Process valves
Process valves: technology, application and the right choice
Process valves examined up close
Process valves sit in the production line itself, where they isolate, divide and protect the process rather than simply closing a pipe. With process valves the difference between a good and a mediocre solution often sits in details that do not show on a drawing. It pays to understand the working principle behind process valves first, because the limits follow from that principle. In petrochemicals high temperature, high pressure, sour gas and strict emission requirements come together in the same plant. There is a clear difference between isolating and controlling, and many problems arise because an isolation valve is given a control duty it was never built for. Isolation valves separate sections so that work can be carried out safely, which makes the tightness requirement a safety requirement. Operating conditions govern the service life of process valves far more strongly than the nominal figures on a datasheet. That principle explains why process valves behaves differently from a standard execution under heavier duty. With process valves it pays to include phase changes in the medium, because those sharply increase the load on the seal. In a pipeline the issues are long distances, varying conditions and limited access, which puts reliability above everything else. A valve is selected on medium, pressure, temperature, tightness requirement and actuation, in that order. The term process valves is used broadly in the market, which is why it helps to define precisely what it means in your case.
Material, seat and construction on process valves
Reproducibility is the core requirement, because a plant that behaves differently each batch cannot be controlled. How process valves behaves under varying load says more about the quality of the selection than behaviour under steady load. The balance between required tightness and available operating force is a recurring tension on process valves. Where several products share a line, material selection has to be based on the most aggressive of them. The sector in which the valve runs additionally determines which standards, inspections and documentation have to be supplied. In chemicals the variety of media is greatest, and material selection is often reconsidered for each section of pipework. Industrial valves together form the control and isolation system of a plant, and their reliability largely determines plant availability. Automation means actuator reliability counts as heavily as valve reliability. We also advise when the conclusion is that a simpler or cheaper type is sufficient, because a satisfied customer comes back. Dutch Valve Vision deliberately works in the specials segment, because that is where technical knowledge makes the difference. On process valves we always check the full operating envelope, including start up and shutdown. We regularly see that a small change in the execution of process valves makes a large difference to maintenance frequency.
Applications of process valves in industry
They are used in chemicals, pharmaceuticals, food production and in plants running batch or campaign production. In process industry the emphasis is on reproducibility, which translates into tight selection and good documentation. Our customers work in chemicals, petrochemicals, pharmaceuticals, power generation, offshore and in hydrogen and ammonia projects. Our customers use process valves in positions where a failure has immediate consequences for production. For process valves the sector determines which documentation and tests belong with the delivery. Demand for process valves reaches us mainly from projects where the standard range falls short. In an existing plant process valves is often part of a wider question about availability and maintenance. In pipelines and tank storage the drivers are isolation, safety and demonstrable tightness over long periods. What defines us is that we would rather spend an extra half hour on the specification than ship the wrong valve that comes back two months later. Dutch Valve Vision operates under a KIWA ISO 9001 certified quality system, which in the RFQ stage of chemical and offshore projects is usually a hard requirement. During turnarounds process valves is regularly on the critical path, and then predictability matters more than the lowest price. We supply process valves both for new build and for replacement within existing installations.
Specifying process valves correctly
Where there is doubt about process valves we quote two executions side by side, with the trade offs stated explicitly. A valve that is technically adequate but lacks the required certification simply cannot be bought by a chemical plant buyer. Total cost of ownership weighs more than purchase price, because a valve that has to be replaced during a shutdown costs a multiple. We start a sector project with the question of which standards are mandatory, because that defines the room available in the rest of the selection. For process valves total cost of ownership weighs more than purchase price, certainly when replacement has to happen during a shutdown. For process valves we ask as standard for DN, pressure class, medium, temperature and required actuation. If a simpler type will do the job, we say so on process valves, even when that means a smaller order. On process valves we check that the actuator is sized on torque at maximum differential pressure and not on an average value. For recurring supply we record the configuration, so follow up orders run without repeated engineering. We supply both individual valves and complete packages for a project scope, including actuation and documentation. For an accurate quotation we need the nominal diameter, the pressure class, the medium, the operating temperature and the required actuation. We never recommend a heavier execution of process valves than needed, because over specification only raises price and lead time.
Process valves supplied with technical advice
For process valves you can come to Dutch Valve Vision for the selection, the delivery and the support afterwards. We work as a technical supplier rather than a catalogue reseller, which means we carry out the selection ourselves on the basis of medium, pressure, temperature and code requirements. We handle an enquiry for process valves on its technical merits rather than as a price request that only produces a number. For repeat orders of process valves we record the configuration, so a follow up delivery is identical to the first. Our specialists are happy to discuss process valves on the basis of your P&ID, your datasheet or simply a photograph of the situation. Documentation such as material certificates, test reports and declarations is supplied as standard, matched to what the project requires. For shutdowns and turnarounds we look at accelerated routes, and in those cases we are honest up front about what is and is not achievable. We keep the configuration data for process valves on file, which saves a great deal of searching if a fault occurs later. Documentation on process valves has to be the kind a buyer or inspector accepts without discussion. We record which execution of process valves was delivered, so a follow up delivery or spare part matches exactly later on. We think along on the spare parts strategy for process valves, so critical positions stay covered. Send us your DN, pressure class, medium and temperature at sales@dutchvalvevision.com, or call +31 (0)70-2210560 to speak to a specialist.
Frequently asked questions about process valves
What exactly does process valves mean?
A valve is selected on medium, pressure, temperature, tightness requirement and actuation, in that order. Isolation valves separate sections so that work can be carried out safely, which makes the tightness requirement a safety requirement. In chemicals the variety of media is greatest, and material selection is often reconsidered for each section of pipework. In petrochemicals high temperature, high pressure, sour gas and strict emission requirements come together in the same plant. We always explain why we arrive at a particular recommendation on process valves, so you can follow the reasoning yourself. If you are unsure about this on process valves, we are glad to put the question alongside the actual process data. Anyone looking into process valves quickly runs into a choice that goes beyond picking a catalogue number. Our market is project driven and international, and we deliver worldwide to installers, EPC contractors and end users.
Which executions of process valves are available?
Industrial valves together form the control and isolation system of a plant, and their reliability largely determines plant availability. We supply both individual valves and complete packages for a project scope, including actuation and documentation. For recurring supply we record the configuration, so follow up orders run without repeated engineering. Reproducibility is the core requirement, because a plant that behaves differently each batch cannot be controlled. On process valves we include start up and shutdown, because that is where the heaviest loading occurs. The answer on process valves depends strongly on operating conditions, which is why we always ask for those first. For process valves this means that construction and operating conditions cannot be judged separately. Dutch Valve Vision operates under a KIWA ISO 9001 certified quality system, which in the RFQ stage of chemical and offshore projects is usually a hard requirement.
Which materials are used for process valves?
Automation means actuator reliability counts as heavily as valve reliability. In a pipeline the issues are long distances, varying conditions and limited access, which puts reliability above everything else. Where several products share a line, material selection has to be based on the most aggressive of them. The sector in which the valve runs additionally determines which standards, inspections and documentation have to be supplied. In most projects process valves turns out to be less standard than it first appears. This is one of the points on process valves where suppliers differ most clearly from one another. What weighs heaviest on process valves in practice is the combination of temperature and differential pressure, not either one alone. Alongside QUADAX and PRUSS we represent Pibiviesse, Schroeder, Striko, Malbranque, Daume, FluoroSeal and Guichon, so we can select the right brand for each project.
What should I watch technically on process valves?
What should I watch technically on process valves?
Which applications call for process valves?
They are used in chemicals, pharmaceuticals, food production and in plants running batch or campaign production. Our customers work in chemicals, petrochemicals, pharmaceuticals, power generation, offshore and in hydrogen and ammonia projects. In process industry the emphasis is on reproducibility, which translates into tight selection and good documentation. In pipelines and tank storage the drivers are isolation, safety and demonstrable tightness over long periods. For process valves a good specification up front is cheaper than a correction afterwards. The answer to this question on process valves changes as soon as the medium or the temperature changes. On replacement we always check the existing installation dimensions for process valves, so the pipework can stay untouched. We think along from the basic specification through to the tag plate, and supply documentation that a buyer or inspector accepts without discussion.
What determines the price and lead time of process valves?
We keep spare parts and overhaul kits mapped per project, so that a breakdown does not start with a search from scratch. We quote a realistic lead time rather than an optimistic one, because a missed delivery date costs more than an extra week in the planning. A P&ID, a datasheet or even a photograph of the existing installation often helps us faster than a long description. For an accurate quotation we need the nominal diameter, the pressure class, the medium, the operating temperature and the required actuation. That makes process valves a subject where discussion up front pays for itself in operation. On process valves we prefer a well founded answer to a fast one that turns out to be wrong later. Dutch Valve Vision stays available after delivery of process valves for technical questions and for parts. Bring us your question at sales@dutchvalvevision.com or +31 (0)70-2210560, even when the specification is not finalised yet.
What about maintenance and spare parts on process valves?
Documentation such as material certificates, test reports and declarations is supplied as standard, matched to what the project requires. For shutdowns and turnarounds we look at accelerated routes, and in those cases we are honest up front about what is and is not achievable. Dutch Valve Vision deliberately works in the specials segment, because that is where technical knowledge makes the difference. On repeat orders we record the configuration, so a follow up delivery is identical to the first and installation holds no surprises. We always explain why we arrive at a particular recommendation on process valves, so you can follow the reasoning yourself. This is one of the points on process valves where suppliers differ most clearly from one another. On process valves we make sure the chosen execution demonstrably meets the stated standards rather than merely looking plausible on paper. Dutch Valve Vision supplies special valves for special applications from its base in Monster, the Netherlands, with QUADAX and PRUSS as the core brands in the programme.
How do I request a quotation for process valves?
If you have an existing tag plate or serial number, send it along, because that lets us work directly from the original configuration. Please also state the connection standard, the required leakage class and any project requirements such as NACE, PED or ATEX. Lead times depend on the execution, because a standard size from a running series behaves very differently from a valve in an exotic alloy with NACE certification. We come back with a proposal that explains why we recommend a particular execution, including the alternatives we considered. The answer to this question on process valves changes as soon as the medium or the temperature changes. This is one of the points on process valves where suppliers differ most clearly from one another. On process valves we come back with a proposal that explains why we recommend a particular execution. Send us your DN, pressure class, medium and temperature at sales@dutchvalvevision.com, or call +31 (0)70-2210560 to speak to a specialist.