an excellent surface finish, ensuring a positive shut-off in high-pressure applications.
• ISO Mounting for Actuators: Valves come with ISO 5211 top pads for easy mounting of actuators or gear operators, simplifying automation processes.
• Double Body Sealing: This design feature ensures effective sealing, even under pipeline stress, providing extra security and leak prevention.
• Tight & reliable sealing of stuffing box area.
• SIL 3 certification ensures that valves meet stringent safety standards. SIL 3 certified valves undergo thorough risk analysis, identifying potential failure modes and implementing measures to mitigate risks. SIL 3 certification is widely recognized and accepted across industries, making it easier for organizations to demonstrate compliance with regulatory requirements.

Application Areas

Soft seated ball valves are widely used across numerous industries including:

• Oil & Gas
• Petrochemical
• Water Treatment
• Chemical Processing
• Power Generation
• Pharmaceuticals
• Paint & Dyes
• Fertilizers

Their versatility, reliable sealing, and ease of use make them a popular choice in all types of systems in various industry sectors.

Conclusion

For industries looking for a reliable, cost-effective, and high-performing valve solution, soft seated floating ball valves are an ideal option. They offer superior sealing, minimal maintenance, and robust construction, making them a trusted choice for flow control applications. Whether you’re upgrading existing systems or installing new ones, these valves deliver quality, safety, and reliability—key components for industrial success.

Optimize your operations with IPC soft seated ball valves — where performance meets reliability!

Excellence in High-Temperature Reformed Gas Applications

Background

Handling steam in boiler applications is particularly challenging and tricky, with valve failure often occurring due to higher pressure and temperature. Our expertise in designing and manufacturing high-quality valves has positioned us as a trusted partner for numerous industrial applications. One such challenge presented itself when a leading Heavy Engineering Giant sought our assistance in handling high-temperature reformed gas application.

The Challenge

The client’s project involved the installation valves of two critical location:

1. Valve that isolate the reformed gas at temperatures up to 430°C.
2. Valve that isolate the reformed gas at temperatures up to 700°C.

Operating valves at such extreme temperatures posed significant challenges:

• Ensuring the valves could operate reliably under high temperatures and pressures.
• Meeting stringent requirements for minimal leakage.
• Developing and manufacturing these specialized valves within IPC’s existing facilities while adhering to required standards.

IPC’s Solution

In response to these challenges, IPC designed and manufactured Forged Globe Valves, sized at 1” #800 and 1” #1500 with Buttweld ends. Our solution included several key innovations:

1. Special Gland Packaging Design: We developed a unique gland packaging design using special packaging materials capable of withstanding the extreme operating conditions, ensuring minimal leakage.
2. Stringent Testing: To guarantee minimal leakage, we conducted Helium leakage tests as per ISO 15848 in-house, simulating the working pressures and temperatures. This ensured compliance with leakage class as per API 598.
3. Compliance and Certification: Each valve was certified with MTC in accordance with EN 10204. Providing the customer with assurance of compliance and quality.
4. In-House Manufacturing: Leveraging our existing facilities, IPC manufactured the valves with a new design that met the respective standards. This allowed us to maintain control over the quality and precision of the valves.

Claiming the Success

IPC successfully supplied the valves, which met all the client’s stringent expectations. Despite initially offering a guarantee of only 3 months due to the high operating temperature of 700°C, the valves have been performing flawlessly for over three years. This remarkable performance underscores IPC’s commitment to delivering exceptional quality and reliability.

“IPC initially assured us that the valve would last only three months due to the severe operation condition high temperature of 700°C. However, they delivered a high-quality product that has performed flawlessly for over three years.” – The client’s Procurement Manager

Pneumatic actuators are essential components in industrial automation applications, providing reliable and efficient control for various applications. Choosing the right pneumatic actuator for your specific needs can significantly enhance your system’s performance and longevity. At IPC Valves, we understand the importance of making an informed decision.

Here’s a step-by-step guide to help you select the perfect pneumatic actuator.

Step 1: Understand Your Application

• Identify the Type of Valve:
  Determine the type of valve you are working with, such as ball, butterfly or globe valves. Each valve type requires a specific actuator configuration.
• Determine the Function:
  Understand the function of the actuator in your application. Will it be used for on-off control, throttling or modulating service? Knowing the function helps in selecting the appropriate actuator.

Step 2: Assess Operating Conditions

• Environmental Factors:
  Evaluate the operating environment. Consider factors like temperature, humidity, dust and potential exposure to corrosive substances. For harsh environments, select actuators with appropriate protective coatings and sealing.
• Pressure and Load Requirements:

  Assess the pressure and load requirements of your system. Ensure the actuator can handle the maximum pressure and load it will encounter.

Step 3: Determine Torque Requirements

• Calculate the Torque:
  Determine the torque required to operate your valve. This is crucial for ensuring the actuator can provide sufficient force. Consult the valve manufacturer’s torque specifications and consider safety factors.
• Select the Right Actuator Size:

  Choose an actuator that meets or exceeds the torque requirements including safety factors. Undersized actuators can lead to operational failures, while oversized actuators can be unnecessarily expensive and consume more energy.

Step 4: Choose the Actuator Type

• Single-Acting vs. Double-Acting:
  Decide between single-acting and double-acting actuators. Single-acting actuators use air pressure to move the valve in one direction and a spring to return it. Double-acting actuators use air pressure for movement in both directions.
• Spring-Return Option:

  For safety applications, consider spring-return actuators, which ensure the valve returns to a default position (open or closed) in case of air supply failure.

Step 5: Evaluate Air Supply Requirements

• Air Supply Quality:
  Ensure your air supply is clean and dry. Contaminants can damage the actuator and reduce its lifespan. Use appropriate filters and dryers to maintain air quality.
• Air Pressure and Volume:
  Verify that your air supply can provide the necessary pressure and volume for the actuator to operate efficiently. Insufficient air supply can lead to performance issues.

Step 6: Factor in Maintenance and Support

• Ease of Maintenance:
  Choose actuators that are easy to maintain and have readily available spare parts. Simplified maintenance can reduce downtime and operational costs.
• Technical Support:
  Consider the availability of technical support from the manufacturer. Reliable support can assist with troubleshooting and ensure smooth operation.

Step 7: Cost and Budget Considerations

• Initial Cost vs. Lifecycle Cost:
  While it’s important to consider the initial cost, also factor in the total lifecycle cost of the actuator, including maintenance, energy consumption and potential downtime costs.
• Quality vs. Price:
  Don’t compromise on quality for the sake of a lower price. Investing in a high-quality actuator can lead to better performance and longer service life, providing better value in the long run.

When it comes to reliable and versatile valve solutions, IPC soft seated ball valve stand out as an exceptional choice. Designed to meet the diverse needs of industries ranging from chemicals, paints, fertilizers, pharmaceuticals, water treatment as well as food & beverages, these valves offer unparalleled performance and reliability.

Key Benefits of IPC Soft Seated Ball Valves

Tight Sealing:

One of the standout features of IPC soft seated ball valve is their ability to provide a tight seal. This ensures that no leaks occur, making these valves ideal for applications where precision and reliability are crucial.

Corrosion Resistance:

Made from high-quality materials, IPC valves are highly resistant to corrosion. This makes them perfect for handling aggressive chemicals in the chemical industry and ensures longevity and durability in harsh environments.

Ease of Installation and Operation:

IPC soft seated ball valves are designed for easy installation and operation. Whether you’re setting up a new system or replacing an existing valve, you’ll appreciate the straightforward installation process. Additionally, the low operating torque makes these valves easy to operate, reducing the effort required for manual operation.

Lower Operating Torque:

The reduced friction between the ball and seat leads to a lower operating torque. This not only makes manual operation easier but also extends the lifespan of actuators used in automated systems.

Sturdy Construction:

Ball valves are generally made from five main parts, including Body & Adaptor, Ball, Stem, Seat and Packing/Sealing. The main body of the valve is often made from a tough, durable material, such as Stainless steel. Our ball valves are well suited for industrial applications that require high temperatures, pressures and other severe conditions.

Safety and Quality Assurance

Safety and reliability are at the core of IPC’s manufacturing philosophy. Our soft-seated ball valves meet SIL 3 safety integrity levels, ensuring reliable performance in critical applications. Designed in accordance with ISO 17292, these valves also feature a fire safe. Additionally, our valves undergo FET testing as per ISO 15848 standards, guaranteeing high performance and leak-tight integrity.

Multiple Applications, One Solution

From handling corrosive chemicals in the chemical industry to ensuring hygienic conditions in food and beverage production, IPC soft-seated ball valves are the versatile solution you need. IPC valves feature an ISO 5211 Mounting pad which simplifies the installation and maintenance of valve actuators by providing a standardized mounting platform, facilitating compatibility and interchangeability in industrial applications. IPC Ball valves are equally effective in various application right from water treatment plants to pharmaceutical plants where maintaining clean and sterile condition is paramount.

Choose IPC

When you choose IPC soft-seated ball valves, you’re choosing a product that combines tight sealing, corrosion resistance and ease of installation & operation. With our commitment to quality and safety, you can trust IPC to deliver the reliability and performance that your applications demand.

Experience the difference with IPC soft-seated ball valves – the one valve for multiple applications.

In industrial valve manufacturing and procurement, design & quality standards are crucial for ensuring the safety, quality, performance and interoperability of valves used in various industrial applications. Industries like Oil & gas, power & boiler manufacturers to name a few, need Valves that conform to specific standards. In last 2 decades, IPC has built a reputation for producing valves that not only meet but exceed industry standards, ensuring reliability and safety in every application.

A Legacy of Quality

Commitment to superior quality is at the core in everything that we do. Every valve that leaves the IPC facility is a testament to the meticulous manufacturing procedures and stringent quality control. From the initial design phase to final inspection, IPC employs a rigorous process to ensure that each product meets the highest standards of excellence.

Certified Excellence

IPC valves are not only designed and manufactured to the highest standards but are also thoroughly tested and certified. The systems & products conform to various major international standards, including:

ISO 9001:2015: This standard signifies IPC’s commitment to quality management systems, ensuring that our products and services consistently meet customer and regulatory requirements.

ISO 29001:2020: With this std. IPC ensures our commitment in ensuring superior quality specifically as per the needs of Petroleum and Petrochemicals sector.

ISO 14001: IPC’s dedication to environmental management is highlighted by this certification, which underscores our efforts in minimizing environmental impact through sustainable practices.

ISO 45001: IPC’s concern towards occupational health and safety is highlighted by this certification. This is a testament to IPC’s continuous effort in following the right guidelines and ensuring good health and safety processes.

PED (Pressure Equipment Directive): CE certification demonstrates that IPC valves comply with the stringent safety requirements for pressure equipment in the European Union.

IBR (Indian Boiler Regulations): IPC valves meet the specific requirements for stem applications in India.

API (American Petroleum Institute): Recognized for excellence in the oil and gas industry, this certification assures that IPC valves are suitable for the most demanding applications.

SIL 3: With SIL 3 Ball Valves and Actuators, IPC ensures safety integrity of equipment and systems, ensuring that they meet stringent standards set by regulatory bodies.

PESO: Conforming to India’s standard for Petroleum & Explosives Safety Organisation, with this certification, IPC proves that our Limit Switch Boxex are ideal and suitable for use in oil and & gas, petroleum and other gas-based applications.

ATEX: This certification indicates that IPC Limit Switch Boxes are safe to use in explosive atmospheres, essential for industries such as chemical and petrochemical.

FET (Fugitive emission testing): Ensuring that IPC valves can withstand extreme conditions and meets the fugitive emission testing standards, this certification is crucial for various critical applications.

The IPC Difference

What truly sets IPC apart is our holistic approach to valve manufacturing. By integrating advanced technology, continuous improvement processes and a customer-centric focus, IPC has created a range of valves products that are not only highly functional but also are reliable and safe.

Conclusion

In today’s market, IPC has set itself as a trusted source of reliable and safe valves, valve automation & accessories. With unwavering commitment to quality, consistency and certification, IPC has a portfolio of products that conform to major international standards. Being dedicated to continuous improvement, IPC has set a benchmark for excellence in industry. If you are interested to know more about IPC, drop an email on Enquiry@ipcvalves.com

In the fertilizer manufacturing, the journey from raw materials to the final product is anything but gentle. It’s a harsh process, demanding robust equipment capable of withstanding corrosive substances, extreme temperatures and high pressures. At the heart of this demanding environment lie valves – essential components that regulate the flow of acids, gases, slurries, steams and other critical substances throughout the production process. Here’s why fertilizer production needs specialized valves tailored to its unique challenges:

Acids, Gases, Slurries and Steams: The Harsh Reality

Fertilizer production involves a diverse array of substances, from nitric and sulfuric acids to gases, slurries and steams. These materials are not only aggressive but also vary greatly in their properties and behaviors. Handling them requires valves capable of withstanding their corrosive nature, high pressures and abrasive tendencies without compromising performance or safety.

Specialized Valve Solutions: Tailored to the Task

Super Duplex Stainless Steel Valves for Nitric Acids:

Nitric acid is a staple in fertilizer manufacturing but can wreak havoc on standard valve materials. Super Duplex Stainless Steel valves offer exceptional corrosion resistance, making them ideal for handling nitric acid without succumbing to degradation.

Special Alloy Valves for Sulfuric Acids:

Sulfuric acid, another common ingredient in fertilizer production, demands valves constructed from special alloys capable of withstanding its corrosive effects. These valves ensure reliability and longevity even in the harshest environments.

Hastelloy/Inconel/Monel Valves for Corrosive Applications:

In environments where corrosive substances abound, such as fertilizer production facilities, Hastelloy/Inconel/Monel valves are pertinent. Renowned for their resistance to corrosion, these valves offer unmatched durability and reliability, making them a go-to choice for critical applications.

High-Pressure Globe Valves for Steams:

Steams generated in fertilizer production processes often reach high pressures, requiring robust valves capable of withstanding these extreme conditions. High-pressure globe valves are designed precisely for this purpose, ensuring efficient steam management while maintaining safety and reliability.

Standard Butterfly Valves for Water Feed Lines:

While some substances in fertilizer production demand specialized valves, others, like water feed lines, can be effectively managed with standard butterfly valves. These valves offer simplicity, cost-effectiveness and reliable performance for less demanding applications.

Leveraging IPC Valves’ Expertise for Fertilizer Manufacturing Excellence

In the demanding world of fertilizer manufacturing, every component must pull its weight to ensure smooth, efficient and safe operations. Valves play a crucial role in this process, regulating the flow of critical substances throughout the production journey.

IPC Valves offers a comprehensive range of valve solutions meticulously engineered to meet the unique demands of fertilizer production. With leading fertilizer manufacturers trusting IPC for their valve requirements, leveraging cutting-edge technology, and tailored solutions designed to optimize efficiency, enhance reliability and drive success fertilizer production processes.

Handling steam in power stations is a bit tricky. Steam plays an important role in generating electricity, but it’s critical and difficult to handle, reverse flow of steam can be dangerous and can impact safety of the crucial equipment in a big way. A critical component in achieving this is the Quick Closing Non Return Valve (QCNRV), particularly in turbine extraction pipelines.

Understanding the Significance

Quick Closing Non Return Valves, often referred to as Swing Check Valves, play a pivotal role in the power generation process, particularly in handling steam. Their primary function is to prevent reverse flow, ensuring that steam flows only in one direction. This simple yet crucial mechanism serves to protect turbines from potential damages caused by backflow.

Safeguarding Turbines: A Necessity

In the context of captive power plants, where turbines are the heart of operations, the need for uninterrupted and safe functioning is non-negotiable. These powerhouses are responsible for converting steam energy into mechanical energy, which is then converted into electrical energy. Any disruption in this process can lead to downtime, loss of productivity and more critically, expensive damages to key equipment.

This blog delves into the operational insights, benefits and sophisticated mechanisms of these valves. This is ensure a seamless, safe and efficient power generation process.

Key Benefits of Quick Closing Non Return Valves (QCNRV)

Rapid Closure:

These valves are capable of closing in less than a second, a crucial feature in preventing the backflow of steam and ensuring the system’s safety.

Complete Disc Closure:

At no flow condition, the valve achieves a complete disc closure, ensuring a tight shut-off and preventing leakage.

Reliable Reverse Flow Prevention:

The primary function of a QCNRV is to prevent the reverse flow of steam, safeguarding the turbine and other critical components from damage.

Innovative Actuation:

Equipped with a side-mounted pneumatic spring return actuator. These valves offer a reliable and efficient operation, enhancing their functionality in emergency conditions.

How do Quick Closing Non Return Valves (QCNRV) Operate

QCNRVs are specially designed swing-disk check valves, integral to the turbine steam bleeding lines of the feedwater preheating stages in modern power station cycles. Their main function is to quickly shut off the bleeding steam pipes in case of a loss of turbine load. This action is crucial in preventing the dangerous phenomenon of water carryover from the preheater back to the turbine, which can cause significant damage and efficiency losses.

The innovative design includes a pneumatic single-acting actuator (Spring Return) mounted on one side of the valve body, linked to the valve disk through a shaft. This setup ensures that the valve can operate automatically in a conventional manner under normal conditions with the actuator air pressure ranging between 4 and 8 bar.

During manual operation, compressed air is fed into the cylinder, loading the spring and allowing the check valve to operate automatically. In emergencies or during turbine upset conditions, the compressed air is vented. This action allows the spring to extend inside the cylinder, causing the actuator piston to rotate the valve disk and intercept the steam-bleeding pipe swiftly. The spring’s main function is to overcome the starting friction on the packing and pivot bearings, ensuring a quick and reliable closure.

Ensuring Operational Excellence

When it comes to power plants operations , where every minute of downtime translates to revenue loss, the importance of proactive measures cannot be overstated. Quick Closing Non Return Valves stand as silent guardians, constantly monitoring and regulating steam flow to safeguard turbine operations.

By integrating IPC Make QCNRV valves into power stations, facilities can achieve a higher level of control over steam flow. This is significantly reducing the risk of damage from reverse flow and water carryover. The rapid actuation, reliable reverse flow prevention and tight shut-off capabilities make these valves an indispensable part of modern power generation infrastructure, ensuring the seamless operation and longevity of turbine systems.