Valve Solutions Archives - ValvTechnologies

Which is Better: Metal Seat or Soft Seat Ball Valve?

Adele El Helou — Mon, 24 Nov 2025 21:56:51 +0000

When selecting a ball valve, seat material determines performance, longevity, and reliability. The seat forms the sealing surface and plays a decisive role in how the valve handles pressure, temperature, and wear.

Two main valve seat types exist: metal seat ball valves and soft seat ball valves. While both have a place in valve design, the difference in performance becomes clear once real-world conditions come into play. For demanding applications, metal seat valves provide superior results, especially when supplied by ValvTechnologies.

What is a Metal Seat Ball Valve?

A metal seat ball valve uses a hard metal-to-metal interface between the ball and seat to achieve a secure seal. The sealing surfaces are coated with advanced materials such as tungsten carbide or chromium carbide, providing outstanding resistance to wear, corrosion, and thermal damage.

The primary advantage of metal seated valves is their ability to withstand high temperatures and severe service conditions. These valves can handle extreme environments, including severe flashing, hydraulic shock, and abrasive process fluids, with operating temperatures up to and exceeding 1,500°F.

Metal seats can also be hardened through coatings and techniques like thermal spray coating, stellite hard facing, chromium carbide, and tungsten carbide, further improving their durability and sealing integrity.

ValvTechnologies’ metal seat ball valves are designed to deliver zero leakage and eliminate secondary leak paths, even under the toughest pressure and temperature extremes. Built for endurance, these valves continue to perform where softer materials fail, minimizing downtime and long-term maintenance costs.

What is a Soft Seat Ball Valve?

Soft seat ball valves use non-metallic materials like PTFE or other thermoplastics to form the sealing surface. They are suitable for clean, light-duty service where chemical compatibility and tight sealing are important.

They typically operate best in medium/low-pressure environments and are suitable for working temperatures below 500°F. However, soft seats are not recommended for process fluids that are dirty or abrasive. They can break down in these environments, leading to leakage and performance loss. Their flexibility is also their weakness, because soft seats can deform, wear, or chemically degrade under stress, resulting in short service life and frequent valve maintenance.

Metal Seat vs. Soft Seat Ball Valve Comparison

Feature	Metal Seat Ball Valve	Soft Seat Ball Valve
Temperature Resistance	Handles extreme heat and cold (up to 1,500°F)	Limited by material type
Pressure Rating	Suitable for high-pressure systems	Moderate pressure capacity
Wear Resistance	Excellent with hard coatings	Poor in abrasive media
Leakage Prevention	Tight shutoff, no secondary leak path	Prone to deformation and valve leakage
Maintenance Frequency	Low, long service intervals	Requires more frequent servicing
Lifecycle Cost	Higher initial, lower lifetime cost	Lower initial, higher lifetime cost

Across almost all demanding services, metal seat ball valves outperform soft seat designs by maintaining tight shutoff and durability through harsh operating conditions.

Why ValvTechnologies Leads in Metal Seat Design

ValvTechnologies has set the standard for metal seat valve technology worldwide. Proprietary coatings, precision machining, and advanced sealing systems enable long-term, leak-free performance.

Every valve is engineered to eliminate secondary leak paths and maintain tight shutoff through years of continuous service. Built for longevity, ValvTechnologies valves are designed for those who expect their equipment to perform under the harshest conditions, not be replaced frequently.

Recommended Applications

Metal seat ball valves are ideal for:

Power generation (steam, condensate, feedwater)
Oil and gas refining and production
Chemical processing and petrochemical plants
Mining and slurry service
Pulp and paper processing
High-temperature / abrasive applications

These environments demand durability and leak-free operation that soft seat valves cannot deliver.

Contact ValvTechnologies today to specify the right valve for your operation and experience the reliability of true metal seat engineering. We also manufacture trunnion ball valves, coking valves, switching valves, slurry valves, and check valves.

The post Which is Better: Metal Seat or Soft Seat Ball Valve? appeared first on ValvTechnologies.

The Ultimate Guide to Industrial Valve Maintenance

Adele El Helou — Wed, 19 Nov 2025 21:56:17 +0000

Industrial valve maintenance is the foundation of plant reliability. Valves are expected to operate for years under extreme pressure, temperature, and chemical conditions, but only when properly maintained.

Industrial Valve Maintenance: An Overview

Different valve types (ball, slurry, coking, and check valves) each have unique maintenance requirements. Factors such as process media, pressure, temperature, and cycle frequency dictate maintenance intervals. For example, a valve in high-temperature slurry service demands more frequent inspection than one used in clean, low-pressure steam.

Common wear areas include the seat, seal, stem, and coating. Over time, exposure to process media and thermal cycling can lead to erosion, pitting, or galling. Recognizing these points of degradation early allows maintenance teams to plan corrective work before failure occurs.

Predictive vs. Preventive Maintenance

Predictive maintenance uses real-time data (like actuator cycle counts and torque readings) to identify when components are nearing wear limits. This data-driven approach reduces unplanned outages and helps prioritize maintenance efforts.

Preventive maintenance follows a structured schedule. For valves operating in severe service, inspections may be required quarterly or semi-annually. By combining predictive monitoring with preventive discipline, facilities can achieve maximum uptime with minimum cost.

Common Failure Modes & Warning Signs

Even the most durable valves will show signs of fatigue. Below are the most common issues and what they indicate:

Seat wear and coating erosion: Early signs include minor leakage or increased torque during operation.
Galling: Metal-to-metal contact leading to surface damage, often from improper lubrication or contamination.
Corrosion: Caused by chemical attack or incompatible materials; visible as rust, pitting, or discoloration.
Mechanical scoring: Resulting from debris or misalignment, leaving grooves on sealing surfaces.
Leakage paths: Often caused by wear, misalignment, or improper reassembly after maintenance.

Root causes of these failures can include:

Improper torque during installation
Misalignment of valve components
Contaminated process media or debris in the system

Warning signs to watch for:

Unusual torque or actuator resistance
Visible external leakage
Deviation in flow performance or pressure control

Technicians should act quickly when these symptoms appear, as minor repairs can often prevent full rebuilds or replacements later.

Best Practices for Inspection & Cleaning

A structured inspection process is key. Start with external checks for leakage, corrosion, or actuator issues. Internally, examine seat and sealing surfaces for coating damage or debris. Clean with approved solvents or media that do not compromise coating integrity.

Recording inspection data (cycle counts, wear depth, and service time) creates a historical record that helps predict future maintenance needs. Plants that track and analyze this information reduce both downtime and cost over the long term.

Valve Maintenance Frequency Guide

Below is a reference table summarizing common maintenance tasks and recommended intervals based on service severity.

Maintenance Task	Clean / Low-Pressure Service	Moderate Service	Severe / High-Temperature Service
External visual inspection	Every 12 months	Every 6 months	Every 3 months
Internal inspection (seats, seals, coatings)	Every 24 months	Every 12 months	Every 6 months
Cleaning and lubrication	Every 12 months	Every 6 months	Every 3 months
Actuator cycle check / torque verification	Every 6 months	Every 3 months	Monthly
Coating inspection / restoration	As needed	Every 12 months	Every 6 months
Full refurbishment / OEM service evaluation	Every 5 years	Every 3 years	Every 1-2 years

This table provides a general framework. Actual intervals should be refined through predictive monitoring and site-specific data. The above table does not include data for Coker, ISO tech, and/or any other Industry specific manufactured valves.

Repair, Refurbishment, Replacement

Deciding when to repair versus replace a valve depends on the extent of wear and service requirements. ValvTechnologies offers certified refurbishment programs that include re-machining, weld overlay, and coating restoration. These processes return the valve to original design performance while maintaining pressure boundary integrity.

Working directly with the OEM ensures proper materials, tolerances, and coatings are applied. This not only extends service life but preserves the safety and reliability of your system.

Read our blog on when to repair vs. replace your valve.

Remember: maintenance begins at installation. Common errors such as misalignment, contamination, or improper torque can shorten service life dramatically. Operators should also avoid rapid actuation or over-torquing, which accelerate wear on seats and seals.

Proper training and adherence to manufacturer procedures help maintain sealing performance and prevent premature failures.

ValvTechnologies provides factory-certified repair, field service, and maintenance training worldwide. Contact us today to learn more.

ValvTechnologies is Your Trusted Valve Manufacturer in Houston, TX

With the right valve maintenance strategy, operators can extend equipment life and prevent costly failures. Partner with ValvTechnologies to plan inspections, refurbishments, and long-term reliability improvements that keep your plant running at its best.

ValvTechnologies’ products and services include metal seated ball valves, zero-leak valves, switching valves, valve service and repair, and more.

Contact us today to speak to a valve expert.

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Comparing Valve Repair vs. Replacement: Cost & Quality Considerations

Adele El Helou — Mon, 03 Nov 2025 21:30:36 +0000

When a valve begins to show wear or performance decline, the choice between valve repair and valve replacement affects operating cost, downtime, and long-term reliability. At ValvTechnologies, that decision is guided by data, precision, and decades of field experience in high-performance valve design and service. ValvTechnologies supports customers through both paths, restoring valves when repair is practical and providing new engineered solutions when replacement delivers better lifecycle value.

What Causes Valves to Need Repair or Replacement

Industrial valves operate under demanding conditions that gradually wear down critical components. Common causes include:

Erosion and corrosion: Continuous exposure to abrasive or corrosive media wears away sealing surfaces and internal components.
Thermal cycling: Repeated temperature fluctuations cause expansion and contraction, leading to fatigue or misalignment.
Mechanical wear: Continuous operation degrades the coating applied to balls and endcaps, valve seats, stems, over time.
Contamination: Debris or particulates in the process stream can damage sealing areas or obstruct movement.
Improper operation or installation: Incorrect torque, alignment, or actuator setup can accelerate wear or cause seal failure.

These factors accumulate over time, eventually reducing the valve’s ability to maintain tight shutoff or reliable control. Knowing these causes helps operators make informed decisions when evaluating valve repair versus valve replacement.

When is Valve Repair Preferred?

Valve repair is often the preferred option when the valve body and major components remain structurally sound. In these cases, precision repair processes can restore performance and extend service life at a fraction of replacement cost.

Repair is generally preferred when:

The valve has localized damage such as worn seats, seals, or minor erosion.
Downtime is limited and repair can be completed faster than sourcing a new valve.
The valve design or material is still current and compatible with the system.
Environmental goals prioritize minimizing waste and resource use.

Benefits of valve repair:

Lower cost compared to purchasing a new valve.
Reduced lead times and downtime.
Proven methods such as Strip and Recoating, re-machining, weld overlay, and coating restore sealing surfaces and tolerances.
Maintains compliance with industry standards such as API 598 and ASME pressure testing through documented inspection and validation.

ValvTechnologies repair specialists restore metal-seated valves to full performance using in-house developed processes including precision machining, advanced coatings, and hardfacing technologies. Repaired valves routinely demonstrate identical sealing performance to new units under test conditions, often exceeding 100,000 service hours before scheduled valve maintenance.

When is Valve Replacement Preferred?

While repair provides clear advantages in many situations, valve replacement is the better choice when damage or wear exceeds repair limits or when the system requires updated specifications.

Replacement is generally preferred when:

The valve body, trim, or pressure boundary components are cracked, deformed, or heavily corroded.
The model or design is obsolete, and parts or materials are no longer available.
Operational upgrades or process changes require new configurations or materials.
The valve operates in safety-critical or high-risk service where full certification is required.

Advantages of valve replacement:

Guarantees full compliance with current design codes and material standards.
Provides the opportunity to upgrade to next-generation materials or improved flow designs.
Eliminates potential hidden damage that might persist after repair.
Reduces lifecycle cost in cases of repeated or severe failure.

When system performance demands a complete update, valve replacement restores full reliability and meets modern performance standards. ValvTechnologies recommends replacement only when the long-term value or operational requirements outweigh the immediate benefits of repair.

Contact ValvTechnologies for Valve Repair and Replacement

ValvTechnologies keeps your valves performing at their best through every stage of operation. With certified valve service centers across the globe, teams are available around the clock to support installation, commissioning, troubleshooting, and maintenance.

When the damage exceeds repair limits, valve replacement options are evaluated based on service data and lifecycle performance. In many cases, restored valves through valve repair match or exceed the reliability of new installations.

For expert evaluation, data-backed testing, and long-term valve performance solutions, contact ValvTechnologies today to determine whether valve repair or valve replacement is right for your operation.

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Different Types of Valve Seats: Integral vs. Inserted

Adele El Helou — Sat, 25 Oct 2025 16:31:54 +0000

At ValvTechnologies, we know the valve seat defines how well a valve seals and how long it performs in service. The seat is not a simple component, rather it’s the sealing surface that determines shutoff reliability, wear resistance, and overall valve life.

In severe service, where zero leakage and extended uptime are expected, the seat design makes all the difference. Two primary seat configurations exist: integral and inserted.

Integral Valve Seats

At ValvTechnologies, the integral seat is a hallmark of our severe service valve design. The seat is machined directly into the valve end piece, creating one continuous solid structure that eliminates any potential leak path around the seat. This metal-to-metal integrity forms a sealing surface that stands up to extreme pressure, temperature, and abrasive or cyclical service.

When combined with our spring-loaded design, the ball and seat maintain tight contact throughout operation, preserving the seal through temperature and pressure changes. This prevents bypass leakage and extends service life far beyond what is achievable with inserted designs.

Integral seats are typically made from the same material as the valve body (carbon steel, stainless steel, or high-alloy materials) and can be overlaid or coated for added hardness or corrosion resistance. This approach delivers consistent performance across all components and eliminates mismatched thermal expansion between seat and body materials.

Integral seats are extremely durable, and eventual wear may require repair by re-machining, weld overlay, or strip and re-coat, rather than part replacement. These repairs are often straightforward and maintain the valve’s original design integrity. For applications where reliability, zero leakage, and long-term performance are non-negotiable, integral seats remain the trusted solution.

Inserted Valve Seats

Inserted valve seats are separate components that fit into the valve body, typically pressed, threaded, welded, or shrink-fitted in place. This approach allows for different materials to be used for the seat and the body, which can be useful in less demanding service or where material flexibility is more important than long-term reliability.

Inserted seats are often made from hard alloys such as Stellite or tungsten carbide, and they can also be coated or hardfaced for wear resistance. When the seat wears out, it can be replaced, which can simplify maintenance for lighter-duty valves or where shutdown time is less costly.

However, this design introduces a secondary interface between the body and seat: a potential leak path that must be sealed perfectly. Under high temperature or cycling conditions, differences in thermal expansion between materials can create stresses at that joint, affecting sealing performance over time.

While inserted seats can perform well in moderate service, they are not ideal for the severe conditions integral valves are built to handle. For high-pressure, high-temperature, or abrasive applications, integral seats provide superior reliability, sealing consistency, and lifecycle cost performance.

Comparing the Two: Integral vs. Inserted Valve Seats

Both integral and inserted seats serve the same purpose (creating a tight shutoff between the ball and body) but they achieve it differently. Inserted seats introduce a secondary interface between parts, while integral seats are machined directly into the valve structure, eliminating that interface entirely.

Durability: Integral seats deliver the most reliable sealing performance over the life of the valve. With no joint between body and seat, there is no secondary leak path or risk of loosening. Inserted seats can be replaced, but their interface adds complexity and potential for leakage under high-cycle or high-temperature conditions.
Maintenance: Inserted seats can be swapped out, but this convenience comes with greater inspection and sealing demands. Integral seats, by contrast, offer long service intervals and can be re-machined or re-coated as needed without replacing parts, reducing lifetime cost and downtime.
Temperature and Pressure: For extreme temperature, pressure, or abrasive applications, integral seats outperform inserted designs by maintaining a secure seal even under expansion and contraction cycles.

Need Help Choosing the Right Seat? Contact ValvTechnologies.

At ValvTechnologies, every valve is built to handle the service it’s meant for. We test every valve design to make sure they hold up where it counts.

So if you’re working on a project or troubleshooting a valve issue, reach out to ValvTechnologies. Our integral seat valve ensures zero leakage and absolute shutoff in the harshest conditions. You can also learn more about our metal-seated ball valves, trunnion ball valves, switching valves, slurry valves, coking valves, specialized coatings and valve repair shop in Houston, Texas.

Contact ValvTechnologies for more info on our integral seat valve designs.

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What Does “Zero Leakage” Really Mean in Valves?

Adele El Helou — Wed, 03 Sep 2025 14:40:52 +0000

What Does “Zero Leakage” Really Mean in Valves?

Leakage in industrial valves is a major concern: lost product, safety risks, and environmental harm can all result from it. That is why the term “zero valve leakage” gets so much attention.

The Industry’s Definition of Leakage

International standards such as API 598, ISO 5208, and MSS-SP-61 define acceptable leakage rates for different valve types and applications. Leakage is generally grouped into two main categories: internal and external.

Internal leakage is fluid passing through the valve seat when the valve should be shut, while external leakage is fluid escaping to the outside of the valve body.

No valve is completely perfect. Every standard allows for some tolerance, so when the industry says “zero valve leakage,” it refers to meeting the strictest allowable limits (not literally zero molecules escaping).

What “Zero Valve Leakage” Means in Practice

“Zero valve leakage” is a performance classification, not a literal guarantee of perfection. For example:

Soft-seated valves often achieve bubble-tight shutoff, which is defined as zero leakage under many standards.
Metal-seated valves are designed for severe service. They are tested under much harsher conditions, such as high pressure, elevated temperatures, and abrasive or corrosive media, and what qualifies as “zero valve leakage” here is far more demanding than in general service applications.

In industries where even trace amounts of leakage can create safety or environmental risks, zero valve leakage means meeting or exceeding the toughest standards consistently.

Testing Methods for Leakage

Different test methods are used to verify leakage performance. Each method provides data on how a valve performs under specific stresses and validates its classification.

Hydrostatic testing: water is used to check for seat and body leakage.
Pneumatic testing: air or gas is used to detect very small leaks that might not be visible with water.
High-temperature steam testing: used for valves in severe service, such as power plants, to simulate real operating conditions.

Cost and Risk of Valve Leakage

Leakage carries both operational and financial consequences. Escaping steam or process fluids can cost more than the valve itself and may shorten the life of surrounding equipment. Hidden leaks can worsen over time, eventually leading to unplanned outages.

For context, traditional standards such as MSS SP-61 and FCI Class V allow measurable fluid loss. A 4-inch, ASME/ANSI Class 1500 reduced port valve under those allowances could lose hundreds of gallons annually. Over several years, that number grows substantially. By comparison, manufacturers that guarantee zero valve leakage commit to no detectable loss for a set test duration and to warranties that rule out leakage during service.

Read Now: The Real Cost of Valve Leakage

Efficiency Through Cycle Isolation

Proper cycle isolation plays an important role in plant efficiency. Even small leaks can allow steam or process fluids to bypass, reducing overall system performance. Advanced performance testing programs use acoustic monitoring to assess valve performance in service, supporting predictive and preventive maintenance strategies. This helps operators identify developing issues before they cause problems.

Why “Zero Valve Leakage” Matters to End Users

For plant operators, zero valve leakage delivers real-world results:

Safety: preventing dangerous emissions, fires, or accidents.
Environmental compliance: meeting strict fugitive emissions regulations.
Operational efficiency: avoiding unplanned downtime and reducing maintenance.
Cost savings: extending valve life and preventing product losses.
Improved decision making: data-driven insights into valve performance and maintenance needs.

Field-proven performance is equally important. Valves must be verified not only in factory testing but also through long-term operation in real service conditions. Case studies from combined cycle power plants, refineries, and chemical facilities confirm that zero valve leakage performance can be maintained over years of use.

From Industry Standards to Proven Solutions

The discussion so far has focused on how zero valve leakage is defined, tested, and why it matters in practice. To close, here is how one manufacturer applies these principles:

The ValvTechnologies Approach

ValvTechnologies supports zero valve leakage with patented sealing technology and engineered metal-seated designs built for severe service. Each valve undergoes hydrostatic and seat leakage testing before shipment, and long-term cycle testing confirms performance under high temperature and pressure.

We back this with a four-year warranty for steam and power applications and a company-wide quality program that drives consistent reliability. This is why industries from power generation and oil & gas to mining and nuclear continue to rely on us.

Learn More About ValvTechnologies

ValvTechnologies has set the global standard for zero valve leakage performance. Our valve solutions include metal-seated ball valves, switching valves, slurry valves, coking valves, trunnion ball valves, and so much more. Our experts can also support facilities through our valve repair shop services.

Contact us today to learn more about our metal-seated, zero-leakage, severe service valve solutions.

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How to Determine If Your Valve Leakage Is Within Tolerance

Dev Upstream — Sun, 17 Aug 2025 17:23:15 +0000

How to Determine If Your Valve Leakage Is Within Tolerance

In industrial operations, even a small leak can create big problems. Control valve leakage not only wastes product, but it can also compromise safety and lead to regulatory concerns. The challenge is that every industry defines “acceptable leakage” differently. So how can you determine if your valve leakage is within tolerance?

What Valve Leakage Means

Valve leakage is the unintended passage of fluid (liquid or gas) through a closed valve. While some standards permit a degree of leakage, the impact depends on the process and industry.

There are different types of control valve leakage:

Internal leakage: Fluid passes past the sealing surfaces inside the valve. (AKA through-seat leakage)
External leakage: Leakage occurs around valve stems, body seals, etc.

Leaks can result from wear, misalignment, thermal cycling, or materials that don’t match the service. In high-pressure steam, corrosive slurries, or other severe conditions, the risks are even greater.

Standards That Define Leakage Tolerance

To bring consistency, several industry standards establish leakage limits and testing procedures:

API 598: Inspection and testing requirements for many valve types.
API 6D: Pipeline valves, including leakage testing.
ASME and ISO standards: Define leakage classes and testing procedures.
MSS SP-61: Pressure testing of steel valves.
ISO 5208: Defines test procedures for industrial valves.

Control valve leakage classifications typically range from Class I to Class VI. Below is a summaryfrom ANSI/FCI 70-2:

Class	Description	Typical Allowance
I	No defined leakage limits, no testing required	N/A
II	Low leakage	About 0.5% of valve capacity
III	Medium leakage	About 0.1% of valve capacity
IV	Tight shutoff	About 0.01% of valve capacity
V	Extra tight shutoff	~0.0005 ml/min per inch of seat diameter
VI	Bubble-tight	Maximum bubbles per minute under test pressure

Metal-seated valves are handled differently since they are built for severe service where soft seats would not last. Some industries, such as nuclear or petrochemical refining, adapts more stringent requirements beyond these standards.

“Acceptable” Leakage

A common belief is that “some leakage is okay.” While technically true under many standards, it can be costly:

Lost product: Even small leaks can accumulate into large losses over time.
Safety risks: Escaping hazardous fluids or gases can endanger personnel and equipment.
Compliance challenges: Environmental and safety regulations are tightening, leaving less tolerance for leakage.

Another common idea is that “bubble-tight” means zero leakage. In fact, bubble-tight (Class VI) applies to soft-seated valves, not metal-seated severe service valves. Achieving true zero-leakage requires different design and manufacturing methods. A valve that passes the standard may still pose risks in high-stakes environments.

How to Judge if Leakage Is Within Tolerance

If you’re uncertain about control valve leakage, consider these steps:

Review OEM documentation: Start with the valve’s design specifications and manufacturer recommendations. Pay close attention to the stated leakage class and testing criteria.
Check against standards: Compare performance with API, ASME, ISO, or MSS classifications relevant to your application.
Test regularly: Conduct leak testing under operating conditions and keep detailed records. Additional tests may apply depending on the valve type.
Consider the service: For high-stakes operations such as nuclear, coking, or slurry applications, even “within tolerance” leakage may be unacceptable. Many operators set internal criteria stricter than industry norms.

By combining published standards with operating data, you can decide if a valve should be repaired, replaced, or upgraded.

Why Zero-Leakage Valves Make a Difference

Industry standards may permit leakage, but zero-leakage technology is available…and often the better choice. Valves designed to eliminate leakage provide:

Greater safety and reliability
Longer service life
Reduced downtime and maintenance
Lower emissions and environmental impact

In high-pressure, high-temperature, or corrosive environments, the difference between “within tolerance” and “zero leakage” can determine if a facility operates safely or faces costly interruptions. Since 1987, ValvTechnologies has focused on metal-seated, zero-leakage valves engineered for the world’s toughest industries. Our solutions help customers operate with confidence even under extreme conditions.

Reliable Zero-Leakage Solutions from ValvTechnologies

ValvTechnologies can help keep your operations safe and leak-free. We provide a full portfolio of valve solutions including metal-seated ball valves, trunnion ball valves, coking valves, switching valves, slurry valves, and more. Our specialized coatings and service support further extend valve performance in demanding environments.

Contact our team to learn more about how our products can help eliminate leakage across your operation.

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