10182017Wed
Last updateTue, 17 Oct 2017 3pm

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Is it Time to Toss Those Commissions?

Is it Time to Toss Those Commissions?

It’s tough to pinpoint exactly wha...

Cybersecurity for Process Control

Cybersecurity for Process Control

Security for any process plant has alway...

Young Valve Professionals: Megan Johnston

Young Valve Professionals: Megan Johnston

In 2014, VMA's leadership created the Val...

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Industry Headlines

Shale Gas Leading to Billions in Chemical Investments

Tuesday, 17 October 2017  |  Chris Guy

After years of high and volatile natural gas prices, new domestic supplies of more affordable natural gas and natural gas liquids (NGLs) have created ...

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Industry Headlines

ValvTechnologies Receives ISO 15848 Certification

13 HOURS AGO

ValvTechnologies’ EcoPack technology has received ISO 15848-1:2015 certification from Odin Heavy Industries. To earn ISO 15848 certification, ValvTechnologies underwent a stringent evaluation process that included a series of 17 helium leak tests and eight thermal cycles on a fully assembled v...

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Emerson Acquires GeoFields, Inc.

5 DAYS AGO

Emerson has acquired GeoFields, Inc., a global supplier of software and implementation services for pipeline integrity data collection, management and risk analysis for the oil and gas industry. GeoFields software enables pipeline operators to collect critical integrity data, perform risk modeling a...

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Shale Gas Leading to Billions in Chemical Investments

12 HOURS AGO

After years of high and volatile natural gas prices, new domestic supplies of more affordable natural gas and natural gas liquids (NGLs) have created a competitive advantage for U.S. chemical manufacturers, leading to greater investment, industry growth and new jobs. Companies from around the world ...

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Oil Demand May Peak in the Near Future

1 DAY AGO

Demand for oil in developed countries will revert to structural decline by 2020, wiping out about four million barrels per day by 2035. In contrast, developing economies will increase their demand for oil by nearly 16 million barrels per day by 2035.

While transport demand will flat-line around 2030,...

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Empire State Index at Highest Level Since 2014

14 HOURS AGO

Business activity grew at a robust pace in New York State, according to firms responding to the October 2017 Empire State Manufacturing Survey. The headline general business conditions index climbed six points to 30.2, its highest level in three years. The new orders index came in at 18.0 and the ship...

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Consumer Confidence Rises in October

1 DAY AGO

The University of Michigan Index of Consumer Sentiment surged in early October, reaching its highest level since the start of 2004. The data indicate a robust outlook for consumer spending that extends the current expansion to at least mid-2018, which would mark the second longest expansion since the ...

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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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