Don’t you hate it when you discover a leaky faucet in your home?
Now, imagine this. Your home is not a house but a large-scale chemical processing plant. How would you feel if you find out that one of the crucial pipes is leaking because of a faulty actuator valve?
The potential for disaster is unimaginable.
If you just look at the big picture, valve actuators seem like just tiny cogs in the machine. Meanwhile, in any industrial plant, there are hundreds and even thousands of valves with diverse functions. These valves are responsible for maintaining key process variables such as pressure, flow, etc.
And it’s the actuator that provides the mechanism for the valve’s primary role: opening and closing.
Actuators are often underappreciated, but it’s time to change all that. Check out these maintenance tips so you can give some well-deserved love to these devices.
Perform a Visual Inspection
This step is just eye-balling your equipment. Start with the external surfaces first. The paint finish might clue you in on the presence of corrosion.
Then inspect the valve assembly and what’s in the pipe. Check the condition of the valve actuator, valve stem, and valve ends.
Look for signs of corrosion such as rust, discoloration, and the presence of mineral deposits. If present, it’s possible that there’s a leak somewhere. Depending on how bad it is, you might need to replace worn parts or the whole valve.
Do a Functional Inspection
This is the part where you test the valve for common problems. The simplest way to do this is to operate the handwheel and confirm that the valve is physically moving in both directions.
The next step is to check for three common valve problems: deadband, hysteresis, and stiction. These issues occur even in automated valve actuators (check out “what is valve automation” for more information).
Deadband is when the valve doesn’t move even if the controller sends a signal. Hysteresis is when the same input signal creates different output results. Stiction (‘stick’ and ‘friction’) is when the valve is stuck in a position.
These problems are often caused by incorrect-sized actuators and loose mechanical linkages. Excessive friction is also a common culprit, which leads us to the next part.
Lubricate Your Valve Actuators
Ask any engineer, and they’ll tell you that most mechanical problems can be solved by slapping on some grease.
Proper lubrication does a lot for any equipment with moving parts. It reduces friction which, in effect, will limit the amount of wear and lower operating temperatures. It extends the life of your valve immensely.
The right lubricant can even minimize metal corrosion. It also helps the valve maintain a proper seal, thus keeping contaminants out of the system.
Always check oil levels and replenish if necessary.
Clean the Area
The simple act of cleaning the valve goes a long way. How you go about it isn’t rocket science. Just wipe the area clean with a cloth or use a wire brush to remove some gunk.
Even if you only clean your valves once a year, it can do wonders for the longevity of your equipment.
The Importance of Preventative Maintenance
It’s easy to overlook the role of valve actuators in the operation of your facility. But if you take care of them, they’ll take care of you. This article is a reminder to check on them regularly.
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