Retrofit solution for Wildcat Point resolves erosion difficulties

A spray water valve installed at the Wildcat Point energy generation facility in Maryland, United States, was experiencing severe erosion and wear due to consistently high flow rates of up to 88,000 lb./hr and a pressure drop of 1100 psi. Critical components such as the trim, spindle, spacer, and seat ring were also rapidly deteriorating.

The installed trim showed significant damage and required a retrofit.

The valve’s coefficient of variation (Cv) ranged from 0.65 to 5.63, yet the data collection system (DCS) indicated multiple outliers exceeding the rated Cv of 6.1, occasionally reaching Cv 6.6.

Working closely with Wildcat’s engineering team, our experts reviewed the full process conditions at the facility to ensure accurate valve sizing, as the data included numerous outliers. Consequently, we charted approximately 2,000 data points and narrowed them down to the five most representative conditions to understand the required Cv bandwidth. We needed to analyse the complete temperature and pressure profiles before finalising sizing parameters.

To ensure precise control across a wide Cv range (0.65 to 6.6), we recommended the use of a disc stack configuration, starting with the highest number of turns (40) in the first few disks for finer control at low flow, and fewer turns at the bottom to manage higher Cv. This helped minimise erosion and wear and tear near the seat, a common issue that leads to trim and flow passage damage, internal leakage, and accelerated wear. Ultimately, it enabled us to significantly lower the facility’s maintenance costs.

To accommodate the observed flow outliers, we designed the bottom end of the trim with fewer restrictions, increasing the Cv rate to 7.5. This ensured that even outlier flow conditions remained within the valve’s safe operating range, improving valve life and process stability.

At our manufacturing and testing facility, we conducted flow testing of the disks for applications with very low or high Cv requirements and custom trim designs. We then used this to simulate actual conditions. We printed and tested each disk used in the stack individually to identify any clogged or underperforming passages. This ensured the upgraded design resolved any previous performance issues and precisely met the customer’s expectations.

Our testing process resulted in an improved solution: a retrofit trim upgrade kit consisting of a disc stack, spindle, seat ring, and valve soft goods kit. This combination of technologies increased reliability compared to traditional trims, and the total cost of ownership would be lower as it replaced expensive components such as the actuator. Our solution also ensured that Wildcat Point avoided the on-site service costs for valve replacement, such as valve cutting, pipe modification, valve welding, post-welding heat treatment, and hydrotesting.

The customised 1” trim and 1” stroke reduced erosion and improved valve reliability with a higher rated Cv. Optimised flow passages and accurate Cv matching ensured stable operation and enhanced process control across the complete control range (0.65 to 7.5). Our solution reduced spare part replacement and labour costs, contributing to overall cost savings. The new trim design was fully compatible with the existing valve body and actuator and required no significant modifications. Rigorous flow testing and Cv validation ensured the final product met performance expectations within ±10%, eliminating historical issues.

The successful retrofitting of the severe duty valve at Wildcat Point’s facility demonstrates how precision-engineered technology can effectively resolve complex flow control challenges in high-pressure, high-erosion environments. By increasing the rated Cv, optimising trim geometry, and validating performance through rigorous disk-level testing, we extended the life of the valve components and delivered significant operational and cost benefits.

This project highlights our ability to adapt standard valve designs into high-performance custom solutions, minimising downtime, reducing total cost of ownership, and enhancing process reliability. This solution proved technically sound and economically advantageous with a retrofitting approach that avoided major mechanical modifications. Our model can be replicated across other severe service applications worldwide.

Cascade trim (Traditional design)

3D printed disk stack trim (Our solution)

For more detail on IMI’s Retrofit 3D solution please visit: Retrofit3D