Feature sponsored by Flow, level & control V
alves are some of the most important components of industrial fluid systems, responsible for controlling and maintaining optimal levels of flow. Their reliable functionality is
critically important to operational efficiency, profitability, and safety - and that means fluid system operators need a plan when it comes to maintaining and repairing their valves. So, what do you need to know about valve
maintenance and troubleshooting valves? Here, Swagelok looks at some of the essentials of valve maintenance.
GOOD MAINTENANCE PRACTICES BEGIN WITH INSTALLATION One common reason that a valve - or any fluid system component - may perform sub-optimally once in service is because it was installed improperly. A properly installed valve should help to reduce ongoing maintenance needs over the course of its life. Follow these best practices to be confident in your valve installations:
Always follow the manufacturer’s installation instructions. Read the instruction manual, attend training sessions, or watch videos in order to understand the proper steps of assembly and disassembly.
Be aware of the capabilities and operating parameters of the system. For example, a valve should never be placed into service where the temperature or pressure inside the system exceeds the ratings of the valve.
Allow adequate space for access and future maintenance. Maintaining a valve is typically a hands-on activity. Make sure you place valves in locations that are easily accessible, when possible.
Mount valves securely to a fixed location whenever possible. Use adequate supports for the tubing or piping where possible on both sides of the valve to minimise vibration.
Ensure the proper orientation of the valve to allow media to flow in the correct direction.
Check for leaks after installation.
Avoid contaminants. You can do this by adding filters to your fluid system to help remove particulates that may interfere with proper valve operation. Such particles can cause damage to valve seats, contaminate your process fluid, and reduce overall flow throughout your system.
How to
Maintain and troublesHoot ValVes
Taking these things into consideration during
the installation process can help best set up your valve for reliable operation over the long term.
PERFORMING PREVENTATIVE VALVE MAINTENANCE AND TROUBLESHOOTING Once the valve has been installed, consider creating a preventative maintenance schedule in order to proactively maintain reliable operation. Preventative maintenance (PM) should help you to reduce the amount of troubleshooting you will need to do into the future. But because no two fluid systems are
identical, your PM schedule should be established based on the needs of your system. Consider that a number of different factors will affect the longevity of your valve’s service life, including pressure, temperature, the chemical makeup of your process fluid, and the number of on/off cycles your valve will see within a given amount of time. It is also a good idea to check with your valve supplier for relevant PM information or advice.
Regardless of your parameters, the goal of
any PM schedule is to periodically verify that your valves are operating properly. The most common indicator of improper operation is a leak, be it minor or significant. Leaks can be detected with your own senses - you may smell a chemical leak before you can find it visually, for instance - or with ultrasonic equipment and liquid leak detectors. Catching a valve leak can help prevent a more serious problem that could occur if the leak were to continue undetected. Some common causes of leakage are
unreliable metal-to-metal seals, contaminants in the system, improperly installed end connections, and poor tubing selection and preparation. These valve troubleshooting techniques can be deployed to help you determine your best course of action:
Test the valve. Verify its operation and determine the nature of the leak. There are two main forms of valve leakage:
A seat leak, where the leak is contained inside the valve, but fluid passes through the seal and the valve is unable to stop the flow
A shell leak, where fluid leaks outside of the valve into the atmosphere, often through the stem or body of the valve.
Inspect the valve. Examine all internal components, including the seats, O-rings, and stem tips for wear or damage.
Repair the valve.Worn components like seats, packing, and stems can often be replaced without the need to replace the valve entirely, based on the results of your inspection. In
20
January 2023 Instrumentation Monthly
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