For a very long time, a number of domestic industries make use of valves as important components of their complex machinery. Valves play an important role in ensuring the safety of heavy machinery used in industries. But over time, these valves tend to get old and fail to function as intended. At those times they are either sold or abandoned as garbage. This can incur a huge degree of manufacturing loss for the industry. Thus it is important to look for ways to repair and maintain the values rather than abandon them as garbage. Repairing and maintenance of valves does not simple include manual repair but includes taking into account the right repair methods and making use of superior repair equipment to get them back to function.
Enhancing the performance of valves:
In any process plant or manufacturing unit, it is common to see hundredths and thousands of control valves. These valves serve as the final control element of the equipment and are responsible for keeping the process variables such as flow, level, pressure, and temperature of the equipment within in desired operating range. These valves and their maintenance are however neglected and this can happen predominantly in two ways,
The importance of the valves is overlooked by engineers, managers, or other personnel who are responsible for enhancing the process efficiently. The second important aspect of neglect is that the control valves are not maintained properly and they cannot function at their desired performance level.
What do the valves actually do for you and your equipment?
The valves are not just mere components that regulate the flow and temperature of the media that runs through the pipelines. Though this is their main function, the value they bring to the operation goes beyond all of that. In a manufacturing unit, product quality is related directly to the consistency of the manufacturing process. The product that comes out at the end of the manufacturing process should be of consistent quality every time. if this doesn’t happen then the business runs the risk of either discarding the product or disappointing the customer.
Valves also contribute significantly to the overall efficiently of the plant, in terms of both production and energy. First of all, they reduce the process variability and they minimize waste in the plant. There is less to throw away from the entire line, both raw materials and finished products.
The values also help in controlling the process variables, they enhance the energy efficiency of the plant. They maintain temperature control and can also improve the heating efficiency of the plant. By improving the product quality and by raising the plant efficacy, the value renders a great impact on the profitability of the plant as a whole.
Consistency in the product relies on the consistency of the manufacturing process. This is exactly the job of the values. By having the right valve size and type installed on the lines and with periodic maintenance of the valves by experts such as F.W. Webb, it is possible to enhance the life of the valve and the quality of the manufacturing process for many years.
Reasons for values performing below their peak performance:
Some of the reasons why valves render sub-optimal performance are as follows
- Dead band: This problem occurs when a controller sends a signal, but the valve doesn’t move. The controller thus has to send a bigger signal that can cause the valve to travel too far and rendering it to open or close more than what is desired.
- Hysteresis:This problem is frequently caused by loose mechanical linkages between different components of the valve assembly.
- Stiction: This is the combination of both stick and friction. This is the situation when the valve gets stuck in a particular position.
- Non-linearity: Valves work best when they respond to a signal in a linear fashion.
Maintenance tips to get the valves working properly:
The biggest problem of all the control valve problems according to F.W. Webb is instability in the control loop of the valve. This often takes the form of dead time. The result is that during such a delay between the controller sending the signal and the valve travelling to its desired position. The process variable level will either be too low or too high. The trick to avoiding dead time and its consequences is to select the right type of valve for the application. Ensure that the valve is installed correctly and appropriately and most importantly follow a plan of regular maintenance and repair for the value from a trusted and dedicated service provider. They will also be able to render their service with the budget of the industry for repair and maintenance over heads.