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✓ Extend Runtime
✓ On-Site Serviceability
✓ Lower Maintenance Cost
✓ Reduce Vibration, Pulsation, & Noise
✓ 10 Year Valve Housing Warranty
1
About Zahroof Valves Inc.
2
Valve Innovation
Patented modular reed valve technology
3
Solutions for a Range of Applications
4
Stacked Straighflo™ Valve
Further Increasing Flow Area
The “Stacked” valve adds a second layer
of inset modules allowing for increased
flow area within the same diameter
5
✓ Increase Performance
✓ Extend Runtime
✓ On-Site Serviceability
✓ Lower Maintenance Cost
✓ Reduce Vibration, Pulsation, & Noise
✓ 10 Year Valve Housing Warranty
…VALUE CREATION
6
Value of the Straightflo™ Valve
7
Economics of Increasing Throughput
Inputs:
• @ $2/Mcf natural gas price
• 30 days per month
• 358 days per year (98%)
8
Valve Repair Economics
Inputs:
• Plate valves: 20 valves / compressor, $725 valve cost, $200 valve
repair, 15% replacement rate, 10 month avg. run time
• Service expense: $50 / hour fully burdened mechanic, 9 hour
travel & service time per call-out
• ZVI Straightflo™ valves: 18 month run time, 40% module
replacement
• Repair cost for both cases is annualized
9
Illustrative Customer Economics
▪ Below are cost savings estimates based on actual results generated in a CO2 EOR application, on a Superior W76 3-stage
compressor. Due to H2S content, the valves are built per NACE MR0175 standards with M-X material.
Suction (pressure = 91 psig, Temperature – 90F), Discharge Pressure – 825 psig. Speed – 585 rpm. 36 6.6” valves, 24 5.6” valves, 8 5.8” valves.
1/3rd of the Valves were serviced every 2 months, with complete replacement every 2 years before SFVs were installed. SFV modules replaced every 3 years.
Two people for two hours to repair/service SFV valves. Two people for 8 hours to repair service plate valves. Labor at @ $50/hr.
*Measured improvement of 6% in power with SFVs. Original power – 2685 hp.
**Additional throughput of 6% if power is used to increase throughput. Original throughput – 14.5 MMSCFD.
*** During valve service, compressor downtime is 24 hours.
**** During valve service, emissions from blowing down the compressor and affected pipeline, followed by purging during start up. 1x represents this quantity of emissions.
Gas Processing February ZVI valves have been running without a single valve service since installation. Gas flow has increased
Blacks Fork, WY
Plant 2014 by 5% while using 7% less power.
OEM valves were being serviced every 2-3 months. ZVI valves have been running without a single
Gas Gathering –
GOM March 2014 valve service since installation. Customer likes onsite serviceability of the valves from the platform
Offshore
without having to send onshore for machining.
OEM valves were being serviced every 1-2 months. After fixing a gasket failure, ZVI valves have
Gas Processing July
Bitter Creek, UT been running without any issues since January 2015. Customer is very happy with its reduced
Plant 2014
maintenance costs and improved run tim.
July OEM valves were failing weekly. ZVI valves have been running without a single service since
Gas Gathering Justin, TX
2014 installation.
Customer was servicing valves every month. ZVI valves have been running without a single service.
CO2 & H2S Buckeye, NM August 2014
Customer has realized performance improvement of 3%.
White Settlement, Customer was servicing valves every 10-12 days. ZVI valves have been running without any a single
Gas Gathering August 2014
TX service since install. Customer has realized a 11% improvement in gas flow.
Customer installed ZVI valves in two separate compressors. In both cases, ZVI valves have been
Gas Gathering Coyote Station, UT March 2015 running without a single service. Customer is pleased with onsite serviceability and elimination of
machining requirements.
Customer installed ZVI valves in two different vapor recovery units, which are very difficult
Reno County, July
Propane applications due to a wide operating range. ZVI valves have exceeded OEM valve life (3 months) by
KS 2015
several multiples and continue to operate without issues.
Customer was having issues with 3rd stage valves and had to shut down the compressor weekly and
July
CO2 & H2S Cordona Lake, TX service the valves. ZVI valves have been running since then without any issues. Customer has
2015
realized a 16% improvement in gas flow and has ordered five additional sets of compressor valves.
“The Zahroof valves showed approximately a 10 PSI lower peak cylinder pressure during the discharge portion of the
stroke. Indicating less differential pressure needed to operate the valve. This effectively changes the valve timing and
increases the volumetric efficiency of the cylinder, in this particular instance by 2.3% on the discharge side and 3.6% on
the suction side. This equates to an increase in volume at these operating conditions of an additional 1.28 MMSCFD
throughput of the Zahroof equipped cylinder as compared to the cylinder equipped with the OEM valves. The increased
flow was accomplished using 6.6% less indicated horsepower/MMSCFD”
Reduced Vibrations/Noise, lower losses with SFV
Field measurements on an
Ariel JGD/2, 1100 rpm
Original plate valves: Pronounced
opening and closing impacts + noise
from flow.
“The Zahroof valves showed an increase in “The ZVI Valves have just passed their one year anniversary
volume at operating conditions of an additional of running. We have not had to touch the valves and plan to
1.28 MMSCFD throughput or approximately 5% run for seven more months before inspecting them as part of
while 6.6% less indicated horsepower/MMSCFD.” our planned maintenance program. Our prior valves were
requiring service about every month.”
Reliability Engineer
E&P Operator Operations Supervisor
Granger, WY Leading Energy Company
Lovington, TX
“Our OEM plate valves have pronounced opening and closing “Use of the StraightFlo Valve has extended our run
impacts as well as the noise from the turbulent flow of the gas time, reduced our annual maintenance costs by
through the valve while it is open. The opening and closing of $70,000 and increased our gas flow 3-4%”
the StraightFlo Valve as well as the noise of the gas flow
through the valve is negligible.”
Maintenance Foreman
Large E&P Operator
Reliability Engineer Vernal, UT
E&P Operator
Granger, WY
“The valves are running in a 85% CO2 recycle facility
with ‘blood guts and feathers’ and we have had zero
“OEM valves were needing to be serviced weekly, the
failures and the data we have gathered shows
ZVI valves have run for over 8,326 hours with no
improvement over a standard plate valve.”
failures”
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Case Study:
Large contract compression operator
Location: East Texas
Unit: GE Gemini DS504
Installed: July 2013
Application: Gas Gathering
Customer Issue:
High liquid and particulate contaminants caused fouling in the legacy
plate valves that required monthly servicing.
Straightflo™ Solution:
1st & 2nd stage valve ran for 3 years without issues until compressor
was moved because the field had depleted. 3rd stage valve repair
frequency extended from monthly to once in 3 years. Additionally, the
Straightflo™ valves are serviced on-site (no machining required) with
only a minimal number of modules changed.
20
Case Study:
Major E&P Company Plate Valve Averaged
23.1 HP per MMscfd
Location: Marcellus
Unit: Ariel JGC/4 Straightflo™ Averaged JFC-C vs JFC-D, Specific Power (Outliers removed)
Installed: December 2015 22 HP per MMscfd JFC C (Plate) JFC D (ZVI) Poly. (JFC C (Plate)) Poly. (JFC D (ZVI))
25.00
Application: Wellhead
24.50 y = 1E-06x3 - 0.1289x2 + 5476.5x - 8E+07
21.50
Straightflo™ Solution:
21.00
As illustrated in the chart, the Straightflo valves (red) have a y = 2E-06x3 - 0.1977x2 + 8401.5x - 1E+08
lower specific power resulting a 4.5% decrease in power 20.50
21
Case Study:
O&G Major
Location: San Juan Basin
Unit: Two Stage Ariel JGK/4
Installed: July 2016
Application: Gas Gathering
Customer Issue:
Customer desired increased efficiency and reliability in dirty service. Installed
Straightflo™ valves on one 1st stage and one 2nd stage cylinder to directly compare
perform against the OEM valve.
Straightflo™ Solution:
• Straighflo™ valves provided 5% efficiency improvement
• OEM Plate valves started failing after 7 months
• March 2017 - compressor experienced a slug of liquid that deformed the piston rod
on a cylinder with plate valves. The cylinders with Straighflo™ valves handled the
liquids and prevented damage.
• Straighflo™ valves have performed flawlessly since 2016.
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Case Study:
Large Independent
of 2019 .
Total Annual Saving $ 418,000
23
Case Study:
Large Independent
Installations
Location: Rockies
Unit: Multiple Jul. 2014: Ariel JGU/4
Installed: Starting mid 2014 Nov. 2015: Ariel JGZ/6
Application: Gas Gathering May 2016: Ariel JGK/4
May 2016: Ariel JGK/4
May 2016: Ariel JGT/4
Customer Issue:
Jan. 2017: Ariel JGZ/4
Customer desired increased performance and reliability. Jan. 2017: Ariel JGK/4
Note: A common practice with plate valves experiencing short valve life is to lower Mar. 2017: Ariel JGT/4
valve lift in an attempt to increase reliability. This negatively impacts compressor Mar. 2017: Ariel JGT/4
efficiency, increases Hp, and often reduces flow. Mar. 2017: Ariel JGT/4
Straightflo™ valves can increase performance and reliability at the same time. Mar. 2017: Ariel JGU/4
Apr. 2017: Ariel JGE/4
Straightflo™ Solution: Apr. 2017: Ariel JGE/4
Dramatically increased valve life and reduced maintenance spend. Apr. 2017: Ariel JGE/4
Jul. 2017: Ariel JGE/4
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Plate Valve after one month
Case Study:
Private producer focused on marginal wells
Customer Issue:
Straightflo™ Valve
The legacy plate valves were salting up and restricting flow requiring monthly
servicing and causing downtime and lost production.
The condition was so severe the plate valves were typically replaced instead
of repaired further increasing maintenance expense.
Straightflo™ Solution:
The Straightflo valve has successfully operated for more than 3 years
without requiring maintenance.
25
Case Study:
Offshore E&P Company
The compressor driver (engine) was 100% loaded and the 7% reduction in fugitive emissions released to atmosphere
due to “blow-downs”
customer was seeking better efficiency to increase production.
Customer was changing valves every 4-5 weeks. Safety:
Noise reduction: Personal on platform noted how much
quieter the unit sounds making it easer to work & live
Straightflo™ Solution: around. Noise reduced by more than 8 decibels
ZVI valves Increased the production from 7.8 MMscfd to 8.3 Serviceability:
MMscfd. (6.4% improvement). Straightflo™ valves have
operated over seven months without servicing. Straightflo valves can be serviced onsite with no
machining which eliminates logistics related to valve
repairs (long boat ride and hot-shot trucking)
26
Case Study:
Offshore E&P Company
Customer Issue:
Legacy plate valves failed 1-2 times per week.
Straightflo™ Solution:
ZVI valves operated for approximate 4 weeks representing a
6x increase in MTBF. Additionally, valves are serviced on
site (with < 5% of modules being changed) eliminating the
need to transport valves to shore for repair. Continuing to
collaborate with customer to further extend valve life.
27
28
Modular Reed Valve Product Innovation
ZVI Dynamic Simulation Program Modules Standard Valves
Plot of Cylinder Pressure vs Angle
MRV
HE
CE
700
600
Pressure (psi)
500
400
Standard modules: 3000 psi , -40 - 450F
300
200
0 30 60 90 120 150 180 210 240 270 300 330 360
Angle (Deg)
Plot of Cylinder Pressures vs Volume
700
HE
CE
600
500
Pressure (psia)
400
300
200
100 200 300 400 500 600 700 800 900 1000 1100 1200
Volume (in^3)
Plot of Valve Lift vs. Angle
0.2
Suction HE
Disch HE
Suction CE
Disch CE
0.15
0.1
0.05
0
0 30 60 90 120 150 180 210 240 270 300 330 360
Angle (Deg)
30000
20000
10000
Force (lbf)
-10000
-20000
-30000
-40000
Open /
Unloaded
Piston is at top dead
center. Gas passes
from cylinder through
piston to the suction
port.
Closed / Loaded
Piston is at bottom
position. The piston
blocks the passage of
gas.