IMI resolves severe valve erosion at Wildcat Point energy facility

Wildcat Point is a large-scale natural gas-fired power generation facility located in Maryland. The plant plays an important role in supporting power demand across the region, with reliable operation of critical steam and cooling systems essential to maintaining consistent generation output.

The issue was driven by high flow rates of up to 88,000 lb/hr and a pressure drop of approximately 1100 psi, which created extreme conditions within the valve. Critical components, including the trim, spindle and seat ring, were deteriorating rapidly, while performance data showed unstable flow behaviour with Cv values exceeding the valve’s rated capacity.

For the Wildcat Point facility, this resulted in reduced control accuracy, ongoing wear and the need for frequent maintenance intervention, increasing both operational costs and system downtime.

To address this issue, IMI worked with the Wildcat Point engineering team to fully assess the operating conditions and identify the root causes of the erosion. Through detailed analysis of approximately 2,000 data points, IMI engineers established the true operating range and refined the valve sizing requirements to ensure accurate performance under real-world conditions.

IMI implemented a retrofit solution using a 3D printed disc stack trim design, engineered to better manage pressure drop and flow characteristics within the valve. The IMI solution distributes the pressure drop across multiple stages within the trim, significantly reducing velocity at critical surfaces and minimising erosion.

The monolithic design integrates the seat and trim into a single component, simplifying installation while improving durability. Crucially, the retrofit approach allowed the upgraded trim to be installed within the existing valve body, avoiding the need for full valve replacement or complex on-site modifications.

Further optimisation of the trim geometry ensured stable control across the full operating range, increasing the valve’s rated CV and enabling it to handle previously observed flow outliers safely. This improved both process stability and long-term reliability.

Roby Buyung, President for Process Automation at IMI, said: “Applications involving high pressure drops and unstable flow conditions can create significant erosion challenges for conventional valve designs.

“At Wildcat Point, detailed analysis of the operating conditions allowed us to optimise the trim geometry and pressure staging within the valve, significantly improving flow stability while reducing wear and maintenance demands.”

Following implementation, inspections indicated reduced erosion and wear alongside improved flow stability and control. The retrofit approach also helped reduce maintenance intervention requirements while avoiding the need for full valve replacement.

¹ This is a turbine cooling feedwater flow control to the HP drum.