API 6A Gate Valve & Mud Gate Valve Replacement for Central Asian Oilfield — JLD Energy — Производитель нефтяного оборудования

Задача

A producing oilfield in western Kazakhstan experienced accelerated valve failure across 15 wellhead clusters due to unexpected H₂S breakthrough and sand production. A total of 45 valves (Model FC manual gate valves, mud gate valves, and check valves) needed emergency replacement while maintaining production uptime. The operator required: (a) delivery within 5 weeks, (b) NACE MR-01-75 compliant materials for the newly detected sour service, (c) full material traceability per EN 10204 3.1, and (d) on-site installation supervision by JLD engineers. Customs clearance at the Kazakhstan border was an additional logistical challenge.

Решение

JLD Energy mobilized a dedicated production line for the 45-valve order. Material grades were upgraded from Class BB (standard carbon steel) to Class DD (NACE MR-01-75 compliant) at no additional charge due to the sour service upgrade requirement. The scope included: 20 Model FC manual gate valves (5,000 PSI, 2-9/16" bore), 12 Model DM mud gate valves for drilling fluid circulation systems, 8 Model DX spring-loaded check valves, and 5 sets of API 6A Type 6B flanges with RTJ ring gaskets. All 45 valves were manufactured, shell-tested, seat-tested, and documented within 3.5 weeks. Air freight was arranged for the main valve shipment while flanges and fittings followed via rail freight to reduce total logistics cost. Two JLD field service engineers traveled to site for installation supervision.

Результат

All 45 valves were installed and commissioned within 8 days of arrival on site. Production restarted with zero H₂S leaks identified during the initial 30-day integrity monitoring period. The operator reported a 30% reduction in valve-related downtime compared to the previous supplier's equipment. JLD Energy has been added to the operator's approved vendor list (AVL) and subsequently received orders for an additional 30 valves for the next phase of field development.

Спецификации

Quantity: 45 API 6A valves | Materials: Upgraded to Class DD (NACE MR-01-75) | Delivery: 4 weeks (air + rail freight) | Service: Sour gas breakthrough, sand-laden fluid | Inspection: EN 10204 3.1 MTRs + Hydrostatic Test Certificates