WHO IS ULTRA CONTROL VALVES Ultra Control Valves is a trading company in the South African valve industry, specialising in control valves for the Water & Mining industry. Automatic control valves is our main focus, but we also offer isolating valves, check valves and air valves – often in special executions. Our main target markets are municipal, government and mining clients as well as suppliers/contractors in these markets. We have since two years ago formed a close relationship with Sizabantu with whom we have developed some unique solutions
Product Range Control valves – Ultra ACV, Maric, ZZ Controls Air valves – ARI Flow Controls Isolating valves – Gate, Globe, Butterfly, Knife gate, Ball Non return valves – Swing, Nozzle, Spherical ball, Silent
U L T R A C V
VALVE DESIGN – SO RUGGED IT HAS STOOD THE TEST OF TIME.
Pilot operated Control valves Ultra ACV • Standard Pressure Rating 40bar • Cast Steel body FBE Coated • All wearing parts are in 316 SS • 4:1 Cavitation resistance which is better than competitors • Large stocks up to 400mm • Local manufacture in process
Pilot operated Control valves Applications
Pilot operated Control valves Comparison with Y-Type Control Valves We believe the Ultra Globe Control valve has superior features
Y-PATTERN CONTROL VALVE - LOW HEADLOSS THRU’ VALVE MEANS IT DROPS ALL THE PRESSURE IN THE SEAT AREA -ONLY CAPABLE OF 3:1 PRESSURE DROP -UNSTABLE DISC REQUIRES V-PORT ON MANY APPLICATIONS -LIGHT DUTY CASTING NOT SUITED FOR HI PRESSURE DROPS
Y-PATTERN FLOW PATH Single Bearing
V-PORT DESIGN - VALVES WITH V-PORTS LOSE 35% OF FLOW CAPACITY - LARGER VALVES ARE REQUIRED TO ACHIEVE REQUIRED FLOW RATE - V-PORT NOTCHES CATCH DEBRIS AND THEN CANNOT CLOSE
Pilot operated Control valves
THE ULTRA ACV CONTROL VALVE - LARGER CAVITATION BREAKING AREA – CAPABLE OF 4:1 PRESSURE DROPS -SPINDLE SUPPORTED AT BOTH ENDS – DUAL BEARING FOR STABLE CONTROL -UNIQUE QUAD SEAL CAN BE USED ON BOTH SIDES -REMOVEABLE COVER FOR EASIER MAINTENANCE
Ratio Pressure Reducing valve • Reduces Pressure in a Ratio if you want to reduce from 12bar to 4bar you use a 3:1 Ratio • No Pilots – no tampering • Instant reaction time • Can use mutiple valves in series without instability • Can handle flows down to low value Ex Extr tremel emely s y simple imple – made made f for or Rur ural al conditions conditions
RATIO REDUCING VALVE AVAILABLE IN RATIOS OF 1,5:1 2:1 3:1 4:1 5:1 SIZE RANGE 15mm – 300mm Pressure up to 100bar
Ratio Pressure Reducing valve
Ratio Pressure Reducing valve Is this a brand new invention ? No o A Ratio Reducing valve product has been available in Australia for many years and used mainly in High Rise buildings. Limited size and pressure o The SA Mining industry have been using SA designed Ratio Reducing valves for many years with great success Ultravalves now have their own Ratio Reducing valve available up to 300mm and 100bar pressure
Maric Flow Control Valve
Maric Flow Control Valve
Maric Flow Control Valve
Maric Video Available on our website www.ultravalves.co.za under Control valves/flow control valves
Special Control Valves Dam Discharge Valves
Special Control Valves Ring Needle Valves Ring Needle Valves
Special Control Valves Tilting Disc Check Valves
Special Control Valves Spherical Discharge Control Valves
Check Valves Silent Check
Check Valves Nozzle check
Check Valves Ball Check
Check Valves Swing Check
Isolation Valves Double Eccentric Butterfly Valves
Isolation Valves Triple Eccentric Metal seated
Isolation valves RSV Gate valves •
Isolation Valves Wedge gate valves
Isolation Valves Knife Gate valves large range for Water, Sewage, Chemicals
Engineering • Ultravalves spend a lot of time with Consulting Engineers to advise on correct valves for applications. • We assist with Water Hammer Reduction by selecting appropriate equipment • We build complete Pressure Reducing stations • We advise and assist with Water Loss reduction methods
Engineering Pressure Reducing Stations
Engineering Safe Pressure Reducing Station • Pilot operated Pressure Reducing valves are used in standard Pressure Reducing stations • Some inherent problems such as reaction delay, tampering and breakages of Pilots makes these stations vulnerable to faulty-operation. • Even though Relief valves are installed, no engineer is confident that a standard Pilot operated PRV Station can ever be safe enough to use in place of Break Pressure Tanks
Engineering Safe Pressure Reducing Stations The use of a Ratio Reducing valve makes a PRV Station INHERENTLY FAIL SAFE • No pilots so not vulnerable to tampering or breakages • Operated by pressure forces the valve will still work even if the seals are broken • Can safely be used instead of a Break Pressure Tank
Engineering Safe Break Pressure Tank
Engineering Water Loss Reduction • Pressure Management has become a very important component in Water Loss Reduction programs as it offers “quick fix” results with fast payback periods. • The technical requirements for standard Pilot operated Control valves to perform Pressure Management can be onerous and often beyond the scope of standard Control valves. • A product is now available which can increase the capability of standard Control valves and also act by itself to provide very simple and “Africa friendly” solutions
Water Loss Savings P1=12bar P2=4bar Leakages in Networks can be reduced if water pressure is P2=2bar reduced during Off-Peak Periods PRV’s with “smart” electronic controllers can reset pressure to lower values during off-peak hours
Water Loss Savings Pressure settings on PRV’s can be automatically altered electronically by two basic methods
Water Loss Savings Pressure Management with the use of Electronic “Smart” Controllers • Costly – Upwards of R50 000-00 additional to valve cost. • Complicated – operators do not understand them • Maintenance intensive – when they stop working operators disconnect the Electronics • Control valves are often forced to operate beyond their capabilities, resulting in short life span and instability Too complicated for Rural Conditions
Water Loss Savings What is the problem for Control Valves ? Cavitation - the Achilles heel of Control valves. Most control valves can handle only a 3:1 pressure drop ratio before cavitation sets in. Example P1 = 12bar P2 allowable = 4bar Cavitation is a phenomena which has to be avoided at all costs as it destroys Control valves in a short period
Water Loss Savings Although some control valves can handle 4:1 pressure drops without cavitation, when conditions are beyond these criteria, 2 x PRV’s have to be installed in series. This usually creates instability which has to be avoided as it can lead to pipe breaks , and negate the purpose of the water saving exercise completely. Ultra ACV Control Valve can handle A 4:1 ratio Example P1 = 12bar P2 allowable = 3bar
Water Loss Savings 2 x Pilot operated valves in series Problems with instability leading to pipe breaks Flow
Water Loss Savings Ratio Reducing valve Uses of Ratio Reducing Valves in Water Loss Savings As a simple PRV with no potential instability issues As an upstream PRV to a Pilot operated PRV without instability issues. Fitted with a Solenoid valve it can be used to easily achieve a lower setting of downstream pressure during Off-Peak times Reduce Pressure – Reduce Water Losses
Water Loss Savings Ratio Reducing valve In Series - Stable Flow Ratio Reducing Valve Pilot Operated PRV
Water Loss Savings Ratio Reducing valve Fitted with Solenoid: energise to activate or de-energise to open the Ratio Reducing valve Solenoid Flow
Water Loss Savings Ratio Reducing valve Flow Ratio reducing valve downstream of Pilot Operated PRV wide open during high demand periods and activated to reduce pressure to lower setting during low demand.
Water Hammer Solutions We have the relevant equipment • Correct Check Valves • Control Valves • Air Valves • Bladder Surge Tanks We can assist with Water Hammer Software analysis through Associate companies
Engineering Ultra Control Valves in association with Sizabantu can assist with • Extending the use of OPVC Pipe • Valve selection • Water Savings • Water Hammer solution Thank You
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