To international soluble silicates manufacturer Case History: PQ Corp. is a leading worldwide producer of specialty inorganic performance chemicals and catalysts materials serving the detergent, pulp and paper, chemical, petroleum, catalyst, water treatment, construction and beverage markets. The company began producing and selling "silicate of soda" or sodium silicate in 1861 to replace rosin in soap formulations. Today, PQ is the world's largest producer of soluble silicates with manufacturing plants across the globe. Problem The plants' dust collecting systems involve abrasive, hot silicate and require a valve that can stand up to water and 60 psi steam. The automated plug valves being used in this demanding process were constantly requiring maintenance and creating interruptions in plant operations. The plug valves were failing after only 6-8 months in service. The frequent failures and questionable quality of the valves were causing serious operational issues for production. In addition, the seals in the actuators were also failing prematurely and needed to be rebuilt or replaced repeatedly. This critical application wasted a lot of money, time, and energy. Solution PQ's Best Maintenance Operating Practices team worked with local distributor GTS Technical Sales to provide a cost-efficient solution. GTS was able to offer an automated package using American Valve's 4000D ductile iron flanged ball valves to replace the faulty plug valves. Benefits PQ Corp. has been rewarded with a much lower cost on the total package (valve and actuator). The actuator sizing could be reduced since the torque is much lower for the American Valve ball valve than the previous plug valves. Additionally, the American Valve products offer a much longer service life and easier operation. Both the valve and the actuators are longer lasting, enabling the plant to stretch out the replacement cycle. Unscheduled down time at the plants has also been eliminated. Once the plug valves were replaced with American Valve models, the BMOP team set up a preventative maintenance program to proactively replace the valves before failures occur. American Valve is now the specified valve of choice for this rugged application. For more information please visit www.gtstechsales.com
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