End User Interview
stringent maintenance protocols , while less critical valves can be maintained at longer intervals or with less intensive methods . Bader also highlighted the importance of considering valve reliability data in the RBM process . Collecting and analysing data on valve performance , failure rates , and maintenance history provides valuable insights into the reliability of different valve types and manufacturers . This information can be used to fine-tune maintenance strategies , optimise spare parts inventory , and make informed decisions about valve replacements or upgrades . Implementing an RBM approach not only enhances plant safety and reliability but also offers significant economic benefits by reducing downtime , extending valve life , and minimising overall maintenance costs . However , successful RBM implementation requires a strong data management system , cross-functional collaboration between teams , and ongoing monitoring and adjustment of maintenance strategies based on performance data . Despite the challenges , Bader strongly advocates for the adoption of risk-based maintenance in the valve industry , as it is no longer a luxury but a necessity in today ’ s complex plants . By embracing RBM , operators can enhance safety , improve reliability , and optimise their maintenance spend , ultimately leading to better overall plant performance .
Valve integrity management program
“ Online inspection techniques and preventive maintenance at set intervals , coupled with major overhauls as needed , form the basis of an effective valve integrity
management program ,” said Bader . He stressed the significance of a comprehensive approach to ensure valve reliability and minimize downtime . Bader emphasized the importance of incorporating online inspection techniques , such as acoustic emission testing and ultrasonic testing , into the valve integrity management program . These techniques allow for the assessment of valve condition without process interruption , enabling early detection of issues and timely intervention . Preventive maintenance at set intervals , based on factors like valve criticality and service conditions , is also crucial and includes activities like lubrication , calibration , and minor repairs . For critical valves or those in harsh environments , major overhauls involving complete disassembly , inspection , and repair may be necessary . Bader stressed the importance of having a well-documented program with clear procedures , maintenance schedules , and record-keeping requirements , as well as regular audits to ensure compliance with industry standards and best practices .
Proper lubricant and sealant selection
Proper valve lubricant and sealant selection was another focus area . Bader co-authored a recent article on this topic , which highlighted key criteria like service compatibility , sealant capability , pumpability , and stability with the process fluid and temperature . Selecting the right lubricant and sealant is essential to ensure valve functionality and reliability , as using incompatible or inadequate products can lead to valve failure , increased maintenance costs , and unplanned downtime . In the article , Bader discussed the challenges posed by the lack of industrywide standards for lubricant and sealant selection . He recommends that end users work closely with their suppliers to ensure the products meet the specific requirements of their valve applications and conduct their own testing to validate product performance under actual operating conditions . By carefully considering these factors and partnering with knowledgeable suppliers , end users can select the right lubricants and sealants to optimise valve performance and reliability , which is a critical aspect of valve maintenance that can significantly impact plant operations and profitability .
Qualification testing for sealants
While international standards are lacking , Bader recommends testing products for consistency , dropping point , fluid stability and heat resistance to qualify sealants for the intended application . “ Improper sealant selection can lead to failures like hardening , dissolution , or poor sealing ability . Taking the time upfront to carefully evaluate products can prevent bigger issues down the line ,” he noted . Bader emphasised the importance of conducting thorough qualification testing to ensure that sealants will perform as expected in the specific valve application . Consistency ( ASTM D217 ) determines the sealant ’ s ability to be easily injected and maintain its integrity . Dropping point ( ASTM D2265 ) ensures the sealant will not melt or flow out under high-temperature conditions . Fluid stability , assessed through immersion testing , ensures the sealant can withstand exposure to the process fluid without breaking down or losing sealing capability . Heat resistance ( ASTM D2595 ) evaluates changes in the sealant ’ s properties after exposure to high temperatures . By conducting thorough qualification testing , end users can have greater confidence in the performance and reliability of the sealants they select . While it may require additional time and resources upfront , investing in comprehensive testing can help to avoid costly failures and downtime in the long run .
Advancing valve engineering standards
When asked about goals for the future , Bader expressed his desire to continue advancing valve engineering standards and best practices to support ever-changing industry needs . Through his roles at Saudi Aramco and participation in standards
16 Valve World September 2024 www . valve-world . net