World record-setting wedge gate valve
Orion Valves Spa has introduced the largest wedge gate valve ever manufactured worldwide: the 114-in. Class 150 cast steel wedge gate valve, designed in accordance with API 600. A true colossus of industrial engineering, this achievement sets a new world record and confirms Orion’s constant drive to push the boundaries of technology and performance.
Designed for extreme industrial applications, this valve combines unprecedented dimensions, functional precision and absolute reliability (FIG. 1). With an overall height of 13.95 m and a weight of approximately 120 tons, its visual impact is remarkable. Yet, what truly makes this project extraordinary is not only its size, but the engineering complexity behind every single detail.
The final application is among the most demanding in the oil and gas sector: the valve will be installed in the flare line collector system of the Amiral Project, a world-class petrochemical complex under development in Jubail, Saudi Arabia, created through a joint venture between Saudi Aramco and TotalEnergies (SATORP). Further elevating the challenge is the valve’s in-line, upside-down configuration, a rare and highly critical installation condition. The combination of extreme dimensions, inverted orientation and stringent safety requirements has resulted in a true masterpiece of industrial engineering.
In projects of this magnitude, no detail can be overlooked. Even the smallest inaccuracy can evolve into a structural or functional issue. For this reason, the design phase required an uncompromising level of accuracy, analysis and control. Throughout the design review process, multiple and in-depth finite element analyses (FEAs) were carried out, considering the worst-case load conditions for both structural integrity and deformation behavior. A safety factor of 1.5 was applied during the valve body testing, ensuring an exceptionally high operational margin.
The valve was engineered to achieve full Class 150 pressure sealing performance. In addition, due to its involvement in flare testing, reliable sealing is guaranteed even at low pressure (5 psi)—a critical requirement for this specific application.
Another major challenge concerned the flange design. As no international standard exists for 114-in. pipeline flanges, Orion developed a fully custom solution. In the Amiral Project pipeline, the process line features a butt weld (BW) end. The engineering response was the creation of a special flanged body equipped with two custom welding neck flanges: one designed for welding to the pipeline, and one dedicated to bolting connection with the valve.
Orion Valves was fully responsible for the flange design, while manufacturing and machining were entrusted to the Galperti Group, a recognized excellence supplier included in Saudi Aramco’s approved vendor list.
Due to the valve’s inverted installation configuration, standard testing conditions were not applicable. To verify proper functionality, it was essential to replicate the final operating orientation, transforming testing into a highly engineered operation. A dedicated testing ditch was constructed with the following dimensions: 4.76 m length, 4.9 m width and 5 mm depth.
The supporting structure consists of steel beams equipped with rails, with a 1.5 mm × 1.5 m cross-section and a length of 11.7 m. Four beams span the testing pit in a cross-beam configuration: two arranged parallel and two positioned perpendicularly above them. Eight adjustable supports, clamped to the rails and fixed to the valve body, ensure overall stability. The entire structure was designed to withstand a total load of 200 tons, including the valve weight and test water.
Key components, including bonnet, backseat, yoke, stem, actuator, packing and gland assembly, are preassembled. The complete assembly is then lifted using a 125-ton crane and positioned upside down onto the steel beams. The gate is maintained in an inverted position, coupled to the stem, and inserted into the bonnet cavity. This operation requires perfect synchronization between the actuator and the crane to ensure precise alignment and controlled insertion. Once completed, the valve body—equipped with blind flanges—is bolted to the bonnet and permanently secured to the supporting structure.
The 114-in. 150 wedge gate valve does not differ significantly from standard gate valves; however, certain precautions must be taken. Specific measures were implemented to protect the body flanges. Instead of the usual wooden planks, Orion Valves designed and installed steel protectors equipped with a Teflon reinforcement layer that comes into contact with the flanges, preventing potential damage. Moreover, since the backseat dimensions are remarkable, a hydraulic wrench adaptation system has been developed; working with the hydraulic wrench and the internal bonnet reinforcements guarantee the proper backseat tightening.
A dedicated shipping skid has been specifically designed to support and protect the valve during transportation. In addition to its shipping function, the skid also serves as an essential equipment during the bonnet, yoke and stem assembly operations. Since the valve is assembled in an inverted position, the spot-facing on the bonnet flange is oriented downward. Consequently, the hydraulic torque wrench must also operate in an inverted configuration. To ensure proper bolting between the valve body and bonnet, a dual hydraulic wrench system with a single control unit is used. This setup allows both wrenches to tighten the bolts simultaneously and in perfect synchronization, ensuring uniform preload and assembly integrity.
For more information, visit https://www.orionvalves.com/company/company-profile/orion-valves-guinness-world-record-largest-wedge-gate-valve
Expanding possibilities in large diameter piping systems in oil and gas applications
Aalberts integrated piping systems (IPS), a global leader in advanced integrated piping systems for the distribution and control of liquids and gasses, has launched its Apollo PowerPress® options in large diameter (LD), an extension of its renowned Apollo® PowerPress® product line.
This new offering (FIG. 2), available in large diameters of 2.5 in., 3 in. and 4 in., represents a significant advancement in piping technology, catering to broader applications and offering enhanced flexibility for large-scale projects.
Key features of the Apollo PowerPress LD make it especially advantageous for oil and gas industry applications. Its hydrogenated nitrile butadiene rubber (HNBR) sealing elements, combined with zinc-nickel coatings for superior corrosion resistance, deliver secure, long-lasting seals in piping systems that transport liquid petroleum/natural gas, fuel oil, industrial gas, engine oil and hydraulic fluids. These attributes make the system well-suited for demanding environments such as fuel transfer lines, gas distribution networks and oil processing facilities, where reliability, leak prevention and chemical resistance are mission-critical.
The system incorporates the innovative Leak Before Press® technology, preventing unpressed connections from holding pressure and thus enhancing installation integrity and safety. For smaller Apollo PowerPress sizes (1/2 in.–2 in.), a color-coded visual control ring (VCR) is featured, with tabs that break away to provide quick visual identification of completed connections. A standout feature of the Apollo PowerPress LD (2.5 in.–4 in.) is the color-coded Visu-Control® foil, which splits for easy removal after press completion. This ensures that unpressed connections are easily identifiable prior to system pressurization, further improving quality control and reducing inspection time.
The Apollo PowerPress LD system is compatible with Ridgid® and Milwaukee Press Tools, increasing installer convenience and allowing for faster installations with commonly used tools. Its full-port flow design maximizes flowrates, enhancing system efficiency and performance in fluid management. Aalberts IPS continues to support its products with comprehensive field service, ensuring successful implementation from pre-construction training to post-installation support. This commitment to customer success has been a key factor in the widespread adoption of Apollo PowerPress technology.
The versatility of the Apollo PowerPress system has been proven in diverse settings, from multi-family housing complexes to international projects. In the Cayman Islands, Aalberts IPS successfully implemented the Apollo PowerPress technology in new constructions for a hospital and a restaurant, demonstrating its effectiveness in critical propane gas applications.
For more information, visit https://aalberts-ips.us/newsroom/apollo-powerpress-large-diameter/
Electric diaphragm pump to enhance efficiency and reliability
ARO, a leader in fluid handling solutions, has introduced its latest innovation: the ARO electric double diaphragm pump EVO 210 (FIG. 3). Designed to deliver a dependable and economical solution for general transfer and batching tasks, this new pump expands ARO's renowned double diaphragm range with a powerful electric option.
The ARO EVO 210 is engineered to provide enhanced efficiency and savings, especially in applications where compressed air is not an available resource or higher efficiency is desired. This model strikes a perfect balance between performance and simplicity, ensuring a cost-effective diaphragm pump solution without compromising on reliability.
Its unique and compact design facilitates a smaller overall footprint, with a simple yet robust drive-train, optimizing the number of components as well as reliability and cost. Additionally, its innovative diaphragm orientation allows for quick and easy maintenance, maximizing operational uptime.
Safety and reliability are at the forefront of the ARO EVO 210 design. Key features include:
Overpressure protection and leak detection: Visual leak protection is standard on all models, complemented by secondary containment preventing pumped media from contacting and damaging the actuator and drive mechanisms in the event of diaphragm leakage. Optional electronic leak detection and over pressure protection are available, as well.
Ease of maintenance: Diaphragms positioned on the same plane offer ergonomic access, reducing maintenance time and enhancing safety. The pump is CE marked and adheres to ISO 12100 standards, with motor options featuring regional certifications.
Additionally, the ARO Protect program is available for this model, further optimizing the total cost of ownership through extended warranties and regular preventative maintenance parts kits. This initiative aims to reduce maintenance time and increase uptime for users.
For more information, visit EVO 210 | Electric Double Diaphragm Pumps | ARO
Heavy-duty slurry pump range expanded with two new high-capacity sizes
The trusted EMW series (Fig. 4) of heavy-duty slurry pumps has been expanded with the introduction of two new, bigger sizes, significantly increasing the performance range of the product family.
Traditionally slurry pumps are needed in mining, minerals and metals processing, fertilizer production and chemical process industries. Additionally, new fields of applications for the equipment arise from decarbonization and carbon dioxide (CO2) capture processes.
With decades of experience in slurry pumping, Sulzer’s EMW series is engineered to deliver superior reliability and low total cost of ownership. The new sizes continue the range’s tradition of extended pump service life and optimized hydraulics at reduced energy use. Spare parts’ consumption is kept to a minimum and standardized components result in lower spare part costs.
With the expansion, the EMW series offers a robust alternative for a slurry pump when performance, durability and serviceability are non-negotiable. To complement the pump range, Sulzer offers lifecycle services onsite and at global service centers from installation and repairs to maintenance kits with high-quality original spare parts.
For more information, visit EMW heavy-duty slurry pump range expanded with two new high-capacity sizes | Sulzer
Rotary lobe pump for maximum flow and application flexibility
NETZSCH Pumps USA, the leading complex fluid handling solutions provider, introduces the TORNADO® T1 XXLB-F Rotary Lobe Pump (FIG. 5), a new high-performance model engineered for demanding, large-scale pumping applications. With flowrates up to 6,160 gpm (1,400 m3/hr) and differential pressures up to 174 psi (12 bar), the XXLB-F extends the TORNADO line into new territory, offering maximum flow in a compact, modular and service-friendly design.
The XXLB-F retains the core strengths of the T1 Generation F platform while expanding capabilities for high-volume applications such as wastewater treatment, biogas, membrane filtration, tank depots, pulp mills, refineries and more. Available in three sizes (XXLB 2F, 4F and 6F), the new model delivers up to 35% more flow than previous T1 pumps, while maintaining excellent energy efficiency and dry installation flexibility.
The pump features a one-piece, flow-optimized housing and improved lobe geometry for enhanced volumetric efficiency and gentle handling of shear-sensitive or solids-laden media. New wider lobe tips reduce backflow, while the axial and optional radial wear plates available in highly abrasive- and chemical-resistant materials extend wear life even in harsh operating environments.
Serviceability remains a hallmark of the TORNADO line. The XXLB-F includes Full Service-In-Place (FSIP®) access, enabling all wetted parts lobes, wear plates and seals to be replaced from the front without removing the pump from the piping. The modular design minimizes wear parts and simplifies seal customization with options including single, double and API-compliant cartridge seals.
The XXLB-F also features the proven NETZSCH Gearbox Security System (GSS), an innovative air-gap barrier between the mechanical seal and gearbox that prevents fluid ingress, protecting gears and bearings from contamination and enabling predictive maintenance. This robust separation helps avoid catastrophic failure in the event of seal wear and reduces total cost of ownership.
Other key advantages of the XXLB-F include high suction capability (self-priming without external vacuum devices), consistent flow across varying back pressures, reversible flow direction, and mobile configurations for emergency or rural installations. Combined with up to 25% higher energy efficiency, this makes the XXLB-F a highly economical choice for complex pumping challenges.
Ideal for use in environmental, energy, chemical and industrial markets, the TORNADO T1 XXLB-F handles a broad range of media, from sludge, biogas slurry and paint to cooked starch, fuels and molasses, making it a flexible solution for both new systems and retrofit projects.
For more information, visit https://pumps-systems.netzsch.com/en-US/news/2025/highlights-tornado-r-t1-xxlb-f-rotary-lobe-pump
Expanded BABAA-approved thermal management solutions for infrastructure projects
Pfannenberg Inc., a global leader in thermal management and signaling technologies, has announced that a full line of products in its portfolio now meet the requirements of the Build America, Buy America Act (BABAA). This designation applies to select options within Pfannenberg’s DTS cooling units, PKS air-to-air heat exchangers and PWS air-to-water heat exchangers, which are now BABAA-compliant and available for use in federally funded infrastructure projects across critical sectors including water and wastewater treatment, transportation, energy and broadband.
Pfannenberg’s BABAA-approved solutions (FIG. 6) are engineered and assembled at its Lancaster, New York (U.S.) facility, where each product achieves the mandated threshold of over 55% U.S.-sourced content and domestic assembly. These cooling units and exchangers are designed for long-term reliability and optimal performance in harsh outdoor or washdown environments, making them ideally suited for safeguarding industrial control panels that house sensitive electronics such as variable frequency drives and programmable logic controllers.
Customers choosing BABAA-compliant Pfannenberg products enjoy dependable thermal management that reduces the risk of overheating, ensures operational stability, and supports mission-critical infrastructure projects with confidence and quality that are backed by U.S.-based support.
With this BABAA determination, system integrators, panel builders and distributors gain access to products that facilitate compliance, reinforce supply chain stability and enable eligibility for federal funding while supporting domestic economic growth. As the company continues to innovate and expand its product lineup, Pfannenberg ensures that its solutions meet stringent regulatory standards and evolving customer needs.
For more information, visit https://www.pfannenbergusa.com/thermal-management/babaa-build-america-buy-america/
Chemically bonded ceramic coating delivers cost-saving, long-term CUI protection
Advanced Polymerics Inc. has released new test data confirming that its patented Permacorr® coating effectively mitigates corrosion under insulation (CUI), one of the most costly and persistent maintenance challenges for carbon-steel assets worldwide (FIG. 7).
CUI occurs when moisture becomes trapped beneath insulation or jacketing on hot equipment, causing aggressive corrosion and chloride stress cracking in carbon and stainless steels. Studies show that corrosion rates increase by approximately 30% for every 10°C temperature rise, and up to 40% of piping maintenance costs in refineries, and solar and chemical plants can be attributed to CUI-related degradation. In fact, CUI is a $276-B problem in North America alone.
Permacorr’s chemically bonded phosphate ceramic technology addresses the CUI problem by forming a molecular bond to the steel surface rather than a physical one. This permanent chemical interaction passivates corrosion cells, effectively protecting the substrate against oxygen and moisture. Even if microcracks form from thermal cycling, the underlying bond remains intact, and corrosion cannot start.
In the industry-standard vertical pipe (Houston) test, which exposes coated and insulated pipe sections to cyclic wet/dry salt spray and elevated temperatures, Permacorr demonstrated no blistering, cracking or corrosion after extended exposure. By contrast, epoxy-phenolic coatings typically show severe degradation after a few cycles.
Permacorr also withstood a six-month cyclic boiling-water test (8 hr immersion, 16 hr dry) with no observable deterioration, conditions that simulate the 90°C–120°C (194°F–248°F) temperature range where condensation, vapor and liquid water coexist and corrosion rates peak.
Because Permacorr is water-based, volatile organic chemical (VOC)-free and non-toxic, it supports sustainability goals without jeopardizing performance. It also does not interfere with non-destructive testing, an important advantage for operators using ultrasonic or radiographic inspection methods.
The inorganic, cementitious nature of Permacorr provides thermal stability up to 250°C (480°F) while maintaining full adhesion and chemical resistance. Only a single coat [at 10 mils–15 mils (250 µm–375 µm)] is required, applied via plural-component spray. The coating’s self-sealing behavior also minimizes surface preparation requirements and allows application over flash rust, reducing both time and cost of application.
Permacorr is suited for insulated tanks, steam lines, process piping, and pressure vessels operating up to 250°C (480°F), including facilities in the oil and gas, petrochemical, biopharma and power generation sectors.
For more information, visit Permacorr: Proven Industrial Corrosion Protection HP