Getting The Most From Control Valves
The onus is on steam plant owners and operators to reduce energy consumption and optimise plant performance. Andrew Prew, Market Development Manager at Spirax Sarco outlines the energy-saving and other benefits of modern control valves and explains why a failing valve can actually be an opportunity to cut energy consumption, improve process control and reduce costs.
It is estimated that more than 70% of existing valves are over-sized because steam load has either reduced since their installation or been overestimated. Failing to take action contributes to energy inefficiency though poor process control, leading to increased costs. (Read More)
Choosing the right control valve
Replacing a failing valve with a modern, correctly-sized unit, whether as an emergency measure or during planned maintenance, will enable your organisation to reduce energy consumption through improved control, as well as maintain productivity and reduce lifetime cost of ownership.
An over-sized valve is not just more expensive to buy and install, it is far more likely to fail. Fluid flow through control valves inevitably causes valves to vibrate. If a valve is over-sized, the vibrations tend to be greater and can even alter the valve’s position. Even a small change can have a large effect on flow, resulting in poor control and, ultimately, increased energy consumption and escalating costs.
Modern control valves also offer a other benefits compared to conventional models. Many conventional valves feature screw-in seats that often seize in place, meaning that if maintenance is required, or if the duty of an existing valve has to be altered in response to changing system demands, it is often necessary to remove the entire valve assembly from the pipeline, risking a further lengthy plant shutdown and associated costs.
Advanced models feature quick-change ‘clamp-in-place’ seats that enable the duty to be altered to match changing plant conditions while the valve is in situ, rather than the entire valve being replaced.
The self-aligning ‘clamp-in-place’ seat also simplifies maintenance so no special tools are required and there is no need to take the valve out of the pipeline.
Immediate savings
Today’s control valves are designed to be easy to install and easy to use. Many models can be supplied ready-commissioned, enabling ‘plug and play’ functionality. Fast delivery and installation is crucial to avoid the disruption of a lengthy shutdown, so look for a vendor that can guarantee to deliver a control valve perfectly matched to your system within 48-hours.
Once in place, steam users will start to reap the benefits immediately. So, the next time your organisation is due to upgrade its control valves, or if a control valve starts to fail, don’t think of it as a nuisance - think of it as an opportunity to improve energy efficiency and process control and save money.
For More Information:
Spirax Sarco, Charlton House
Cheltenham, Gloucestershire
GL53 8ER, UK
Visit: www.SpiraxSarco.com/uk
Telephone: 01242 521361
