06282016Tue
Last updateTue, 28 Jun 2016 3pm

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Fugitive Emissions—Issues and Opportunities

Fugitive Emissions—Issues and Opportunities

Fugitive emissions, ppm, consent decrees...

Problem-Driven Innovation

Problem-Driven Innovation

Developing Alternative Technology to Imp...

Valve Repair Takes Center Stage in Houston

Valve Repair Takes Center Stage in Houston

Attendees gathered June 2-3 in Houston t...

What Internal Best Practices Can Do for Valve Selection

What Internal Best Practices Can Do for Valve Selection

As time goes by, technology moves forwar...

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Industry Headlines

MSS Publishes Revised Standard for High Pressure Knife Gate Valves

Tuesday, 28 June 2016  |  Chris Guy

The Manufacturers Standardization Society (MSS) announces that recently revised Standard Practice, SP-135-2016, High Pressure Knife Gate Valves, has bee...

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Industry Headlines

MSS Publishes Revised Standard for High Pressure Knife Gate Valves

-1 DAYS AGO

The Manufacturers Standardization Society (MSS) announces that recently revised Standard Practice, SP-135-2016, High Pressure Knife Gate Valves, has been approved by the American National Standards Institute (ANSI) as an American National Standard (ANS).

The first edition of MSS SP-135 was published in...

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Admiral Valve Joins VMA

-1 DAYS AGO
Admiral Valve Joins VMA

This week the Valve Manufacturers Association (VMA) welcomed Admiral Valve LLC dba CPV Manufacturing , our sixth new member in 2016.

Admiral Valve, LLC designs and manufactures high-performance filtration systems for marine and aerospace use from their 30,000 square foot facility in the Philadelphia su...

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Global Upstream Spending Slashed by $1 Trillion

4 DAYS AGO

Global upstream development spending from 2015 to 2020 has been cut by 22% or $740 billion since the oil price started to drop two years ago, according Wood Mackenzie's research . When you include cuts to conventional exploration investment, the figure increases to just over $1 trillion. Expect to see...

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EPA Bans Fracking Wastewater Disposal at Public Treatment Plants

6 DAYS AGO

The EPA has finalized a rule establishing pretreatment standards for discharges of wastewater from onshore unconventional oil and gas (UOG) extraction facilities to municipal sewage treatment plants (also known as publicly owned treatment works, or POTWs). The rule is designed to prevent the discharge...

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Consumer Confidence Climbs to 8-Month High

-1 DAYS AGO

The Conference Board Consumer Confidence Index, which had decreased in May, improved in June. The Index now stands at 98.0 , up from 92.4 in May. Those stating business conditions are “good” increased slightly from 26.1% to 26.9%, while those saying business conditions are “bad&rdquo...

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How Will Brexit Affect the Manufacturing Industry?

21 HOURS AGO

The day after the Brexit decision, National Association of Manufacturers (NAM) chief economist Chad Moutray addressed the UK vote to leave the EU and its effect on the manufacturing industry as well as the element of uncertainty it adds to the global marketplace.

According to Moutray, “If you are...

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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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