Nobody wants a headache! You were meant to be getting your head down on something important but that peskey valve in Area 1 is playing up again………

Now what? 

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What to do when your process Valve doesn’t work properly.

At some point you will be faced with a valve that isn’t working correctly or is wearing prematurely.

  • It’s not been right since it was installed
  • There was a change in the system design and it’s been problematic since
  • It’s what you have always used on site
  • It’s what Dave in maintenance said to buy

There are a variety of different problems that can occur with valves and often the way of plants is to muddle on until it goes wrong, or fails completely which is when it’s a case of “just fix it, I don’t care what you fix it with, we need to get up and running”.

It’s like a twisted ankle, it won’t stop you from walking but if you broke your leg you would know about it.

Sometimes you have to do a complete reset, forget what you have been told and ask the question “is this the right valve for the job”?

What’s the starting point?

  • Get clear on what is actually going through the valve? Pressure, temp media, even viscosity. Is there something abrasive or corrosive being processed?
  • Where is the problem presenting itself? Is it how the valve seals? Is it a rapid wearing of the internal parts? Is it air leaking? Is the valve sticking?
  • When did the problem start? Is it intermittent or constant? Did it occur after a change of use or the process itself has changed?
  • Do a top to bottom fault find. Isolate and test each part of the assembly in the case of actuated valves. Is it actually an instrument air supply problem rather than the valve itself? This is the point at which you need to be a bit Sherlock Holmes about is.
  • Identify the issue. Is the part at fault or not fit for the purpose on which it is being use? If not try something more suitable or robust.

 

When to get some help in

These are a few questions you can ask, which save outright valve replacement.

If you are still getting problems, get some advice, maybe even a site survey and work with your supplier to see whether there is a solution.

Remember – good suppliers will be supplying plants 24/7 so there is a very good chance they have seen the problem you present previously, know how to overcome it, and in a way that not only gives better reliability and durability but also cost saving over continual downtime. You will get a different perspective which may be unbelievably obvious and simple to implement but which was overlooked. Better still longstanding suppliers may have historical knowledge of your specific plant going back years which is invaluable.

 

What if a new solution is more expensive? The cost vs value question.

If the cost of shutting your plant in downtime is say £100 and you do this 6 times a year that’s £600 a year, add to this the fitters costs in removing and replacing the valve each time at say £100 a time plus your time spent you can easily be burning £1200 a year on a valve that doesn’t work properly. That’s before you factor in electricians (in the case of actuated valves).

I am being hypothetical as there is every chance these costs will be far higher.

Imagine that cost over many years.  What if your solution was in a valve that cost £1200 and lasted 5-10 years with minimal repair & maintenance – it’s a no brainer really isn’t it?

If you want a FREE, No Obligation site survey then get in touch with us or schedule a call to discuss your requirements in some more detail.

If you want a FREE, No Obligation site survey then get in touch with us or schedule a call to discuss your requirements in some more detail.

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