Setting a pneumatic valve up for success and implementing a preventative maintenance schedule can ensure reliability and maximum life expectancy. Being proactive in design and support allows you to achieve optimum uptime and fewer problems.
Installation
Operate within manufacturer’s specifications: Review pressure, temperature and voltage ranges in solenoid-operated valves. Filter incoming air. Operate within the recommended frequency recommended. Select a valve with enough flow capacity.
Clean pneumatic piping systems: Blow out all fittings, tubing and piping before installation. Small metal shavings and particulates can enter the valve and create malfunctions and leakage.
Protect valves from the environment: Some environments are more difficult than others, such as extreme temperatures and wet or dirty ambient conditions. In some cases, mounting the valve within an enclosure may be best. Consider exhaust mufflers or pipe all venting ports to route the exhausting air remotely rather than exposing the open port to debris from the dirty environment. Consider system design alternatives such as remote air-piloted valves for difficult or hazardous operations and pilot them with manual or solenoid valves from afar.
Follow diagnostics: Diagnostic equipment and software analyze information like maintenance history, design data and performance records to identify areas of the valve that need attention. Running diagnostics also allows you to process variables that influence valve function.
Calibrate: Check each valve component before use and make appropriate adjustments. Testing promotes long-term valve efficiency and reliability. Check cylinders, actuators and upstream air preparation equipment to verify they function within specified parameters.
Lubricate components: All moving parts create friction which can increase the rate of wear. If valves and other components in the system operate better with lubrication, add an airline lubricator to the air preparation equipment.
Create Repair Protocols
Proactively establish procedures to minimize downtime and support prompt resolution in the event of a valve troubleshooting or failure. Implement a safe shutdown procedure and close off the valve to isolate it from the system. Depressurizing is essential and ensures a safe working environment for the repair team.
Other emergency repair protocols include:
- Wearing personal protective equipment
- Conducting a visual inspection for signs of damage and leaks
- Running diagnostic tests to pinpoint the failure
- Implementing repairs, including component replacement, welding or fabrication
- Completing follow-up tests to verify the operation integrity
- Documenting the incident and updating the maintenance log
Implement Valve Monitoring
Consistent monitoring allows you to make adjustments to minimize the risk of valve failure.
Types of valve monitoring include:
- Manual monitoring via physical inspections
- Automated monitoring using digital systems to transmit real-time data
- Condition-based monitoring that focuses on specific parameters to indicate a valve’s operating condition
Valve monitoring allows you to keep an eye on functionality and detect risks early. That can prevent minor issues from escalating into expensive repairs or replacements. Conducting consistent assessments helps you verify if a valve is achieving the desired flow rate and pressure rating.
Keeping valves in working order also supports safety practices and keeps your equipment in compliance with industry standards. That decreases the risk of unsafe operating conditions, accidents and injury.
Establish a Training Routine
Educating operators on preventative valve maintenance promotes safety, enhances operational efficiency and assures regulatory compliance. Industry certification, manufacturer training and in-house programs prepare your team to provide precise maintenance and emergency repairs.
Conducting training sessions also helps you verify your team adheres to protocols and procedures for evaluating, diagnosing and calibrating valve components. Improving operator skill development reduces the risk of human error, which can improve the longevity of your valve equipment.
Valve Maintenance Insight from Humphrey Products
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