Valves are key in directing the passage of air or fluids via pipes or tubing, and it’s all too easy to forget all about them until something goes wrong. valve maintenance, on other hand, can help prevent problems in the first place.
Now, since valve maintenance is quite essential, it is imperative to know what to do so that you can enhance the performance and overall durability of the valves. Therefore, in this article, we are going to look at the different ways you can maintain and repair valves. Continue reading to find out more!
Benefits of Valve Maintenance
1. Ensuring Your Valves in Good Functioning Order
The goal of obstructive maintenance is to keep your valves running better for longer. You may notice that your valves are hard to turn or won’t open or close if you don’t perform this maintenance. This could be because of a number of factors, including worn-out valve seats or elastomeric seals. If you don’t deal with these problems right away, they could evolve into difficulties that require an emergency shutdown later.
2. Increasing security
The most important thing you can do to safeguard the safety of your equipment and workers is to have routine maintenance conducted by properly trained valve experts. Regular maintenance lowers your chance of an emergency and the tragic repercussions of a valve malfunction, such as an explosion, by maintaining your valves in good operating order.
3. Taking Steps to Reduce the Need for Shutdowns
Proactive valve maintenance reduces the number of emergency and scheduled shutdowns. A great deal of servicing can be done while valves are in operation and under pressure using today’s technologies.
4. Putting Money Aside
Regular maintenance enhances the life of your valves, requiring fewer replacements and cutting the level of repair work required during the valve’s useful life. For example, strengthening the bolts on sleeved plug valves in extremely corrosive situations may be enough to remedy a leaking problem and give your valves years more life.
5. Getting Rid of Fugitive Secretion
Valves that aren’t working properly are a major source of fugitive emissions. According to research published in Chemical Engineering magazine some few years back, leaking valves are responsible for 60% of fugitive emissions in distilleries. Regular maintenance retains your valves in top form, making your projects more environmentally friendly.
Valve Maintenance Procedures
1. Clean Them
Cleaning your valves is one of the simplest methods to extend their life. Cleaning cycles vary per person, but it’s a good idea to clean your valves at least once a year. You should clean your surroundings more occasionally if it is dirty or dusty. Cleaning the valve casing using a towel or wire brush is the simplest method. It will last longer if you keep it clean because it will prevent accumulation on the valve stem and other working parts.
2. Assessments on a Regular Basis
Your valves should be examined and checked on a regular basis. Valves that are subjected to significant stress (temps or force) should be monitored more frequently than others. When you push a valve to its limit, it will fail faster.
Ascertain that the enclosure is suitably ventilated. Make sure all bolts, nuts, and other hardware are securely fastened. To make sure the valves aren’t jammed, open and close them as often as feasible. If you discover any leaks, you should fix them right away.
Fugitive secretions are frequently caused by leaking valves. Mineral accumulation or corrosion on the casing can immediately reveal leaks. To confirm that the valve position indicator is producing an accurate signal, test valves that are generally static.
3. Routine Shutdown Maintenance
Mineralization, tarnish, and wearing will corrode the parts inside your valves over time. Machinery shutdowns are an ideal time to inspect your valves. Disassemble them, clean the inside, and restore any damaged or broken parts. There are a number of rubber and plastic parts that may need to be changed in conjunction with metal elements. If you find any brittle or rotting pieces, replace them as needed.
4. Lubricate the Valves
Oiling is among the most Ignored but cheap parts of valve maintenance. Miss this Process and you may experience convulsion or, at the very least, declining in performance. Lubrication on a Repetitive Basis can also help valve seal, prolonging their service life. The key is to turn the valve to allow the lubricant to enter the valve cavity.
This will Lengthen the valve’S life by reducing abrasion. Valves Maintenance requires you to select the appropriate lubrication for your specific valves, Relying on the setting. Do Not Just Get the First Thing You Seize. Lubricants come in Various attributes.
Water-impenetrable, Lithium-based, high temps, Carbon dioxide resistance, and other attributes are all a possibility. For Instance, in stick-type lubes, clay or similar solid-based thickening agents may be added, which can solidify and leave solids in the valve, causing it to the clutch.
In addition to lubing, you may need to protect your valves from temp changes in the air, particularly if the pipes are on the exterior side. If this is the case, adding and maintaining protective insulations to your valve maintenance routine may be needed.
How to Test Industrial Valve
Why is Testing Essential?
Control valves that operate with accuracy are critical to the smooth and safe functioning of industrial procedures and machinery. When valves properly regulate process factors such as temperature, stress, and movement, the production value is at its best.
Valve testing and performance monitoring improves product quality and, more significantly, security. Several factories or refining explosions have been blamed on valve failure. To maintain security, they adhere to established norms and industry standards.
What Techniques are used to Test Industrial Valves? (How they are conducted)
1. Pressure Test(Globe and Throttle Valves)
Throughout the strength test of the globe and throttle valves, the valves are generally positioned in a pressure test rack, the valve disc will be opened, the material is pumped to the stated value, and the valve body and valve cover are examined for sweating and leaking. The strength test can also be performed on a single piece. Only stop valves are utilized in the sealing test.
Throughout the test, the sealed valve’s valve stem is perpendicular, the valve flap is unlocked, and the medium is supplied to the given value from the valve flap’s underside. Close the valve flap and release the other end of the valve to check for leaking after passing the test.
If one or both valve strengths and constriction tests are to be conducted, the stress should be dropped to the appropriate tightness test value, and the packers and gaskets should be examined before closing the valve flap and opening the outlet end to check for spillages on the sealing surface.
2. Pressure Test Method(Gate Valve)
The ultimate strength test for the gate valve is equal to the globe valve. The gate valve sealing test can be done in two ways.
- Open the gate, close the gate, and immediately eliminate the gate valve to examine the gaskets on both sides of the gate for leaks, or introduce the test medium to the indicated value straight into the plug on the valve cover to surge the pressure inside the valve to the predetermined value. The test of intermediate pressure is what the approach above is called. This method is ineffective for sealing tests on gate valves with nominal diameters less than 32 mm.
- The other way is to open the gate, close the gate, and open the blind plate at one end to see if the sealed surface is seeping in order to elevate the test pressure of the valve to the prescribed value. Turn the head and reapply the above exam till it passes. A pneumatic gate valve packing and gasket sealing test must be performed prior to the gate sealing test.
3. Pressure Test Method(Butterfly Valve)
The globe valve strength test is similar to the pneumatic butterfly valve strength test. The butterfly valve’s sealing production test will necessitate the test material from the inflow end of the media, the butterfly plate open, the other end closed, and the injection pressure to meet the particular value; after testing the tight seal and other seals without leakage, close the butterfly plate, open the other end, and check the butterfly plate. It meets if there is no leakage at the seal. The butterfly valve that controls the flow cannot be inspected for seals.
Valve maintenance is as essential as understanding the relevance of getting the quality of the valve right. That is why at SIO, we conduct a series of tests to ensure that what gets to you is beyond the industry set standard. Contact us for any inquiries you may have concerning valves. Best of luck!