withstand the severe environment without the repeated shutdowns.
A game-changing retrofit
A solution was proposed to evaluate the exisiting valve trim andretofit it with the FM- 1500 TM trim. The plant operators, wary after years of frequent failures, were cautiously optimistic but agreed to put the trim to the test. Inspection photos taken at regular intervals presents a robust trim( Fig 5).
Demonstrated performance and operational impact
The performance exceeded expectations:
• Maintained full sealing integrity despite sustained exposure to hightemperature acidic slurry.
• Eliminated delamination, demonstrating superior durability compared to thermal spray coatings over time.
• Required no unplanned maintenance, enabling continuous operation without disruption.
The service life increased fivefold, extending operational uptime from six months to over 2.5 years. This improvement resulted in significant cost savings, reduced maintenance interventions, and enhanced overall plant reliability.
Importance of evaluating valve trim
What can be seen from these results is that evaluating coatings and valve trims is extremely important. When the most suitable trim is used in valves, such benefits will be noticed: 1. Eliminates unplanned shutdowns, valve failures due to delamination and better reliability for HPAL and POX plants.
2. Significant cost savings, such as reduced service intervals and the need for spare parts and labour costs.
3. Trim that can be universally compatible, such as the FM-1500 TM trim that can be installed in all OEM valve designs, requiring no modifications to valve actuation.
4. Sustainability and reduced environmental impact as there are fewer valve replacements, meaning less waste and reduced resource consumption. Lower energy costs associated with shutdowns and replacements are also an added bonus.
Valve Coating
Conclusion: the new standard for severe service valve trim
The FM-1500 TM valve trim represents exciting innovation opportunities in severe service valve technology, offering excellent erosion resistance, corrosion protection and long-term sealing reliability. Whether for new valve installations or retrofitting existing ball valves, it provides an incredible performance advantage in the harshest industrial environments.
About the author Evelyn Ng, PhD, MBA, is a Chartered Professional Engineer in both Australia and Canada and is based in Western Australia. With 15 years of experience in the resources sector, she specialises in materials performance and asset integrity in extreme service environments. Recognised at both the state and national levels with the Women in Resources Technological Innovation award, she is the Group Manager Materials & Innovation at Callidus Group. She is passionate about delivering practical, high-impact solutions that improve safety and extend equipment life.
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