How to Reduce Industrial Valve Downtime
Valve failures can have consequences far beyond the valve itself.
A failed isolation valve may require a process shutdown.
A critical valve can therefore become a significant source of production downtime if it is poorly selected or maintained.
The good news is that many valve problems can be reduced through better planning.
1. Select the Correct Valve
The first step is selecting a valve that matches the application.
Consider:
- Media
- Pressure
- Temperature
- Solids
- Abrasion
- Corrosion
- Operating frequency
Incorrect selection can result in premature wear.
2. Understand the Application
A valve operating in a tailings pipeline should not be treated the same way as a valve handling clean water.
Understand the actual process.
3. Maintain Critical Spares
Identify which valves are critical.
Then determine which components should be kept in stock.
This can dramatically reduce repair lead times.
4. Monitor Valve Performance
Look for changes in:
- Operating time
- Leakage
- Noise
- Vibration
- Actuator performance
Changes can indicate developing problems.
5. Train Operators
Operators are often the first people to notice something unusual.
Training should include:
- Correct valve operation
- Normal operating behaviour
- Warning signs
- Isolation procedures
- Reporting requirements
6. Keep Accurate Records
Record:
- Valve model
- Size
- Location
- Installation date
- Maintenance
- Repairs
- Parts
- Failures
This creates useful historical data.
7. Review Repeated Failures
If the same valve repeatedly fails, don’t simply replace it.
Ask:
Why is it failing?
The problem could be:
- Incorrect valve selection
- Excessive abrasion
- Incorrect operation
- Wrong material
- Pressure conditions
- Installation problems
8. Work With the Manufacturer
Valve manufacturers can provide application-specific guidance.
This is especially valuable for severe slurry applications.
Final Thoughts
Reducing industrial valve downtime starts before the valve is installed.
Correct selection, good installation, appropriate maintenance and spare-parts planning can all contribute to improved reliability.
Need Help Improving Valve Reliability?
CMO Africa can assist with valve selection and application requirements for mining and industrial plants.
FAQ
How can industrial valve downtime be reduced?
Downtime can be reduced through correct valve selection, proper installation, preventive maintenance, critical-spares planning, operator training and monitoring of valve performance.