Optimal flow control helps reduce manufacturing costs

Oil and gas companies around the world are challenged to increase production and deliver quality products while reducing manufacturing resources and costs. Process control has a financial impact and therefore reducing process variability is therefore a key factor in maximizing quality production and reducing costs. Extensive studies of control systems have shown that up to 80% of control loops have not performed satisfactorily in reducing process variability. In most cases, the control valve was found to be the main cause of the problem. Despite this, the impact of the flow control The valve on dynamic performance is often overlooked.

Optimal flow control is imperative; Control and throttle valves are subject to a variety of technical phenomena and careful selection of the right control valve for each application is crucial.

Superior design features include the valve material, which must be resistant to the chemical composition of the flow medium. For example, solid tungsten carbide discs and internals, known for its erosion and cavitation resistant properties. Industrial diamond coatings inserted into discs have also produced very good results under severe conditions. The sealing surface must not be in contact with the flowing medium to ensure that the tightness of the seat can be guaranteed for a longer period of time. The construction of the internal parts must ensure that the downdraft of the rear disc is resistant to abrasion. This removes most cavities and erosive material from the sealing surfaces as well as the valve body. The design of the trim must be able to absorb turbulence in the flow so that the outflow is more laminar. Rotary Throttle Disc Valves are recommended for extremely severe applications.

Flow control is also optimized by using throttle holes of different shapes and sizes in the rotating discs. This affects the Cv value of the valve and has a crucial impact on the control of the process. The correct valve size and trim must be chosen to match process conditions.

For both new and existing applications, to ensure that downtime is kept to an absolute minimum and no additional costs are incurred, flow control valves should be ideally designed to fit existing plumbing without modification. This also ensures that any replacement can be done efficiently.

Ultimately, these design features, along with serviceable internals and easy maintenance, maximize production, reduce life cycle costs, and extend mean time between failures, providing an overall reduction in total cost of ownership. .

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