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The importance of industrial valve maintenance

Proper maintenance is essential to keep valves running smoothly

The maintenance, revision and regular calibration of safety valves is an essential activity to maintain the quality of these systems and ensure the proper functioning of a production plant. It is also a mandatory procedure by law.

 

The control and safety valves of an industrial plant are a real investment, and they are crucial in ensuring efficient, safe and long-lasting production processes. The efficiency and smooth operation of plants depend on them. Failure or malfunction can cause significant losses in time and money, and even lead to production disruption. Preventing failures is absolutely necessary, and that’s why maintenance is such an important activity and regulated by law.

 

Regular maintenance and calibration activities, carried out by qualified personnel - such as ECI -, are essential, and the controls to which the valves are subjected are very accurate. Find out more!

 
 

The decree regulating verification

 

The periodic verification of PSV (Pressure Safety Valve) safety valves is an action prescribed by D.L.gs 81/2008 and DM 329/2004. These decrees require that all pressure equipment and its components (such as VHPs) be subject to periodic checks every two years, thus demonstrating the importance of maintaining valves in optimum working conditions for industrial applications.

 

DM 329/2004 provides for controls from the outset, through commissioning. As reported by Ecolav, "the legislation provides that for equipment or pressure assemblies installed and assembled by the user must be carried out a verification of correct installation, called verification of initial installation or commissioning". The decree also regulates the periodicity of checks according to two tables attached to the D.M. itself, which depend mainly on the fluid contained within:

 

  • group 1 fluids, that is to say the fluids classified as "dangerous" ( the substances or preparations defined by art. 2 paragraph 2 of D. Lgs 52/97, as "explosive", "extremely flammable", "easily flammable", "highly toxic", "toxic" and "comburent"). In such cases, the periodic review shall be carried out every two years.
  • Group 2 fluids such as air, air/water, nitrogen, argon, carbon dioxide, etc. Here the cadence can also be three or four years depending on the category.

 

Calibration of valves

 

Article 13 of the D.M., called "Verification of operation on the occasion of periodic verifications", specifies: "For safety valves, the verification may consist of verifying that calibration has taken place within the time limits set by the manufacturer and in any case within the limits relating to the periodicity of re-qualification verifications".

 

Calibration is therefore a fundamental operation, both for commissioning and routine maintenance. This is done mainly by two methods:

  • bench calibration, an inspection carried out on the test bench of a specialized workshop (by disassembling the valves and stopping production);
  • in-service calibration: the maintainer goes to the production facility to carry out this calibration with specific machinery. In this case the production activity is not stopped, since the valves are not disassembled from the plant. It is a task to be carried out by highly qualified personnel who are able to work even in extreme workplaces.

 

What is valve maintenance for

 

Calibration is therefore an important task to be carried out regularly. In addition to this, however, it is always good to carry out the scheduled maintenance of the safety valve.

The periodic maintenance of PSV valves meets the quality and safety standards of operators in the workplace, meets the legal requirements and the requirements of the standard that requires the employer to check the internal integrity of the equipment - it is a question of seals, springs, buffers, etc.

 

Operating the scheduled maintenance allows to reduce the risk of failure and consequent downtime of plants, with several other advantages:

  • extending the life of the valve and maintaining its constructive qualities;
  • reduction of energy losses due to malfunctions;
  • guaranteed quality and safety standards;
  • cost savings on repair of worn parts and special repairs.

What operations are carried out?

 

When scheduled maintenance is carried out, a number of operations are carried out to check the calibration and correct functioning of the safety valves. Among the various activities carried out, we find - all but not necessarily in the course of the same audit:

  • maintenance, calibration and testing of safety valves;
  • calibration, generally in operation, by means of a trolley;
  • maintenance, calibration and testing of control valves;
  • the maintenance and testing of the ball valves, the manually controlled interlock valves, the self-operated valves and the de-heaters are then carried out.

 

ECI valves: safe and high quality solutions for various industrial applications

 

ECI industrial valves are safe and reliable systems for a wide range of industrial applications. They guarantee high quality performance and versatility in every operational context. They are designed and constructed with quality materials, such as brass, bronze and cast iron, which ensure a great resistance to corrosion, pressure and high temperatures.

 

These features contribute to long-term durability, minimising downtime and maintenance costs. In addition, of course, the proper maintenance required by law. ECI aims to offer the customer the skills and technical tools necessary to ensure performance at the height of every point of view.

 

The valves supplied by the company offer an efficient and precise operation, fundamental to obtain an effective control of the flow of fluids in all operating conditions and guarantee the safety of industrial processes. They are versatile and suitable for different applications and operating environments. They are available in a variety of sizes, configurations and materials to meet the specific needs of each industrial application. Among the many solutions proposed are:

  • bottom valves
  • butterfly valves
  • globe valves
  • ball valves
  • check valves

 

And several other valves and accessories. Thanks to a long experience in the sector, ECI - European Casting Industry - provides specialized advice and tailor-made solutions for the specific needs of each client, offering valves made with different standards and ensuring a wide distribution of its products, always subject to proper maintenance.

 

For more information on ECI valves, contact us!