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Last updateMon, 08 Feb 2016 7pm

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Introduction to Pressure Relief Devices - Part 1

Introduction to Pressure Relief Devices - Part 1

When the pressure inside equipment such ...

Is Your Company Ready for The New Reality?

Is Your Company Ready for The New Reality?

Since August, 2015, when VMA’s 201...

Offshore Oil Extraction and Transportation

Offshore Oil Extraction and Transportation

Offshore oil facilities come to the fore...

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Industry Headlines

GE Oil & Gas and Diamond Offshore Enter Landmark Service Agreement

-1 DAYS AGO

GE Oil & Gas and Diamond Offshore Drilling, Inc. announced the offshore drilling industry’s first-of-its-kind contractual service agreement that transfers full accountability for BOP performance to GE Oil & Gas. Under this model, Diamond Offshore will compensate GE Oil & Gas only w...

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Watson Valve Announces Watson Valve Services, Australia

3 DAYS AGO

Watson Valve Services Inc. announces Watson Valve Services, Australia. Watson Valve will now have the ability to support the supply of its severe service valve products to non-U.S. domestic sites from its Australian based service agent, Process Plants International (PPi) under the name, Watson Valve...

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U.S. Oil Inventories Now at Record High

3 DAYS AGO

Several factors have played a part in pushing U.S. crude oil prices below $30 per barrel, including high inventory levels of crude oil, uncertainty about global economic growth, volatility in equity and non-energy commodity markets, and the potential for additional crude oil supply to enter the mark...

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FERC Approves $3.2B Sabal Trail Pipeline Project

3 DAYS AGO

Sabal Trail Transmission, LLC, a joint venture of Spectra Energy Partners, LP, NextEra Energy, Inc. and Duke Energy, received a certificate of public convenience and necessity from the Federal Energy Regulatory Commission (FERC) to construct and operate the Sabal Trail interstate natural gas pipelin...

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Labor Productivity Down More Than Expected in Fourth Quarter

-1 DAYS AGO

U.S. labor productivity decreased at a 3.0-percent annual rate during the fourth quarter of 2015, the U.S. Bureau of Labor Statistics reported, as output increased 0.1% and hours worked increased 3.3%.

Manufacturing sector labor productivity decreased 0.4% in the fourth quarter of 2015, as output i...

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U.S. Adds 151,000 Jobs, Unemployment Rate Down to 4.9%

2 DAYS AGO

Total nonfarm payroll employment rose by 151,000 in January, and the unemployment rate dropped 0.1% to 4.9%, the lowest since Feb. 2008. Job gains occurred in several industries, led by retail trade, food services and drinking places, health care and manufacturing. Employment declined in private edu...

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Three Golden Rules for Severe Service Valves

If you’d just bought a new high-performance sports car, you’d likely protect your investment by following the manufacturer’s instructions for breaking in the engine. You’d also probably leave the spare tire in the trunk so that a flat wouldn’t leave you stranded on the side of the road.

The same logic applies to severe service valves. These valves protect and control some of a plant’s most essential and costly equipment, such as turbines, compressors and pumps. They handle high-pressure fluids and are integral parts of a plant’s most critical processes. They’re usually costly, custom-designed and highly engineered, making them significant financial investments. It only makes sense, therefore, to take the proper steps when bringing a new plant online and to be prepared to make repairs when the unexpected happens.

By following three simple guidelines, plant operators can keep their plants running efficiently and safely, minimize downtime and maintenance costs, and prevent catastrophic damage to vital equipment.

  1. Follow recommended commissioning/start-up procedures when installing a new valve. The use of start-up trim during commissioning ensures that trash in the lines does not damage the valve’s trim and other equipment down the line.
  2. Always have recommended spare parts on hand. It will not only reduce downtime, but can save millions of dollars in lost production and rush charges.
  3. Whenever possible, install valves with smart positioners and advanced diagnostics that monitor the mechanical condition of the valve and provide early notice of potential issues.


Perform Proper Commissioning/Startup

As a plant is constructed or expanded, it is perfectly normal for debris, trash and weld slag to accumulate in the lines. If not flushed out before the plant startup, these materials can clog and damage the valve’s trim, compromising its performance and potentially damaging equipment downstream.

Properly commissioning valves before startup reduces the potential for damage to the valves and other equipment and helps ensure the valves will deliver optimal performance, including tight shutoff when closed, and fast, accurate response when open. That not only protects the plant’s investment and warranty coverage, but also reduces the risk of a costly and time-consuming restart of the plant.

Commissioning involves installing “dummy” trim, gaskets and packing to protect the valve’s seating surfaces, plug, stems, seat rings, diffusers and cages. This dummy trim has larger holes than the operational trim, allowing slag, debris and trash to easily pass through as the lines are flushed. Once the lines are clean, the dummy trim is replaced with the fully operational trim and normal operation can get underway. Proper startup and commissioning can take several hours to two weeks to complete, depending on the size of the valve and plant. Always complete recommended commissioning procedures before a new plant goes online. Many plant operators include commissioning as part of routine maintenance processes.

Valve manufacturers will usually provide instructions for properly commissioning their valves. Plant operators should emphasize to whoever is installing or maintaining their valves—whether it’s a general contractor, an outside valve technician or an internal maintenance team—the importance of a clean, thorough commissioning process.

It’s a small investment that buys a powerful insurance policy. A severe service or critical valve can cost $500,000 or more. The cost of a commissioning kit is 10% that of the valve itself (or less). That kit will protect not only the valve, but also the equipment that is the very heart of the plant—equipment that can cost 50 times more than the valve.

Take, for example, the $350,000 valve that recently was installed in a new plant. The plant operator opted not to protect its investment with a commissioning kit. Weld rod from an unrelated part of the plant clogged the valve trim, rendering the valve useless. Because it was a custom valve that had been designed and manufactured specifically for this plant, the lead time for replacement trim was significant. The valve manufacturer scrambled to supply the parts as quickly as possible, but the customer still faced delays and additional costs that could have been easily avoided.

 

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