05252016Wed
Last updateWed, 25 May 2016 7pm

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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

End users and contractors alike strive t...

Stop Check Valves

Stop Check Valves

Stop check valves are vital to several i...

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Industry Headlines

ValvTechnologies Names Garcia, Mermelstein to New Positions

1 HOUR 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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Emerson Automating UK Waste-to-Energy Plant

2 HOURS AGO

Emerson will provide control systems and project services for a new waste-to-energy power plant near Knaresborough Allerton, North Yorkshire, UK. Construction is expected to be completed in 2017, with the plant fully operational in 2018.

The plant , which will also incorporate biogas and recycling faci...

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Oil Industry Expects Cuts for Record Third Straight Year

-1 DAYS AGO

According to Statoil ASA, “[g]lobal crude supplies will start to dwindle in as little as two years, boosting prices, as the industry cuts investment to weather the worst market collapse in a generation,” Bloomberg reports .

“Despite signs the supply glut is easing, companies are prepar...

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House Approves Overhaul of Toxic Substances Control Law

3 HOURS AGO

The U.S. House of Representatives, by a vote of 403-12, passed a reform of the nation's chemical safety law, the Toxic Substances Control Act of 1976 (TSCA). It enables the EPA to regulate the thousands of chemicals manufactured each year and used in common household items -- including known carcinoge...

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Markit PMI Shows U.S. Manufacturers Stagnating in May

1 DAY AGO

The U.S. manufacturing sector crept closer to stagnation in May, with the seasonally adjusted Markit Flash U.S. Manufacturing Purchasing Managers’ Index (PMI) registering only slightly above the neutral 50.0 mark at 50.5. This was down from 50.8 in April and signaled only a marginal improvement...

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Why Innovation is the Key to U.S. Manufacturing Growth

2 DAYS AGO

Manufacturing may be facing some headwinds, but it’s undeniably in the midst of a technological renaissance that is transforming the look, systems and processes of the modern factory. Despite the risks — and despite recent history — industrial manufacturing companies cannot afford ...

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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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