Every valve project in the process industry is different. Sometimes, customer requirements can be met with a standard solution, while other projects call for exceptionally large valves, special solutions and installations that require more planning, expertise and resources than usual. In these cases, a fully customized solution is needed, combining special assemblies, careful valve project management and KLINGER Finland’s in-house workshop expertise.
We recently completed a project for one of our customers that demonstrates KLINGER Finland’s ability to deliver customized project solutions. The delivery included a total of 28 actuated 3Z three-way plug valves, eight in size DN150 and twenty in DN200.
This was not only a large valve delivery, but also a technically demanding project. A specific actuator configuration was designed for the project that had not previously been implemented with this type of 3Z three-way plug valve. The actuators were installed at KLINGER Finland’s workshop in a crosswise orientation with a special configuration to meet the customer’s requirements. Due to their size and weight, a crane was required throughout the actuator installation process.
A customized assembly required careful planning
The scale of the project was clearly visible at our workshop.
A single 3Z three-way plug valve supplied for the project weighed more than 100 kilograms, while the pneumatic actuator installed on it weighed approximately 47 kilograms. With the mounting kit and other required components included, the total weight of a single valve assembly reached nearly 200 kilograms.
Before delivery to the customer, the project occupied nearly 30 pallets in our warehouse. The scale of the delivery and the crane-assisted installation of the actuators required careful logistical planning, as our normal daily warehouse operations and other customer deliveries continued uninterrupted at the same time.
While the size of the valves was impressive, the success of the project was ultimately based on careful planning, precise assembly and quality assurance. Each valve was assembled, adjusted and inspected according to the customer’s specific requirements before delivery.
Our in-house workshop enables solutions tailored to customer requirements
KLINGER Finland’s workshop enables us to supply valves that are adapted to the specific requirements of each customer’s process.
Having our own workshop also enabled us to complete this project as a fully assembled, ready-to-use delivery in accordance with the customer’s requirements.
Our workshop services include:
- valve modifications to meet specific customer requirements
- installation of actuators and accessories
- design and manufacture of special mounting kits
- valve pressure testing and other testing according to customer requirements
- safety valve maintenance, adjustment and testing.
By completing the assembly before delivery, the customer receives a customized, ready-to-use solution that can be commissioned on site smoothly, efficiently and safely.
Careful project management ensures a successful outcome
In large and demanding valve projects, success depends on more than selecting the right products. Effective project management is equally important.
At KLINGER Finland, each project is assigned a dedicated project manager and project team responsible for managing the delivery from start to finish. Regular progress meetings are held both internally and with the customer to ensure that all parties remain up to date throughout the project.
When required, our product designers produce dimensional drawings and 3D models to verify the suitability of the valves for the application already during the design phase. The valves are also tagged according to the customer’s requirements and can be equipped with QR codes providing access to installation, operating and maintenance instructions.
Before delivery, every valve is inspected, documented and photographed. Packaging is carried out according to the customer’s specifications, including requirements such as colour coding or plant area codes. Delivery progress is monitored and reported regularly, and all project documentation – including operating and maintenance instructions, datasheets, dimensional drawings and assembly drawings – is compiled and delivered to the customer as a complete documentation package.
Special projects are part of what we do
Although actuated three-way plug valves of this size are relatively rare, this project is a good example of the types of requirements our customers rely on us to handle.
The project demonstrates that a demanding valve delivery involves much more than supplying products. Success comes from combining the right products, technical expertise, customized assemblies and careful project management into a complete solution that supports the customer’s objectives.
When a valve project requires more, our customers can rely on us to deliver a complete solution that is ready for commissioning – safely, to a high standard and on schedule.
Planning a demanding valve project?
When a valve project requires customized solutions, we help you find the right solution for your application. Our in-house workshop and experienced project organisation enable us to deliver valve projects according to customer requirements – from design and assembly to testing and documentation.
Contact our valve specialists to discuss the requirements of your project.
