VALVE MAINTENANCE
maintenance checklists . Include specific checks based on valve type , application , and criticality . Ensure these checklists are comprehensive and aligned with industry standards and best practices .
• Condition monitoring : Implementing condition monitoring techniques such as vibration analysis , temperature monitoring and leakage detection can help detect early signs of valve degradation or malfunction , allowing for proactive maintenance .
• Training and competence : Ensure maintenance personnel are adequately trained and competent to perform maintenance tasks effectively and safely . Provide ongoing training to keep them updated on new technologies and best practices in valve maintenance .
• Valve condition inspection database : Developing a valve condition inspection database is an excellent approach to systematically tracking maintenance activities , monitoring performance and enhancing future programs based on data-driven insights .
By focusing on these aspects , industries can enhance the reliability , efficiency and safety of valve operations , thereby minimising downtime and maximising productivity .
Quality and reliability
Three important aspects to ensure the quality and reliability of replacement parts are design engineering , material requirements , and inspection and testing . For example , the replacement of metallic seat rings with new inserts requires the minimum design demonstration that the seat ring is manufactured from the material with equivalent performance to the original , including the dimensional tolerances and profiles . The material needs to be backed up with traceability evidence , such as a material certificate , and evidence that the material truly comes from the qualified manufacturer with all properties verified . The inspection and test should be performed in conjunction with the seat performance test , including after the valves stroke several times under full differential pressure to ensure the stability of the seat ring and its insert . The cavity relief functionality needs to be demonstrated if required . For sealing elastomers , the minimum design of calculations for fill , squeeze and extrusion must be verified including the surface finish of its contact surface . The traceability of the material and the test report must be truly representative and supplied by qualified manufacturers . The inspection and test shall be performed with performance testing .
Figure 5 : Example of valve maintenance checklist
By adhering to these aspects , the quality of replacement parts can be ensured , maintaining the integrity and safety of the overall system . The know-how of reverse engineering , along with appropriate facilities and thorough inspection , is crucial for ensuring the reliability of repaired valves .
Guidelines and procedures
To ensure the quality of the valve repair process , it ’ s crucial to develop detailed and robust procedures that supplement standard codes and specifications . In the context of upstream oil and gas operations , key industry guidelines include :
• The American Petroleum Institute ( API ) 6D 25th edition , which includes specific requirements for valve repair and remanufacture .
• API RP 621 , which provides guidance for reconditioning metallic globe , gate and check valves .
These standards offer essential frameworks for maintaining quality and consistency in valve repair and maintenance processes .
Key takeaways to ensure valve reliability
Valve repair demands a comprehensive approach to meet quality requirements , contributing to operational efficiency and safety in industrial operations . This approach begins with selecting capable and trustworthy vendors or workshops , a crucial step in ensuring high-quality repairs and avoiding issues such as conflicts of interest and workmanship problems . The valve repair process must be qualified , tested and supervised by the client to maintain quality and compliance with industry standards . Integrating these elements enhances confidence in the repaired valves ’ reliability , longevity and adherence to regulatory standards , fostering transparency and accountability between service providers and clients . Attention to best practices , such as the inclusion of grease injection ports , is vital for maintaining valve longevity and performance . These features ensure that lubrication reaches critical areas , preventing wear and ensuring smooth operation over time . Properly integrating and testing these ports can significantly enhance equipment reliability and lifespan . By embracing these principles and practices , industry professionals can improve the outcomes of valve repair and maintenance efforts , leading to more reliable , efficient and safe operations in demanding industrial environments .
Reference “ Optimizing Valve Performance : A Holistic Approach through Comprehensive Repair and Rigorous Testing for Oil and Gas Plant ”, presentation Valve World Asia Conference 2024 : Irawan Josodipuro , Richard B . Napitupulu , Kelvin O . Djohan
46 Valve World October 2024 www . valve-world . net