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:
- Valve that isolate the reformed gas at temperatures up to 430°C.
- 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:
- 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.
- 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.
- Compliance and Certification: Each valve was certified with MTC in accordance with EN 10204. Providing the customer with assurance of compliance and quality.
- 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