Control Valve Troubleshooting or Testing

A1) It can't.

A2) It cannot be moved by hand.

Q3) Why is this facility storing junk instead of weighing it in?

Thank you for your replay. Still I am not sure.

What is the procedure to say the valve is mechanically bad or good? How you test the valve`s shaft motion or rotation? Let consider the valve is already in production line. How you decide specifically the valve is bad? On another saying, how you identify the actuator (positioner) is good but the valve is bad? Please comment more if you have detail experience in this area.

Q4) Does this facility have a Planned Preventative Maintenance programme?

Q5) What information is derived from Quality Management initiatives?

Q6) Where are the bottlenecks in the production facility?

Q7) If there are so many dud parts on the shelf, what are the Instrumentation Technicians actually doing?

Q8) If there is a need to ask a global engineering forum how to service a valve and a positioner, how did the Instrumentation Technicians get their jobs and how do they keep their jobs?

Q9) Why is the training programme for Instrumentation Technicians ineffective?

Q10) If the facility has hired so many non-productive Instrument Technicians, how does their supervisor keep in a job?

Q11) What is the facility's procedure for writing-off dud assets from its books, and why is the procedure not being followed?

Q12) What is the facility's record in regard to loss prevention and product re-work?

Q13) What is the facility's record with regard to heaalth and safety?

Hi again,

When I wrote this post I already announced that I have lack of experience in this specific area.

I guess, the objective of CR4 is cooperation on positive idea. Negative ideas or questions are not helpful as do positive ideas. I appreciate if you answer the key question to the point. Big job is undone due to lack of a key idea. I am looking for that key idea from this CR4.

I guess, when you are not answering to the point that tells me we are at the same experience level. That is normal, our experience depend from our exposure. So it is better to wait for CR4 members who have experience and willingness to share knowledge. I believe that there are numbers of CR4 members who are volunteers to help others.

Not all valves are the same. The manufacturer is the only one who can tell you what the acceptance criteria will be.

Do as any good engineer would do. Contact the valve maker and ask them to educate you.

Take the valves apart and look at them. You need the experience.

If after re-assembling the valve won't move, trash it.

You should know how to test the actuators.

Please share with us how one goes about getting a job for which one is not qualified.

Hi,

Thank you for your comment;

Can you list few items about what to look on disassembly/assembly? What are common issue regarding to hard to rotate the Valve´s shaft? Can I try to drive by using cordless power drive machine (tool)?

Thank you

WHAT KIND OF VALVES?

There are numerous styles of valves/actuators.

Some rotate, some are driven by a coil/spool.

Ball valve?

Hydraulic cartridge valve?

D03, D05

Butterfly?

36" diameter, or 1/4" diameter?

Pneumatic actuation?

Etc Etc Etc.

Thank you so much for your comments,

All are rotary valve: ball valves or butterfly valves. One example is "nels controls valve" type B1JU8/25. I tried to search for the manual but I could not find any.

I am looking to get general strategy to test:

1) To drive should be there a process flow through the valve?

2) Can I use more lever force or cordless power tool? I am worried in case I break some interlocking mechanism due to lack of detail.

Thanks a lot

I expect that, using your method of testing, the OP will be able to quickly separate the "good" valves from the "bad" valves.

And if the tester (OP) is as intelligent as I think he is, he will make sure that the "bad" valve barrel is at least twice as big as the "good" valve barrel.

And there they are.

I assume these valves are quite large, so it is no surprise that you cannot rotate them by hand. That is why they have actuators, nearly all of which are designed to exert more torque than can normally be applied by hand. I doubt if your 'cordless' tool will be effective at all.

Generally, the thread on the spindle will have rusted/ corroded/ become dirty and will become difficult to turn, or the bearings/ bushes have seized and the valve requires an overhaul. The valve 'plug' itself is only something attached to the spindle.

You need to note that 'butterfly' and 'ball' valves are not designed to rotate fully in valve the body. They generally operate only over 90 deg/ quarter turn. Only 'gate' valves run in a vertical guide where you can turn the spindle continuously until closed.

Therefore, you can see actually whether the butterfly valve is worth repairing, you need to open the ball valve and check the condition of the ball and seats to make a call for scrapping, and you can see inside 'gate' valves as to whether the plug is seized up in the guides or whether it's just the spindle sticking. Where some of the valves may be 'globe' valves, I wouldn't scrap these unless the body casting is suspect.

There is no formula...except the top dog wants to get rid of some valves because the premises are resembling a scrap yard.....make him happy.

This is something that has come about continuously over shops. Unfortunately some shops do not have a QA/QC program in place that would always require paperwork. Maybe this is something that you maybe able to bring to management's attention. Some type of traceability of paperwork usually always helps it can't hurt. To answer your question, depending on size of the valves you may be able to hold the valves stationary in a vise or a valve clamp and try opening it. Depending on how this has been stored check the seating areas to make sure debris is not in the patch of the seat if visible. Prior to trying this maybe start some type of paperwork to list all particular of valve or instrument. There are many reports that can be filled out for this, if your facility does not have one. A seat leak test and shell test can be done to see if the valve is salvageable (if valve can be functioned). This is just a start and after this a detailed report can be attached with the stored product so the next one looking at this valve will have something to go by. Make sure the product(s) are stored correctly. Tags on valves are not always what they say they are, so be careful with that as well, you must provide your customer with adequate application. If the valve has changed the tag does accommodate the properties as well. I am sure you can accomplish this with little time and patience.

kindly read carefully the valves instruction manual and find the driving force (needed to operate the valve the more force can damage the seats of it.otherwise open the valve and examine the axis of it (to find the reason for sucking)