I}IAITITETIATIGE

REPAIR

aY PATRrcr(

EASr<

IheGase

rr 0lil

Eeilifieil

alue

e[air

 

n

oday's

ompetitive

usiness

nvi-

I ronment,

yriad hallenges

ace he

owner/operator

f

an ndustrial

rocess

plant.

Witheconomic

ressures

o

ge t

more

utof nvested

ssets, steady

ro-

gression

oward

ruly

lobal

upply

chains

nd nd-user

arl<ets,nd

more

stringent

egulatoryonstraints,

he

industr ial

or ld

s ncreasinglyomplex.

To

prosper

n his

environment,

wner

operators

re elying

ore nequipment

suppliers

ndbusiness

artners

o ensure

compliance

o

regulatorytandards

nd

to

everagehe atest

evelopments

n

technology.

dd o his

mixelevated

rit-

icality f

safety

n

he

rena,

nd

it isclear

ndustry

ustmal<ehe

most f

every pportunity

o effectively

anage

complexity

nd

mitigate

isl<s.

Between

isl<nd

Reward

In managing

business

n th is envi ron-

ment he

proper

balance

etween

isl<

and reward

must be establ ished

nd

maintained.

ora

process

lant

he

most

potent

isl<s re

hose hat threaten

afety

or

reduced

rocess

ptimeor availability.

Despitehe

high associated

isl<,

ot all

process lant

owneroperators

elysolely

on 0EM

parts

or engineered

quipment

or 0EM or 0EM-cert i f ied

hi rd

part ies

for serv ic ing

hatequipment. se

f non-

0EM

parts

and

non-certif ied

ervice up-

pl iers

are arguably

he one common

sourcing

ractice

hat

poses

he highest

safety

nd/or

downtime

isl< n a modern

process

lant.

Further,

t can be argued

that 0EM sanctioned

upply

f

parts

an d

serv ice

s

part icu lar ly

rudent

or sup-

port

of industrial

alve ssets.

0f al l

the equipment

n a

process

plant,

valves are

perhaps

the most

omnipresent

nd

criticalcomponents

nd

are subjected

o the

ful l brunt of the

process

low stream.

For example, s he

final co ntrol element,

control

valve

must eliablyhrottle

while

being

ubject-

ed o the

orces f

luid low, emperature

and

pressure.

naccuracies

r

s luggish-

ness

of

controlcaused

y

poor qual i ty

f inal control

e lements

annotbe over-

come

with the

instal lat ion,

advanced

oop uning

or state-of-the-art

measurement

evices

ndschemes.ther

industr ia l

valves,such

as emergency

shutdown

r safety

elief

valves,

lay

a

cr i t ica l

ro le

in maintaining

afe

plant

operations.

rom ight

shutoff

solation

and overpressure

rotection

o emer-

gency

hutdown,

wide

range f critical

functions re

performed

by industr ial

valves.

Safeguarding

our

nvestment

Thesignificant

nvestment

n valves

ith-

in any

industr ia l

rocess

lant

must be

safeguarded

ith efforts o

sustain

ig h

quality

and

reliable

erformance.

xact-

ing

factory design,

manufacturing,

est-

ing and certification

f

industrial

alves

mustnot be compromised

ater hrough

i l l -advised

maintenance

ractice.

In

many cases

he compromise

o

product

integrity hat

resultshrough

ourcing

f

non-cert i f ied

alveserv ic ing

ntroduces

significant

isl<s f

performance

egrada-

tion

n control

r safety

unction.

n

some

instances,efects

rom improper

ervic-

ing can

ead

o

process

owntime

r even

catastronhic

onsequences

n the event

f

valve a i lure.

The mpactof

poor per formance

r

fai lureof

industr ia l

a lves s c lear ,

but

why does

uncertified r

worse/

unquali-

f ied,

serv ice

pose

such a

high r is l<

o

proper

alve unct ion?

Unquali f ied

ech-

nicians sing

mproper erv ice

methods

can affect

he

quality

of individual

alve

component

arts,

nd

mproper

ssembly

technique learly

an affect

overall

alve

performance

integrity.

When

using

sources

ot sanct ioned

y the OEM

for

valveservice,

he

process

wner

cannot

be assured

hat

industrystandards

nd

equipment

ert i f icat ions

re

mainta ined.

Indeed,

NSI, ASME,

PED,0SHA,

FM

and

other

ndustry nd

product ual i f ica-

tions and

certifications

an

be compro-

misedhrough

mproper

erv ice r

main-

tenance

practice.

Furthermore,

non-sanct ioned

ources

sing

mproper

serv ic ing

ractice

an

compromise

asic

function,

erformance

r safety

ntegrity

of the

valveas or ig inal ly

esigned

nd

manufactured.

imply

put

poor

serv ice

technique

ie lds oor

valve

quali ty.

nd

of course,

poor

valve

quali ty

impacts

process

eliability ndsafety.

In addit ion

o

increased

ncidencef

problems

Table

), the

useof

non-sanc-

HOW

OFITITI

II OEiI{ENTIFIETI

AGITTTT

You're

esponsible

ormaintaining

alves,

ctuatorsnd ontrols

nan ndustrial

application,

nd

ou

ecognizehe

mportance

f using EM

or 0EM-certified

service

acilities.

uthow o

you

o

about

ocatingEM

or 0EM-certified

alve

repair nd ervice

acilities?

t's

simple.Turn

o hemembers

f he

ValveRepair

Council

see

istof

membersn

page

1) .

TheVRCwas

ormed 0

years

go

whenhemember

ompanies

f heValve

Manufacturers

ssociationf

America aw

a need o

promote

oth

afety nd

quality

nvalve nd

ctuator

epair. sa

result,heservice

perations

fVMA

membersanded

ogether

o create

heValve

Repair ouncil.

embership

n

thecouncil

sopen

o allVMA

members

hohave ither

n-houseervice

pera-

tions r out-of-plant

ervice

acilities,

swellas

heirauthorized

ndependent

facilities.

To earn

more bouttheValve

epair ouncil,

isitVMA.org

nd licl<

n he

ValveRepair ouncil

inl<,r email

Marc

Pasternal<,VRC

xecutive

irector,t

mpasternal<@vma.org.

42 Ualve

rtrltrt

 

tioned ervice

roviders

ives

he

plant

owner/operatoress ecoursen

product

liability ases.EM manufacturersypi-

cally onothonor arranty bligationsf

non-qualified,hird-party

ervicingaus-

esanydeteriorationf

product

ntegrity.

Similarly,egal ecourses i mited s

he

owner/operatoras

contributedo the

problem

yaddingisk hroughheuse f

non-qualfied upplers.

To ensure

roblems

on'toccur, nly

the

OEM

candrawupon <nowledgef

product

esign

etails nd

ready

ccess

to themost elevantxperiencen

prod-

uctspecif icppl icat ion

l<i l l .

oensure

designntegritysmaintained

hroughout

the

product

ifecycle,ervicings deally

performed

y he

0EM

or

0EM-certified

service rganizationshatdeployechni-

cians

ho

are rained xtensively

rior

o

certification . fter receiving othclass-

roomand hands-onxperience,echni-

ciansypically re ested

hrough

ritten

and

practical

pplication.ach ertified

service rganizationustalsomaintain

proper

ertificatesf authorization,uch

as hose

rom ASME, in

addit ion o

maintaining

EM

certificationnforced

through

egular

udit.

A Range f

Services

Furthermore,ost

0EMs

offer

a

broad

range f servicesotavailablerom

he

non-OEM,onst i tut ingwhole

etof

capabilityhat canbedescribeds

"ser-

vice o improve" ather han

trepair

to

restore." hile henon-OEM

ourcean

Table .Numerous

roduct

ntegrity ompromises

anoccurwhen alves re ervicedynon-

sanctioned

acilities.

A valve echnicianworkson a repairat Dresser irect,acertified

facility n DeerPark,TX.

typical ly nly econdit ionr repair

valve

o

"as

was" condit ion,he

0EM

has ul l echnicalacl<ingo

help

end-

usersmprove alve

erformance

nd

rel iabi l i tyhrough dvancedervices

suchas diagnost ics,

design ndappl icat ion

engineeringupport,

and migrat ion

to

improved

echnology.

Even or

non-cr i t ical

valves eing econdi-

t ioned,OEM-cert i f ied

technicians,

hrough

their

valveexpert ise,

are betterequippedo

deploy

reventive

ain-

tenance

ract ice

hat

translates

nto

signif i -

cant

reduct ion

of

unplanned mainte-

nance. hatcapabi l i ty

coupled

ith higher

ual i ty

f

repair

from

he0EM can

yield

ignificantav -

ingsn

product

ife-cycleosts.

To reduce

he

risl<

f

valve

perform-

ance

roblems/

alve ailures

r

process

downtime,

processlant

owner pera-

tor

s

best ervedy

using

EMorOEM-

cert i f ied

epair

hroughout

he valve's

lifecycle.

EM servicend

epair

nsures

the

proper

echnicalxpertisendmain-

tenance

ractice

eadso reliable

roduct

performance

nd

ncreased

rocess

vail-

ability. ivenhe mportancef ndustrial

valve

assets,heir contributiono safe

and

profitable lant

operation nd he

ris l<sntroduced y non-sanct ioned

repair,

EM cert i f ied nd

warranted

servicings heonlyway o

go.

w

Plrnrcr Lemr is

director

of strategicmarketing

for Dresser asoneilan.each

im

at

patrick.

eask@fowcontrol.dresser.com.

WHAT

GtrIIGO

WROIIG?

Gomponent

imensionalntegrity

Impact

Improperit of

guiding

urfaces

Improperlange

asket

inish

Inaccurate

eat

eometry

Materials f Construction

Seat eakage;horterrim life

Shorterrim life;unexpected

art

ailure

Improper eat reator surfacereatment Shorterrim life;

possibleart

ailure

Improper se

f lubricants/sealants

Seizing

f moving

arts;

ccelerated

corr05t0n

Improperorquing f bolted

oints

Compromisef

pressure-containment

Improper

ositioner

albration

Improper eat lignmenVsealssembly Excessiveeakage

Poor

ctuator

lignment

Processingnd Certifi ation

Excessive

ear; horterife

Lack

of

non-destructivexamination Failure

f

pressure-containingart

Lackof

positive

aterialdentification

Failure f rim component

Lackof code

ualification

Compromisef

safety-

elated ntegrity

Improper

estand

nspection

Increased

evel

of defects t startup

t l r t r r 200s 43