Vital fire suppression line remains live while AVT EZ Valve is installed

Vital fire suppression line remains live while AVT EZ Valve is installed

Texas City, USA


An inoperable valve controlling flow from a secondary fire water pump house.

12-inch carbon steel pipeline


  • An inoperable valve controlling flow a secondary fire water pump house meant vital repaid work could not be completed.
  • 12” EZ Valve
  • Team of three installers took two hours to install
  • No service interruption
  • Saved the client $1 to 2 million in shut down lost revenues

The Valero Texas City Refinery is located on the Texas City Ship Channel and provides significant feedstock flexibility and product diversity to Valero’s Gulf Coast operations. The plant dates to 1908 and was originally built to process 1,500 barrels per day of Oklahoma crude oil. Today, thanks to upgrades over the years, it processes 130,000 barrels per day.

A vital element of any refinery is its ability to be constantly ready to respond to a fire, so when Valero found an inoperable valve on its 12” carbon steel fire suppression line and was in need of a way to add a valve to their system without shutting down the line, their maintenance and repairs contractor, ISS, suggested installing an AVT EZ Valve.

Installers prepares the pipe before fitting the AVT EZ Valve

The inoperable valve was used to isolate a secondary fire water pump house which required repairs and without the AVT EZ Valve, there was no way to isolate the pump house – this meant, to carry out repairs, a portion of the plant would have to be shut down at a cost of $1 to 2million a day.

Valve parts A and B fitted
Applying grease and fitting the gasket

ISS accessed AVT’s RentEZ program, which enables installing companies to rent the EZ Valve Kit that includes everything needed for installation, including an innovative end milling (EM) machine that mills a 120° slot round the pipe, eliminating the need to cut a coupon or remove a section of the pipeline. This design allows the AVT EZ Valve to be installed under pressure, enabling faster restoration than alternative solutions, preserving pipe integrity, and allowing installation with no need to shut off the water supply. The 4 to 12” kit is rented free of charge when installers commit to purchasing an agreed number of valves thus significantly cutting the up-front cost of install.

Milling a 120o slot round the pipe
Fitting the bonnet to the valve

ISS’ team of three installers took just two hours to install the valve, reinforcing their decisions to recommend the AVT EZ Valve. The traditional method of installing a valve, along with having to shut off the water, takes between two and three days, needs twice the manpower and heavy install machinery.

Valero now has plans to install additional 8 to 12” AVT EZ Valves across the Texas City Site.

The AVT EZ Valve is available from 1.5 to 24” and has been installed in a range of applications from process plants to municipal water lines for more than a decade.

The completed installation