“ Valves made of carbon steel can be stored outside provided that the manufacturer ’ s procedures are followed ,” says Peter Börjesson . Picture shows the latest addition to X-series ball valve family , the Neles™ XH ball valve .
Inspect before flushing
In the following years , Peter himself has witnessed numerous valve problems that were actually caused by shoddy on-site workmanship . “ At Valmet , we take good care to properly package our valves . However , when goods like valves arrive on site , the packaging is often removed for inspection . That is fine , but if the valve is going to go into storage for another twelve months prior to installation , a responsible authority such as the project manager should ensure that the valve is then properly repacked . That isn ’ t rocket science , it is all down to good working practice . Note that this issue is not just restricted to some localities but occurs world-wide .” Further discussing the need for correct packaging and storage , Peter notes that a valve made of carbon steel can be stored outside provided that the manufacturer ’ s procedures are followed . “ If not , the body could corrode , forcing the seat to push against moving parts such as the ball , which increases friction . Whilst small increases in friction will not cause issues for wellengineered valves , they can be exacerbated by additional internal damage . On many occasions I have seen items like welding rods , helmets , detritus , etc , removed from pipework during commissioning . If such items pass through the valve during flushing , they can lead to damage on for example coatings or seats . After a few strokes the valve may then stick . Again , that ’ s another start-up issue which could have been prevented by better advance inspection of the pipework prior to flushing .” To help ensure valve integrity , some EPCs will open valves to remove trims before flushing and / or will ( partially ) dismantle valves for inspection prior to start-up . In such cases , Peter advises that spare parts should be ordered well in advance and that the work be carried out by properly trained and qualified personnel . “ Take an off-centre split ball valve , where you will definitely need to have replacement soft parts available . Same goes for ball valves fitted with a backsealing arrangement that might need replacing . And if you remove the disk or segment from certain butterfly and segment valves to check behind the seat , then you will also require new pins for reassembly . If you are planning to open the valve , do check with the supplier first to ensure you have all appropriate spare parts to hand , yet without purchasing unnecessary items .”
Problem-solving
Smoother start-up
Based on his experience , Peter is adamant that the ideal , most cost-effective scenario would be to have someone inspect the intended storage location , to train the people who will be receiving the goods on how to properly handle the products and also to ensure the entire team responsible for valve installation – including not just the pipe fitters but also the electricians , etc - know which procedures to follow . And perhaps more importantly , why they should be followed . That should include issues which might seem self-evident , such as pointing out the installation , maintenance , and operation ( IMO ) manuals , where instructions detailing correct valve installation can be found , etc . He also indicates that a reliable valve manufacturer will happily oversee , inspect during tag check out and also give advance training to those people responsible for installation . Peter ’ s key message to EPCs and end users is , therefore , that a little advance thinking and a more methodical , common-sense approach to testing and commissioning can assist in pre-empting valve issues . The result will be a smoother start-up . “ Which won ’ t simply make life easier for the managers and engineers , the plant owner can start to generate revenues that much earlier too !”
Capital project commissioning and start-up
Valves , critical for brownfield and greenfield projects , demand careful attention for successful plant start-ups . David Anderson ( Director , Flow Control Services , Valmet ) kindly offers the following key recommendations :
1 . Prioritize safety : ensure teams comprehend risks and good handling practices outlined in Installation , Maintenance , and Operation ( IMO ) manuals .
2 . Communicate effectively : maintain a continuous line of communication with Valmet ’ s flow control service teams for successful handovers and support .
3 . Plan storage adequately : Prevent deterioration with proper storage planning and follow Valmet Flow Controls BL ’ s detailed recommendations .
4 . Prepare for contingencies : have commissioning spares ready , especially for projects in remote locations .
5 . Check for signs of contamination or damage : inspect valves before and after installation to detect issues early .
6 . Flush the pipeline carefully : Avoid damaging closing elements and seat surfaces during flushing .
7 . Ensure correct installation : follow Valmet ’ s flow controls manuals for correct support , insulation , and expert supervision to guarantee proper installation .
8 . Consider expert supervision : evaluate the cost versus the benefits of Valmet ’ s flow control expert supervision for faster issue resolution .
9 . Identify control loop issues early : use Valmet PlantTriage for automated loop tuning and diagnostics .
10 . Arrange training for operation and maintenance teams : ensure teams are prepared , especially for critical valves and intelligent devices .
11 . Set up systems correctly from day one : ensure correct data and recommendations are in place , and utilize state-of-the-art tools .
12 . Leverage data for optimal spares inventory : use data to build a spares inventory that matches operational needs while minimizing capital tied up in spares . www . valve-world . net Valve World March 2024
25