E-Series
The E-Series sets a new standard in choke performance.
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.
E-Series designs enhancements
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%.
5CB Trim is Born
As the heart of a choke, the flow trim material is crucial to the ultimate performance of a valve. In particular, there are three properties 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.
What is "5CB"?
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.
Erosion Resistance
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.
Corrosion Resistance
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.
Toughness Comparison
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.
Summary:
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.
Benefits
- Longer valve life
- Less downtime
- Less maintenance
- Lower life-cycle costs
- Maximized value
- Improved flow capacity
- Interchangeability with existing Master Flo valves