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Specialists in Bespoke Solutions

Custom Gate Valve Solutions for Critical Duty Applications

Custom Gate Valve Solutions for Critical Duty Applications

The Problem

Dwr Cymru Welsh Water approached us with a need for reliable valve solutions capable of withstanding critical duty. The valves had to be engineered to handle high-flow conditions, provide corrosion resistance, and ensure long-term, trouble-free operation in harsh environments. This was essential for maintaining the smooth operation of the water and wastewater management systems.

The Solution

At T-T Flow®, we’re experts in delivering custom valve solutions. Using advanced computer-aided design (CAD) and finite element analysis (FEA) software, our experienced design engineers developed a bespoke solution to meet the unique needs of the application.

We manufactured the valves with the following key enhancements:

  • Weld overlay seats able to withstand higher flow velocities, improving durability and lifespan.
  • Copper-alloy wedge shoes/channels to reduce operating friction and torque ensuring smooth, long-term operation.
  • Polyurethane topcoat applied over fusion-bonded epoxy for ultimate corrosion resistance.

This custom solution delivered a durable, efficient, and reliable valve system that ensured seamless operation under demanding conditions.

We supplied two DN500 metal seat gate valves with reduction spur gearboxes. These valves are ideal for isolating flow in applications such as potable water, raw water, and wastewater with low solid content.

Design Summary:

  • Compliant with BS5163 and EN1074-2 standards
  • Rated for 16 Bar
  • Flanged to EN1092-2 PN16 (other flanges available upon request)
  • Hydraulic testing to EN12266 standards
  • Size range: DN50 to DN1200 (larger sizes available)
  • Flow velocity up to 4m/s (consult T-T Flow® for higher velocities)

Key Features:

  • Ductile iron body for excellent weight-to-strength ratio
  • Copper-alloy seating for reliable sealing
  • Corrosion-resistant stainless steel stem with reduced operating torque
  • Fusion-bonded epoxy coating for superior corrosion protection
  • Inline replaceable stem seals for easy maintenance
  • Full-bore design for low head loss
  • WRAS-listed materials with third-party compliance testing
  • Self-draining wedge to prevent contaminants
  • ISO9000 quality standards with full traceability

The Results

T-T Flow’s custom-engineered gate valves met Welsh Water’s critical needs, ensuring the reliable management of water and wastewater flow. The enhanced features, including weld-overlay seats, copper-alloy wedge shoes, and advanced coatings, delivered long-lasting performance with minimal maintenance.

This project highlights T-T Flow’s commitment to providing tailored, high-quality solutions that meet the toughest standards for critical applications in the water sector.

Custom Valve Manufacturers

See more bespoke valve manufacturing projects here – or get in touch with a member of the team to discuss what we can for your site by emailing ttflow@ttpumps.com, calling 01630 647200 or completing an online enquiry form.