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The
E-Series sets a new standard in choke performance.
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Using our purpose-built erosion test facility, we investigated
methods for improving valve life. This resulted in the E-Series
Choke, which combines design enhancements and new material developments
to drastically improve valve life.
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Starting with a detailed evaluation of the flow dynamics in our
existing valve design, we focused on all potential wear areas-around
the trim, the body cavity, and the outlet. Once a baseline for
performance was established, we were able to quantify the effectiveness
of any proposed changes.
We implemented design changes to the flow ring, nozzle, and retaining
sleeve that dramatically reduced throttling wear in the flow trim
and localized wear in the retaining sleeve. As well, changes to
the outlet profile significantly increased the life of the valve
body. Our tests confirm that these patented design enhancements
improved valve life by over 100%.
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As the heart of a choke, the flow trim material is crucial to
the ultimate performance of a valve. In particular, there are
three propertied that are critical to the longevity of the trim:
erosion resistance, corrosion resistance, and toughness (resistance
to impact). Working closely with materials suppliers, we developed
a new material that optimizes these three properties.
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5CB is a tungsten carbide with a micrograin 5% composite binder
developed specifically for Master Flo. It combines erosion and
corrosion resistances with toughness to provide a superior all-purpose
trim material for a full range of applications. In fact, we found
its properties to be so advantageous that we have standardized
on 5CB as our preferred tungsten-carbide material for valve trims.
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The high hardness of carbide materials makes them ideal for erosive
applications. What sets different grades of cemented carbides apart
is the binder; the ability to resist the loss of the binder element
translates into better erosion resistance.
We tested various grades of cemented tungsten carbide under controlled
conditions flow rate and abrasive concentration. The results confirm
that 5CB resists erosion better than any of the other grades. By comparison,
the mass loss of the 5CB grade was only 13% that of the 6%-Ni grade
and 66% that of the nearest challenger.
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To compare the corrosion resistance of 5CB, three grades of tungsten
carbide were sent to a third-party facility where they were immersed
in an HCl solution at a temperature of 50 C and saturated with H2S and
CO2. The results show that 5CB had the lowest rate of material loss.
By comparison, 6% Ni lost material at a rate 223% that of 5CB.
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The toughness of a material relates to its ability to resist fracture
on impact. Three grades of tungsten carbide were sent for testing by
a third party to determine the fracture toughness by the Palmqvist method.
Results were reported as KIC values, which refer to stress intensities.
Again, 5CB came out ahead.
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Summary:
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The E-Series improvements result in longer valve life with reduced
downtime, fewer inspections, and fewer replacement parts required. This
results in a product that truly optimizes life-cycle costs.
These enhancements were implemented across our product line and are
interchangeable with existing valves.
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