Case Studies

The Challenge

A major Gulf Coast petroleum refinery was experiencing chronic internal leakage on their duplex lube oil filter transfer valves. The existing ball-type valves allowed cross-contamination between the active and standby filter circuits, causing contaminated oil to bypass the standby filter and reach the compressor bearings. Maintenance crews were performing emergency shutdowns every 6–8 weeks.

The Solution

Northeast Controls Inc. specified HYCOA JR-33 3-Way Transfer Valves with Viton shoe seals for the compressor lube oil unit. The patented shoe seal design provides positive zero-leakage shut-off — the shoe retracts during changeover to eliminate frictional drag, then seats firmly to block all bypass flow. Installation was a direct flange-for-flange replacement with no piping modifications required.

Results

• Zero internal leakage confirmed on API 598 seat test
• Emergency shutdowns eliminated — 18+ months continuous operation
• Changeover time reduced from 45 minutes to under 2 minutes
• Full API 614 compliance achieved for rotating equipment protection

The Challenge

A 500 MW combined-cycle power plant was required to bring their gas turbine lube oil system into compliance with API Standard 614 as part of a major overhaul. The existing transfer valves were non-compliant — they lacked positive mechanical lockdown and showed measurable seat leakage. The plant needed a drop-in replacement that would fit existing flange connections without repiping.

The Solution

HYCOA JR-33 6-Way Same-Side Transfer Valves were selected for the duplex lube oil filter circuit. The same-side port configuration matched the existing piping layout exactly. The positive mechanical lockdown feature prevents accidental mid-position operation, and the shoe seal design meets API 614 zero-leakage requirements. Stainless steel trim was specified for the turbine lube oil service.

Results

• API 614 compliance achieved — passed third-party inspection
• Existing piping retained — no modifications required
• Positive mechanical lockdown eliminates accidental mid-position risk
• Stainless steel construction compatible with turbine lube oil additives

The Challenge

An offshore production platform needed to replace aging Kraissl transfer valves on their duplex fuel oil filter system. Replacement Kraissl parts were no longer available, and the existing valves were showing seal wear and increasing leakage. The platform required a direct replacement that would fit the existing Kraissl flange pattern without cutting and re-welding the piping.

The Solution

Using the HYCOA Kraissl cross-reference table, Northeast Controls identified HYCOA JR-33 3-Way Transfer Valves as direct dimensional replacements for the existing Kraissl units. The HYCOA valves use the same ANSI Class 150 flange pattern and face-to-face dimensions. Buna-N shoe seals were specified for the fuel oil service.

Results

• Direct bolt-in replacement — no piping modifications
• Kraissl cross-reference confirmed dimensional compatibility
• Buna-N shoe seals rated for fuel oil service to 250°F
• Spare parts inventory simplified — single supplier for all sizes

The Challenge

A steam turbine operator was experiencing rapid seal degradation on their EHC (Electro-Hydraulic Control) hydraulic system transfer valves. The system uses phosphate ester hydraulic fluid, which is highly aggressive to standard Buna-N elastomers. Seals were failing within 3–6 months, causing internal leakage and EHC system pressure loss.

The Solution

HYCOA JR-33 6-Way Inline Transfer Valves with Viton (fluorocarbon) shoe seals were specified for the EHC system. Viton is fully compatible with phosphate ester fluids and rated to 350°F. The inline port configuration matched the existing straight-run piping layout, eliminating the need to reroute any EHC hydraulic lines.

Results

• Viton seals fully compatible with phosphate ester EHC fluid
• Seal life extended from 3–6 months to 3+ years
• Inline porting matched existing piping — no rerouting required
• EHC system pressure stability restored to design specification