OEM Replacement Case — High-Pressure Butterfly Valve Replacement in Power Plant Steam System

1. Project Background

The client is a thermal power generation company operating high-pressure steam systems for continuous power production.

The system was originally equipped with a 10” Class 600 LB high-pressure pneumatic butterfly valve from KSB, used for controlling superheated steam at approximately 442°C.

After long-term operation under high-temperature and high-pressure conditions, the valve showed signs of aging, increasing maintenance cost, and declining reliability, leading the client to seek a more stable and cost-effective solution.

2. Challenges

The client faced several key issues:

• High maintenance and spare parts cost

• Long spare parts lead time (typically 3–6 months)

• Aging valve leading to leakage and sticking risks

• Reduced system stability under continuous operation

3. Our Solution

Procetek provided a customized replacement solution based on the Form-Fit-Function approach.

The solution was designed to:

• Fully match the original valve structure and installation dimensions

• Enable seamless replacement without modifying the existing pipeline

• Withstand 442°C superheated steam and Class 600 LB pressure

• Maintain stable sealing and flow control performance

4. Scope of Supply

• Penta-offset high-pressure pneumatic butterfly valve

• Replacement for original KSB 10” Class 600 LB valve

• Procetek Model: D665Y-600LB DN250

Equivalent / Reference Model Mapping

Original Model	Procetek Replacement
KSB 10” 600LB	D665Y-600LB DN250

5. Implementation

• On-site inspection and parameter verification

• Pre-testing before delivery

• Installation completed during scheduled shutdown

• On-site and remote technical support

• Commissioning and performance validation under real conditions

6. Results

The project achieved clear improvements:

• Maintenance cost reduced by 30–35% 

• Spare parts lead time shortened to 7–15 days 

• Improved sealing performance and system stability

• Unplanned downtime reduced by over 85% 

7. Why It Worked

The success of the project was driven by:

• Strong understanding of high-temperature steam applications

• Engineering-based replacement design

• Proven Form-Fit-Function compatibility approach

• Reliable performance under continuous operation

8. Conclusion

This project demonstrates that reliable and stable operation can be achieved without dependence on the original international brand, while improving cost efficiency and system reliability.

9. Call to Action

If you are facing similar challenges with aging valve systems, long spare parts lead times, or rising maintenance costs,👉 contact us for reliable replacement and upgrade solutions.