Figure 4 : Flushing and greasing during maintenance at offshore facility π www . valve-world . net Valve World October 2024
VALVE MAINTENANCE
Figure 3 : Example of ball valve re-assembly and fit-up process . Fit Up Test : “ Blue Check ” to ensure the ball and seat are fit and there is no gap . It can be seen from the fully rounded mark on the ball surface . There are also other methods that could be used .
Reverse engineering becomes particularly valuable when :
• Engineered valve parts are out of stock from major manufacturers
• Parts are no longer in production
• Parts are unknown or difficult to find A single valve failure could result in significant delays and costly downtime . Reverse engineering provides a solution by creating a newly rebuilt system and restoring its functionality . 5 . Reassembly , testing , marking , documentation :
• The repaired valve is returned to its operational location , reinstalled and put back into service . Ongoing field maintenance is conducted to ensure continued reliable operation .
• After repairs , the valve is reassembled and undergoes rigorous testing to ensure it meets required specifications . Proper marking and documentation of the maintenance performed are completed .
The reassembly of newly refurbished components with the existing valve structure is a critical phase , demanding precision and attention to detail . To ensure compliance with valve repair and testing requirements , it ’ s essential to adhere to established standards such as API 598 , API 6D and specific end user specifications . The comprehensive testing protocol includes :
• Conventional leak and pressure tests
• Additional performance tests
• Functional tests
• Safety tests These additional measures are crucial to guaranteeing the integrity of safety features in the repaired valves , ensuring that they not only meet but surpass operational standards . 6 . Return delivery , installation and field maintenance : The repaired valve is returned to its operational location , reinstalled and put back into service . Ongoing field maintenance is conducted to ensure continued reliable operation .
• Field maintenance : Valve maintenance is critical for both repaired and new valves to ensure reliable operation and prevent costly failures in industrial settings . This is especially important in sectors like oil and gas , where valves play a crucial role in controlling fluid flow and maintaining safety .
Key aspects of effective valve maintenance include :
• Regular greasing : Proper lubrication helps prevent friction , wear and corrosion on moving parts of the valve . This extends the valve ’ s lifespan and ensures smooth operation . Regular greasing intervals should be defined based on operational conditions and manufacturer recommendations .
• Open-close operational checks : Regularly exercising valves through open-close cycles helps verify their functionality and identify any operational issues such as sticking or jamming . This also helps prevent valves from seizing due to prolonged periods of inactivity .
• Continuous improvement of maintenance checklists : Learning from past maintenance experiences and feedback , continuously improve
Figure 4 : Flushing and greasing during maintenance at offshore facility π www . valve-world . net Valve World October 2024
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