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120 tonnes and is designed to operate in a fail-open configuration. In normal service the valve remains closed, but in the event of an overpressure scenario it must open automatically. The 16-tonne wedge is therefore designed to move under its own weight in a failure condition. Because the valve operates inverted in service, it was mandatory to test it in the same orientation. This introduced a further layer of complexity to both assembly and testing.”
Engineering and execution challenges
The first major challenge was designing the valve body.“ The combination of extremely large dimensions and low-pressure service imposed unusually thin wall thickness requirements, making casting particularly demanding,” explains Mr Rossi.“ The Orion team worked closely with specialist Italian foundries to develop a geometry that provided the necessary mechanical strength and deformation resistance while remaining castable without defects.” More than twenty companies located in the region were involved in the construction process to ensure full control over quality and lead time. The final design had to meet strict structural criteria while also being optimised for manufacturability.“ The second challenge was logistics because every component required dedicated handling procedures,” Mr Rossi continues.“ Transporting the stem, wedge, body sections, and bonnet demanded exceptional lifting and transport arrangements. Even moving individual components within the factory required bespoke handling equipment and carefully planned routes.” The third challenge was testing.“ The valve had to be assembled and tested in the same inverted orientation in which it would operate in the field. This requirement dictated the selection of the manufacturing site, which had to accommodate not only assembly but also a deep test pit more than five metres in depth. The fully assembled valve, fitted with blind flanges and filled with water, exceeded 200 tonnes, requiring specially designed fixtures to support and stabilise the valve during testing.” Despite these constraints, the valve was successfully tested at both full hydrostatic pressure and at the extremely low operating
Company President Luca Farina is presented with an award from the Mayor of Trieste, Roberto Dipiazza.
The Orion Valves team celebrates the culmination of their efforts: the Guiness World Records certificate.
pressure of five psi, in line with the process requirements.
Quality assurance and delivery
Given the scale and complexity of the project, there was no margin for rework. Mr Farina:“ Transportation permits and logistics planning were fixed well in advance, leaving no room for delays. Every operation, from machining to welding, coating, and final assembly, was executed to the highest quality standards.” The project was subject to continuous inspection by representatives from Saudi Aramco, TotalEnergies, Hyundai, and independent third-party inspectors. The valve remained in the inverted configuration throughout assembly and testing and was only rotated into the upright position after final painting. From contract award to completion, the full project duration was approximately one year. The valve will be installed in Saudi Arabia later this year, where it will function as a flare header collector. The official presentation of the completed valve took place on 11 December, and was attended by 600 people, including representatives from Saudi Aramco and Hyundai, all Orion Valves staff past and present, and the Guinness World Records staff. The project demonstrates Orion’ s ability to deliver highly complex, safety-critical equipment at the very limits of current valve engineering. It reinforces the company’ s position as a long-term technical partner capable of executing exceptional projects in the most demanding operating environments. www. valve-world. net Valve World February 2026
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