VALVE MAINTENANCE
3 . Valve sealing failure : This can result from various factors including noncompatible operating conditions , rapid decompression , erosion , improper material selection , improper installation and inadequate maintenance .
4 . Erosion of internal valve parts : This is a common issue in the oil and gas sector due to particulate matter or solid objects in the fluid , as well as high velocity flow . All these problems can significantly affect valve performance , leading to leaks , reduced efficiency and potential safety hazards .
Methodology and process
The valve repair and maintenance process , from an oil and gas operator ’ s perspective , consists of six key steps : 1 . Dismantling , delivery and receiving :
• The valve is dismantled from its operational location , delivered to the maintenance facility and received for further processing .
2 . Disassembly , cleaning :
• The valve is disassembled into its component parts and each part is thoroughly cleaned to remove contaminants or residues .
3 . Evaluation :
• Detailed assessment and failure investigation of the valve ’ s condition to determine the extent of wear and tear , damage , or any other issues that need to be addressed .
4 . Repair / remanufacture : Damaged or worn-out parts are either fixed or replaced . This step may include reverse engineering . What is the difference between remanufacturing and repair ?
Figure 1 : Four most common types of valve damage
i . Comprehensive vs . basic : Remanufacturing restores the valve to like-new condition , whereas repair focuses on basic maintenance to restore functionality . ii . Inclusion of manufacturing operations : Remanufacturing includes machining , welding , heat-treating and other manufacturing operations . Repair does not include these processes . iii . Extent of part replacement : Both processes exclude valve body replacement , but remanufacturing allows for a broader scope of part restoration and replacement . iv . Outcome : Remanufacturing results in a valve with an extended lifespan and potentially improved performance , while repair returns the valve to functional condition without extensive restoration . Reverse engineering : This is a crucial part of the repair / remanufacture step . When parts need to be recreated or improved , reverse engineering techniques are employed to ensure the valve meets or exceeds original specifications . In fact , reverse engineering capability is one of the most important aspects of reliable valve repair and remanufacturing . This engineering process involves deconstructing , evaluating and replicating parts without access to design files or original specifications . It can reproduce another manufacturer ’ s product or that of an OEM ( Original Equipment Manufacturer ) following a detailed examination of its construction or composition .
Figure 2 : Example of ball valve repair process
44 Valve World October 2024 www . valve-world . net