GreenLine to add 1,500 LNG-powered trucks
GreenLine will add 1,500
INDIA & MIDDLE EAST
July 2023 – Issue 28
Inside
•S
 potlight on:
Valmet and Neles: Forward
together with a stronger
base p4
• Sustainable aviation fuel p18
• Control valves p22
• Valve failure p27
Galfar wins USD 726M
contract from PDO
Galfar Engineering and
Contracting SAOG have been
awarded a multi-year contract
with an estimated value of RO
280M covering the delivery of
off-plot facilities for the Qarn
Alam oil field.
The contract was awarded
following a competitive tender
process, and Galfar was selected
for its strong track record in the oil
and gas sector. The company has a
long history of working with PDO
and has previously been awarded
contracts for the development of
the Marmul and Harweel oil fields.
The contract is expected to create
hundreds of jobs and will boost
the local economy. Galfar is
committed to using local suppliers
and contractors, and the contract
is expected to have a positive
impact on the local community.
to diesel thereby bringing down
liquefied natural gas (LNG)
trucks to its fleet in the current
financial year, ending March
2024.
The company, part of the Essar
Group, aims to decarbonize
heavy trucking in India and is
paving the way for widespread
adoption of LNG-powered
freight transportation, which
offers better mileage compared
Silal partners with Desolenator
Silal, Abu Dhabi’s food,
agriculture, and technology
company, and Desolenator, a
solar thermal desalination
company headquartered in the
Netherlands, have launched a
pilot project deploying solar-
powered desalination
technology to turn saline water
into pure water for irrigation
and provide a sustainable
cooling option for greenhouses.
MGL to set up compressed biogas plant in Mumbai
Mahanagar Gas Limited has
signed a memorandum
of understanding with
Brihanmumbai Municipal
Corporation (BMC) for setting
up a Compressed Biogas
(CBG) plant in Mumbai.
The CBG plant having the
capacity to process up to 1000
Tonnes Per Day (TPD) of deeply
segregated food and vegetable
waste would be set up on a
parcel of land to be provided by
BMC. The waste, also known as
CBG feedstock, will be collected
from hotels, restaurants,
banquet halls, and large
vegetable markets/mandi in the
operating costs.
Currently, the company has a
total of 160-170 vehicles running.
An LNG truck typically costs
around Rs 85 lakh on the ground
with the trailer including
insurance, RTO, road tax, etc.
The idea behind Greenline was
to decarbonise the entire
logistics value chain, he
explained, adding that the
Causing zero environmental
harm, the unique project aims
to contribute to the
decarbonization of food
production in desert climates
by significantly lowering the
carbon footprint of the
desalination process.
The project is supported by
an AED 100M R&D fund
launched by ADQ, an Abu
Dhabi-based investment and
city. The daily supply of required
feedstock for the CBG plant will
be managed by BMC through
dedicated vehicles and will
include collection, segregation,
and delivery.
The Biogas plant, once
completed, will provide a three-
company first started with CNG
vehicles (Tata 151 and Eicher
vehicles) with the maximum
weight carrying limit for CNG
being up to 15 tonnes.
holding company, in 2022. The
fund forms part of its ‘Growth
Lab’, a community of
innovators across ADQ’s
portfolio that realizes the
company’s commitment to
accelerating innovation and
R&D, focusing on unlocking
growth opportunities and
driving value creation and
sustainability across priority
sectors of the UAE’s economy.
in-one solution, functioning
as a Biomass waste treatment
plant, an organic fertilizer
production plant, and green
fuel production. The Compressed
Biogas produced by the plant
will be consumed within BMC
limits.
Valve World India & Middle East | issue 28 | July 2023
colophon Contents
July 2023 edition – Issue 28
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Forward together with a stronger base control valves
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Valve World India & Middle East | issue 28 | July 2023 3


Valmet and Neles: forward together
with a stronger base
For decades, Neles has enjoyed
recognition as a best-in-class
player in the world of valves and
valve automation thanks to a
portfolio of quality products and
digital services. Of late, the
company has further accelerated
its agenda following the 2022
merger with Valmet. The main
message for customers, says
Haroon Azmi, is that the
company’s capabilities and
know-how are better than ever.
“Today we are operating from an
even stronger base and with a
wider offering, covering more
markets, and leveraging our
global reach.”
By David Sear
As widely reported in the
press, Neles Corporation
merged into Valmet Oyj on
April 1, 2022. The alliance
created a company with a
unique, even stronger
offering for global process
industries and a solid
platform for further business
growth in flow control
solutions. All being driven by
a team of 17,500
professionals around the
world.
“The merger went very
smoothly, delivering positive
benefits all round,”
comments Haroon Azmi, who
is Vice President for the MEIA
(Middle East, India, and
Africa) market area for
Valmet’s flow control
business. “Importantly for our
customers, be they looking
for complex project
packages, MRO or services,
we continue to offer the
4 Valve
spotlight
expertise and flow control
portfolio they can rely on.
This encompasses industry-
leading valves, valve
automation solutions, and
related services, under the
renowned Neles™, Neles
Easyflow™, Jamesbury™,
Stonel™, Valvcon™, and
Flowrox™ product brands.
Frankly speaking, our
customers have known and
respected these leading
brand names for decades,
rightly associating them with
reliability, safety, and
expertise.”
Asked to define the customer
base for Valmet’s flow control
business, Mr Azmi points to
traditional sectors such as
pulp & paper, gas processing,
LNG, industrial gas,
chemicals, energy, and
refining, as well as emerging
markets such as Power-to-X
and renewable energy.
“Moreover, thanks to the 2021
acquisition of the valve and
Valve World
World India
India &
& Middle
Middle East
East || issue
pump business of Flowrox we companies located in India
have cemented our position and Middle East, Mr Azmi
in the mining and metals
industry. Our business line’s
expanded offering of valves,
pumps and services for
mining, minerals and
metallurgical applications is
now more complete than
ever.”
The acquisition brought
together two flow control
solution portfolios with
zero overlap, confirms
Mr Azmi. “The Flowrox pinch
valves and knife gate valves
were a welcome addition to
our existing offering for the
industry. Slurry pumps were
also added to the portfolio.
All in all, we are now a
formidable player in Brand alignment: From July 2023
mining, minerals, and onwards the traditionally red
metals, which are amongst Flowrox pumps and valves will
be shipped in the typical blue
the most demanding coloration that all Valmet flow
applications for flow control products have in common
control technologies.” - carrying the torch for mining
and metals industry excellence
These strengths will be of under Valmet ownership. Image
definite interest to shows a pinch valve.
issue 28
28 || July
July 2023
2023

Haroon Azmi: Vice President
for the MEIA market area for
Valmet’s flow control business.
notes. “We have witnessed
increasing demand for
metals, ore depletion and
investments in more efficient
processing in these
geographies. With good
long-term fundamentals,
service intensity, and a
different cyclical nature
balancing out cycles of the
business line’s traditional
core industries, mining and
metals is an attractive
industry for Valmet.”
Global footprint
Plant managers and
engineers who rely on
sophisticated products like
valves set high store on
having support available
Powerhouse: Valmet’s flow control business boasts three state-of-the-art manufacturing plants in India.
Image shows the Ambernath premises.
spotlight
locally. Recognizing this, the
flow control business of the
company has over the years
created a wide network of
flow control experts to
ensure customer proximity.
As a case in point, consider
the Flow Control Business
Line’s eight technology
centres, forty-plus service
centres and numerous
manufacturing locations. In
addition, a new distributor
model has also been
launched. “Expanding
geographical coverage and
improving market reach are
important steps toward
increasing our presence in
the market. By enhancing
our distribution network, we
can effectively cater to a
wider customer base and
ensure quick customer
response times and
delivery,” says Mr Azmi.
Reflecting on Valmet’s
global presence, Mr Azmi
further notes that India is a
powerhouse when it comes
to valve manufacture.
“Valmet’s flow control
business boasts three
state-of-the-art
manufacturing plants in
India situated in
Valve World India & Middle East | issue 28 | July 2023
Business opportunities in vibrant India
In 2023, India became the world’s most populous
country. Meanwhile, the economy continues to post
solid and sustained growth rates. These two factors
unite to create an extremely vibrant climate for
business, states Mr Azmi.
“Domestic opportunities continue to emerge in all
sectors. These include our flow control business’
traditional markets such as chemicals, energy, gas
processing, LNG, industrial gas, refining, fertilizers,
pharmaceuticals, pulp and paper, etc. And now,
following the acquisition of Flowrox, we have a stronger
offering for sectors such as mining, minerals processing
and metallurgy.”
A reputation for supplying flow control solutions for both
standard and critical applications, along with extensive
experience plus the installed base in numerous plants
worldwide, strengthens Valmet’s position, comments
Mr Azmi. “Our track record demonstrates our reliability in
delivering mission critical valves to industry.”
Amongst the many growth sectors in both India and
Middle East, refining and petrochemicals continue to
stand out, says Mr Azmi. “With our strong flow control
product offering that supports the needs of the industry,
ranging from steam cracking units to downstream
process systems, we are well-positioned to cater to the
requirements of the petrochemical sector.”
Maharashtra - Ambernath, processes to provide
Dombivli and Vadodara quality products that fully
(Gujarat), together match global standards.”
employing approximately These plants are fully aligned
500 highly qualified with the government’s ‘Make
individuals. All plants are in India’ initiative, continues
equipped with modern Mr Azmi. “These facilities yield
machinery and automated a wide range of products that
not only cater to local
demands but are also
available for export. By
manufacturing various
products locally, we support
the domestic market and
reduce dependence on
imports. Additionally, the
ability to export these
products showcases India’s
manufacturing capabilities
and contributes to the
country’s economic growth
through international trade.”
Turning his attention to the
Middle East, Mr Azmi adds
that Valmet’s flow control
business also benefits from a
strong valve manufacturing
presence in Saudi Arabia.
“Our factory in Damman was
established in 2020 and staff
numbers have already
doubled since then.
5

Customer service: across the board, fulfilment in customer service is a top objective for Valmet. The Dombivli location is pictured.
Machinery and equipment
have been installed to
facilitate the assembly of
valves up to 36 inches in size.
Furthermore, collaborations
with local manufacturers
have been initiated to
enhance the local content of
the production process.”
“Our operations in Saudi
Arabia fully embrace and
align with the Kingdom Total
Value Add program, actively
contributing to the country’s
growth. Our Dammam factory
has successfully partnered
with local manufacturers to
strengthen the local content
in our production process. As
a result, our facility has
gained approval from all
major oil and gas companies,
solidifying our position as a
trusted and preferred
supplier in the region.”
Neles NDX – the
intelligent valve controller
The Neles NDX™ intelligent
valve controller has been a
runaway success in many
parts of the world and no
more so than in the Middle
East, where oil and gas
companies are early adopters
of the very latest
technologies.
Comments Mr Azmi: “Valmet
has experienced significant
6 Valve
spotlight
developments in its product
sales and customer usage.
Many of our major clients
have started utilizing the
Neles NDX, which
demonstrates the growing
adoption and recognition of
this innovative offering.”
Asked about the Neles NDX’s
competitive edge, Mr Azmi
lists the device’s high
pneumatic capacity,
advanced diagnostics and
easy usability. The large and
clear local user interface is
also a highly regarded feature
as is the availability of
multiple local languages.
“Perhaps most impressive of
all is the NDX’s reliability and
durability. The very first NDX
valve controller – which just
happens to be located in
Asia - it is still in full
operation with no major
issues reported after over six
years of operation. Following
the recent launch of the
latest update, the Neles NDX
2.0, I am sure our intelligent
valve controller will enjoy
continued popularity.”
Promoting sustainability
World-wide, sustainability is
high on the agenda of
governments, business
communities and citizens
alike. In this respect, Mr Azmi
Valve World
World India
India &
& Middle
Middle East
East || issue
issue 28
states that India is actively
investing in emerging sectors
such as green hydrogen and
renewables. “The market in
these sectors is currently
consolidating, and investors
are exploring competitive
technologies to capitalize on
the opportunities.
Additionally, biofuels and
plastic waste recycling are
gaining momentum as
sustainable solutions.”
Demand for renewable
energy sources is also
increasing throughout the
Middle East. “Hydrogen, solar
energy, and windmills are
being sought after to meet
growing energy needs and
reduce reliance on traditional
fossil fuels. The shift towards
renewable energy aligns with
global efforts to mitigate
climate change and promote
sustainable development.”
“At Valmet, we have long
recognized this need and
proactively enhanced our
flow control product offering
to cater to growing demands
Leveraging digitalization
Using the Valmet Performance Monitoring (VPM) pilot
program staff can, amongst others, offer preventive
maintenance programs for critical valves, enabling
customers to plan for obsolescence and maintenance
proactively.
28 || July
July 2023
2023
from such emerging
industries. Yet whilst
hydrogen and oxygen might
sound new and exciting, we
actually have a long history
of supplying valves that can
safely handle such
challenging media. The
degreasing and cleaning
processes are critical during
oxygen valve manufacture.
That is why Valmet has
dedicated clean rooms in five
different countries. Currently,
we have some 30,000
installed valves in active
oxygen service.”
Valmet also strives for
sustainability in its own
processes. Mr Azmi:
“throughout the entire value
chain, we recycle, repair and
reuse our products and parts
responsibly in line with
circular economy initiatives.
By designing and developing
products that are long-lasting
with a modular structure, we
extend the life cycle and
decrease our environmental
impact. We provide a service

stocking model for
customers allowing us to
place a repaired product
back in the customer’s
production process to give it
a new life in another
solution.”
Valmet is actively
contributing to the circular
economy. When it comes to
flow control solutions, as an
example, recycled materials
are used in the casting
process whilst metal scrap
from machining and
processing is also recycled.
Mr Azmi: “Within product
design, modularity and
reusability are key to
extending the life cycle by
easy repair or potential reuse.
Also, by further enhancing
seat technology for superior
tightness, we help clients to
limit energy losses via fugitive
emissions in production
processes.”
Leveraging digitalization
Across the board, fulfilment
in customer service is a top
objective for Valmet. Mr Azmi:
“my motivation comes from a
deep sense of purpose and
responsibility towards the
company. I am driven to lead
and guide the organization
towards achieving its
strategic goals, while creating
an environment where the
talented team can thrive.
Additionally, we work on
constant pursuit of growth
and innovation, as we strive
to identify new opportunities,
stay ahead of the curve, and
contribute to the overall
success and impact of the
organization.
Providing an example,
Mr Azmi recalls how a client
recently reported challenges
related to unexpected
breakdowns, production
losses, and inefficient spare
parts inventory management.
“Recognizing these issues, our
team ran a remote analysis
on data from ten separate
positioners using the Valmet
spotlight
Hydrogen and oxygen: Valmet thoroughly degrease and clean valves for certain critical applications.
Image shows UV light inspection for cleaned valve parts taking place in a clean room.
Performance Monitoring requirements to reduce greater efficiencies and
(VPM) pilot program. By greenhouse gas emissions. productivity are possible in
comparing this data to our Simply put, the extraction of these and other sectors.”
thresholds and analyzing metals such as copper, gold, As to the future, Mr Azmi
diagnostic information, iron, nickel, etc, needs to be therefore remains optimistic
and driven. “In common with
all my Valmet colleagues, I
am motivated by an internal
“Our expanded offering of valves, pumps and work culture that fosters
services for mining, minerals and metallurgical enthusiasm and inspired by
applications is now more complete than ever.” opportunities to serve our
customers directly and in
turn society as a whole. There
several critical issues were accomplished using less is no finer feeling than being
identified. Based on these energy, less water and with part of a well-knit team
findings, we provided specific far fewer fugitive emissions. which, in close liaison with
recommendations for each We believe that digitalization clients, can deliver effective
issue and offered a is the solution. With solutions to critical industry
preventive maintenance innovation and digitalization, issues.”
program for critical valves,
enabling the customer to Valmet’s flow control solutions
plan for obsolescence and Valves: Ball, butterfly, control, automated
maintenance proactively.” on-off, eccentric rotary plug,
Understandably, the client emergency shut-down, globe,
was delighted with the capping, solenoid & air operated,
improvement in plant uptime. knife-gate, pinch, railroad, segment …
Digitalization is however not Valve automation: Actuators (pneumatic, electric,
simply a tool for problem- linear, manual), valve controllers,
solving but can also be of limit switches, process
networking,….
merit in improving
Pumps: Peristaltic, dosing, metering,
sustainability, says Mr Azmi.
progressive cavity,…
“The green transition is metal Services: Spare parts, repairs, maintenance,
intensive, and the mining and maintenance planning, lifecycle
metals industry needs to find services, valve performance
ways to respond to ore management…
depletion and the
Valve World India & Middle East | issue 28 | July 2023 7

From nanotech to
face-to-face
As a self-professed handyman,
painting is a regular chore to
ensure that all windows and
doors remain in good condition.
But until recently I had never
really thought about the paint I
was skilfully applying. Until, that
is, Prof. A S Khanna started to
submit a series of excellent
columns about protective
coatings.
This month, for example, his
article looks at nanotechnology,
whereby particles as small as 1
nm can be added to coatings
with very beneficial effects. As
Prof. Khanna writes, “With
relevance to the coating
industries, nanoparticles have
shown significant potential for
much stronger, tougher and
durable coatings.”
I am sure his messages could
have real merit for the valve
community, so why not read for
yourself, starting on page 12.
In other areas, too, the valve
industry continues to throw up
surprises. Take the concept of
brand equity, which I had
always associated with high-
profile, high-end consumer
products like cars, jewellery
and expensive clothes. Well,
Bob Donnelly put me right on
that score (see page 32) with a
column about social media,
online configurators and
digitalization.
But if you prefer shaking hands
to talking AI, then please be
advised that another major
Valve World event will be
taking place soon. The
inaugural Valve World
SouthEast Asia expo and
conference will be held in
Singapore on 26-27 October.
And yes, companies from India
and Turkey will be there, too!
David Sear
8 Valve
india news
NTPC begins work ONGC to invest up to Rs 1 trillion
at its AP by 2030
hydrogen hub
ONGC will invest up to Rs. 1
NTPC has initiated work for a trillion by 2030 on energy
hydrogen hub in Andhra transition goals as part of its
Pradesh to set up manufacturing target to go carbon neutral by
facilities for equipment, 2038, ONGC Chairman Arun
production, and export of green Kumar Singh said recently.
hydrogen and green ammonia. The Maharatna company also plans
“NTPC is entering into hydrogen to raise electricity generation from
and energy storage solutions in renewable sources to 10 gigawatt
a big way Recently, work for a (GW) by the end of the decade
hydrogen hub at Pudimadaka, from 189 Mw now. In a post-result
Andhra Pradesh was initiated. media conference in Mumbai,
Also, a storage tender for 9000 Singh said the company signed a
MWh has been opened,” said pact with the Rajasthan a series of projects. Its joint
Jaikumar Srinivasan, director - government to set up a 5-GW plant venture ONGC Petro additions
finance, NTPC, at its Q4 FY23 in the state. He said the company and its subsidiary Mangalore
earnings conference call. was still scouting for opportunities Refinery and Petrochemicals are
He added that a non-binding to establish projects worth at least expected to implement the
MoU has been signed with the 5 GW more and will look at offshore expansion plans.
Government of Andhra Pradesh wind as well. It is also planning a 1 The company is targeting to
for the development of a mmtpa (million metric tons per double the production of these
hydrogen hub near annum) green ammonia plant in companies to 8 mmtpa by 2030.
Visakhapatnam. The project will Mangalore, he added. This will involve establishing new
involve setting up manufacturing ONGC is also looking to quickly facilities for the direct synthesis of
facilities for hydrogen related expand its oil production through compounds from crude.
equipment, production, and
export of green hydrogen, green
ammonia.
“NTPC has an operational
renewable energy capacity of 3.2
GW and total RE capacity in the
pipeline has exceeded 20 GW
with various agreements in place,”
added Srinivasan.
Sandhya Organic
to set up new unit
Sandhya Organic Chemical is
planning to set up a pesticide
intermediate, pesticide
technical, and speciality
chemicals manufacturing unit
with a capacity of 21,574 tpm at
Vapi in GIDC, Valsad district of
Gujarat. The proposed unit will
spread over 4.77 acres of land.
As per the updates available,
Sandhya Organic Chemical is
awaiting terms of reference for
the project. The company will
appoint contractors and
machinery suppliers as it
receives approval. The company
expects to begin the work on
the project by November 2023
and complete it by mid-2024.
Valve World
World India
India &
& Middle
Middle East
East || issue
issue 28
28 || July
July 2023
2023

Indian Oil to build MAH unit
McDermott International has se-
cured a project management
consultancy contract from Indi-
an Oil for the Maleic Anhydride
(MAH) unit at the Panipat refin-
ery and petrochemical complex
in India. Under the contract, Mc-
Dermott will provide project
management and consultancy
services for the MAH unit.
india news
The scope of services includes
front-end engineering design, re-
view of engineering activities,
construction supervision services,
assistance in start-up, pre-com-
missioning, commissioning, per-
formance guarantee test run, and
project closure.
Commissioned in 1998, the Pani-
pat complex is located 100km
from New Delhi in Panipat, Harya-
na. The refinery had an initial ca-
pacity of six million metric tonnes
per annum (MMTPA) which was
then expanded to 12MMTPA in
2006 and to 15MMTPA in 2010.
Further expansion of the refinery’s
capacity to 25MMTPA is under
execution.
According to McDermott, the
new MAH unit at the Panipat re-
finery and petrochemical com-
plex is India’s first mega-scale
MAH plant to manufacture
chemical products.
The plant is also expected to pro-
duce other chemicals including
Butanediol, which is used in engi-
neering-grade plastic and biode-
gradable fibres, and Tetra Hydro
Furan, which is widely used in
adhesives and vinyl film. Work on
the project is expected to be
carried out from McDermott’s
Center of Excellence in Gurugram.
N. India NPP update
The first unit of North India’s
inaugural nuclear power
plant, situated in Gorakhpur
village of Fatehabad district
in Haryana is likely to com-
mence operations in June
2028. The information was
recently provided in a meet-
ing regarding the coordina-
tion of officers of Haryana
government and Gorakhpur
Haryana Anu Vidyut Pariyoja-
na (GHAVP) presided over by
the chief secretary Sanjeev
Kaushal.
EIL eyes RE
State-owned project consul-
tancy company Engineers In-
dia Ltd(EIL) is eyeing renewa-
ble energy (RE) projects as
well as overseas market as it
pivots shift from the con-
struction of fossil-fuel plants
for its next phase of growth,
its chairman and managing
director Vartika Shukla has
said.

India’s Largest Processor of

FLUOROPOLYMERS
www.horizonpolymer.com

Valves qualified ISO 15848-Part 1. 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

Pipework qualified ASTM F 1545 FOLLOW US ON:

Valve World India & Middle East | issue 28 | July 2023 9

 india news
Portables for profit
There are reliable, cost-
effective portable machines
available in market, such as
lapping machines, flange
facing machines and boring
machines. The question is: how
do we use these machines for
the benefit of valve
manufacturers to enhance
daily productivity? In the
author’s experience, using
these machines it is possible
to double the output.
Valve assembly lines typically
have one welding machine
and a seat lapping machine.
Every assembly station has a
single line flow with set IED
norms. Any disturbance due to optimisation of existing
re-lapping, re-serration assembly lines can be
reduces the set output of the achieved.
shift. This in turn results in The author, Mr. N.S. Rao, would
slippage of planned be delighted to provide more
despatches. information on portable
Alternatively, we can make use machines. He has spent over
of portable machines, by thirty-five years in the valve
setting it on the mouth of sector and is experienced in
body and ensure desired valve design, manufacturing,
lapping finish with angles, to vendor development, foundry
get close tolerances between development, quality,
seats. By smartly using these approvals, presentation, and
portable machines, huge marketing. He can be reached
capex savings are possible and on: valvemen@gmail.com.

WAPCOS, NLCIL collaborate

on hydropower

WAPCOS Ltd. and Neyveli The MoU was exchanged

Lignite Corporation Limited between Shri Anupam Mishra,
(NLC) India signed a Director (Comml. & HRD),
memorandum of understanding WAPCOS, and Shri K Mohan
with an objective for Reddy, Director (Planning &
strategic collaboration for Project), NLC. Sh. Arvind Dev,
the development of General Manager, WAPCOS;
various projects related to Sh.D.P.Singh, General Manager,
the pumped storage, run of Projects & BD NLC, and other
river and hydropower sector in senior officers of WAPCOS and
India. NLC India were also present.

10 Valve
Valve World
World India
India &
& Middle
Middle East
East || issue
issue 28
28 || July
July 2023
2023

Rays Power Infra wins Rs 650 cr-water
project in UP
Rays Power Infra has won a
water project worth Rs 650
crore in Uttar Pradesh, which
aims to provide clean drinking
water to over one crore
households by March 2024.
The latest catch marks the
company’s forays into the water
engineering, procurement, and
construction (EPC) business,
Rays Power Infra said in a
statement.
“Rays Power Infra has announced
its foray into the water
engineering, procurement, and
construction business. It has
won the prestigious Har Ghar Jal
Yojana project in Uttar Pradesh
worth Rs 650 crore,” the
company said, adding its order
book now stands at around Rs
1,800 crore.
The company has also initiated
the development and execution
of solar parks and solar plants
Seamless Flow,
Unparalleled Quality
Leading
Manufacturer of
Industrial Valves
Nalisha Valves and Automation Limited,
Plot No. 37, Road 5A, Kathwada GIDC,
Ahmedabad – 382430, Gujarat, India
Call Us: +91 93277 27340
Email: info@nalishavalves.com
Website: nalishavalves.com
india news
aggregating to 2 GW in the next
24 months.
Ketan Mehta, MD and CEO, of
Rays Power Infra said, “We are
proud to announce our entry
into the water EPC business,
which is in line with our goal of
promoting sustainable growth
and development. We see a
Valve World India & Middle East | issue 28 | July 2023
synergy between our solar
power and water businesses
and we aim to grow both
verticals with equal focus and
capital allocation”.
Rays Power Infra is one of India’s
leading solar energy players
with a commissioned portfolio
of 1.30 GW.
More wells in AP
Hindustan Oil Exploration
Company plans to drill 18
wells in Arunachal Pradesh
to quadruple oil production
from the Kharsang field.
Dairy project in Nagpur
Union Minister Nitin
Gadkari on Sunday said
Mother Dair y will invest Rs
400 crore in Nagpur in a
project for which the
government will give 10
hectares of land.
Rajasthan’s OCTG deal
Hunting Plc has reported a
new, significant Oil Country
Tubular Goods contract
from Cairn Oil and Gas,
Vedanta Limited. Hunting
said its Asia Pacific
operating segment has won
the O C TG contract,
estimated to be worth up
to USD 91 million for Cairn
Oil and Gas’ operations in
Rajasthan, India.
11
 Coatings
Nanotechnology in paint coatings
coating volume. Also, the anti-bacterial, anti-corrosion
In the fourth of his series of six articles on coatings,
micro sized pigments always and anti-graffiti etc. These
Prof. A S Khanna, Retd. IIT Bombay, Chairman SSPC
bring side effects like unique properties are the
India, addresses nanotechnology in paint coatings. The
reduction in flexibility, outcome of outstanding
author looks at applications of nanoparticles for paints
adhesion, unwanted changes aspect ratio, excellent surface
and coatings and goes into detail about the theory of
in optical properties etc. interaction and high modulus.
distribution of nanoparticles. He concludes with
Improvement of one Numerous papers have been
various practical examples, such as water proofing, fire
functional property occurs at published on the
retardance and acid resistant coatings.
the compensation of the other. enhancement of performance
For example, improvement of properties of polymer coatings
Background out around 40,000 years ago. mar resistance* occurs at the by the addition of
The demand for functional Since then, this field has been cost of weathering resistance nanomaterials[1-4]. Due to the
coatings, such as higher developed quite broadly, and flexibility. One of the high surface area of the
chemical resistance, covering a range of effective ways to face these particles, even a small amount
hydrophobicity, anti-fungal, applications such as for challenges is to use nano-size of addition can bring a big
anti-fog, self-cleaning and decoration, protection against pigments. Due to the large change in the performance of
self-healing is continuously corrosion and abrasion, fire surface area of nanoparticles, the coating. One can create
increasing. To meet this retardancy, anti-fungal and the amount of pigment magic using nanotechnology
demand, many innovative microbial, water repellent and requirement will be very low. in the field of coatings. This
formulations have been so on[1]. Modern applications Thus, one can formulate a needs an understanding of
developed in which demand coatings with smart, protective and high- material selection, size effect
nanotechnology plays an additional functional performance functional and importance of
important role. In order to properties. This has led to coating using a variety of nano- morphology of the
discover the potential innovative technologies in the additives and pigments[2]. nanoparticles. Also, the
advantages of nanoparticle field of surface processing of polymer-nano
pigments in paint composition, functionalization, Application of nanoparticles composite is critical. If the
several studies from different nanocomposites, smart for paints and coatings synthesis process is
labs are reported, highlighting, coatings etc. However, there Nanoparticles are engineered inappropriate, we may end up
their effect on the physical, are still certain areas in paint structures at nanoscale with agglomerates in the
mechanical and chemical and coatings which need whose sizes range from1 to coatings which is undesirable.
properties of the coating. Also, additional focus. For example, 100 nm, at least in one Perfect distribution of
it is important to understand photo degradation due to direction. These are used in nanoparticles in the polymer
the impact of their size, shape, sunlight, presence of micro coatings as pigments or matrix reflects the best
and distribution in the coating defects, damage due to additives, opacifiers and possible outcomes. This
matrix. In the present article, abrasion and many more that semiconductors. problem can be overcome by
application of various can lead to localized corrosion Nanotechnology has led to using dispersing agents and
nanoparticles and their effect of the metal components breakthrough advancements methods like ultra-sonication
on the coating characteristics which is more dangerous than in coating industries because or functionalization with
has been described, the uniform corrosion. Hence, nanomaterials have the silanes and fluoro-compounds.
specifically the effect of the coating should have good potential to overcome Compatibility of nanoparticles
nano-ZnO, nano-TiO2, and corrosion protection and challenges faced by the and the polymer matrix is also
nano-Fe2O3. Finally, a few mechanical properties such as coating industries. a very important factor.
practical examples of adequate strength, resistance With relevance to the coating Functionalization of surface of
commercial coatings, such as, to impact wear and abrasion industries, nanoparticles have the nanoparticles with silanes
water proofing, fire retardance and must be able to resist shown significant potential for is the most common method
and acid resistant coatings are weathering and should have much stronger, tougher and followed to achieve
discussed to illustrate the low water permeability[1]. durable coatings[1]. They offer compatibility, improve
superiority of nano-modified Addition of pigments, unique contributions when bonding and decrease
paint systems. extenders, fillers and additives, dispersed in coatings. For agglomeration[1].
generally used in conventional example, they can be used for Among all the pigments,
Introduction paint coatings, have sizes in formulating functional smart nano-inorganic materials are
Paints and coatings are being the range of 50-200 µm. But coatings like super- considered to be most
considered as essential loading levels for these micro hydrophobicity, anti-icing, advanced to improve
requirement in our life, since sized pigments is rather high anti-fogging, antireflective, mechanical and performance
the first cave painting carried i.e. from 10 to 30 vol. % w.r.t to anti-fouling, self-healing, properties. Nano-TiO2, ZnO,

*According to ASTM D5178-13, mar resistance of coating is the ability of a coating to resist damage caused by light abrasion.

12 Valve
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 Coatings
(silica) SiO2, (alumina) Al2O3, Figure 2(a), which shows that Table 1: Nano-materials used for the enhancement of specific
functional properties
carbon black etc., are even 10% of ZnO is unable to
commonly used for serving protect the epoxy matrix and Property Nano-material to be used
different purposes [1-3]. Each deterioration occurs when
kind can perform more than UV light falls on the matrix. UV resistance TiO2 (rutile), ZnO
one function. For example, Now compare a similar
Mechanical
nano-ZnO can be used as UV instance but taking 0.1% of SiO2, ZnO, Al2O3
properties
blocker but it can also improve nano-ZnO particles with the
the scratch and abrasion achieved distribution as Anti-corrosion CeO2, TiO2, Fe2O3, Halloysite
resistance [1]. Hence, shown in Figure 2(b). It can be
classification of nanoparticles seen that the matrix is almost Water-repellent SiO2, ZnO
based on function is difficult. covered by nano-ZnO
From the literature, different particles, uniformly Self-cleaning TiO2, SiO2
functional properties achieved distributed in the resin
by various nanoparticles are matrix, so the chance of Fire retardant TiO2, SiO2, Bentonite clay, Halloysite Clay
shown in Table 1. sunlight falling on the matrix Anti-bacterial Cu, CuO, Ag, ZnO, TiO2
is very low. Now take the
Theory of distribution of third example of 0.01% Anti-graffiti SiO2, ZnO, Al2O3
nanoparticles in coatings graphene particles (2D
The role of nanotechnology structure). They cover the at an even lower and its shape. Figure 3 shows
can be understood from whole surface in an even concentration (Figure2(c)). three different oxides, ZnO,
Figure 1. As is well known, a better fashion, thus showing Another important factor in TiO2 and Fe2O3, in two different
coating is made based upon that the addition of 2D nanotechnology in paint sizes and shapes. Their effect
the chemistry of the resin, graphene nanoparticles is coating is the selection of on paint properties varies
which determines how even more effective, and that suitable size of nanoparticle based upon the size and shape
durable a coating is in a
particular environment.
Additional properties, such as
color, strength and processes
such as drying time, UV
blocking etc. are decided by
the choice of pigments and
various additives. It is now
established that as the particle
size of the pigments/additives
decreases, there is
enhancement in the basic
properties of the coating such
as corrosion resistance,
mechanical properties, and
many other specific properties
such as bond strength,
waterproofing tendency, etc. It
is now also well established
that size and shape of the
nanoparticles is very
important. The next important
factor is the concentration of
nanoparticles[5-6]. Usually,
nanoparticles are required in Fig. 1: Schematic representation of the paint selection process and the role of pigments and additives
and their size on coating performance
very low concentration. Higher
concentration leads to
agglomeration.
Let us now consider an epoxy
coating where almost 10%
micro-sized ZnO was added
to take care of UV blocking
(A) (B) (C)
resistance. Distribution of
Fig. 2: Epoxy coating with additives of varying sizes and concentrations: (A) 10% additive (micron-sized)
such particles in epoxy in paint matrix, (B) 0.1% additive (nano-sized) in paint matrix, (C) <0.01% additive (high aspect ratio e.g.
matrix can be as shown in Graphene) in paint matrix

Valve World India & Middle East | issue 28 | July 2023 13

 Coatings
A
Practical examples of some
B C
nano-additives modified
coatings

Nano-modified
waterproofing compound
Waterproofing is one of the
severest problems in the old
buildings. Lots of
D E F waterproofing formulations
available in the market are
based upon the selection of
resin with some additives in
micro sizes. This results in
leaving enough matrix space
in the resin where micro-
pores can form and water
Fig. 3: Showing the sizes and shapes of nanoparticles, ZnO, TiO2 , rutile, and Fe2O3. (A) ZnO 30nm granular, may start leaking. This
(B) ZnO 90nm granular, (C) Nano ZnO flakes, (D) Rutile 130nm, (E) Fe2O3 75 nm sphere, (F) Fe2O3 rods 180nm nano-modified compound is
now available with a name
called Thermacool WP-. Its
19 Spherical Fe2O3 2.8 Spherical Fe2O3 application works in three
Tensile strength (MPa)

18
Rod Fe2O3 Rod Fe2O3 steps:
17 2.3 2.3 1. Identify all leaking visible
Modulus (GPA)

16 2.1
15 15 2.01 cracks or sites. Make small
1.8
grooving in that. Apply a
13 14
paste made from 50%
13 1.3
11 11 mixture of Thermacool
0.8 WP1 and white cement
9 0.88
0.58 0.79 and some water to fill all
0.3 0.4 these cracks.
7 7
0 0.5 1 1.5 0 0.5 1 1.5 2. After drying of these
Concentration (W%) Concentration (W%) cracks, apply Thermacool
Fig. 4: Effect of spherical and rod-shaped nanoparticles on the tensile strength and modulus of epoxy WP1 over the whole
coatings surface area to be
protected using a brush.
and also on the optimum 1wt % loading, the values the range of influence gets This is called absorption
concentration as described start to become constant. disturbed and the optimum coat which helps to seal
above. Fig.4 shows the effect of The nanoparticles start to property will be lost as all micro-pores in the
size and shape and agglomerate at this point shown in Figure 6. concrete.
concentration of nanoparticles and a further increase in the
on some of the paint concentration of
characteristics. nanoparticles will lead to
Figure 5 shows the Taber detrimental effects. bare 0.5 1 1.5
150 150
abrasion index of epoxy The dispersion of 150
Taber abrasion Index (mg)

coatings modified with nanoparticles in the coating

spherical and rod shaped matrix reflects its final
Fe2O3 nanoparticles at properties. Hence
various concentrations. optimization of the synthesis 100 87
80
There is a significant method plays a major role.
increase in the abrasion Due to the high surface
54 51
resistance with addition of energy of nanoparticles, they
these particles in the tend to agglomerate. As per 50
31 29
coating. The size, shape, continuum theory, the effect
distribution of nanoparticles of each nanoparticle
in the coating, and distributed in coating matrix 0
compatibility of has its range of influence. In
nanoparticles with the the event that the Spherical Rod
matrix, affects the abrasion nanoparticle is overcrowded Fig. 5: Taber abrasion index of epoxy coatings modified with various
resistance of the coating. At or non-uniformly distributed, concentrations of spherical and rod shaped Fe2O3 particles

14 Valve
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& Middle
Middle East
East || issue
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July 2023
2023

a b
Well Dispersed
Fig. 6: Examples of nanoparticle dispersion
3. Finally, 1mm thick paste of
50% mixture of
Thermacool WP1 and
white cement is uniformly
applied on the whole
surface to fully seal it.
Fire-retardant nano-coating
A transparent nano-modified
fire-retardant coating was
developed to either extinguish
the fire or retard its rate of
burning, on any substrate, such
as wood, plastics, or metal. As
shown in Figure 7, after seven
minutes of burning the coated
surface, the surface was largely
unaffected. In the same way a
standard PE floor mat burned
immediately compared to the
same, coated with nano-
modified fire-retardant coating
DLFR-26. (For the DLFR-26
technical data sheet, please
read the online version of this
article at: https://valve-world-
india.com/nanotechnology-in-
paint-coatings/.)
Acid-resistant nano-
modified epoxy coating
A highly corrosion resistant,
brushable epoxy based
coating DL-AR was developed
Fig. 7: Wood coated with DLFR-26
shows little sign of surface damage
after seven minutes of burning
Coatings
c
Poorly dispersed Overcrowded
for such applications where
very strong corrosion
resistance from acids, alkalis
or other strong mixed media
is required. This is especially
made for battery rooms in
ships and submarines,
pickling side walls which
constantly get acid vapours
from acid tanks in 7 tank
process, sewage treatment
plants and refineries and
chemical plants where SO2,
H2S vapours can occur. The
epoxy is modified with
nano-PVDF particles[5].
Coated panels are resistant
to attack at any pH ranging
from 1 to14 and in various
organic solvents. (For a test
image depicting that nano-
modified 2K epoxy-
polyamide coating is not
affected by acids like H2SO4
or HCl, plus the DL-AR
technical data sheet[5], please
read the online version of this
article at: https://valve-world-
india.com/nanotechnology-
in-paint-coatings/.)
Conclusion
Nanotechnology is no longer a
new term as it has spread its
benefical effects in various
sectors ranging from medical
to engineering technology to
biology with hundreds of
different applications. Its use
in paint coating is also far from
new. Use of nano-pigments
and nano-additives not only
enhances the physical,
chemical and mechanical
properties of paints but also
helps in reducing the amount
of raw materials. It has been
found that both size and
Valve World India & Middle East | issue 28 | July 2023
Sphere of References
nanoparticle 1. John Mendel, Dispersions
influence and Coatings, in
“Nanostructure Science
and Technology, A
Worldwide Study”, R.W.
Siegel, E. Hu, M.C. Roco
(eds.), NSTC, (1999)
pp35-48.
Nanoparticle 2. Swati Gaur & A.S.Khanna,
Functional Coatings by
incorporating
shape of nanoparticles as well nanoparticles, Nano
as their concentration is Research & Applications,
important to achieve the 1(7) 2015,
optimum properties of the 3. Shalini Dolai and A S
coatings. Care should be taken Khanna, Construction,
to properely disperse the Infrastructure and
nanoparticles using a high Architecture World, Dec.
shear process to avoid any 2021, p 37-42.
kind of agglomeration. The 4. Dhoke SK , Bhandari R,
examples of size, shape and Khanna AS, Effect of
concentration of nano-ZnO addition on
nanoparticles has been shown the silicone-modified
to affect the paint properties alkyd-based waterborne
such as Tabor abrasion, UV coatings on its
blocking and extent of mechanical and heat-
yellowishness. Also, three resistance properties.
examples of commercial Progress in Organic
coatings, such as nano- Coatings 6 4(2009)
waterproofing coatings, 39-46.
fire-retardent coatings and 5. M.Tech Thesis, Banti
acid resistant coatings have Kumar Singh, IIT
been given. Bombay, 2017-18.
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
15
 Meeting Point
Valve World Southeast Asia Expo & Conference
The Valve World Southeast Asia Expo & Conference
2023 will welcome end users, manufacturers and other
members of the valve supply chain to share industry
knowledge and expertise at the Max Atria, Singapore
Expo, Singapore on October 26 and 27 2023. Among
those set to take part are six suppliers from India and
Turkey, which are profiled below.

The “Valve World” series of up the flourishing Southeast

exhibitions and conferences is
being expanded. After starting
in Europe in 1998, and then
spreading to the Americas
and Asia, a new event will
soon see the light of day in
Singapore. This will be the first
Valve World Southeast Asia
Expo & Conference.
Singapore is a sound choice
because of its geographical
location, trade environment,
social order and economic
strength. This event will help
global valve suppliers open
Asian market, bringing more
business opportunities and
fostering new highlights of
growth in the valve market.
Given the previous successful
shows from the “Valve World”
series, 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 instrumentation ball valves,
complete as of early June instrumentation needle
2023). valves, instrumentation
• Founded in Mumbai, India manifolds, floating ball
in 1995, Bhola Engineers double block & bleed
Private Limited today valves and pipeline ball
boasts a wide range of high valve. The company claim
quality and technically they believe in total
advanced valves. For satisfaction of the
example, the company customers with mutual
offers precision double understanding and lasting
compression tube fittings, trust.

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16 Valve
Valve World
World India
India &
& Middle
Middle East
East || issue
issue 28
28 || July
July 2023
2023

• Lee Spring Company India
Pvt. Ltd. – founded in 1918,
Lee Spring is recognized as
a leader in manufacturing
stock springs and custom
springs as well as formed
metal parts and related
products. The company´s
wide range includes
compression springs,
extension springs, torsion
springs, LeeP™ Plastic
Composite Springs,
constant force springs etc.
The company prides itself
on offering a wide selection
around the world, available
for immediate delivery.
• 
A subsidiary of Larsen &
Toubro, L&T Valves Limited
is considered one of the
leaders in flow-control
solutions. Their valves can
be found in key sectors
such as oil and gas, power,
Meeting Point
petrochemicals, chemicals,
water, defence and
aerospace. They claim they
put emphasis on enhancing
customer value by
providing support for the
entire lifecycle of the valve.
The company offers a wide
range of valves: gate, globe
and check valves, plug
valves, ball valves, butterfly
valves, dual-plate check
valves etc.
• 
Founded in Turkey,
SMS-TORK Endüstriyel
Otomasyon has been
offering solutions and
services for the needs of
customers with their wide
product range in fluid
control. For example, the
company offers multiple
designs for actuators,
solenoid valves, pulse valves
and control valves. The
https://valve-world-sea.com/#
Valve World India & Middle East | issue 28 | July 2023
company states that:
“TORK, which carries out its
production in IMES
Organized Industrial Zone
in Dilovası, in its facilities
established on a closed
area of 17.000 square
meters, produces solutions
for its customers with 100%
domestic products, which it
designs and produces in our
country, with its R&D team.”
• 
Based in Navi Mumbai and
Sanand, India, Steelstrong
Valves (I) Pvt. Ltd. has grown
into a reputed valve
manufacturer since their
beginnings in 1982 by
offering premium products
that are manufactured
according to the standards.
They offer gate valves, globe
valves, check valves, ball
valves and cryogenic valves.
Steelstrong´s services
include design, material
procurement,
manufacturing, assembly
and testing of valves. They
claim they aspire to be one
of the leading valve
manufacturers of
international repute.
• 
UNP Polyvalves Pvt. Ltd was
founded in 1988. With its
corrosive application valve
manufacturing plant in
Vadodara, Gujarat, they
have been supporting the
Indian valve market ever
since. The company offers
solid plastic and lined ball
valves, plug valves, butterfly
valves, diaphragm valves,
ball check valves, swing
check valves, sampling
valves, double window and
full view sight glasses, Y and
T type strainers, lined pipes
and fittings.
17
 Market outlook
SAF – cleaner and greener flying for all?
Going green is the way to go – that is the general tendency in
industries nowadays and aviation is no exception. As per
International Energy Agency, aviation contributes almost 3%
of the overall climate impact which amounts to 1bn tonnes of
CO2 per year. Seeing as the demand for air travel is constantly
growing, this number will only keep increasing. The aviation
sector is, therefore, facing the challenge of having to meet the
needs of the market and at the same time ensure a net zero
future. Is SAF perhaps the answer to nature´s prayers?

By Lucija Kozina ways to describe non-fossil with conventional jet fuel

What is SAF?
SAF is liquified alternative
aviation fuel produced from
renewable waste feedstock
and sustainable raw materials.
It can be made from a wide
range of sources. For instance,
it can be obtained through
processing used cooking oil,
rendered fats and greases, but
can also be created
synthetically by capturing
carbon directly from air.
Using SAF, the aviation
industry is trying to minimize
the emissions of CO2.
According to the
International Air Transport
Association (IATA), SAF
reduces CO2 emissions by up
to 80%. Unlike fossil fuels
which emit carbon and
contribute a high share of the
overall CO2, SAF recycles the
CO2 that has been absorbed
by the biomass used in the
feedstock during its life.
Sustainable aviation fuel
should not be confused with
biofuel. There are numerous
hydrocarbon fuel, however, the
aviation industry is quite
careful with using terms that
do not specify the
sustainability aspect of these
fuels. The term biofuel often
encompasses fuels produced
from non-sustainable
feedstocks, such as palm oil or
crops that require
deforestation. If the production
of a certain fuel entails any
additional environmental
damage, it cannot be
considered sustainable. In
order to make a distinction
between sustainably and
non-sustainably sourced fuels,
sustainable fuels are often
referred to as ´advanced
biofuels´.
New fuel, same
infrastructure
Blended with conventional jet
fuel, SAF is already being used
in commercial aviation.
Currently, however, the blend
limit has been set to 50% due
to the possibility of engine
leaks. Such leaks do not appear
thanks to its specific
composition. Nevertheless,
newer engines have been
tested with 100% SAF with
favourable results. According to
the main authorities, it is highly
probable that 100% SAF will be
certified in the near future.
One dilemma remains: does
the appearance of a new type
of fuel imply an overhaul of
infrastructure? The answer to
this question is quite
convenient, both financially
and logistically. SAF is also
known as ´drop-in fuel´ which
means that it can
automatically be incorporated
into existing airport
infrastructure. Modifications
are not required on pipelines,
fuel farms, trucks, tanks,
engines etc. SAF is fully
compatible with existing
engines and delivery systems,
however, it is of utmost
importance that the non-fossil
fuel has the same properties
as the conventional jet fuel.
That is why a strict system of
tests and inspections is in
Sustainable Aviation Fuel
Offsets and carbon capture
New technology, electric and hydrogen
Infrastructure and operational efficiencies 
Achieving net zero by 2050 will
require a combination of maxi-
mum elimination of emissions
at the source, offsetting and
carbon capture technologies
place, to make sure that the
quality of the fuel meets the
standards. By this not only
pollution in general is
reduced, but also pollution
from aircraft engine operation.
Predictions for the future
As per the European Union
Aviation Safety Agency, SAF
provided approximately 0.1%
to 0.15% of total aviation fuel
in 2022 which indicates that
there is still a lot of space for
improvement. Nevertheless,

Latest developments for SAF in India SAF - potential difficulties

•• Aug 2018 – SpiceJet operated the first test flight
using SAF
•• Dec 2022 – InDigo and Indian Institute of Petroleum
to manufacture and distribute SAF globally
•• Feb 2023 – LanzaJet and IndianOil signed MoU to
explore the production of SAF
•• Mar 2023 – Groupe ADP and GMR Airports signed
MoU with Airbus, Axens and Safran to conduct a
study on SAF
•• Mar 2023 – Vistara became India’s first carrier to
operate a wide-body aircraft using SAF on a long-
haul route
•• Full implementation will require a lot of time
•• Collection and distribution of waste – availability of
feedstock
•• Capacity increases in renewable energy needed
•• Waste oils limited in volume
•• Currently 2-5 times more expensive than conventional
jet fuel
•• High risk - strong competition, but no one dares to
break the ice fully
•• Will the passenger and customers adapt to the higher
prices?
•• Travel pattern constantly being changed

18 Valve
Valve World
World India
India &
& Middle
Middle East
East || issue
issue 28
28 || July
July 2023
2023

Pathways and processes
Fischer-Tropsch Synthetic
Paraffinic Kerosene (FT-SPK)
Hydroprocessed Esters and
Fatty Acids (HEFA-SPK)
Hydroprocessed Fermented
Sugars to Synthetic
Isoparaffins (HFS-SIP)
FT-SPK with aromatics (FT-
SPK/A)
Alcohol-to-Jet Synthetic
Paraffinic Kerosene (ATJ-
SPK) [isobutanol]
Alcohol-to-Jet Synthetic
Paraffinic Kerosene (ATJ-
SPK) [ethanol]
Catalytic hydrothermolysis
synthetic jet fuel (CHJ)
High Hydrogen Content
Synthetic Paraffinic
Kerosene (HHC-SPK)
The table shows all the biofuel production pathways that are currently certified to produce SAF. They perform at operationally equivalent levels
to Jet A1 fuel.
according to the IATA
estimate, 450 billion liters will
need to be produced annually
to achieve the goals set for
2050. As stated on IATA´s
website, SAF could contribute
around 65% of the reduction
in emissions needed by the
aviation sector to reach
net-zero by 2050. As of April
2022, SAF has been used by
over fifty airlines in over 450
000 commercial flights.
As far as SAF is concerned,
the future seems to be bright.
Research continues apace
regarding the next generation
of raw materials. It is possible
that some new feedstocks
will be used for production of
advanced biofuel, such as
algae. This would, perhaps,
solve the problem of
availability of feedstock.
Regulations and policies will be
crucial in achieving emission
reduction. Governments are
encouraged to develop policies
Market outlook
Feedstock options
biomass (forestry residues, grasses,
municipal solid waste)
algae, jatropha, camelina
microbial conversion of sugars to
hydrocarbon
renewable biomass such as
municipal solid waste, agricultural
wastes and forestry residues,
wood and energy crops
agricultural waste products
(stover, grasses, forestry slash,
crop straws)
agricultural waste products
(stover, grasses, forestry slash,
crop straws)
Triglyceride-based feedstocks
(plant oils, waste oils, algal
oils, soybean oil, jatropha oil,
camelina oil, carinata oil and
tung oil)
biologically derived
hydrocarbons such as algae
and positive incentives which
would be an effective tool for
the production and
deployment of SAF.
The future of SAF in India
India is among the top five
CO2-producing nations in the
world; however, the country is
strongly committed towards
achieving net zero status by
2070. And as the third largest
civil aviation market in the
world, India could play a
leading role in reducing
carbon emission through the
implementation of SAF.
Indian key players realized
the need to adopt
sustainable fuels in the
aviation industry and are,
therefore, determined to fully
honor India´s commitment to
reduce greenhouse gas
emissions according to the
Paris Agreement.
Hence an inaugural step was
taken in 2018 when the Indian
Valve World India & Middle East | issue 28 | July 2023
Producers using Current blending
Date of approval
the pathway limit
2009 up to 50%
Alt Air 2011 up to 50%
Amyris 2014 up to 10%
2015 up to 50%
Gevo 2016 up to 30%
LanzaTech 2018 up to 50%
ARA and
2020 up to 50%
Euglena
IHI World 2020 up to 10%
Government launched the such as priority lending,
National Biofuel policy. It was assistance from public banks
aimed at reducing import of and carbon credits.
oil and gas and focusing on SAF is a fairly new concept in
using renewable biomass the Indian market and as yet
sources such as municipal no regulatory framework has
solid waste in order to been established.
produce biofuel. This policy Nevertheless, SAF needs to
set out ideas and ways on how meet very strict criteria and
to use advanced technology standards, similar to
and available feedstocks and conventional jet fuels. The
waste to produce sustainable authority that mainly regulates
fuel. A number of financial certifications for civil aircrafts
incentives have also been is the Directorate General of
implemented for this cause, Civil Aviation.
Resources:
https://www.iea.org/reports/aviation
https://www.iata.org/en/programs/environment/
sustainable-aviation-fuels/
https://aviationbenefits.org/environmental-efficiency/
climate-action/sustainable-aviation-fuel/producing-
sustainable-aviation-fuel/
https://www.easa.europa.eu/en
https://www.mondaq.com/india/aviation/1285156/
future-of-aviation--sustainable-aviation-fuel
19

CLG lands contract for Saudi
graphite complex
Chevron Lummus Global (CLG),
a process technology licensor
for refining hydroprocessing
technologies and alternative
source fuels, has announced
that it has been awarded a key
contract by Saudi energy group
Taqat Development for a new
75,000 tonnes per annum
(TPA) needle coke/synthetic
graphite complex in Rabigh.
Strength of the metal
Infrastructure
With a Factory built up area of 62,000 sq ft. and
the land area of 7,700 sq. yd. CTPL has the latest
technology machines.
Testing Facility
Chemical Testing Hardness Testing
Mechanical Testing IGC Testing
NDT(RT,UT,LPT,MPT)
PRODUCT RANGE &
CAPACITY
Any Component in the rage of 10
Grams to 80 Kgs Can be Casted.
100MT/Month Investment
Casting
All Type of Ferrous, Non-Ferrous
& Super Alloys can be casted
Website: www.calistotechnocast.com Email: info@calistotechnocast.com Phone: +91 90334 80393
20
Regional news
Oil projects in
Kuwait
A joint venture between US
energy major Chevron and
Lummus Technology, CLG is a
global leader in catalyst system
supply. It offers the most
complete bottom-of-the- design, and additional
barrel solution for upgrading engineering and operations Kuwait Oil Company (KOC) intends to award
heavy oil residues. support. The feedstock will be 22 projects to local and foreign firms in the
Under the agreement, the supplied by Rabigh Refining & next few months, a newspaper reported on
Chevron JV will provide pilot Petrochemical Company recently. KOC, which manages the OPEC
plant testing, licensing, basic (Petro Rabigh), it stated. member’s upstream oil industry, will
gradually award those contracts after they
are approved by the Central Agency for
Public Tenders, the Arabic language daily
Alanba said, quoting KOC sources.
The projects include the installation of
One Stop Solution For All Your pipelines at KOC’s facilities in West
Investment Casting Requirments Kuwait, providing maintenance services
at KOC’s export terminals, building
Calisto Technocast Pvt. Ltd. is an India based pipelines at Jurassic gas areas in North
company engaged in the manufacturing and Kuwait, and the construction of power
supply of Stainless Steel, Non-Alloys Steel and
Alloys Steel Casting with the process of Lost Wax networks in some areas.
Casting widely known by its name of Investment According to the report, KOC awarded 41
Casting.
contracts in Kuwait with a combined value
of around Kuwaiti dinars 630M (USD 2.8bn)
in the first four months of 2023. The paper
said another project will be awarded soon
by the Kuwait National Petroleum Company,
the Gulf state’s downstream investment
arm, for civilian construction work at Kuwait’s
Al-Ahmadi oil refinery.
Methanol-to-
olefins complex in
Uzbekistan
Uzbekistan’s Gas Chemical Complex MTO
Central Asia LLC has signed an industrial gas
processing agreement with Air Products to
build a methanol production facility. Known
as Methanol Island, the facility would have a
capacity of 1.34 million tons per year, as a
part of the Methanol-to-olefin (MTO) gas
chemical complex in Uzbekistan.
The facility, to be built in the Karakul Free
APPROVALS FOR MORE Economic Zone situated in Uzbekistan’s
INFORMATION Bukhara region, will cover 15 hectares. It is
planned to enter operation in 2025 for an
PED 2014.68.EU
ISO expected operational life of 25 years.
Using world leading innovative technologies,
IBR
AD 2000-Merkblatt W0
LLoyds Marine
Uzbekistan’s GCC MTO complex is designed
for deep processing of specific natural gas
Approval Corporate Video Company Website
with a low content of valuable components
into high value polymer products with a
production capacity of over 1,110,000 tons
per year.
Valve
Valve World
World India
India &
& Middle
Middle East
East || issue
issue 28
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July 2023
2023

Fast-track valve overhaul in
South Asia
Valve overhauls demand the very best from supervisors
and technicians. A team led by Vivek Sharma (Valve
Service Expert, supporting HORA, standing center in
main image) recently went the extra mile and then
some more to complete the work.
By David Sear
For a recent valve overhaul
assignment, Mr. Sharma
travelled from his office in
Delhi to a destination in
South Asia. His task was to
oversee valve-related
maintenance work at a power
plant. By way of background,
he comments: “This was a
combined-cycle gas turbine
(CCGT) power plant with a
contractual capacity of over
400 megawatts. It was
commissioned about eight
years ago and is primarily
gas-fired with high-speed
diesel as its backup fuel.
Mr Sharma recommends critical
control valves be inspected
every two to three years
Case History
During construction, HORA
– a well-known German
manufacturer of high-quality
control valves and actuators
– had supplied a complete
high- and low-pressure
turbine bypass valve package,
consisting of nine valves.”
Mr. Sharma had been tasked
to supervise the valve
activities. “I was deputed at
site as a valve supervisor.
Local manpower – a team of
four technicians - had been
arranged by customer. We
were called in as the power
station had noted some
energy loss due to passing of
the main high-pressure bypass
valve. Our job was to perform
the overhauling of that valve
as well as water control and
water stop valves.”
Overhauls of this type require
thorough preparation,
according to Mr. Sharma.
“Detailed analysis was
performed in advance by the
HORA application engineers
with respect to the DCS
After dismantling, foreign
particles were discovered jammed
inside the control valve internals
Valve World India & Middle East | issue 28 | July 2023
operational data (upstream
and downstream pressure,
temperature as well as valve
position). Following this
analysis HORA’s application
engineer created a list of
recommendations for
inspecting and overhauling the
internal valve components.”
During the overhaul, other
hurdles came up. “We
Example of plug damage on a
control valve
discovered that the valve
internals were suffering from
severe damage. For example,
the valve seat and plug were
jammed inside the valve
body along with foreign
particles. Moreover, the
customer brought the
schedule forward so we
literally worked around the
clock to meet the new
deadline. All in all, we
completed the overhaul work
in five days.”
Mr. Sharma and his team have
received positive feedback
for their work. He emphasizes
that prevention is always
better than cure. “HORA
always recommends
customers that critical
control valves such as on
steam turbines should be
inspected inside and out
every two to three years to
ensure the smooth operation
of the valves.”
21

The advantages of high-pressure
recovery control valves
Widely applied and appreciated in gas turbine use, high-pressure recovery control valves have however yet to make any
real inroads in other applications. In his latest article, control valve expert Hans Baumann explains the function, test
results, and advantages of this valve concept which, he believes, could be of real benefit in other industrial sectors.
By Hans D. Baumann
High-pressure recovery
valves (see Figure 1), have
been used for quite a
number of years as fuel
control devices to regulate
gas flowing to burners of
gas-turbine generators.
Such valves bring significant
benefits. For example, the
most important feature of
this valve is the great energy
savings it offers. The device
can control large amounts
of liquids or gases whilst
sacrificing only limited
amounts of pressure drop
– just 10 per cent of inlet
pressure for gases, for
example.
Also of interest is the
unique function of this
device to be able to
operate within a significant
range of pressure
reductions and within a
laminar flow regime. This
flow regime experiences no
turbulence, nor the
associated sound.
The question arises, why
hasn’t this concept been
employed in general
industry? The answer may
simply be a lack of
familiarity.
In order to provide a viable
alternative for general use,
the author has therefore
designed a special valve
type as shown in Figure 2.
Description of the device
As Figure 2 shows, the
design is quite simple and
lends itself to low-cost
manufacturing. There are
22
Control valves
only three moving parts.
The appearance draws
itself to a butterfly valve.
Yet, this vane does not
close in the vertical
direction, but is tilted
about 30 degrees from
the horizontal axis.
Significantly, in this
position, all side surfaces
along the vertical axis are
in contact with the inner
wall of the housing in order
to provide shut-off, thus
providing a tilted wall Fig. 1: Design of a high-pressure recovery control valve
across the housing (see
also the vertical view in
Figure 2).
The reason for tilting the
vane is to provide an overall
length which is twice that of
a comparable vertical vane.
The result is that all planar
surfaces are located less
than 20 degrees (α) from
the vertical axis, thus
providing sufficient pressure
recovery.
Unfortunately, nothing is
perfect. In this case, the
device cannot meet Class
IV leakage (although it will
meet Class II). In addition,
the travel is limited to 30
degrees. This means that
the shaft will need a 2”
extended lever to satisfy 1”
actuator travel. On the
other hand, with such high Fig. 2: Author’s design of a high-pressure recovery control valve - patent
leverage and low operating applied for
torque, a 25 square inch
actuator would be able to University of Utah for 100% travel and 0.49 at 20%
operate a 4” valve. evaluation, using water as travel. Instability at 100 psig
test medium. inlet and o psig outlet =
Test results Here are the results: none. Torque: nil, not
A 2” prototype was built and Rated Cv = 60, Fl at 100% measurable.
submitted to the Water travel = 0.72, Fl at 20% Choked flow occurred
Research Lab at the travel = 0.63, Xfz = 0.35 at between 19% to 22% of inlet
Valve
Valve World
World India
India &
& Middle
Middle East
East || issue
issue 28
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July 2023
2023

A 2” HRV exhibits CONSTANT FLOW RATES with various
outlet pressures
450
400
350 100% open
300
GPM
250
200
150 50% open
100
50 20% open
0
20 40
Outlet pressure with 100 psig inlet pressure
Fig. 3: Flow rates from a 2” prototype high-pressure recovery control
valve.
pressure (equivalent
choking gas at 9.5 to 11% of
P1). Resultant flow
downstream stayed
constant within +/-2% as
indicated in Figure 3.
Sound level
measurements
A microphone was placed
downstream of the test
specimen during most of
the test runs. Figure 4 shows
the results of a typical test
run. The sound levels were
exceptionally low. Part of
the reason was that about
one third of the pressure
range happened to be in
the laminar flow regime.
Fluid mechanics tells us that,
in a laminar flow regime,
there can be no turbulence,
hence, no sound.
In order to dramatize the
about 14 dB sound
reduction, the author
plotted the sound emitted
from a conventional
butterfly valve having the
same data input. See Figure 4.
Once the choked flow
induced constant flow and
velocity is achieved, the only
constant sound level comes
from turbulence inside the
downstream pipe,which
typically only measures
70-80dB. Higher levels can
only be expected from the
final pressure drop at the
end user.
Control valves
60 80 psia
Adherence to acoustic laws
Assuming Xfz = 0.35,
Xy = 0.675:
The first stage:
Lp1 = 30 log(1 / 0.5Xfz) = 22.7 dB
The second stage: Lp2 = 10
log(Xfz / 0.5 Xfz) = 3 dB
Third stage:
Lp3 = 60 log(Xy / Xfz) = 17.1 dB
Fourth stage:
Lp4 = -60 log( X/ Xy) = -10.2 dB
With the basic sound level
(A + B) from the ‘Baumann
ABC’ method = 57 dB, then
we can find a maximum
noise level to occur at Xy,
which then is 57 + lp1 + lp2
+ lp3 = 57 + 22.7 + 3 + 17.1 =
99.8 dB (Figure 4 shows 99
dB). Note, that the line
between 0.5Xfz and Xfz in
Figure 4 is linear, which
proves that there is laminar
flow; hence the 10 log in Lp2.
The data indicates that there
is a 3dB increase in external
sound in the second stage,
even though laminar flow
cannot produce sound. The
real reason is, that in this
region, the pipe transmission
loss decreases by 3dB due to
orifice velocity changes
between 0.5 Xfz and Xfz.
Note: While the above data is
based on measurements with
water, using fluid mechanic
laws, there should be no
appreciable differences if
such a valve is used for
gaseous fluids as long as FL2
is substituted for Xfz.
Valve World India & Middle East | issue 28 | July 2023
Sound Level comparison between 2” High-Recovery
Valve (HRV) and 2” Z-Disk Butterfly
140
120
Xy
100
0.5Xfz Xfz
Noise (dBA)
80
60 HRV (dBA)
Z-Disk (dBA)
40
Conditions: 100 psi water inlet pressure, Cv = 60, FL = 0.6, Fd = 0.35, XFz = 0.35
20 *HRV Test Data Source: Utah Water Research Laboratory Report 5/14/2022
X = 0.175 X = 0.35
0
0 20 40 60 80 100 120
Differential pressure (psi)
Fig. 4: Sound comparison between a 2” high-recovery valve (HRV)
and a 2” Z-Disk butterfly valve
Applications be a viable alternative to
The range of applications conventional control valves
for this device include: since they do not depend on
• P ressure reduction for high turbulence for fluidic
gases and liquids (with energy conversion.
reduced cavitation effects) The author hopes that
• F uel flow control for oil this article may inspire
and gas to burner nozzles others to revisit the high-
• P ump cavitation avoidance pressure recovery valve
• A steady flowing quantity and develop it for the
regardless of tank level benefit of other
makes it ideal for the applications.
filling of tanks
• P ump discharge pressure References
regulator “A simple aerodynamic
• C onstant flow through fire noise estimating method-
hoses regardless of altitude. why not”, by Hans D.
Baumann, VALVE WORLD,
Conclusion issue 10, November 2016
The above data demonstrates (copies available from the
that high-recovery valves can publisher).
About the author
Dr. Baumann, a former President of the
Baumann valve company and a former
VP of Masoneilan and Fisher Controls, is
now an international consultant. He is
credited with 106 US patents and has
authored 140 publications and eight
books, including the Control Valve Primer now in its fifth
edition. Dr. Baumann is an Honorary Member of ISA
and a Fellow Member of ASME. He can be reached at
hdbaumann@phbinc.net.
23
 Project Report
Part 1: Steel complex for Saudi Arabia
Aramco, one of the world’s leading integrated energy and
chemicals companies, Baoshan Iron & Steel Co., Ltd.
(Baosteel), a leading steel conglomerate, and the Public
Investment Fund (PIF) have signed a shareholders’ agreement
to establish an integrated steel plate manufacturing complex
in the Kingdom of Saudi Arabia.

As released in May this year, advancing the regional steel

the plans call for a joint
venture complex located in
Ras al-Khair Industrial City,
one of the four new Special
Economic Zones recently
announced by His Royal
Highness Prince Mohammed
bin Salman bin Abdulaziz Al
Saud, Crown Prince, Prime
Minister and Chairman of
the Council of Economic
and Development Affairs.
Uniting the strengths of
Aramco, Baosteel and PIF, the
steel complex would be the
first facility of its kind in the
Kingdom and the GCC region,
industry ecosystem. The
project aims to enhance the
domestic manufacturing
sector through localizing the
production of heavy steel
plates, transferring
knowledge and creating
export opportunities.
The facility is expected to
have a steel plate
production capacity of up to
1.5 million tons per year. It
would also be equipped
with a natural gas-based
direct reduced iron (DRI)
furnace and an electric arc
furnace, which aims to
reduce CO2 emissions from
the steel-making process by
up to 60% compared to a
traditional blast furnace. The
DRI plant would be
compatible with hydrogen
without the need for major
equipment modifications,
potentially reducing CO2
emissions by up to 90% in
the future (see facing page).
Saudi Arabia would be the
project’s primary target
market, with plans to export to
the GCC and broader MENA
region. It is expected to create
new jobs and significantly
reduce reliance on imported
steel, serving customers in
several strategic industrial
sectors including pipelines,
shipbuilding, rig manufacturing,
offshore platform fabrication
and tank and pressure vessel
manufacturing. It also would
aim to serve the construction,
renewables and marine
sectors.

• Explosion-proof protection type Ex IIC T4

• New robust Combi-switch or magnetic pen

operation for navigation and settings

• Commissioning Assistant ensures perfect

installations
For Oil & Gas Industry
• Large operating temperature range -65 - +75 Deg C

• Battery powered display and output contacts

• Remotely mounted controls possible

• 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

24 Valve
Valve World
World India
India &
& Middle
Middle East
East || issue
issue 28
28 || July
July 2023
2023
 Project Report
Part 2: Potential for hydrogen valves?
specified in the European Pressure certain amount of water, which
The massive project to develop an integrated steel plate facility
Equipment Directive 2014/68 / EU.” must be let out of the system.
in Saudi Arabia (see facing page) will be of great interest to
Mr Weisschuh continues by Currently, this is mainly done via
valve suppliers. Noting the hint that a hydrogen infrastructure
saying that the use of special cyclonic. A more efficient
might also be required in the future, we took a quick dive into
high-strength materials that alternative is to collect this water
the requirements placed on valves for hydrogen service.
often work in other challenging in a header that works like a
The need for due care and below the yield strength, it is situations, unfortunately does condensate trap and then drain
attention when working with hydrogen embrittlement.”1 not solve this problem. “On the it. This requires an abrasion-
hydrogen is immediately Further indications as to the need contrary, these materials are resistant blowdown valve, which
apparent when reading relevant for caution can be found in a blog even more vulnerable to is a product that we have
literature and resources. For post from AS Schneider’s Thomas hydrogen embrittlement. The supplied in thousands for use in
example, Technical Consultant Weisschuh2. He writes that: “Tiny lowest sensitivity to hydrogen steam power plants.”
Davi Sampaio Correia writes that: hydrogen atoms can penetrate the embrittlement is found in
Resources
“Typically, whenever one thinks of crystal structure of solid metal and face-centered cubic metal grids
potential issues that can arise remain there. This effect leads to such as those in austenitic steel 1. https://valve-world-americas.
com/valves-for-hydrogen-
with hydrogen and metals, increased pressure and internal (e.g. 316 / 316L) or aluminum.”
service-challenges-in-
hydrogen embrittlement comes stresses without any corresponding Nevertheless, enterprising
materials-selection/
to mind. The ASM handbook increase in the strength of the companies are looking to 2. https://as-schneider.
cautions us, however, that material. Hydrogen absorption can support the growing hydrogen blog/2022/01/19/hydrogen-
hydrogen embrittlement is just make the metal walls brittle, which sector wherever possible. PRUSS, valves-and-typical-
one type of hydrogen damage may lead to crack formation and for example, can assist in application-challenges/
mechanism from a broader eventual failure. Furthermore, the collecting hydrogen produced by 3. https://hydrogentechworld.
category of potential issues. tensile strength, toughness and PEM electrolyzers. Says CEO com/wp-content/uploads/
When material failure is ductility of the metal are reduced Wilfried Drehmel3: “The hydrogen sites/22/2023/03/Hydrogen-
associated with reduced load that can result in violating the gas coming out of the PEM Tech-World-Cover-Story-
carrying capability or fracture elongation-at-break requirement electrolyser stack still contains a April_2023.pdf

Valve World India & Middle East | issue 28 | July 2023 25

 Technology
Oxford Flow gas regulators succeed
with no maintenance requirements
Installed in a UK gas
network, gas regulators
(IM100) from Oxford
Flow are approaching a
four-year period of
continual operation with
no required maintenance
or servicing.

Oxford Flow engineer and

produce innovative flow
control valves for gas, liquid,
and multi-phase applications
across various markets
worldwide, including gas
distribution and transmission. Image shows Oxford Flow´s IM gas regulators in an active-monitor configuration
In December 2019, Scotia Gas
Network (SGN) installed incumbent, as is common three years continuous asset which can be utilised
Oxford Flow’s 4” wafer IM100 with traditional valves. operation to date, with zero as part of our responsibility
gas regulators at a District However, the IM100 being maintenance activity. The in maintaining security of
Pressure Governor (DPG) in more compact in size and lock-up properties of the IM supply. Ideal valves are
Ayrshire, UK. SGN owns and lighter in weight, enabled were also tested regularly, those that perform well,
operates the gas network easy installation by hand. with the IMs passing at every and once installed can be
across Scotland and the south During service, the IM100 phase. managed and maintained
of England. performed excellently, Matthew Skeoch, SGN with less frequency, the IM
The Oxford Flow regulators operating with an Transmission Maintenance valves clearly do this. They
were installed with their PRX1 intermediate to medium Team Manager, commented: have set a high standard
Pilots, in both Active and pressure of 7-2 bar in the “We’re highly impressed with and we highly commend
Active-Monitor configurations. SGN network. The regulators Oxford Flow’s IM regulator them.”
Unlike conventional maintained a setpoint and were pleasantly Neil Poxon, Oxford Flow’s
regulators, which use a accuracy of +/-2.5%, surprised by their ease of CEO said: “It’s great news that
diaphragm, the IM100 utilizes stabilising in 5-10 seconds installation. Operating SGN have confirmed the IM
piston-technology which compared to the replaced maintenance free for over regulators are highly reliable,
significantly reduces wear and incumbent, which 3 years, this brings us cost effective, low
eliminates fugitive emissions. depending on demand, substantial maintenance maintenance and easy to
SGN was impressed from the required up to 15 minutes management and cost install. Hopefully our
commissioning experience to reach stability. No failures benefits, but most products will be adopted in
- heavy lifting equipment were experienced importantly it provides us other areas of their network.
was required to remove the throughout the more than the flexibility to adopt an Our latest IM-S gas regulator
revision extends customer
advantages as it is even lighter
Available in India / Middle East in weight, has a shorter
Oxford Flow´s Marketing Manager, Michael Barough, was happy to share with VWIME
face-to-face length, provides
that the company have already sold products to their distributor partners in the Middle a higher flow capacity, has
East. Their regulators have also recently completed trial installations. a lower differential, is
“With our own offices in UK and US, a strong strategic partnership with Koso Kent Introl, hydrogen-ready and provides
and network of local agents, our territorial market is expanding rapidly,” said Michael an even greater service
Barough. He explained that Oxford Flow manufactures and sells a range of liquid interval of 10 years! We
regulators and gas regulators worldwide as well as their zero-emission, stemless ES anticipate this revision will
actuated valves which were awarded the Albert (Al) Woelfel Best Mechanical bring even greater customer
Engineering Achievement (BMEA) Award by the American Society of Mechanical benefits and become the
Engineers (ASME) at the Offshore Technology Conference (OTC) in 2022. regulator of choice in new
markets.”

26 Valve
Valve World
World India
India &
& Middle
Middle East
East || issue
issue 28
28 || July
July 2023
2023
 Failure analysis
Understanding valve failures pays dividends
Valve malfunctions are often unexpected and always
inconvenient. With pressure being put on maintenance crews
to come up with quick solutions there can be scant time for
root cause analysis. However, performing a proper failure
analysis can help prevent future failures, delivering significant
costs savings for plant owners.

By Bernard Horsfield thousands of dollars,

Every business will
experience equipment
failures, which are certainly
not just found in valves.
However, it is how businesses
respond to such failures that
is important. Correctly
Identifying why equipment
has failed not only saves time
and cost but improves plant
efficiency.
There are also sound
environmental arguments for
understanding valve failures.
Reducing the incidence of
such failures will enable
companies to lower their
carbon footprints and reduce
carbon offsets.
Consequences of
equipment failure
Failure of an item of process
equipment such as a valve
can lead to one or more of
the following: a process
upset, increased potential of
safety risks, impact on
production/manufacturing
output, logistic issues,
increase in costs.
Given that an outage in a
facility can easily cost tens of
Material analysis of plain bearing failure
companies would do well to
keep the incidence of
equipment failures to an
absolute minimum.
Conducting investigations
into failures will of course
cost time and money.
However, proper failure
analysis is an investment
which, over time, is recouped
thanks to increased plant
efficiency and a reduction in
cost. In the author’s
experience, many end users
do not fully appreciate the
value that improving
functionality can deliver.
Even something as simple as
carrying out more detailed
inspections during scheduled
service can provide valuable
insights into whether items
have failed, are likely to fail or
are in good condition. This
can help plants to better plan
schedules and servicing, as
well as to find better-
performing products that will
improve efficiency.
Causes of valve failures
In practice, valve failures and
malfunctions can be due to a
variety of reasons:
•• mechanical operation
•• design
•• materials
•• media
•• operational (system), etc.
Let’s look at some of these
aspects in more detail:
Design
The core design of an item
(especially a valve) can
dramatically affect its
performance. With designers
often following the ‘keep it
simple’ mantra to reduce
costs it is important to know
which features may have
been omitted. For example, if
a specific valve design uses
just one seal instead of the
usual two, then that less
expensive valve may only last
a short time in service. Cost
reduction usually means
taking something away, the
goal being to create a valve
that is as simple as possible
yet without compromising
the product’s functionality.
But ultimately, designing and
manufacturing a product to
last longer means higher
quality and cost.
A proper knowledge of the
design standards as well as
field experiences is a
considerable advantage
during failure analysis. For
example, an Indian
petrochemical company
installed low temperature
valves carrying hydrochloric
acid with the stem in the
horizontal position. However,
the standards only allowed
for a 45-degree maximum.
Needless to say the stem
seals/packing failed and the
valve was compromised
causing the plant to leak
hydrochloric acid everywhere
which turned the whole
facility brown (stainless valves
and pipework).
Repairs can sometimes
dramatically affect
performance so the use of
‘Equipment passports’
identifying what work has
been carried out on a valve/
actuator during servicing is
recommended. Ready access
to details such as the service
history, prior maintenance,
etc, are of immense value
during failure analysis. Details
should also be recorded for
actuators and especially the
re-use of any scored or
repaired actuators. These are
known to have greater air
leakage and lower operation
times than undamaged
actuators. Hence records of a
scored actuator* will inform

* Vane actuators can, unlike other actuators, withstand being scored in the air chamber through contamination through dirty air. The author
has regularly seen them returned to service despite manufacturer’s recommendations.

Valve World India & Middle East | issue 28 | July 2023 27


A background in testing valves helps when using Finite Element Analysis. The example shows a 20-foot
skid container
the operator that what he/
she is seeing is actually
‘normal’ air usage for this
scored actuator and not
necessarily a cause for an
outage.
As a pressure element, valves
are obviously devices that
firstly need to comply with
international standards
(minimum wall thicknesses
etc) but should also be
robust enough to withstand
the stresses and strains
applied in service. Using FEA
(Finite Element Analysis) is
often cited in this respect,
but in itself FEA is not a
panacea for stresses and
strains. Far from it. The
engineer needs to be able to
read the results much like a
doctor does an X-ray. It is
very useful to have a
background in testing valves
as you gain the ability to
correlate the FEA results with
the actual results which is an
important part of the FEA
analysis.
As a tool, FEA can be used to
identify weak points in
multiple components and
assemblies that may have
failed, such as valves, support
brackets, hangers, etc. Note
that the Middle East is
extremely vulnerable to
corrosion - even onshore –
hence the importance of
building in a sufficient
corrosion allowance etc.
Materials
Material issues are often
straightforward in that
28
Failure analysis
failures tend to be more
obvious and there are plenty
of third-party laboratories
who can conduct
microscopic, physical and
chemical tests, as well as the
FEA mentioned above.
Afterwards, an expert is
required to interpret results
and suggest the most
suitable solution.
By way of example, an
ammonia plant in China
reported that a number of
valves required an increased
torque during operation.
After dismantling and
examination, it was
discovered that the shaft
bearings had galled and were
inhibiting rotation. The
primary cause was identified
as incompatible design
parameters, material and
point loading.
Erosion, chemical
incompatibility or a galvanic
reaction could all be due to
the wrong selection of
material for the specific
process. This said, erosion
due to pressure and media
i.e. steam, is a world apart
from erosion caused in a
polymer discharge valve.
Valve design is another factor
that needs to be taken into
account when reviewing
materials.
Media
Failures caused by the media
either in the pipeline or
within the surrounding
environment are usually
quite obvious. Failure analysis
Valve
Valve World
World India
India &
& Middle
Middle East
East || issue
whilst the valve is still in situ.
Proper observation now
enables potentially useful
information to be gathered
which may become
compromised during the
removal process. This can be
an asset during the root
cause analysis.
So, a step-by-step
procedure - adapted to the
failed item - will be
extremely useful. This
should apply to all items
is therefore often that require disassembly.
straightforward – typically the There are tell-tale signs and
materials being used are marks which are easily
incompatible with the missed yet can help to
application. However, it is not provide the whole story. The
always obvious that the individual responsible for
media is the cause. For running the analysis should
example, there may be therefore have an ‘expert
unknown elements or even eye’. This can also prevent
contamination. exactly the same equipment
The Middle East oil fields are being re-installed to the
particularly difficult in that detriment of the plant’s
materials selected for internal performance.
valve components need to be Proper inspection is also to
suitable for sour service. be recommended during
‘regular servicing’ as this can
Failure analysis in practice provide the user and
Depending on the failure, manufacturer with a great
analysis should ideally start deal of information. As a
Valve failures in practice
Throughout his career, Bernard Horsfield has witnessed multiple
valve failures. Clockwise, starting top left: severe erosion on a
ball valve, NJ ball valve with a worn surface, valves should only
be disassembled according to a careful disassembly procedure
or with an experienced person in attendance to preserve and
record evidence of failure, external corrosion on a valve.
issue 28
28 || July
July 2023
2023
 Failure analysis
result, the time between
scheduled servicing can be
extended. Take as an
example; in the
polyethylene business (gas
phase) it is common
practice to change out or
service all reactor valves
and actuators every two
years. However, very few end
users make any attempt to
understand why this is
required (other than one or
two tag locations failing at
that time) even though they
wish to extend the service
interval to every three years.
Capturing this information
could also be a real asset
elsewhere, such as helping
valve manufacturers to
improve designs and
assisting relevant authorities
in producing new design
standards.
Working around time
constraints
When a valve fails, this can
result in a process upset or
a manufacturing delay. In
consequence, maintenance
crews can be under
significant pressure to
resolve/repair/replace the
item to get the production
process running again. This
urgency means that the
time to analyse is very short
unless of course a direct
replacement is at hand,
enabling a more leisurely
examination of the faulty
equipment. However, most
items are quickly repaired or
serviced with no attempt
made to identify the root
cause. Note that this does
not mean that analysis is
impossible, but it is more
important than ever to have
an experienced person
available who can supervise
the work and at the same
time capture important
information. Simply
reviewing all the
components after dis-
assembly may be sufficient
to reveal important insights.
Creating an image file is
highly advised; this enables
a detailed analysis even
after the valve has been
reassembled and also
facilitates the preparation of
a written report at a later
date. The equipment
supplier may even provide
this service.

About the Author

Bernard Horsfield has been in the
valve industry since 1990. With
extensive work experience in the
Middle East and Asia, he is highly
skilled in cryogenic design,
applications and Gas Phase Polymer
Discharge reactors.
Starting out with Neles Jamesbury,
career highlights include designing
the first LNG valve train assemblies
for Shell Brunei and later upgrades for UCC’s gas phase
polymer reactors in Europe and the Middle East. He later
became Engineering Manager for Metso Automation’s
800.345.7546 • 814.542.2545
‘Jamesbury’ Product line, focusing largely on the Middle
East and India. 814.542.9977 fax
Bernard is currently a Director at Rodefish Ltd, which was
initially set up in 2005 to project manage the DBB safety www.bonneyforge.com
valves for Shell Oil’s Corrib Project. Rodefish provides a
suite of services to the broader valve sector, including
design, quality, customer support, etc. Based in both the
UK and Abu Dhabi, UAE, the company also provides ‘In
country’ technical/sales support for UK and US
companies not in country.

Valve World India & Middle East | issue 28 | July 2023 29

 Regional news
Bahrain launches IWPP, more may follow
His Royal Highness Prince Salman bin Hamad The station was established by Bahrain’s
Al Khalifa, Bahrain’s Crown Prince and Prime Electricity and Water Authority in partnership
Minister recently inaugurated the Al Dur 2 with Acwa Power, a leading Saudi developer
Phase Two Independent Water and Power and operator of power generation, water
Project (IWPP) which has been built at a total desalination, and green hydrogen plants
investment of USD 1bn. worldwide, and Japanese companies.
It is an extension of Al Dur Phase 1, which was The IWPP generates 1,500 MW of electricity
inaugurated by His Majesty King Hamad bin Isa and processes 50 million gallons of
Al Khalifa, reported BNA. desalinated water daily. Speaking at the
The key facility is the first production station in inauguration, His Royal Highness highlighted with the private sector and in line with its
the kingdom connected to the high-voltage the kingdom’s commitment to developing comprehensive development, led by His
electricity transmission network of 400 KV. energy production projects in partnership Majesty King Hamad bin Isa Al Khalifa.

TEADIT appoints Robbie Riggs as CEO

TEADIT Group is pleased to
announce that Robbie Riggs has
been appointed to the position
of Chief Executive Officer of
Teadit North America. Formerly
the Vice President of Sales &
Marketing, Robbie is a degreed
mechanical engineer with
nearly 25 years of experience in
the industry. He has overseen all
global marketing, North
American sales and strategic
developments for the company
for the past five years.
Robbie holds several patents
on innovative sealing solutions
in the oil & gas and chemical
process industries and he looks
to continue the improvement
of products in the field of
industrial sealing and gasketing
technology.
“I am thrilled to be leading
TEADIT North America at such
a formative and fast-paced
time for the company’s
increased growth. It is a very
exciting time in the company’s
evolution and I am honored to
have the opportunity to
participate in Teadit Group’s
continued success,” Riggs said
of his appointment.

Annual Conference 2023 and CEO
Meets of IVAMA Association
Indian Valve and Actuator
Manufacturers Association
(IVAMA Association) has
planned its Annual Conference
2023 on September 15th, 2023,
at Sofitel Mumbai BKC. To give
positive thrust to the flow
control industry and enhance
the future business of our
members, the theme of the
conference is selected as
“Flow Control Innovations for a
Sustainable Future”. The
following sessions are
considered in the conference
- Green Hydrogen Production
and End User Industry,
Renewable Energy, Electrolysis
Industry, New Technologies,
Artificial Intelligence (AI),
Internet of Things (IOT) and
Data Management. 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.
More than 200 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
Participants of the recent IVAMA CEO Meet held at Hubli on 20th May 2023
IVAMA Column
face-to-face interactions and
discussions between members
and customers. IVAMA looks
forward to see you all again
during the conference.
IVAMA is preparing “Second
report on the Status of Indian
Industrial Valves and
Actuators Industry’. It is
targeted to release the
updated report during the
annual conference for the
benefit of members as well
as the industry. Anyone
interested in participating in
the conference, please get in
touch with Admin@ivama.in.
CEO Meet
IVAMA CEO Meet held at
Hubli on 20th May, 2023,
provided a great learning and for Creating a New Age become members of the
networking opportunity. The Organization - by Dr. Aravind association recently – Emerson
importance of growth and the Chinchure. He emphasized the Process Management (I) Private
need for collective efforts to impact of convergence of Limited, Pune as Executive
strengthen our global technologies and the need to Member and M-torQ Controls,
footprint were the main adapt concept of SMART Pune as Manufacturer Member.
theme of the meet. With this factories & SMART products, We look forward to
in mind, the deliberations to move from linear to enthusiastic participation
revolved around “Vision for exponential growth. The of all members in the activities
Future” with two high impact sessions followed with Q&A & of IVAMA Association,
and insightful sessions. Session a CEO roundtable discussion particularly in above Annual
1: Create a Culture of Agile to address matters related to Conference and CEO Meet.
Collaboration in a VUCA involvement of IVAMA Membership is also available
World - by Mr Amit members in engineering to valve and actuator
Soundalgekar, who highlighted college curriculum and future manufacturers, supply chain
the importance of building a of the Supply Chain. companies and engineering
culture of Vulnerability, back offices. Interested
Humility & Authenticity to New members companies may register
stay relevant & achieve a IVAMA Association is very for membership by
purposeful growth. Session 2: pleased to inform the logging on the website
Building the Future: Strategies following companies have (https://www.ivama.in/register).
R Muruganantham, Director
General, IVAMA Association,
www.ivama.in; Admin@ivama.in,
+91 9841289271.
Scan to register for the
Annual Conference
Valve World India & Middle East | issue 28 | july 2023 31

Marketing, brand equity & the valve industry
Historically, marketing and
the concept of brand
equity were consumer-
related ideas. Major
companies spent millions
annually to keep brands
favorably positioned in
customers’ minds. Procter
and Gamble is probably
the epitome of the success
of this strategy.
Then came Amazon with
their online “customer
centric” approach to their
virtual “everything store”.
Now with a mouse-click
you can order almost
whatever consumer
product you need from the
comfort of your home or
on the go with a smart
phone. These strategies
have significantly altered
the customer journey and
made it “easy” to get
consumer products online.
Column
The industrial marketplace
has been slower to adopt
such marketing concepts.
Being technically process
control oriented with a
myriad of sophisticated
applications across a broad
spectrum of industries, the
concept of a “one-size-fits-
all” valve brand solution
did not resonate with a
typical industrial process
control engineer.
However, with the advent
of social media marketing
and the packaging of
standard valves/valve
automation packages via
sophisticated online
“configurators”, marketing
has arrived in the valve
industry. Today, young
engineers who have grown
up alongside sophisticated
algorithms and now
artificial intelligence are
utilizing such tools to solve
process control application
requirements.
They see no need to
struggle to determine what
valve automation
components will work best
for their specific
application when all that
information has been
digitized and can be
developed more efficiently
and accurately using digital
devices.
Thus, major valve
manufacturers and certain
valve suppliers have
incorporated online
configurators into their
marketing activities to
promote their brands and
grow brand equity. By
creating portals to their
configurators, they are
positioning their brands to
own a place in the minds
of process control
engineers – exactly what
consumer goods
manufacturers have been
doing for years.
Just take a look at recent
editions of this magazine
and you will see a plethora
of ads from major valve
manufacturers touting their
platforms that allow for
“easy” automated solutions
for end user applications
utilizing their valves and
automated valve solutions.
Meet Bob Donnelly
Bob Donnelly
is the Vice
President of
Business
Development
for Flo-Tite Valves &
Controls. He can be
reached at:
rmdonnelly@aol.com

PNEUMATIC
ROTARY ACTUATOR

Head Office & Factory Address :

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

32 Valve World India & Middle East | issue 28 | July 2023