EXTERNAL leaks from valves during valve cycling are common problems for plant operators. These leaks can have disastrous consequences, contaminating the environment and endangering workers with hazardous materials, resulting in major downtime for the company.
Delta Industrial™ knife gate valves can guarantee zero leakage for plant operators in difficult process applications, said Weir Minerals global product manager for valves John Abbott. “This isolation is very important because it ensures safe and consistent plant operation, minimises downtime and provides lowest total ownership cost.
“Our customers can install Delta Industrial valves into problem areas secure in the knowledge that they will achieve long-term performance with exceptional isolation results, protecting their people, their plant and their environment,” he said.
Weir Minerals Delta Industrial guided shear gate valves are designed to repeatedly close and provide bi-directional zero leakage isolation, no matter what the process fluid may contain.
“Our knife gate valves guarantee no process will come past the closed valve, even abrasive slurry or when operating under high temperatures,” John Abbott stated.
This is a significant feature of the Delta Industrial valves and one which provides numerous important benefits to the customer, providing some insight into why Weir Minerals acquired and continues to invest in the company.
Delta Industrial Valves was founded in 1987 and began designing and manufacturing high quality knife gate valves in 1989. It is an industry leader in the valve industry and with the backing of Weir Minerals continues to pave the way in high quality knife gate valves.
“Weir Minerals acquired Delta Industrial in July 2015, increasing our market presence in the hard rock mining, oil sands, pulp and paper, and power industries,” John Abbott said.
Delta Industrial’s advantage
Not all knife gate valves are the same - many allow for leakages which can leave plant operators exasperated.
When asked what makes the Delta Industrial product different from many others on the market John Abbott replied, “Their construction provides a zero leakage guarantee to external environments due to their unique transverse seal design. Couple this with Delta Industrial’s long history in the design and production of valves, and it consistently proves one of the highest performing valves in these heavy duty applications.”
While many different types of knife gate valves have been designed and manufactured since the 1950s, they have all had serious limitations. The Delta Industrial shear gate design combined with its unique seating arrangement ensures exceptional pipeline isolation and zero leakage to the atmosphere, resulting in performance customers can rely on every time the valve operates.
“Although there are at least five distinct types of knife gate valves marketed in the industry, we only produce absolute knife gate valves in our Delta Industrial range, capable of cutting, shearing and closing against solids while still producing a tight shut-off,” he said.
This unique design is capable of offering the highest performance in the most severe applications where solids are in solution, suspension or both, making it the world’s premium isolation valve for scaling applications where traditional valves are inoperable due to cementation or precipitation of solids.
“What’s great about our Delta Industrial knife gate valves is that they even operate in clear solutions, an area where traditional knife gate valves are not appropriate.”
John Abbott says Delta can design and build a tailored valve solution for customers if they have a special requirement, providing them with a unique solution.
“Our knife gate valves have demonstrated their ability to deliver low cost of ownership over the life of the valve, resulting in reduced downtime and increasing productivity for customers.”
The valve manufacturing process employs tight tolerances and minimum clearances to ensure reliable performance and longevity of the highly engineered product.
Applications and projects
“The Delta Industrial valve is designed to work in severe service applications, providing customers from a range of sectors, superior performance at high pressures,” John Abbott said.
They are utilised in many industries, including oil sands, pulp and paper, and power generation.
John Abbott said, “In oil sands the Delta Industrial knife gate valves provide innovative, custom products well suited for the harshness of this industry. The valves are heavily entrenched in the oil sands process, where performance is critical and leakage, both external and internal, cannot be tolerated.
“For pulp and paper mills Delta Industrial knife gate valves are used in a range of processes including refiners and heavy duty cleaners, areas where traditional designs often fail to perform. The valves work flawlessly in the most difficult applications, preventing untimely and costly shut downs.
“Lastly, Delta Industrial knife gate valves are ideal for power generation applications because of their reliable performance and low maintenance requirements.
“Delta Industrial knife gate valves have made a significant impact on many applications but there is one in particular that comes to mind as a standout. An international mining company was repairing a major valve on their tailings line every three months, which was extremely inefficient and costly, and they asked four our help. A Delta Industrial knife gate valve was specified and installed, and this valve has been operating for four years without any unscheduled maintenance,” he said.
The team at Weir Minerals are working on complementing their range of ASME 600 rated valves. There are also developments being tested which will provide enhanced performance in high pressure applications. “We are all very excited about the product development and new design innovations and cannot wait to see these unfold,” John Abbott concluded.