Increasing the Lifespan of Industrial Valves
Industrial valves are a key component in factory processes. Efficient and proper use of various types of industrial valves is essential for moving any fluid under any pressure or viscosity in most industrial processes.
However, working within industrial processes and controlling pressurized fluids under different physical and chemical conditions leads to valve wear and tear. Naturally, you do not want to be a victim of this erosion. But are there ways to increase the lifespan of industrial valves?
Adhering to these tips impacts the lifespan of industrial valves in general factory and refinery processes, etc. Keep in mind that wear and tear of valves, especially in tough industrial processes, is completely natural.
However, we do not have to unintentionally accelerate this erosion. Instead, by following key principles in installation and maintenance methods, we can improve the useful operation of the valves and contribute to their increased lifespan. But what are these solutions?
Thorough Understanding of Various Industrial Valves
When you have a good technical understanding of various industrial valves, you will certainly use them under appropriate process conditions while observing all technical requirements. The first step in maintaining industrial valves is their proper use in industrial processes.
An informed design engineer knows well what type of valve with what physical and mechanical properties to use for completing the upcoming process. Understanding the working mechanism, valve design material, fluid pressure level, fluid physical and chemical properties, and their compatibility with valve technical requirements play a role in selecting industrial valves.
You need to have precise information about the technical specifications and design methods of industrial valves. When you have complete information on the operation of each valve, you can better plan to increase the lifespan of industrial valves. Therefore, fully read the information label on each valve and evaluate its suitability for the system where it will be installed.
Useful information from studying the label or the valve’s manual will be available to you. For instance, you will know what materials the different parts of the valve are made from, the pressure range the valve operates under, and the temperature range the fluids can pass through it. This information is useful for proper installation and increasing the lifespan of industrial valves.
When you know the type of valve, its design method, and operation, you will certainly understand what type of process and fluid control each valve is suitable for. For example, ball valves are designed for On-Off operations.
These valves should be either fully open or fully closed. Therefore, they are not suitable for fluid flow control design. On the other hand, they are not suitable for installation in paths containing solid particles. In contrast, gate valves (sliding) are designed to operate in a semi-open state and control fluid flow.
Selecting Industrial Valves with Suitable Technical Specifications
Merely obtaining technical information and studying the mechanical specifications and materials of various valves does not enable you to select a suitable example. Your information is just a guiding pattern. But the next step is to ensure the presence of a suitable valve at the project level. Therefore, you need to match the technical specifications of the valve with the fluid specifications in the industrial process.
Industrial valves must be completely compatible with the passing fluid both physically and chemically. Therefore, checking items such as the following is essential:
- What is the nature of the fluid being transferred?
- What is the temperature range of the fluid being transferred?
- What pressure tolerance is the fluid being transferred under?
- Is the primary operating state of the valve closed or open?
Answering these simple questions step by step leads you to a more suitable industrial valve compatible with the passing fluid. Hence, by making the right choice before installation, you have taken a key step towards increasing the lifespan of industrial valves in future processes.
Proper Installation of Industrial Valves
Proper installation has a deep impact on the correct and optimal operation of various valves. In many cases, the lack of knowledge of the installers or non-compliance with the technical parameters stated by the valve manufacturer during installation leads to heavy damages and failures in the mechanical structure.
All industrial valves, even the simplest ones, have standard installation and commissioning patterns that must be observed in all details. Otherwise, we are facing a valve operating non-principally, which will naturally cause their breakdown in the long run.
Proper installation is one of the most important points for maintaining industrial valves. Any negligence in how to install causes damage to the technical and mechanical parts of industrial valves. Knowing the correct installation method includes observing operating pressure, operating temperature, proper use of connections, pipes, etc.
There are various threading and flanged connection methods for connecting industrial valves. Also, bolts and nuts or welded connections are used for the type of connection. It is important to have a plan for the correct and optimal connection of industrial valves. Correct connection increases the lifespan of the valves.
Each industrial valve has many technical and mechanical parts that operate under its principle mechanism. You need to know the design mechanism of each valve’s mechanical parts and be aware of the presence of all the mechanical parts of the valve. Lack of awareness causes some factory settings of the valve to change.
These changes sometimes lead to incomplete valve operation and increase the likelihood of their failure. Observing all technical considerations is more effective than any other measure in increasing the lifespan of industrial valves.
Installing industrial valves means placing them under ideal and unchanged conditions. Therefore, it is important to follow the key points of the installation stages of various industrial valves. These points include many details that differ in each valve. For example, does the metal pipe in the industrial installations have enough strength to bear the weight of the valve? If not, you need to install the valve on a stand.
If you need a stand, what should the conditions of this stand be? Can metal structures be used, or should concrete stands be designed? At the same time, what should the installation position of the valve be? The industrial valve should be installed in a way that its control element is accessible to the operators.
Pre-Installation Care of Industrial Valves
Many failures or problems occur before the valve is installed and the fluid flows. A failure that you probably never notice until the fluid enters. But as soon as the valve operates within the system, the negative consequences reveal themselves. Removing the cover of the valve inlets during storage or transportation is one of such problems.
These covers are used to prevent dust and foreign objects from entering the industrial valves. Their presence ensures the valve’s health until its final installation in the industrial process. At the same time, proper storage and keeping the valve in a dry place, away from direct sunlight, and away from chemical and physical stimuli before final installation is mandatory.
Cleaning the Surface of Industrial Valve Shells
Cleaning, whether in annual, monthly, etc., regular programs, impacts the lifespan of industrial valves. Industrial environments are inherently polluted spaces that quickly damage mechanical structures. It is enough to neglect cleaning process units so that heavy pollution negatively impacts all the technical parts of your sensitive systems.
Industrial valves are among the most sensitive process equipment that is completely affected by pollution. Clean valves influence the continuation of their optimal performance. In any case, each valve has mechanical parts with rotational or linear movement patterns that are disrupted when dirty. Keep them clean to increase the lifespan of industrial valves.
Coating Industrial Valves
The outer shell of industrial valves is a key but sensitive part of these equipment. Any shell erosion causes valve failure in the long run. If you are inattentive to this erosion, you will soon face unusable valves and numerous process problems.
The shell of industrial valves is made from durable materials such as steel, cast iron, aluminum alloys, etc. However, even these hardy materials are destroyed under long-term exposure to the harsh industrial environment. With the coating technique, we can better maintain them and increase the lifespan of industrial valves.
There are multiple methods for coating (plating). Thermal coating is a common method usually carried out under the Oxy-Fuel process. This coating increases the thermal resistance of industrial valve shells to a suitable level. There are different types of coatings. Nickel plating, nickel-chrome, powder-coating, electroplating, stainless steel, etc., are common methods of coating industrial valves.
Coating (plating) is essentially a thin metal coating on the surfaces of industrial valves. Initially, this coating is fluid and forms a uniform layer over all metal surfaces of the valve. Then, the layer dries, resulting in a uniform and completely insulated surface.
There are various types of coatings, ranging from sanitary coatings to those used in heavy refinery processes. However, nickel, stainless steel, brass, epoxy coatings, and others are more common.
Regular Inspection of Valves
In designing each process system, hundreds of valves may be present. These valves may be installed in remote places or restricted areas with difficult access. The large number of valves or difficult access does not mean you should neglect their continuous inspection.
Each valve is a mechanical device composed of various technical parts to control fluid movement. You need to have a scheduled and professional inspection plan for checking all process valves and thoroughly reviewing their standard and optimal operation each time.
A scheduled program is one of the best methods for inspecting all industrial valves. In an industrial unit, hundreds of valves of different types in various sizes may be used. Certainly, you cannot inspect all the unit
valves in one day. However, scheduling the inspections allows you to inspect all the valves step by step.
In an industrial space with multiple process units, planning monthly or weekly inspections is optimal. At the same time, it is necessary to schedule daily inspection programs for all sensitive parts and valves. When these inspection programs are not organized, the possibility of industrial valve failure increases.
Regular Lubrication
All mechanical systems have a system of mechanical lubrication. This simple yet influential operation can prevent many process failures. In any case, many mechanical components of industrial valves move linearly or rotationally. Continuous lubrication is essential for ensuring the correct and optimal movement of each valve component.
When lubrication is insufficient, friction between metal parts increases, resulting in erosion of components. Even if the components do not wear out, the lack of lubrication disrupts the performance of industrial valves. As a result, regular lubrication is a practical and effective solution for improving the performance of various industrial valves.
Final Words
Industrial valves are part of the mechanical and process equipment of any factory. Efficient and optimal operation of these devices, which control the movement of all kinds of fluids, depends on the principles of their maintenance and how to use them. In any case, a more professional approach to maintaining and using industrial valves results in increased durability and lifespan.
Source: inergy
