Galli & Cassina S.p.A.
Sector: Production of plug valves (lubricated male valves)
“I appreciated the willingness, the questioning, the not giving up despite initial failures. It took time but in the end, we managed to find the right product for us.”
Galli & Cassina is an Italian company that designs and manufactures a complete range of plug valves.
Since 1919, Galli & Cassina's goal was to produce valves in line with the growing demand of the domestic market. That was, until 1991 when the company turned its attention to the global Oil & Gas market.
With a massive production of plug valves, the company has become a supplier of choice for all international Oil & Gas companies worldwide.
Using a lubricating grease in plug valves performs the dual function of pressure isolation and the modulation of friction between the plug and valve body.
In order to improve product performance and optimise stock management, Galli & Cassina needed a lubricant solution capable of guaranteeing the right compromise between the valve plug movement torques (starting torque, running torque and break-to-close), tightness to hydrostatic testing up to operating pressures of 420 bar (Class 2500) and extension of the operating temperature range down to -30° C, in respect of the solution used previously.
To formulate the most suitable solution, we started with the chemical and structural characterisation of the lubricating grease utilised prior, availing of a precision rotational rheometer in our laboratories.
Visco-elastic and visco-dynamic curves were produced in the temperature range of -30° to +80° C. The prototyping phase was based on the use of raw materials of fully synthetic origin in order to guarantee the required thermal performance. The SpeedMixer rapid prototyper made it possible to quickly create formulations and characterise them in order to achieve the optimal solution. The chosen sample was subsequently produced in the pilot reactor in quantities of 50 kg, enabling Galli & Cassina's testing department to carry out validation performance tests.
After a number of modifications to the basic formulation, the lubricating grease was finally approved and used in production, making it possible to: