Unplanned downtime is one of the most expensive problems facing industrial plants.
While valves may appear relatively small compared with major equipment, a single failed valve can interrupt an entire process.
Why Do Industrial Valves Fail?
Failure can result from:
- Incorrect valve selection
- Abrasive wear
- Corrosion
- Poor installation
- Incorrect actuator sizing
- Incompatible materials
- Lack of maintenance
- Operating outside design conditions
Start With Application Data
One of the most effective ways to improve valve reliability is to ensure that the valve is correctly specified from the beginning.
Record:
- Media
- Pressure
- Temperature
- Solids
- Flow rate
- Valve size
- Operating frequency
Monitor Repeated Failures
If the same valve repeatedly fails, don’t simply replace it.
Look for patterns.
For example:
If sleeves repeatedly wear through, investigate the slurry.
If actuators repeatedly stall, investigate actuator sizing and operating conditions.
If gates struggle to close, investigate solids accumulation and valve design.
Keep Critical Spares
For critical valves, plants should consider keeping appropriate spare components available.
This can reduce the time required to restore operation.
Think Lifecycle, Not Purchase Price
A valve that costs less initially but requires frequent replacement may be more expensive over five years than a higher-quality application-specific solution.
Conclusion
Valve reliability starts with correct engineering.
The combination of correct specification, installation, monitoring and maintenance can significantly reduce avoidable downtime.