Red Valve Type A Pinch Valves Improve Pump Protection & Reduce Maintenance Costs at Dead Sea Works

Challenge

Dead Sea Works (DSW), the primary company extracting resources from the Dead Sea, operates large pumps that move seawater at rates as high as 100,000 gallons per minute. When these pumps are shut down for maintenance or freshwater flushing, massive amounts of water backflow through the pipes, damaging the pumps. To combat this, DSW used gate valves to isolate the pumps, but this led to significant issues. The valuable minerals in the seawater would cling to the metal valves, requiring millions of gallons of freshwater for flushing annually. Additionally, the metal valves were highly susceptible to corrosion due to the rich mineral content of the water, causing further maintenance challenges. These issues posed a challenge for DSW in terms of operational efficiency and cost control, particularly with the high volume of freshwater needed for valve maintenance.

Solution

In search of a more efficient and cost-effective solution, DSW decided to replace the metal gate valves with the Type A Air-Actuated Megaflex Pinch Valve from Red Valve. The design of the Type A valve addressed several key concerns. Its all-elastomer pinch sleeve isolates the valve body from the process, preventing the valuable minerals from sticking to the valve and eliminating the need for freshwater flushing. Additionally, the elastomer material is highly resistant to corrosion, a critical factor when dealing with the mineral-rich seawater.

Given the need for fast operation, DSW required a valve that could open fully within five seconds. The Type A valves were custom-engineered with three integral ball valves to release air quickly, allowing the elastomer sleeve to open in under five seconds, ensuring the rapid operation required for their pumps. The simple and compact design of the Type A valve also made installation and maintenance easier, reducing potential downtime and maintenance efforts.

Results

After installing the Type A valves, DSW experienced significant operational improvements. The installation of one 48-inch Type A valve on each of two pipelines led to annual savings of $700,000 in freshwater flushing costs. The new valves provided reliable, low-maintenance isolation service, reducing the need for frequent repairs and maintenance.

The success of the initial installation prompted DSW to expand the use of Type A valves. After two years of successful operation with the initial valves, DSW purchased additional valves to protect other pipelines. They installed six 48-inch and five 66-inch valves, replicating the same protection and cost savings across their operations. This solution not only reduced costs but also improved the longevity and efficiency of DSW’s equipment, ensuring smooth and continued operations at the Dead Sea resource extraction site.