06282017Wed
Last updateWed, 28 Jun 2017 5pm

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Lubricants: Always Important—Sometimes Essential

Lubricants: Always Important—Sometimes Essential

Most valve professionals take more notic...

Why Air Valves are Needed in Water Applications

Why Air Valves are Needed in Water Applications

Air valves are hydromechanical devices d...

Achieving Profitability Through Maintenance Management

Achieving Profitability Through Maintenance Management

One of the distinctions between maintena...

Control Valve Positioner Performance Diagnostics

Control Valve Positioner Performance Diagnostics

There has been discussion for some years...

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Industry Headlines

U.S. Crude, Petroleum Exports Have More than Doubled Since 2010

Wednesday, 28 June 2017  |  Chris Guy

U.S. crude oil and petroleum product gross exports have more than doubled over the past six years, increasing from 2.4 million barrels per day (b/d) i...

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Industry Headlines

Emerson in Talks to Acquire Software Company Paradigm Ltd.

1 DAY AGO

According to Bloomberg , Emerson is in talks to acquire software company Paradigm Ltd. for approximately $1.5 billion.

“Paradigm specializes in seismic data interpretation and imaging equipment to help oil and gas companies know where to drill. The logic of such a deal seems sound and will help Eme...

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VMA Members Lead MDM Top Industrial PVF Distributors List

2 DAYS AGO

Modern Distribution Management (MDM) recently published its Top Distributors list for 2017. Four of the top 5 distributors in the Industrial PVF category ; MRC Global, NOW Inc., Wolseley Industrial Group and FloWorks International; are currently VMA members.

“While oil & gas markets have start...

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U.S. Crude, Petroleum Exports Have More than Doubled Since 2010

3 HOURS AGO

U.S. crude oil and petroleum product gross exports have more than doubled over the past six years, increasing from 2.4 million barrels per day (b/d) in 2010 to 5.2 million b/d in 2016. Exports of distillate, gasoline, propane, and crude oil have all increased , but at different paces and for different...

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Mountain Valley Pipeline Gets Environmental Approval

1 DAY AGO

The Federal Energy Regulatory Commission (FERC) determined that construction and operation of the Mountain Valley Pipeline would result in some adverse environmental impacts, but the majority of these impacts would be reduced to less-than-significant levels. This determination is based on a review o...

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IMF Lowers Forecast for U.S. Growth to 2.1%

5 HOURS AGO

According to the newest forecast from the International Monetary Fund (IMF), growth in the U.S. is expected to rise 2.1% both this year and next, driven by continued solid consumption growth and a cyclical rebound in private investment. In its last forecast the IMF predicted 2.3% growth this year an...

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U.S. Durable Goods Orders Fell the Most in 18 Months

1 DAY AGO

New orders for manufactured durable goods in May decreased $2.5 billion or 1.1% to $228.2 billion, the U.S. Department of Commerce announced. This decrease, down two consecutive months, followed a 0.9% April decrease. Excluding transportation, new orders increased 0.1%. Excluding defense, new orders...

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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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