INDEX

Powerflo Solutions Office Locations ..................................................................2

Background .......................................................................................................3

Equipment .........................................................................................................4

Mobile Workshops.............................................................................................5

OVERHAUL & REPAIR OF SAFETY RELIEF VALVES ..................................6

Quality Assurance .............................................................................................7

Safety Valve Overview ......................................................................................9

Scope of Work.................................................................................................10

OVERHAUL & REPAIR OF CONTROL VALVES ..........................................13

Control Valve Overview ...................................................................................14

Scope of Work.................................................................................................14

TECHNICAL COMMENTARY ........................................................................17

Valve Identification ..........................................................................................18

Painting ...........................................................................................................18

Valve Connections ..........................................................................................18

Thread Patterns ..............................................................................................18

Inspections ......................................................................................................18

Contaminated Valves ......................................................................................18

Standards ........................................................................................................19

SUMMARY OF PAST REPAIR WORK ..........................................................20

SUMMARY OF PAST CONTROL VALVE REPAIR WORK ...........................22

IMAGES ..........................................................................................................23
Powerflo Solutions Pty Ltd Valves Services

POWERFLO SOLUTIONS

COMMISSIONING SUPERVISION,
OVERHAUL & REPAIR & TESTING
OF

SAFETY RELIEF VALVES

CONTROL VALVES

REGULATORS

ISOLATION VALVES
Powerflo Solutions Pty Ltd Valves Services

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Over the past 90 years, Powerflo Solutions has earned an Australia-wide

reputation for engineering excellence. We are leading importers and
manufacturers of a wide range of products – principally high quality Control
Valves, Safety Relief Valves and Instruments – serving virtually every industry
in which liquids or gases are controlled or measured.

While our Engineered Products are inevitably subject to the continual change
necessary to meet the latest demands of industry – and often rapid advances in
technology – our business philosophy remains the same as it was when our
Company was established in 1911, ie Quality, Service and Value.

Powerflo Solutions has manufactured Consolidated Safety Relief Valves under

licence to Dresser-Consolidated, in Australia for the last 40 years.

To further expand this capability, we acquired the name and assets of a

Company known as ‘Valve Service Company’ in 1993. Valve Service Company
was based in Sydney and specialised in the overhaul of Wedge and Parallel
Slide Gate Valves, with its main customer base being the petro-chemical
installations in New South Wales.

Suitable premises were purchased at Condell Park which would accommodate

both the Manufacturing and Valve Service Operations. This facility allowed us
to expand our business to suit the needs of our customers. We moved this
facility to our Melrose Park Head Office Warehouse and Manufacturing complex
in 1999.

Part of our expansion included the design and installation of a high pressure,
high capacity air test facility. This Test Rig is unique in Australia. It has
sufficient volume to accurately set Valve blowdown. Digital measuring
instruments allow us to measure and record both the valve set pressure and
blowdown settings in accordance with the Australian Standard AS1271.

We are the only MARC (Masoneilan Accredited Repair Centre) in Australia

supporting Masoneilan Control Valves and Level Controllers. As well, we
maintain extensive stocks of new Control Valves and spare parts to suit our
wide Customer base operating within the Oil and Gas, Power, Mineral
Processing and Petrochemical markets, to name a few.
Powerflo Solutions Pty Ltd Valves Services

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IDENTIFICATION No. DESCRIPTION

VM 01 Kasto BSM 253 power hacksaw
VM 02 Okuma LB 1511 CNC lathe
VM 03 Hitachi Seiki 3NE300 CNC mill
Colchester Centre Lathe with taper turning attachment
VM 04 Hitachi Seiki VA50 CNC milling machine
VM 05 Hafco BM-20E manual vertical mill
VM 06 Herbert WKT 41/25 four-post drill
VM 07 Dashin Prince manual lathe – 1 meter between centres
VM 08 Clemco BNP/300/RPC 1 blast cleaning machine
VS 01 Webster & Bennett vertical borer – 900mm x 600mm travel
VS 02 Denham lathe – 2 meters between centres
VS 04 Heald 25A rotary table grinder
VS 05 Hafco SBD20 pedestal bench drill
VS 06 Burwell shot blast cleaner
VS 07 Godfrey bead blast cleaner
VS 11 Snow ring grinder
VS 12 Ensign pedestal drill
VM 16 Clark 2-tonne fork lift
VS 13 B & G hydraulic press
VS 14 ESAB LTF150 TIG welder
VS 15 CIG oxygen / acetylene set
VS 16 High Pressure air compressor (21,000kPa)
VS 17 Servex air compressor (1600kPa)
Lapping Equipment
VM 09 Lapmaster 14inch lapping machine
VS 03 August Hauerwas lapping machine – gate, Globe valves
Lapmaster 22inch lapping machine
14 inch cast iron lapping plate
14 inch diamond impregnated lapping plate
Optical flatness tester – (lightbands)
VM 10 Enerpac IPP-2532 pedestal press
Spray Paint booth – air extraction.
Testing Stations
VS 18 APS pressure test rig for control valves (air)
VM 13 APS safety relief valve test rig (high capacity)
VS 19 APS pressure test rig for Low Pressure/vacuum vent
valves (air / vacuum)
VM 11 APS safety relief valve test rig (low capacity)
VM 12 APS safety relief valve test rig (low capacity)
VM 14 APS Hydro test rig (water) – 70,000kPa
VM 15 APS Hydro test rig (water) – 20,000kPa
All pressure gauges NATA certified
Powerflo Solutions Pty Ltd Valves Services

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 High capacity air test stand up to 15000kpa, valve sizes from 15mm to
300mm ( under construction )
 Low capacity high pressure air and water test stand up to 35000 kpa air &
50,000kpa water, valve sizes from 15mm to 400mm
 Pressure and vacuum test stand for tank vent valves, valve size ranging from
50mm to 450mm.
 Lapping plates
 Centre lathe
 Spray booth
 Pedestal drill
 Wire wheel & polishing wheel
 Over head crane
 Compressors
 Grit blaster
 Hand tools

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 Centre lathe
 Low capacity high pressure air and water test stand up to 35000 kpa air &
50,000kpa water, valve sizes from 15mm to 400mm ( under construction )
 Wire wheel & polishing wheel
 Lapping plates
 Grit blaster

22 xx M
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 Specifically designed for the Origin Contract.
Powerflo Solutions Pty Ltd Valves Services

OVERHAUL & REPAIR

OF

SAFETY RELIEF VALVES

Powerflo Solutions Pty Ltd Valves Services

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Powerflo’s Valve Service has achieved Accreditation to ISO9001:2008 for
manufacture and repair of Safety/Relief valves overhaul and servicing of
industrial valves. A copy of Certificate No. 201531 is attached.
Powerflo Solutions Pty Ltd Valves Services
Powerflo Solutions Pty Ltd Valves Services

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Our High Capacity Test Rig is unique in Australia. It ensures accurate set
pressure with full valve lift. This Test Rig also has sufficient volume to
accurately set the valve blowdown. The Heise Digital Pressure Gauge read out
allows us to record accurately the valve set pressure and blowdown setting.

Other repairers that offer on-site Facilities, cannot, by the use of nitrogen gas
bottles, provide adequate volumes that would ensure that the Valve obtains a
full lift. This gas bottle method provides at the very best a simmer point, not the
lift pressure and thus cannot comply with AS1271 Set Pressure Accuracy.

With the Overhaul & Repair of Safety Relief Valves, we offer the following
capabilities.

After repairing your valves we set them in accordance with Australian Standard
AS1271, which requires the measuring of blowdown*. This can only be
achieved by setting the valves on our test Rig or by lifting the valves and setting
them on your plant which can obviously cause you noise, environmental
problems and production losses.

As we manufacture and stock steel / bronze and stainless steel safety valves,
we may be in a position to supply a new valve from stock in the event of a valve
being unrepairable.

* Blowdown – The difference between set pressure and reseating pressure of

a pressure relief valve, expressed as a percentage of the set pressure, or
pounds per square inch gage.
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1 Test check set pressure (pressure relief valves)

2 Strip valve totally, grit / bead blast and inspect

3 Machine end connections if required *

4 Machine body seat(s) if required *

5 Lap body seat(s)

6 Machine valve member seat(s) if required *

7 Lap valve member seat(s)

8 Hand-lap mating seat surfaces

9 Machine body / bonnet joint faces *

10 Machine and polish spindle if necessary

11 Pressure test pipeline valves; adjust and set pressure relief valves

12 Reassemble and paint

13 Complete documentation and prepare for despatch

* Additional work that will be quoted at time of repair.

Powerflo Solutions Pty Ltd Valves Services
Powerflo Solutions Pty Ltd Valves Services
Powerflo Solutions Pty Ltd Valves Services

OVERHAUL & REPAIR

OF

CONTROL VALVES
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We are the Australian MARC Repair Agents of Masoneilan Control Valves. We
stock both spare parts and new valves; in the event of a valve being
unrepairable we will be able to replace it with a new valve in most instances.

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For Control Valves

Control Valve Sub-Assembly:

1 Components marked to ensure correct orientation upon reassembly,

and are tested, to reflect an ‘as received’ condition.
2 Complete disassembly.
3 Grit Blast and inspect all pressure containing components.
4 Supply written inspection report.
5 Recut, polish and Lap seat angles.
6 Hone Packing bore area to ensure no leakage through packing box.
7 Remachine flange gasket surfaces.
8 Replace all soft parts and hard parts as required.
9 Reassemble.
10 Test and Calibrate.
11 Paint.

Actuator & Associated Instrumentation

12 Complete disassembly and replace soft parts and hard parts as

needed.
13 Reassemble.
14 Set Bench Range and calibrate.
15 Paint.

Re-Assembly

16 Remount all accessories.

17 Replace all tubing and fittings with stainless steel tube/fittings.
18 Test and calibrate valve assembly, including accessories.
19 Install new name tag with Work Order No. and other pertinent
information.
20 Prepare Test Certificate for the Customer and register in Valve Keep.
Powerflo Solutions Pty Ltd Valves Services
Powerflo Solutions Pty Ltd Valves Services
Powerflo Solutions Pty Ltd Valves Services
Powerflo Solutions Pty Ltd Valves Services

TECHNICAL

COMMENTARY
Powerflo Solutions Pty Ltd Valves Services

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All valves are tagged with metal (316 s/s) tags to show the set pressures (if
applicable), date of testing and the contractor’s name, and/or a lead seal fitted
using stainless steel wire.

88.. P
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All valves are grit blasted to remove all rust, oil, grease etc.

We have included in our pricing one coat to be painted on all valves.

Stainless steel/brass/bronze body valves will be cleaned but left unpainted.

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All valve inlets and outlets of the valve will be sealed for shipment.

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All threads will be lubricated and sealed during painting so that paint does not
clog thread patterns.

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Powerflo’s Valve Service will be available for your personnel to inspect valves at
any pre-arranged time at our premises.

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All valves to be overhauled must be de-contaminated and chemical data safety
sheets supplied by the owner prior to shipment to our premises.
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Powerflo Valve Service is AS/NZS ISO9001:2008 Accredited and all repairs are
in accordance to the Standards below where applicable.

AS 1271 Valves, water gauges and other fittings for boilers and
unfired pressure vessels.
AS 2129 Flanges for pipes, valves and fittings
AS 3788 Boilers and pressure vessels – in service inspection
API 527/576 Commercial seal tightness of safety relief valves with
metal to metal seals.
ANSI/FCI 70.2 Flanges for pipes, Valves and fittings seat leakage.
Powerflo Solutions Pty Ltd Valves Services

Powerflo Solutions
Valve Services
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Contractor/Project Product Description

S.E.C.V. Yallourn “W” Crosby-JO-Series Repairs and Overhaul complying

Stage 1 Units 1 & 2 Farris with AS 3788
Okano – Supero Deaerator steam, hot/cold
Reheater Safety valves. Inlet
connections 50mm-200mm

S.E.C.V. Hazelwood Dresser-Dewrance Repairs and overhaul. Boiler Color

Power Station Port Water Level Gauges

B.H.P. Port Kembla Dresser-Dewrance Repairs and overhaul, complying

with AS3788
Boiler-Superheater Drum Safety
Valves

Yallourn “W” Power Dresser-Dewrance Repairs and overhaul 200mm

Station Boiler Feed Pump Check Valves,
Stellite depositing

Austa Electric QLD Dewrance Refurbishment 4 Boiler

Callide “A” Hopkinsons Feedheating Plant Units
Power Station  20 Boiler/Superheater Drum
4 Units Safety Valves
 40 Feedheating Plant Relief
Valves

ICI Botany Operations Various Brands of Major Shut down – Chemical Plant
Alkatuff Plant Safety Relief  122 Safety Relief Valves
 Pressure/Vacuum Vents

Shell-Montell Consolidated Major Shut down – Chemical Plant

PPU No. 2 Unit Farris Safety Relief, Trunnion Mount Ball
Clyde, NSW Crosby and Changeover Relief Valves,
Fukui Safety sizes 15mm through to 200mm
Relief Valves
Neles-Jamesbury
Ball Valves
Powerflo Solutions Pty Ltd Valves Services

Contractor/Project Product Description

Department of Dewrance High Pressure, 900lb Class,

Defence (Navy Supply) John Parallel Slide and Quick Acting
Blow Down Valves

Transfield-NEPCO Consolidated Boiler and Process Plant Safety

Joint Venture Crosby Relief Valves
Smithfield, NSW Inlet connections 80mm to 200mm
Co-Generation Facility

Queensland Nickel P/L Consolidated Boiler Drum Safety Valves

Townsville, QLD

Clyde Babcock Hitachi Consolidated On-site commissioning,

ISIS and Macnade Boiler/Superheater Safety Valves
Sugar Mills QLD

Energy Developments Consolidated On-site commissioning, Boiler/Co-

Pine Creek Power Generation Safety Relief Valves
Station QLD
Powerflo Solutions Pty Ltd Valves Services

Powerflo Solutions
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Contractor/Project Product Description

Akzo Masoneilan Various Camflex II

Qenos Various <100 Masoneilan Globe
valves up to ANSI 2500#.
Also Fisher and Valtek
Valves in the Surfactants
Plant.
Minara Resources HORA 30” 900# HORA Valves
Qenos W&T 20” 2500# PRDS Valves
Nestles Masoneilan Camflex II
BHP Various ARCA, Valtek, Fisher
Uncle Ben’s Masoneilan Camflex II and Samson
Manildra Ethanol Various Fisher, Samson, M/N
Visy Paper Various 200 various Masoneilan
Valves including
Masoneilan, Fisher, Samson
and HORA Power Plant
Valves.
Yokogawa Masoneilan Many 35K and 21K Valves
Buchmann Laboratories Masoneilan Camflex II

Sammy’s Road Service Masoneilan Camflex II

Bridgestone Masoneilan Camflex II
Berrivale Orchards Masoneilan Camflex II
Kimberley Clark Masoneilan Camflex II
S.A. Generation Corporation Masoneilan Varimax
Honeywell Masoneilan Camflex II
Q.U.F. Masoneilan Camflex II
Pinkenba Terminal Masoneilan Camflex II & Lincoln Log
Valves up to 2500# Class 8”
NB
Powerflo Solutions Pty Ltd Valves Services

Contractor/Project Product Description

Mauri Yeast Masoneilan Varipak 28000 Series

Kemcor OLEFINS Masoneilan All Types of Globe Valves
Powerflo Solutions Pty Ltd Valves Services
Powerflo Solutions Pty Ltd Valves Services
Powerflo Solutions Pty Ltd Valves Services
Powerflo Solutions Pty Ltd Valves Services
Powerflo Solutions Pty Ltd Valves Services
Powerflo Solutions Pty Ltd Valves Services
Powerflo Solutions Pty Ltd Valves Services
Powerflo Solutions Pty Ltd Valves Services
Powerflo Solutions Pty Ltd Valves Services
Powerflo Solutions Pty Ltd Valves Services

Powerflo Service Team at work on a Plant Outage

Powerflo Solutions Pty Ltd Valves Services

Brisbane Workshop
Powerflo Solutions Pty Ltd Valves Services

Miles Field Service Fleet Queensland

Powerflo Solutions Pty Ltd Valves Services

Units on Site Yellow Bank Gas Field

Powerflo Solutions Pty Ltd Valves Services

Unit in Operation Coal Seam Gas Field

Powerflo Solutions Valve Service

Powerflo Solutions Pty Ltd

ACN 000 004 884

Sales Offices: 1300 658 701

Sydney
1 Mary Street, Melrose Park, NSW 2114
Tel: 02 9877 8100 Fax: 02 9804 6282
Email: [email protected]

Melbourne
Level 3, Building 4,
48/195 Wellington Road, CLAYTON VIC 3168
Tel: 03 8541 7888 Fax: 03 8541 7899
Email: [email protected]

Brisbane
6 Imboon Street, DECEPTION BAY QLD 4508
Tel: 07 3897 8100 Fax: 07 3293 4261
Email: [email protected]

Perth
Unit 6/27 Tacoma Circuit, Canning Vale, WA 6155
Tel: 08 9456 9600 Fax: 08 9350 6644
Email: [email protected]

New Zealand
Unit 6/27, Penrose, Auckland NZ 1061
Tel: (64 9) 525 5454 Fax: (64 9) 525 5461
Mob: (64 2) 176 4053
Email: [email protected]

Head Office & Manufacturing

Safety & Relief Valve Manufacture & Service
FICO Instrument Manufacture & Service
1 Mary Street, Melrose Park 2114
Tel: 02 9877 8100 Fax: 02 9804 7193
Email: [email protected]
[email protected]

Valve Service
Miles QLD
21 Lynagh Street, MILES, QLD 4415
Tel: 07 4627 1154 Fax: 07 4627 1306

Website: www.powerflo.com.au