A well-implemented asset management program can provide outstanding performance and long-term durability from equipment used in process industries. VWIME is therefore pleased that Mr. Alireza Aslarabi Sardroudi has kindly agreed to prepare a series of articles highlighting all the important steps towards implementing an asset management program for an industrial safety valve.
Valves have a large number and variety
Today, asset management is a growing topic in all industries, businesses, and sectors. Since 2008, when the UK Institute for Asset Management (IAM) introduced the PAS55 standard to the world, maintenance has been transformed into asset management. With the publication of ISO55000 (and later ISO55001 and ISO55002) in 2014, this move was completed. Organizations are challenged by both standards based on the four main factors of efficiency, risk, cost, and empowerment to succeed in comprehensive asset management.
In the beginning, these patterns were considered at the level of leading industries such as oil and energy, automobiles, and steel. However, due to (i) a large number of physical assets such as infrastructure, public buildings, ports, hospitals, schools, and hotels, and (ii) the effectiveness of this management, today asset management is mandatory and extensively used in service centers and industries, whether they are public or private.
The main goal of Asset Management is to get the maximum value from the assets and in this regard to systematically coordinate all activities to achieve this maximum value, this can be in the form of maximum production or service, fast return on investment, low life cycle costs, reducing safety hazards, or any combination of these factors.
The basic idea is to be able to define a value for every asset and then to identify relevant core activities to achieve that value, which could be efficiency (production or service), risk (safety and environment), and cost (life cycle). After that, they must activate and align.
Valve inventions are among the earliest inventions of people to reach industry today; wherever fluids are discussed, solid, liquid, or gas, you’ll find dozens or hundreds of industrial valves that control them. This can be done either manually or automatically and intelligently.
There are many types of valves, some of which are very important and expensive because of their composition, and others which are important and expensive due to their size. A valve goes through a complex process from being chosen by the end-user, designed by engineers, and manufactured and tested in the factory. In this way, an initial value is created, which is mainly economic.
Valves are very important in industry and infrastructure
However, the main value of valves displays when they work. This value corresponds to the core value of creating industry or infrastructure. In other words, if the valve is not working, only its economic value (15% of its real value) will be equal. But when we use an industrial valve, its true value indicates. Which is the control of liquids for production or service. Which is more than 80% of its true value.
Valve scrapping or removal can also recover valuable materials for use in the valve regeneration cycle (less than 5% of the actual value).
In other words, industrial valves are valuable to us throughout their life cycle. From the time they build to the time they operate and maintain to the time they are dragging. That value dictates that we find a means of asset management for them.
According to the classic asset management model (ISO55001), you should design a system that addresses the following seven issues:
- The organization’s context determines the type of activity, the area of business, and whether assets require.
A leader must determine how to manage asset management.
A life cycle planning that explains how and when asset management needs to manage.
- Support refers to the creation or provision of infrastructure and arrangements needed for program implementation.
- The operation of tracking and executing programs.
A performance appraisal evaluates and grades the effectiveness of assets based on the results of operations and compliance with plans.
- Continuous improvement, which, based on the evaluation results, suggests improvements in leadership, planning, support, and operations.
3 Preventive Measures For Maintaining The Industry Valves Rightly
In light of my thirty years of experience in the industry and the published documents on asset management. I must say that these documents explain the implementation requirements in good conditions. But do not explain how to implement them.
Thus, each organization, according to its context and the diversity and number of assets. They design a system establish on the above requirements. Which is usually specific to that organization or industry and cannot be apply to other organizations.
To achieve asset management in the valve industry, we need to separate three organizational groups. The first group is the manufacturers, who manufacture valves in factories.
The second group is engineering design, procurement, and construction (EPC) companies that design, purchase, and install equipment based on the main process request, and the third group is businesses that use assets as owners or operators. In this group of valve users, the main benefit of the industrial valve is that the valve has a longer life cycle.
The top valve manufacturer advises scheduled maintenance. This is the reason perhaps why preventive maintenance of valves is necessary to fight against downtime and high replacement costs. With that sayings, let’s have a quick look at 3 preventive measures. That keep in mind for proper preventive valve maintenance:
1) SCHEDULED SHUTDOWN MAINTENANCE
Annual maintenance should be a significant part of every plant or facility. The all-around quality of the product of a plant revolves around its machines’ performance and systems. It becomes vital to guarantee that all types of equipment and its parts are performing in peak condition to produce quality results.
Planning shutdown maintenance is necessary to prepare beforehand regarding faulty parts which may need replacement. However, sticking to a compact plan can minimize any sudden disruptions and make the process work smoothly.
2) ROUTINE INSPECTIONS
In addition to annual checks, valves should review and examine on a regular basis. The control valve regulates flowing liquids like steam, gas, water, and chemical compounds and is the general final control component. Such valves automatically control the pressure or flow rate and handle the plant’s functioning at various pressures and temperatures. It is thus highly instruct to conduct special monitoring of all control valves that operate under high temperature and pressure.
The shut-off valves form another important part and are pneumatic. During emergencies, shut-off valves help in avoiding disaster by detecting any leaked gas or chemical. When closed, these valves provide a cent percent closure, and when in the open state, they give a cent percent full bore. Here are a few steps that adopts regularly for the thorough inspection of the valves:
- You should tighten the bolts and nuts properly. Open and close the valves to see that they do not get jam.
- Valve leakage can identify through the mineral deposit or corrosion and rusting on the casing. Likewise, you should test static valves for determining an exact reading given by the valve position indicator.
- Examine everything in the plant system for defects like brittleness and cracks and anything that might create leakages.
- Perform alarm tests to find out if they are working fine by buzzing at the slightest emission of hazardous substances.
- Inspect systems comprehensively and make them safe for your co-workers and users
- Look at valves closely to make a better inspection. See the way the valves bend and check their alignment. Check out for bents or warped stems within the valves as they have a bearing on the working of the valves.
- Valves that manage pneumatic air, gasses, or refrigerants can read with a plain soap and water mix. You can spray this combination and look out for the formation of bubbles. Another method is by applying an electronic leak detector which can detect small leaks and marginalize the dangers of error.
Leakage detection in various parts of the industrial valves is integral. It might lead to revenue loss and in rare cases, can even cause loss of lives.
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Once all the inspections are complete, cleanliness is the next essential step. Cleaning is essential to boost the life of your valves. It highly suggests employing thin oil coats upon the rods and adjusting the excess loose or tight linkages.
To tidy the valve casing, a towel, as well as a wire brush, will utilize. Valves in dusty facilities or the ones that deal with corrosive agents need to clean every 6 months or more on the seriousness of the problem.
We Aira Euro Automation Pvt Leading valve manufacturer and exporter in India. We offer various types of industrial valves like control valves, ball valves, plug valves, Pressure Relief Valve, Pressure Reducing Valves, etc. Valve maintenance and valve inspection is necessary part of the routine maintenance of any process plant. There are several reasons why you should have your valves checked. It is also important to know that valve maintenance is cost-friendly. If you aren’t sure how to go about it, contact your valve manufacturer. As an after-sales service provider like us, and they will be there for your help.