In an industrial process, valves are used to control flow and pressure in pipelines carrying liquids, gases, fumes, etc.
To this end, we will address here the use of conventional globe valve models and also piston valves.
Conventional Globe Valve
Widely used in industrial processes for fluid flow control and pressure regulation, this type of valve is characterized by its globe-shaped body.
Conventional Globo valves use gaskets as sealing elements. This type of sealing material offers reliability and is recommended for a wide range of industrial applications.
however, the use of gaskets on globe valves, develop recurrent leaks and replacement of this material is necessary. However, this gasket change is hampered by access to it and also by the need to depressurize the entire line, since this maintenance must be done without any pressure on the valve.
This type of valve also uses a gasket between the body and the bonnet. This type of seal may leak and, sometimes, results in erosion of the sealing surfaces, requiring replacement of damaged parts.
Bearing in mind that globe valves also use internal metal type seals / metal, it is possible for leaks to appear, because, considering that this type of fence falls into class IV, dripping is allowed. Besides that, considering that this type of seal does not have the perfect contact, dirt may accumulate on the sealing surface and erosion of these surfaces may occur.
It is important to note that, any loss of vapor must be analyzed and corrected, because it means wasted time, operation and also money.
Loss of vapor through leakage to the atmosphere (kg per hour)
SOURCE: UTILITY LEAK PREVENTION
*THE STEAM JETS ARE MEASURED ONLY IN LENGTH
Considering the table above, that relates the size of the leak jet to the maximum steam flow, if we take as an example a line pressure 9,3 bar, and a jet of steam leak from 90 cm – the vapor loss will be 26,8 approximately kg / h.
Also considering the operating time: 24h / he; 30 days / month – the total steam lost per month will be = 19,3 tons.
Assuming a cost of R $ 60,00 per ton – the total lost will be R $ 1.157,76 a month.
The warning point in the case of the conventional globe valve is that, all these setbacks presented result in a high maintenance cost, waste of inputs and unwanted production stops, considerably harming the cost x benefit of using these valves.
Piston Globe Valves
The Globe Piston valves in turn, present cost x benefit that make the investment feasible.
The piston valve sealing system, occurs through graphite rings that are in contact with the piston. This type of fence, class VI, ensures tightness for both the line and the atmosphere.
The exclusive sealing system of KLINGER piston valves ensures Class VI sealing according to ANSI / FCI70-21 Standards, referring to the passage of fluid to the line.
The efficiency of these graphite rings is given by the insertion of expanded stainless steel sheets and by the special physical properties of the graphite that allow its use in temperatures from -40ºC to 400ºC, being suitable for thermal shocks and vapor changes / condensed.
This seal is based on the contact between the piston (plug) and the inner surface of the seal rings, contact with the lower ring (seat) makes the flow block to the pipe and the contact with the upper ring makes the seal for atmosphere. This contact between the piston and the upper ring replaces the gaskets and the gaskets of the bonnet, that are used in conventional valves.
Piston valves have low cost maintenance, because normally, it is necessary to replace only the sealing rings, items that have a cost of approximately 5% of the cost of the valve. Maintenance is also easier, since the valve can be repaired by keeping the body installed in the pipeline.
Considering the presented characteristics of piston valves, it can be said that this type of valve offers greater reliability against accidents caused by leaks.
Besides that, energy savings and other inputs inherent to the process result in an irrefutable cost x benefit.
In addition to steam and condensate collection systems, the KLINGER piston valve has proven effectiveness in applications such as thermal fluids up to 350 ° C, chemical fluids (stainless steel version) and gases.
This type of valve, also available with special trim for fine adjustment. Yet, this feature is unique to the KLINGER piston valve.
CORONAVIRUS (COVID-19) STATEMENT 2020
As you, we at KLINGER Advantage have watched the events unfold over the last few months with the spread of the Coronavirus pandemic. There is no denying the severity of the virus and those it is affecting. We would like to reassure our customers and employees that during this time we are continuing with business as normal. However, we have taken steps to ensure as much as possible that none of our current projects and customers are impacted by the events.
Currently, we do not see any risk to our supply chain, and we are continually reviewing our contingency plans that we have put in place, these include the following:
- At present we are not expecting any delivery delays and We will continue to proactively work with our suppliers, be it international or global, to maintain supply.
- Our suppliers and factories are working at full capacity and the production is running on time.
- We have reviewed and updated our cleaning schedule across all Klinger Advantage sites.
- All non-essential overseas travel has been cancelled and rearranged where possible or alternative solutions be found to conduct the meetings such as Skype.
The safety of our employees is at the forefront of our business and we are monitoring the changes in the advice released by CDC (Centers for Disease Control and Prevention) and The Government in Louisiana/Texas and USA ensuring our employees safeguarding. Relevant information concerning prevention, how to spot it and what to do, provided by the NHS and WHO has been communicated to our employees.
If you have any questions, please do not hesitate to contact us
Acquisitions enable manufacturing and provision of plant safety products and solutions directly in Switzerland
The KLINGER Group has purchased the Swiss Aargau-based companies FRANZ GYSI AG and GYSI Dichtungstechnik. Effective January 1, 2020, the two companies are now part of KLINGER. The businesses of former owner Mr. Franz Gysi provide gaskets and valves for several core markets, including district heating and cooling, process heat, gas, water & wastewater, cooling and loose materials as well as for the biotech, food, chemical, petrochemical and pharmaceutical industries. Their addition will enable the KLINGER Group to directly deliver products and solutions to the Swiss market.
The FRANZ GYSI AG with its headquarters in Suhr, Switzerland, was formed in 1927 and operated as a family enterprise for 93 years. More than nine decades have already been spent collaborating with KLINGER, especially in the fields sealing technology and fluid control solutions. The second company, the Rheinsulz-based GYSI Dichtungstechnik, was incorporated after taking over a sheet punching subsidiary from today’s KLINGER Kempchen. This enabled the former owner Mr. Franz Gysi, himself the third generation to run the business, to add metal gaskets and expansion joints to the product portfolio. With a total of around 50 employees, the companies play an important role as suppliers for the Swiss industries district heating and cooling, process heat, gas, water & wastewater, cooling, and loose materials. Furthermore, they also provide a wide range of specialist gaskets and valves for food, chemical, petrochemical, pharmaceutical and biotech applications.
“I am deeply moved by the trust that Mr. Franz Gysi, the KLINGER management and our employees have placed in me. It will be an honor to continue the Franz Gysi success story as a member of the KLINGER Group.”
Daniel Läubli, Managing Director of FRANZ GYSI AG and GYSI Dichtungstechnik
KLINGER to continue operation of both business locations
Following the acquisition, Mr. Franz Gysi will retire from the operative business. He will, however, provide his expertise as a member of the supervisory board. “Due to the lack of a successor in our family, I had to look at other options to safeguard the companies,” explains Mr. Gysi, and adds: “The KLINGER Group, which had proven itself to be a reliable and long-term partner, was the ideal choice.” According to the former owner, this solution caters to the needs of all stakeholders: “Our customers and suppliers can rest assured in the knowledge that they will continue to have a trusted and reliable partner at their side. And thanks to the way the KLINGER Group goes about its merger & acquisition activities, our in total around 50 employees at both business locations will retain their workplaces to also supply the highest level of quality for the Swiss market in the future.” Former co-executive Mr. Daniel Läubli will take over as Managing Director. Asked to comment on his new function, Mr. Läubli stated: “I am deeply moved by the trust that Mr. Franz Gysi, the KLINGER management and our employees have placed in me. It will be an honor to continue the Franz Gysi success story as a member of the KLINGER Group.” CEO Daniel Schibli, who also hails from Switzerland, has welcomed the latest acquisitions with open arms: “It fills me with joy to see our respective companies that have already been working together for more than nine decades, and thus spanning three generations of the Gysi and four generations of the Klinger family, now combine forces for an even brighter future together. Effective immediately, we can provide the Swiss market with our plant safety products, services and solutions via our very own local company. This is perfectly in line with our strategy, which focuses heavily on customer proximity as a means of offering the highest quality – wherever and whenever its is required.”
To find out more about the FRANZ GYSI AG and GYSI Dichtungstechnik, please visit:
Technical solution for ecological challenges – sustainability in process technology.
One of the most important functions of industrial valves in process technology is the tightness to the outside in order to protect people and the environment against dangerous influences. Active environmental protection begins here. Responsible and future-oriented solutions are characterized by the highest degree of tightness and ecological sustainability.
In order to meet the highest requirements for tightness to the outside, the dynamic sealing of the stem by means of a metallic bellows and a downstream safety stuffing box is ideally suited.
In the ball valve type INTEC K200-S-STD-EC a metallic bellows seal the stem to the outside. Due to the torsion-proof, multi-walled bellows and a downstream safety stuffing box, the stem seal is permanently technically tight. The leakage rate to the outside is at least 10-6 [mbar ∙ l/s]. This makes the ball valve particularly suitable for toxic, aggressive and fugitive media.
- Reliable permanent tight and safe sealing to atmosphere.
- Fulfils the highest tightness requirements with min. 10-6 [mbar ∙ l/s].
- TA-Luft and emission conformity according to VDI 2440 / ISO 15848.
- Worldwide unique design.
- Although a 90° movement is performed for actuation, the bellows only performs an axial movement.
Highest tightness and ecological sustainability combined in the future-oriented solution!
Intelligent technical solution for a sustainable future.
Environmentally hazardous media are not harmless to humans and the environment. For this reason, strict regulations apply to process plants in the chemical industry and the valve components used must meet high requirements for technical tightness. Gases or liquids must never escape uncontrolled.
The specific requirements of the chemical industry are characterised by the high variety of media, the pressures to be controlled (vacuum to high pressure) and the very different temperature levels (cryogenic to high temperature). These requirements make the chemical industry probably the most demanding user sector for industrial valves.
The worldwide unique stem sealing system of the INTEC system technology, which realizes the permanent springing of the primary and secondary sealing with flexible graphite. The cone ring principle used here ensures optimum force distribution and guarantees a permanent seal. When assembled, the graphite has a density of ρ= 1.8-1.9 g/cm³ and a springback behaviour of 10% proportional to the axial height.
- No use of O-rings, therefore universally applicable.
- No use of disc springs, therefore no loss of elasticity or risk of breakage.
- Constructive structure excludes any contact of the medium with graphite.
- Sealing system absolutely resistant to aging and temperature resistant up to +225°C.
- TÜV-certified with 100,000 switching cycles, from 0 bar to 40 bar and -40°C to +225°C.
- Tightness <1×10-6 mbar*l/sec. with 99.996 pure helium (He) over the entire life cycle.
- Adjustable even with mounted actuator.
Smart safety and protection for human and environment without compromise!
Wear attacks and service life of metal-seated ball valves.
Wear parts are the weak points in ball valve technology. In particular, the ball and ball seats must withstand extreme loads. The spectrum of dynamic wear forces is very extensive and results from the loads of high temperatures, high pressures, high switching frequency, aggressive media, abrasive solid particles, abrasion, erosion, vibration, cavitation and flow velocity.
Tailored and application-specific selection of surface coatings of the ball and ball seats based on hard metal (such as chromium carbide, tungsten carbide, chromium oxide, Tribaloy etc.) improve wear resistance, leakage in the port and the service life.
Characteristics such as good wear resistance or high wear resistance, low cold welding tendency, very good sliding properties, high hardness, high thermal load capacity, good load-bearing capacity at high surface pressure, low adhesive resistance and high adhesive tensile strength characterise the quality of the metallic coating of the INTEC system technology.
An efficient surface coating is dependent on the chemical composition, layer porosity, pore size, layer hardness, structure, adhesion to the carrier material, the inner bond and the layer thickness and its uniformity.
- Metallic sealing system (floating or mounted ball valve version).
- Paired ball and ball seats, lapped onto each other.
- Surface hardness of the coating from 60 up to 70 HRC.
- Leakage rate A – absolutely gas-tight – continuity tightness 1×10-4 mbar helium.
- Temperature resistance up to 800°C.
- More than 12 up to 15 different hard material coatings for the optimal solution.
Get the maximum service life out of technical possibilities!
KLINGER Group acquires Italian valves producer
We are happy to announce a new addition to our Group. As of July KLINGER has closed a Share and Purchase Agreement with the Italian valves producer Burocco Industrial Valves s.r.l. based in Northern Italy. With immediate effect Burocco is now part of the worldwide KLINGER network and fully operative to serve domestic and global customers.
About Burocco Industrial Valves
Burocco offers a wide product range in the industrial valves sector specialized in control valves, on-off valves, manual valves, but also ball valves. The company’s product portfolio perfectly complements our current array of products and serves as a strategic addition to our Intec and KFC range. Burocco is a well-established supplier to the chemical and general manufacturing industry but also serves as a partner for many other industries. The recently launched cryogenic valves range is especially known in the medical and pharmaceutical industry. Burocco’s net sales have been continuously on the rise for many years and profitability remains at a high level. Burocco currently employs 26 people.
The KLINGER Group Management sees the opportunities of this acquisition twofold: First, it is a major addition to the KLINGER Italy product range giving them the opportunity to better serve the domestic market. Secondly, it gives the Group further cross-sale options in order to strengthen and broaden our customer base. Due to its sound market position Burocco will remain a stand-alone company for the time being and will be managed by Raffaele Pittaluga, MD of KLINGER Italy. He is taking over from the previous owner who will retire after handover. Beneficial to a smooth integration process is the fact that KLINGER has had business relationships with Burocco for more than 5 years. Burocco is a customer currently served by KLINGER Italy who started supplying gaskets back in 2014.
The integration of Burocco into the KLINGER group is a perfect addition to our portfolio and our Group of companies.
CTP-DUMAG benefits from proximity to KLINGER Gebetsroither
CTP-DUMAG can trace its origins back to the 1930s. As a combustion technology expert, it focuses on the manufacturing of industrial burners and lances. Its unique and globally competitive Austrian engineering know-how is also applied to construct entire burner systems. And it has a company address our customers might well be familiar with: Am Kanal 8 - 10 in Gumpoldskirchen, which is also the address of the KLINGER business park in Lower Austria. Robert Schröger, CTP-DUMAG’s executive manager, tells us how this came about and what it is like to be the next-door neighbor of your supplier.
When we catch up with Robert Schröger, he is in the final preparations of a business trip to Asia. “We are a globally active company with a strong presence in Europe. 70 percent of our sales, however, are generated in China, Thailand and Malaysia,“ explains the executive manager, adding: “We are currently in the process of establishing a second business location in Asia.” The products that form the basis for the upcoming expansion of CTP-DUMAG are industrial burners and lances for a wide range of industries, including the chemical and the petrochemical industry, waste incinerators and energy providers. “Our mission is three-fold,” explains Schröger, “we destroy waste, we reduce CO2 and our technology provides process energy.” Asked about the company’s connection to KLINGER, he states: “I joined the predecessor company DUMAG after the completion of my studies in machine engineering in 1992. Even back then, KLINGER Gebetsroither was already on the vendor list.”
Moving in together
The company, as it exists today, was formed after a merger between CTP and DUMAG in 2011, which also led to new offices being required. Hearing about this, a business partner mentioned that office space was available right next to KLINGER in Gumpoldskirchen. “In the more than 30 years of our collaboration, we never had a single problem with the valves and gaskets supplied by KLINGER Gebetsroither,” explains Schröger, and adds: “The advantages of being very close to such a supplier made the decision a simple one.” CTP-DUMAG uses KLINGER valves and gaskets for the control and combustion systems in its burners and in the meantime has its company seat in the KLINGER business park, where it calls 300 square meters of office space its own. And one of its main suppliers is only around 500 meters away. According to CTP-DUMAG’s executive manager, this leads to numerous synergies: “In our business it is imperative that the equipment manufacturer and his suppliers act in concert. This also includes a lot of flexibility when it comes to the selection of components as well as meeting the required specifications. KLINGER Gebetsroither fulfills all the criteria.”
“Today the Dow Chemical Company is one of our major customers. But the tracks for this positive development were set back then in KLINGER’s test facilities.”
Executive Manager of CTP-DUMAG
Asked about the most memorable event in the cooperation between CTP-DUMAG and KLINGER, Robert Schröger remembers: “Somewhere between 2012 and 2013 we were awarded a project by the Dow Chemical Company, a major player in the chemical industry. And one of the many advantages of having KLINGER as your next-door neighbor, is that you can hold your acceptance tests for entire plant components there. And this is what we did.” According to Robert Schröger, the outcome was even better than expected. All the tests went flawlessly, and the customer was highly impressed with the level of professionalism and by the precision with which the test were carried out. “Today the Dow Chemical Company is one of our major customers. But the tracks for this positive development were set back then in KLINGER’s test facilities,” explains Schröger. And the success story of the two companies is still ongoing: Acceptance tests are still held on the KLINGER premises on a regular basis and the colleagues from KLINGER Gebetsroither often visit to update Robert Schröger and his team on the latest in sealing technology, valve automation and new standards. Which once again proves that customer proximity pays off – even if it is actually the customer who moves closer to the supplier.
Pictures © Ondrej Getzel, Photography
KLINGER Dichtungstechnik honored for long-term commitment to environmental protection
EMAS – the Eco-Management and Audit Scheme of the EU is a voluntary management instrument. It helps organizations to assess, manage and continuously improve their environmental performance. KLINGER Dichtungstechnik was recently recognized by the Austrian Federal Ministry of Agriculture, Forestry, Environment and Water Management for its long-term participation in the EMAS program. We asked Stephan Piringer, amongst others also responsible for environmental
and safety matters at KLINGER Dichtungstechnik, to tell us more.
KN: Mr. Piringer, Federal Minister Elisabeth Köstinger recently named KLINGER Dichtungstechnik one of the country’s EMAS pioneers. Can you tell us why you have been awarded this title?
SP: EMAS was opened for participation in 1995. KLINGER Dichtungstechnik obtained its registration as an EMAS company in 1998. Looking at the register, there are only 20 companies left today that can point to an earlier registration date. We were among the first Austrian companies to embrace its environmental protection principles. And according to the Federal Minister, that makes us pioneers.
KN: What exactly is EMAS?
SP: EMAS is a regulation, created by the European Union. Meeting the requirements of EMAS, which can be summarized as successfully taking an active stance for the environment, i.e. conserving resources and reducing waste, leads to the company being entered into the register of the Federal Environmental Agency. Last but not least, the ISO 14001 certification, which specifies the standards for an environmental management system, is itself an integral part of EMAS.
KN: What are the most important pillars of EMAS?
SP: An EMAS company must have an environmental policy, an environmental management system, and an environmental program. The environmental statement of a company – and EMAS stipulates it must be accessible by the public – is a key item: It ensures that everybody can check what the corresponding EMAS company is doing to protect the environment.
KN: So how does one go about becoming an EMAS-registered company?
SP: The environmental statement is at the core of the process. It requires the listing of mandatory figures, for example the amount of waste generated, or the amount of electricity or water consumed. This information has to be determined, assessed and ultimately published. An independent auditor is called upon to validate the results. He examines how the company has compiled its data by analyzing the processes, for example by inspecting the electricity meters and so forth. If everything checks out, he confirms the submitted key figures and the applying company is added to the register.
KN: Why are environmental certificates and regulations such as EMAS important for KLINGER Dichtungstechnik and other KLINGER companies?
SP: We have committed ourselves to preserving the environment for future generations with our company value
“Sustainability”. Some KLINGER companies, first and foremost KLINGER Fluid Control, KLINGER Schöneberg and Kempchen Dichtungstechnik, have already joined us. We hope that our role as EMAS pioneers will encourage others to follow suit. Last but not least, next to being the right thing to do, EMAS also offers advantages with regard to Austrian Environmental Management Law.
KN: Such as?
SP: Plant approval processes, for example, require significantly less administrative effort. The reasoning behind this is that a wide range of relevant factors, such as for example noise levels, toxins or other emissions, are already annually checked by a trusted auditor in the course of the EMAS registration. As a consequence, a lot less documentation has to be submitted, which greatly simplifies matters. The other main benefit has to do with the so-called consolidated decision. KLINGER Dichtungstechnik has been the recipient of uncountable decisions over its 130 years of existence: “The company is hereby authorized to do this… The company is hereby authorized to erect that facility et cetera.” EMAS companies are allowed to combine individual decisions into consolidated decisions, which results in legal certainty for all our activities.
KN: How do your customers profit?
SP: Our high-quality gaskets significantly contribute to keeping the environment clean. That said, our resource conservation and environmental protection efforts, which have been validated by an independent third party, are documented in the environmental statement we have to make public. This level of transparency regarding the effects of a business is rarely found outside the framework of EMAS and creates trust. Eco-aware customers can therefore review our environmental performance published online and decide whether we are a suitable candidate for their orders.
KN: How well does EMAS work with your other certificates?
SP: We operate an integrated management system that comprises all our ISO certificates as well as EMAS. This allows us to apply a single view, in which all our subsystems are interlinked. In our gasket manufacturing process, for example, quality assurance has a direct effect on our environmental management system: If the quality of a gasket meets our high standards, then the performance in the field will be as expected and the emissions will also be reduced to a minimum.
KN: Do you have any closing words you would like to share with us?
SP: 20 years of EMAS is a long time and involves a lot of effort. I would like to thank Ingo Denniger for his major contributions. And Walter Kubista: More than two decades ago, he convinced the management to embrace EMAS. I think we can be proud of how far we have come since then. And we are fully committed to remaining a part of EMAS.
Pictures: © Zelislav Rudolf Slamaj