Valves in harsh abrasive industrial environments, such as steelworks, endure extreme conditions. High-pressure process water filled with abrasive solids rapidly wear down sealing surfaces. This leads to costly downtime and frequent replacements.
At a major steelworks facility in the UK, a triple offset butterfly valve was failing prematurely, struggling with both abrasive wear and an unreliable actuator. The cost of constant repairs and overhauls would have been unsustainable.
Powerite provided a smarter, more durable alternative: a rubber-lined butterfly valve with a Flucast AB/E anti-abrasive liner and a 1.4027 stainless steel disc, paired with a Kinetrol spring return actuator with speed controls. Their goal? Enhanced longevity, reliability, and control.
After three months in operation, the results were clear—no visible signs of wear.
The Challenge: Valve Failures in Abrasive Process Water
The steelworks facility required a reliable valve for its process water system, operating at 6 bar pressure and 40°C. The existing triple offset valve wasn’t holding up against the abrasive particles, leading to:
✔ Rapid wear on sealing surfaces
✔ Actuator failures, causing unreliable operation
✔ High costs from frequent repairs and replacements
Every failure resulted in costly downtime and maintenance. The plant needed a solution that could withstand the conditions without constant intervention.
The Solution: A Concentric Rubber Lined Butterfly Valve.
After assessing the application, we recommended a rubber-lined butterfly valve specifically designed for abrasive media. The reasons why:
🔹 Flucast AB/E liner – Superior resistance to wear, preventing premature failure.
🔹 1.4027 stainless steel disc – High durability in demanding conditions.
🔹 Kinetrol Model 16 actuator with speed controls – Precise, reliable actuation.
This combination provided a cost-effective alternative, extending the valve’s lifespan and improving performance.
The Results: Proven Performance Over Multiple Years
The initial installation of the rubber-lined butterfly valves showed no visible wear after three months. Over time, their reliability led to further orders and extended use.
In total, four valves were installed across two applications, serving as slam shut valves from 2016 onward. Their reliability led to additional purchases for modulating applications, with the first modulating unit installed in 2020.
Valve installation timeline:
- On/Off applications:
- 1 installed in 2017
- 1 installed in 2020
- 2 installed in 2021
- 2 installed in 2023
- Modulating applications:
- 1 installed in 2020
Throughout their time in service, there were no reported failures before the process was decommissioned.
Conclusion: A Smarter, Cost-Effective Solution for Abrasive Media
This case study proves that selecting the correct valve is critical to the reliability of a process. In abrasive applications a triple offset design will often fall short. By switching to a rubber-lined butterfly valve with an anti-abrasive liner, the steelworks facility achieved:
✅ Longer valve lifespan – No signs of wear after months of use
✅ More reliable actuation – Consistent performance with Kinetrol speed controls
✅ Lower maintenance costs – Reduced need for frequent overhauls
If your process involves abrasive media, choosing the right valve can mean the difference between constant failures and a trouble-free, cost-effective operation. Contact us today to discuss how we can improve your system’s performance.