• CASE STUDIES

At Zahroof, we manufacture reciprocating compressor valves, but what we really do is - create staggering long -Term results.

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case study 1

Gas Gathering Application

ZAHROOF VALVES
INCREASE RUN TIME
FROM WEEKS TO YEARS

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High liquid and particulate contaminants are fouling
the legacy plate valves of a large contract compression
operator. Valves must be serviced monthly, resulting in lost
production and increased maintenance costs.

Straightflotm result

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Upon installation, StraightFlo™ first and second stage valves
run for 3 years. Third stage valve repair frequency goes
from once a month to once in three years. And service takes
place on site, with no machining, saving time and money.   

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  • Segment: Contract Compression
  • Location: East Texas
  • Compressor: GE Gemini DS504
  • Date Installed: July 2013
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Valve repair frequency
goes from once a month
to once in three years.

    Operator’s Legacy Valves

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    Zahroof Replacement Valves

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case study 2

Wellhead Application

ZAHROOF VALVES
REDUCE POWER
CONSUMPTION BY 4.5%

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With multiple StraightFlo™ Valves already in
use, a major E&P company asks Zahroof to
once again help improve flow and valve life in
additional wellhead compressors.

Straightflotm result

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The StraightFlo™ valves average 22HP per MMscfd versus the plate valves they were using average of 23.1. The lower specific power results in a 4.5 % decrease in power consumption.   

StraightFlo™ valves have long since surpassed the previous plate valve’s average life of five months and continue to operate successfully without incident 6-years later and counting. 

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  • Segment: Majjor E&P Company
  • Location: Marcellus Shale
  • Compressor: Ariel JGC/4
  • Date Installed: Dec 2015
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6 years Later and counting
zahroof valves operate
without incident.

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case study 3

Hydrogen Make Up/Recycle Feed Application

ZAHROOF VALVES
eliminate unplanned
shutdowns

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Intermittent valve failures at a large US refinery are causing unplanned shutdowns every three to six months. OEM valve life does not allow the compressors to run the full time between scheduled turnarounds every 2 years.

Straightflotm result

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StraightFlo™ Valves solve the reliability problems, eliminating unplanned shutdowns and enabling maximum refinery production

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  • Segment: Large Refinery
  • Location: Upper Midwest
  • Compressor: Multiple
  • Date Installed: Oct 2018
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StraightfloTm Valves
solve the reliability
problems.

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case study 4

Amine Plant / Sour Gas Application

ZAHROOF VALVES
increase mtbf by 7x

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OEM valves are failing monthly at an amine plant of a large pipeline and midstream company. In addition to the issues of downtime, lost production, and increased labor and parts expenses—servicing the compressor was a major safety concern due to the presence of 30% sour gas.

Straightflotm result

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Since Jan of 2019, StraightFlo™ Valves have operated without a single safety or maintenance incident—a 7X increase in mean time between failure (MTBF).

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  • Segment: Pipeline/Midstream
  • Location: East Ford Shale
  • Compressor: Ariel JG/4
  • Date Installed: June 2018
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since 2019 straightflotm
valves have operated
without a single safety
or maintenance incident

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case study 5

Gas Gathering: Dirty Service Application

ZAHROOF VALVES
Increase efficiency
5%, save compressor
from major damage

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major Oil & Gas company sought to increase efficiency and reliability in dirty service. StraightFlo™ Valves were installed on one first stage and one second stage cylinder to directly compare

Straightflotm result

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StraightFlo™ valves increase efficiency by 5% and more than double previous valve life, performing flawlessly for years, while OEM plate valves fail in seven months.

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In March 2017, the compressor experiences a slug of liquid that deforms the piston rod on a cylinder with OEM plate valves. The cylinders with StraightFlo™ valves handle the liquid with no issue and prevent damage.

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  • Segment: Major O&G Co.
  • Location: San Juan Basin
  • Compressor: Two Stage Ariel JGK
  • Date Installed: July 2016
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Straightflotm Valves
last years, OEM plate
valves only lasted months.