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The Limits of Standard Manual Globe Valves for Throttling

The Limits of Standard Manual Globe Valves for Throttling

A common practice in process services is...

Industry and Regulatory Changes in Offshore Operations

Industry and Regulatory Changes in Offshore Operations

On May 13, 2016, the offshore oil and ga...

Strategies for Successful SIS Valve Diagnostic Implementation

Strategies for Successful SIS Valve Diagnostic Implementation

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Stop Check Valves

Stop Check Valves

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Industry Headlines

Additive Manufacturing Industry Hit $5.1 Billion in 2015

-1 DAYS AGO  |  Chris Guy

According to Wohlers Report 2016, the additive manufacturing (AM) industry, consisting of all AM products and services worldwide, grew 25.9% (CAGR) to...

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Industry Headlines

Weir Opens New Safety Relief Valve Facility in Malaysia

21 HOURS AGO

Weir has opened a new facility to increase the global reach and competitiveness of Weir valves by establishing a manufacturing and assembly plant close to Malaysia’s capital Kuala Lumpur.

The Malaysian operation has already successfully supplied several large and strategic projects, especially ...

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ValvTechnologies Names Garcia, Mermelstein to New Positions

5 DAYS AGO
ValvTechnologies Names Garcia, Mermelstein to New Positions

ValvTechnologies, Inc. has named David Garcia director of manufacturing and Steve Mermelstein as regional director, Americas and director, channel management.

Previously, West Point graduate Garcia served as director of operations for Merla Wellhead Solutions and held plant manager positions at Hallib...

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What’s Behind Growth of U.S. Natural Gas Use

-1 DAYS AGO

U.S. consumption of natural gas is projected to rise from 28 trillion cubic feet (Tcf) in 2015 to 34 Tcf in 2040, an average increase of about 1% annually, according to EIA's Annual Energy Outlook 2016 . The industrial and electric power sectors make up 49% and 34% of this growth, respectively, while ...

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Industry Survey Finds U.S. Wind Power on the Rise

-1 DAYS AGO

Wind power, America’s fastest growing new source of electricity, will stay on pace to grow to supply 10% of U.S. electricity by 2020, that’s according to the American Wind Energy Association (AWEA). Helping to grow wind energy in the U.S. are a mix of stable federal policy, passed late las...

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Additive Manufacturing Industry Hit $5.1 Billion in 2015

-1 DAYS AGO

According to Wohlers Report 2016, the additive manufacturing (AM) industry, consisting of all AM products and services worldwide, grew 25.9% (CAGR) to $5.165 billion in 2015. The CAGR for the previous three years was 31.5%. Over the past 27 years, the CAGR for the industry is 26.2%. Wohlers Associat...

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Second Quarter GDP Forecast Points to 2.9% Increase

-1 DAYS AGO

The Atlanta Federal Reserve’s GDPNow model forecast for real GDP growth in the second quarter of 2016 is 2.9% on May 26, up from 2.5% on May 17. The forecast for second-quarter real gross private domestic investment growth increased from -0.3% to 0.4% following this morning's durable manufacturi...

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Documentation to Diagnostics: Trends in Valve Repair

vmspr12_valve_repairA growing number of OEM service centers offer rapid valve replacement programs that can provide quick-ship valves in as little as 24 hours.Not long ago, car owners often performed basic repairs and maintenance tasks themselves. Also not so many years ago, shoppers had to visit separate stores to purchase groceries, clothing, electronics, hardware and medicines. Neither of these scenarios applies to most of today’s consumers. The complexity of automobiles means even routine repairs and maintenance must be completed by trained mechanics using specialized equipment and computers. As far as shopping, the “super center” retailers offer the convenience of one-stop shopping for a vast array of products.

Similar shifts have taken place in the valve maintenance and repair industry. The driving factors behind those shifts include today’s fast-paced and highly competitive business environment, increasingly complex facilities, more stringent regulatory requirements, leaner in-house staffs, more advanced valve technologies and lessons learned during natural disasters such as Hurricane Katrina and the earthquake and tsunami that damaged Japan’s Fukushima nuclear power plant.

This article explores these trends, the forces behind them and how plant personnel can adapt to the changing landscape.


DOCUMENTATION

Discussions with end users reveal that the number one repair trend today relates to asset and repair documentation.

Thorough documentation of a facility’s valves—the types and locations of all valves in the plant, their specifications and their maintenance and repair histories—can aid personnel in planning maintenance activities, help technicians diagnose valve problems, streamline repairs, facilitate inventory management and help plant personnel fulfill reporting requirements.

Hurricane Katrina and Fukushima also illustrated to the world the importance of ensuring that valve data is protected offsite, available remotely in the event of an emergency. Hurricane Katrina waterlogged plant after plant along the Gulf Coast, destroying records or making them difficult to retrieve. At Fukushima, the records themselves were not destroyed but dangerous radiation levels made it impossible to retrieve them.

Having learned from these situations, a growing number of end users are looking for asset management systems that are accessible 24/7 via the Internet. Such systems mean that in the event of an emergency, personnel can easily order replacement valves and accessories, access repair records and reference valve specification information, such as temperatures and pressures.

These tools are becoming more widely available every day, and they are more powerful, user-friendly and adaptable than ever before. Service providers and original equipment manufacturers (OEMs) can differentiate themselves by offering such tools—and the added-value service of developing and maintaining their customers’ databases. (For more information about asset management tools, see “Asset Management: A Plant Manager’s Best Friend” in the Fall 2011 issue of Valve Magazine.)


MANUFACTURER-AUTHORIZED SERVICE PROVIDERS

The second-most-often cited trend in the valve repair business is end users’ growing preference for working with manufacturer-authorized service providers. The complexity of today’s facilities requires well-trained technicians who can troubleshoot and solve a variety of valve problems. In the past, many facilities had this expertise in-house, but cost-cutting measures and the retirement of experienced personnel have made that situation increasingly rare.

In today’s litigious environment, working with a third-party provider that is not OEM-trained and is not certified to the appropriate regulatory standards, such as those from the American Society of Mechanical Engineers (ASME), is inviting trouble. As a result, using OEM-authorized technicians to complete repairs and turnarounds continues to gain momentum.

RAPID VALVE REPLACEMENT PROGRAMS

Another often discussed issue is whether to repair a valve or replace it. There is no easy answer to this age-old question because too many situation-specific variables must be considered. Still, rapid valve replacement programs are making replacement a viable option in more cases.

A growing number of OEMs offer such programs, which substantially shorten turnaround times for simpler types of valves that are not critical or specialized. This is partly because participating OEM-authorized service providers have on-hand stock that can be quickly pulled from the shelf and configured to meet short delivery windows—sometimes same-day or even in as little as a few hours. Not all valves today have to be ordered through the factory; some valves can be replaced within a repair or outage cycle, giving the end user a brand new valve under full OEM warranty.

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