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Innovative Solutions. Dependable Designs.

Creative engineered solutions through partnership result in application specific designs

Changing people’s perceptions and work habits are the biggest challenge when offering creative solutions. And, creative engineered solutions are developed when MOGAS partners with end users.

Throughout MOGAS’ history, we have had the desire to innovate. We listen to our customer’s issues and concerns. We visit their plants to see the problem first-hand. And we engineer customized valve solutions.

Application specific valve designs are born from investigative analysis.

Innovation also comes from examining why valves fail. During a ‘take down’, engineers and service personnel analyze failed or underperforming valves to discover their weakest links. By finding out what works and what doesn’t, improvements to design and material are made.

While most valve manufacturers target price as the primary goal when designing their valves, MOGAS' philosophy is to design their valves for longevity. This is how we can offer a PERFORMANCE GUARANTEE. We provide dependability. We offer confidence.

Application Specific Design

Valve design is really about flow control, not about the valve. To understand what type of valve works best in a particular application, which materials are chosen and what features are incorporated, you have to understand the complications of what flows through the valve.

  • How fast and how often is shut off required?
  • What is the temperature and pressure range, and how fast do they change?
  • What are the contaminants that will contribute to corrosion and erosion?
  • How will the temperature/pressure/catalyst change the media?

MOGAS has a history of partnering with plant and process engineers of end users to understand their whole flow process—and what they are trying to achieve—so a solution can be proposed.

Coatings Innovations video chronicles MOGAS' experience in coating development visualised through a timeline and in discussion with MOGAS VP Engineering, Jonquil Hill.
  • Built to last designs — Our design philosophy

    MOGAS ball valves are designed from the inside out. Since the heart of valve is the ball, we start with the bore size and design it slightly smaller to accommodate future wear from erosion and corrosion, so the ball is always within specifications even after years of punishing use.

    Demonstration video of effective mate lap ball and seat sealing of MOGAS ball valve.

    A wider seat is designed to provide greater contact to the ball. Because the ball and seat are mate lapped, this wider contact area creates greater vacuum where air cannot penetrate between the two surfaces; the more vacuum sealing force, the more it will seal. The engineering of the seat for width and sealing force is most important in severe service applications.

    The ball diameter is calculated next, and is based on the contact surface area of the seat on the ball when open or closed. When the seat is in the fully open position, it should not overlap any of the same area when it was in the fully closed position. This is because while the actuator may be set to rotate the ball 90deg, tolerances of other components, such as stem and adapter, may not be as exacting, so it is possible for the ball to rotate 93deg to closed. On some competitor ball valves, this would leave gap to the bore. MOGAS valves are designed to open and close from 0 to 97deg without overlapping this common contact area. By not overlapping, combined with a vacuum-tight seal and a leading edge wide seat to clean the surface, MOGAS ball valves provide absolute shut off.

  • Tailored trim design solutions

    Designed for Reliable Isolation

    Metal-seated floating ball designed for on/off applications
    • Pressure energized sealing
    • Application-specific seat designs
    • Replaceable metal seats
    • Wide seat-sealing surface
    • Uni-directional or bi-directional sealing
    • Size Range: 1/2 to 42 inch (12 to 1100 dn)
    • Temperature Range: -58 to 1652 °F (-50 to 900 °C)
    • Pressure Classes: ASME 300 – 4500 & API 6A

    Control for Precision Modulation

    Metal-seated trunnion ball designed for temperatures <400 °F
    • Pressure energized sealing, plus o-ring sealing
    • Variable control trim
    • Unlimited rangeability
    • Pressure Drop Ratio: >0.3
    • Size Range: 3 to 42 inch (80 to 1100 dn)
    • Temperature Range: -58 to 400 °F (-50 to 205 °C)
    • Pressure Classes: ASME 300 – 2500

    Control for Extreme Temperatures

    Metal-seated floating ball designed for temperatures >400 °F
    • Pressure energized sealing
    • Variable control trim
    • Unlimited rangeability
    • Pressure Drop Ratio: >0.3
    • Size Range: 1/2 to 42 inch (12 to 1100 dn)
    • Temperature Range: 400 to 1652 °F (205 to 900 °C)
    • Pressure Classes: ASME 300 – 4500 & API 6A
  • Fundamental differences in valve types

    Serious industrial processes require serious valve choices. Understanding the fundamental differences in valve types can assist with those important decisions.

    When it comes to valve types, there are distinctive differences in design, intent and purpose. Whether a valve has rotary operation or linear action is a critical part of the longevity and performance of the valve in severe services. Exposed sealing mechanisms versus protected sealing surfaces can make a big difference. Commodity valves manufactured for clean environments at ambient or low temperatures are simply not engineered to withstand the strenuous demands of extreme operating conditions.

    Ball Valve Advantages
    • Recessed seats are protected from continual exposure to the process flow
    • Ball is wiped clean with each operation of the valve
    • Rotates on own axis, thus no volumetric displacement
    • Packing area is protected from potential media erosion, maintaining integrity of stem seal area while reducing risk of fugitive emissions
    • Non-rising stem design meets EPA VOC packing leakage standards for greater number of cycles
    • Pressure-assisted sealing
    Gate Valve Disadvantages
    • Sealing components in the line of flow lead to potential wear and corrosion attack
    • Geometry of the exposed sealing surface wears and loses the ability to hold tight seal
    • When operated, flow path is interrupted causing volumetric displacement of the process fluid which must occur from behind the plug back into the flow stream
    • Multi-turn rising stems can pull destructive catalyst and pipe scale up through the interior diameter of packing area leading to possible hazardous atmospheric leaks
    • A sliding stem valve will not provide the length of service life or number of cycles due to the stem moving through the packing box along with the process fluid
    • Relies on vertical thrust by the stem to drive the sealing plug into the seat
    Globe Valve Disadvantages
    • Damage to sealing surfaces due to exposure of the seats when the valve is open
    • Sealing trough / rib erodes over time and can capture flow particles
    • When operated, flow path is interrupted causing volumetric displacement of the process fluid which must occur from behind the plug back into the flow stream
    • Multi-turn rising stems can pull destructive catalyst and pipe scale up through the interior diameter of packing area leading to possible hazardous atmospheric leaks
    • A sliding stem valve will not provide the length of service life or number of cycles due to the stem moving through the packing box along with the process fluid
    • Torque seated to activate seal — thermal cycling relaxes stem
  • Materials & Coatings

    Metallurgical selection plays a significant role in valve design, performance and, ultimately, plant and employee safety. And the valve area that is most affected by the process fluid flow is the ball and seat. This area should be constructed from material that will provide the longest service life of the valve specific to its application. By using materials of construction that will not react with the process fluid or become corrosive, the mechanical integrity of the valve is maintained.

    Valve material selection is also important in applications involving thermal shock, where high temperature or high pressure fatigue metal, particularly those on cyclic operation.

    Short animation showing the thermal expansion rate of both the ball/seat and coatings materials flexing together to maintain a positive seal during sudden temperature changes.

    To ensure the best coatings solutions are available for our customers, MOGAS has an ongoing research & development (R&D) program that includes:

    • continual field investigations
    • coupon testing (with traceability to each coating batch)
    • laboratory analysis
    • collaborative alliances with selected authorized coaters

    As part of our coatings research and development, MOGAS continually analyzes samples for strength and durability. Some examples of our testing and evaluation include:

    • Abrasion tests
    • Slurry erosion tests
    • Micro hardness tests
    • Adhesion tests
    • Corrosion tests
    • Porosity analysis
    • Impact testing
    • Residual stress analysis
  • Liners and Thermal Sleeves

    Image of erosion sleeve
    MOGAS' patented thermal sleeve solves premature stress cracking in end connects.

    Liners
    High pressures, slurry debris and corrosive media that flow through valves accelerate the deterioration of components and surrounding pipeline. Depending on the application and customer requirements, MOGAS’ proprietary coatings are applied to the ball and seat, and along the entire flow path of the valve. The coating provides good metal-to-metal wear protection because of its erosion resistance and low coefficient-of-friction properties. As a mechanical redundancy, a replaceable sleeve can be designed to protect the entire valve body and end connects from severe erosion, saving on the capital equipment.

    Thermal Sleeves
    In severe service environments, such as the transfer of catalyst from an ebullated bed reactor, isolation valves are often subjected to frequent and extreme temperature and pressure cycles. This causes premature thermal fatigue stress cracking in valves, which are also be subject to erosion from the abrasive nature of the catalyst.
     
    MOGAS' newly patented tubular member with thermal sleeve liner is effective to inhibit thermal fatigue stress cracking in the end connector near the seat—the area of most concern. Comparative finite element analysis studies revealed that a valve without MOGAS' patented sleeve in such severe environments reached a peak stress intensity at the end connector at 841 MPa. According to ASME's fatigue design curve, this valve's design life would be 50 to 200 cycles. Under the same conditions, and employing MOGAS' patented sleeve, the peak stress intensity was reduced to 321 MPa (46.6 ksi), which would result in a valve design life of at least 30,000 cycles.

  • Purging

    Typical purge locations

    The majority of critical isolation services are located in plant systems that require redundant controls to achieve higher reliability and longer run-times. A typical system will have redundant control valves with double isolation—upstream and downstream—for each control valve. This redundancy allows operations to switch from one control valve (train) to the other (train) without taking the process offline, while performing maintenance or repairs.

    Coking formation—sometimes referred to as asphaltene—can occur in high-fouling applications, depending on temperatures and pressures. This coke material has a tendency to harden and adhere to internal surfaces of the valve body, seats, and ball. Once this occurs, the required valve service break torque increases significantly from start-of-run to end-of-run, and may eventually cause valve seizure or lock-up.

    Purging has been demonstrated to be effective to reduce or eliminate the effects of coke formation. MOGAS highly recommends specifically designed purge systems for valves in high-fouling applications to maximize their operating service life. When the correct purge system is selected for each service, unscheduled plant shutdowns and undesirable circumstances may be avoided, which influences overall plant reliability.

  • Research & Development

    Computational Fluid Dynamics showing the dissipation of kinetic energy and velocity control.
    This CFD simulation in a control valve shows that by forcing process fluid to turn through a pre-determined series of right angles, kinetic energy is dissipated and velocity controlled.

    MOGAS’ continued commitment to R&D is evidenced through our formalized programs to develop critical applications involving valve coatings and flow control. Our staff includes dedicated research scientists who are experts in tribology, materials, applied coatings and fluid dynamics.

    Already an industry leader in coatings, MOGAS continues to advance our technology with significant improvements in the process and quality of coatings. Our patented nano-structured titanium coating has achieved an increase of 10-15% in coating hardness, 200% improvement wear resistance and a 250% improvement in corrosion resistance.

    To analyze and solve problems that involve fluid flows, MOGAS valve design engineers use computational fluid dynamics (CFD) software. CFD analysis can predict the complex flow characteristics inside the pipeline and valve, where issues such as the formation of vortices and complex cavitation phenomena can be visualized. When used with finite element analysis—to simulate material stresses—and a flow loop, CFD gives engineers a complete picture of where to improve valve performance.