Valve refurbishment: Factors to consider

Valves are an essential piece of equipment and shouldn’t be considered a ‘fit-and-forget’ item. The price of replacement may depend on the size, type and application of each valve and, wherever possible, refurbishment should be considered. There are tangible cost benefits associated with refurbishment, however there are a multitude of other benefits to take into account.

Certification

When valves are professionally refurbished, specialists are obliged to follow the certified processes of the International Organization for Standardization and American Petroleum Institution. 

ISO 9001:2000 provides guidance on statistical techniques identifying ways to improve the effectiveness of the quality of products and processes. API BS EN ISO 4126 for safety devices provides guidance for protection against excessive pressure. 

The plant will be supplied with an up-to-date audit trail, with a record of the condition of each valve, which means individuals on-site can monitor the health of the plant and its equipment with ease, and begin to recognise and keep track of areas for future repairs.

Optimisation

Valves not only direct the flow of fluid but regulate temperatures. Properly used and maintained, they can improve process efficiency and lower costs. Although they are liable to deteriorate under standard wear and tear, it is often a more serious issue which causes the customer to isolate their process. In this instance, there is the option to order reconditioned valves from stock on a service exchange basis. Service providers can ensure same day dispatch/delivery for a wide-range of refurbished and tested valves. 

By refurbishing and recertifying valves on a regular basis, the chances of system downtime are reduced and steam users will benefit from improved system efficiency and lower operating costs.

Legislative compliance

For pressure relief valves, regular testing and maintenance is not optional, it is mandatory. Since 2002, most pressure equipment placed on the market must meet the requirements of the Pressure Equipment Regulations 1999, which ensures all systems are properly maintained.

Under the Pressure Systems Safety Regulations 2000, plants must comply with a number of rules and regulations to ensure safe operation. For example, a maintenance programme should be in place to look for signs of problems. Whether it be a control valve suffering from corrosion, or a leaking safety valve, the purpose of maintenance under this regulation is to ensure the safe operation and condition of the system.  In spite of this requirement, a fault in a safety critical part of the system could remain undetected unless appropriate safety checks are included as part of the maintenance programme. It is therefore important for valves to be regularly tested and inspected. A specialist can provide a complete service, managing annual boiler inspections and recertification – as well as carrying out any necessary repair and refurbishment.

Safety best practice

Managers of a workplace have a duty to manage the risks associated with the site. For example, valve failure and its associated risks can be a significant cause of disruption to production, plant and people. Poor maintenance can create a risk of injury which makes following the correct safety guidelines, and conducting best practice, absolutely paramount. If an incident occurs, and valves have been serviced, audit records will provide vital evidence of compliance. 

One for all

Companies specialising in valve refurbishment can often refurbish a variety of valves, including control valves, globe valves, parallel slide valves, gate valves, and other manual and safety valves. Refurbishment can vary from a stripdown to a paint and dispatch with test certification, and can be completed on- or off-site.

It is difficult to say by how long refurbishment can extend a valve’s life, but the cost to refurbish in some cases may be more attractive than the cost of a replacement. Refurbishment costs may average between 50 and 70% of the price of a new valve, but can be a little as 30%. At the very least, maintenance managers should ask themselves whether a complete replacement is really necessary.