VALVE INNOVATION
Table 7 : Flow coefficient ( Cv ) values and pressure drop |
Valve Size ( inches ) |
Wafer type nonoblock valve ( Cv ) |
Ball calve ( Cv ) |
Pressure drop ( psi ) |
2 |
40 |
30 |
10 |
4 |
120 |
85 |
15 |
6 |
250 |
180 |
20 |
Table 8 : Expected lifespan and failure rates Valve type |
Expected lifespan ( years ) |
Annual failure rate (%) |
Wafer Type Monoblock |
20 |
1.5 |
Ball Valve |
15 |
3.5 |
Table 9 : Emissions and waste generated during manufacturing |
Valve type |
CO2 emissions ( kg per unit ) |
Waste material ( kg ) |
Wafer Type Monoblock |
25 |
5 |
Ball Valve |
40 |
10 |
Table 10 : Material recyclability and energy consumption |
Valve type |
Recyclability (%) |
Energy consumption ( kWh / year ) |
Wafer Type Monoblock |
85 |
120 |
Ball Valve |
60 |
150 |
• Focus on eco-friendly materials and energy-efficient manufacturing processes
These innovations are likely to strengthen the position of wafer type monoblock valves as a leading choice in sustainable industrial practices .
Figure 3 . High-pressure wafer monoblock valves , suitable for challenging environments like oil and gas processing .
environmentally friendly choice for industries aiming to reduce their carbon footprint and improve overall sustainability .
Case studies
• Case study 1 : Oil & gas industry application
In a recent project within the oil and gas industry , the use of wafer type monoblock valves led to a 25 % reduction in installation costs and a 15 % increase in system reliability due to fewer leak points and lower maintenance requirements . This project demonstrated the valves ’ superiority in high-pressure environments where traditional ball valves were previously used ( Brown and Green , Journal of Industrial Valve Design , 2017 ).
• Case study 2 : Chemical processing plant A chemical processing plant replaced ball valves with wafer type monoblock valves in its high-temperature pipeline
Figure 4 . Installation of wafer type monoblock valves in an industrial fluid control system .
system . The result was a 20 % decrease in operational downtime and a 30 % reduction in maintenance costs over a two-year period ( Martinez and Rivera , Journal of Pressure Valve Technology , 2016 ).
Future trends and innovations
Ongoing advancements in materials and design are expected to further enhance the advantages of wafer type monoblock valves . Future developments may include :
• Integration of smart technologies for real-time monitoring and predictive maintenance
• Use of advanced composite materials for improved performance in extreme conditions
Conclusion
Wafer type monoblock valves offer significant advantages over ball valves in terms of space efficiency , cost-effectiveness , operational efficiency , durability , and environmental impact . Their robust design and superior performance in high-pressure environments make them valuable across various industries . As demand grows for reliable , sustainable , and easy-to-maintain valve solutions , wafer type monoblock valves are poised to play a crucial role in modern fluid control systems . Industries adopting these valves can expect benefits including reduced operational costs , improved system reliability and a smaller environmental footprint .
About the company Batu Valve Türkiye is a manufacturer specialising in innovative valve solutions for the energy , oil , gas and petrochemical industries . With a focus on LPG applications , the company offers a range of valves designed to meet the demands of high-pressure and high-temperature environments , ensuring safe and efficient operation in LPG stations and other gas infrastructure projects .
24 Valve World October 2024 www . valve-world . net