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8/12/2019 Avoiding Ethylene VALVE Failure
http://slidepdf.com/reader/full/avoiding-ethylene-valve-failure 1/5
Maximize uptimeand profits.
The 5 keys to
avoiding ethylenevalve failures
8/12/2019 Avoiding Ethylene VALVE Failure
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2 The 5 keys to avoiding ethylene valve failures
1. Select the right seats and seals.When it comes to olefin processing, valve leakage
is a maintenance headache, a waste of money, and
most of all, a safety risk. Advanced stem seal designs
limit fugitive emissions, extending the valve lifecycle. The right valve seat material can minimize
seal performance issues and instantly lower your
overall costs. Your valve supplier should be offering
ethylene-specific sealing technologies that use
advanced materials and complementary seat
geometries proven to:
• Eliminate leaks
• Prevent material buildup
• Improve shut-off performance
• Provide superior upstream and
downstream seals
• Withstand higher temperature
and pressure extremes
• Increase valve longevity
As the demand for ethylene has risen, so has the need for specialized valve
solutions. The steam cracking process requires valves to operate flawlessly
in temperatures up to 750-850º C/1380-1560º F in furnaces. Propanedehydrogenation calls for valves to optimize the process while reducing
fugitive emission. Now, more than ever, the industry needs repeatable, reliable
and accurate valve performance. Here are 5 keys to avoiding ethylene valve
failures while ensuring longer, trouble-free process performance that saves
millions of dollars by eliminating unscheduled shutdowns.
The 5 keys to avoidingethylene valve failures
2. Select the right coating materials.An optimal combination of coating processes and
materials provides a cost-effective method of
attaining increased performance of a component’s
surface. They are carefully chosen for their corrosion,abrasion, erosion and thermal expansion
compatibility with the substrate. Application
processes include:
• Electroplated – coating is applied in acid
or catalyst vat
• Thermal Spray & Fuse – coating is applied
by flame or vacuum furnace
• High Velocity Oxy Fuel – powder coating
is applied with gas jet
• Plasma Transfer Arc Welding – coating is
welded to the substrate
Specialized coating materials are chosen for
thickness, hardness and substrate compatibility.
They provide important benefits such as:
• Reduce coefficient of friction
• Mitigate galling
• Extend the life of the valve
• Improved bond strength and surface hardness
Material Combinations for Specific Ethylene Applications
8/12/2019 Avoiding Ethylene VALVE Failure
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The 5 keys to avoiding ethylene valve failures 3
3. Know the quality of the valvesyou’re buying.
Because of global sourcing, valves can be
manufactured anywhere, making the integrity of
raw materials and castings a problem to consider.
Conformance to standards does not guarantee a
manufacturer delivers the quality you need. The
“standards” only outline minimum requirements. Tighter limits and more stringent quality controls
are crucial in order to optimize olefin processing
performance and keep your costs low. To protect
yourself, make sure your valve supplier details the
steps they take to eliminate casting quality issues.
Ideally, they should be able to constantly test their
products in their own or contracted engineering
and metrology labs, and on the factory floor.
4. Find a trusted single resource foryour valve package purchases.
Dealing with a single source valve supplier canprovide convenience and cost savings. But more
importantly, valve packages perform more reliably
because their components are designed and
engineered to work together. Parts and materials
have also been manufactured to the same stringent
quality standards using best practices and the latest
technologies. Your supplier should treat the entire
valve automation package as a single, functional
solution. Everything should be designed to work
together and warranted as one package. This
mitigates risk, cuts initial investment, and minimizes
total cost of ownership.
5. Keep up with requiredmaintenance.
Ethylene valve uptime and ownership cost
reduction doesn’t begin and end with hardware.
Understanding your specific application demands
and what it takes to minimize, predict and prevent
downtime is essential. Create routines for checking
the performance of specific valves based on theirknown life cycles – and keep track of data in
historical databases in order to analyze trends and
performance behaviors. Much of this can be
automated. Valve networking solutions allow for
systematic, remote monitoring of on/off valves,
while digital valve controllers enable advanced
diagnostics and predictive maintenance for control
valves. Pre-shutdown valve audits can also help
identify where problems are likely to occur and
what contingencies are required to address them.
These strategies can also help you extend
maintenance intervals, especially since many
valve owners schedule shutdowns earlier than
they need to. With the right data, you can pinpoint
the exact timing for maintenance and possibly
extend runtime.
Temperature requirements
• Construction materials
• Thermal expansion
of materials
High cycle applications
• Type of valve
• Coatings
Incorrect seat designs
• Material buildup
• Upstream / downstream
sealing
Actuator sizings
• Clean torques versus
“in process” torques
Type of valve
• Linear, rotary
Material / Coatings
• Corrosion
• Erosion
Leading Causes of Valve Failure
8/12/2019 Avoiding Ethylene VALVE Failure
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4 The 5 keys to avoiding ethylene valve failures
Don’t just spec a valve.Spec a valve partner.At Metso, we understand the critical needs of
the olefin industry. We offer a comprehensive
ethylene-focused product line along with complete
service and support that improves performance,
minimizes problems and increases your revenues
throughout the entire product life cycle. Expectresults with our:
• Dedicated technical support
• 24/7 field service
• Maximum product availability
Working with a
valve partner who
understands optimal
seat design and
surface coating
combinations for
each application
within the ethylene
process is critical.
Metso’s experts
know these variables
and have engineered
a full line of Neles®,
Jamesbury® and
Mapag® control,
safety andautomated on/off
duty valves. They’ve
been proven to last
7-9 years without
problems, compared
to only 3-4 years for
competitive valves.
8/12/2019 Avoiding Ethylene VALVE Failure
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Europe
Vanha Porvoontie 229, P.O. Box 304FI-01301 Vantaa, Finland
Tel. +358 20 483 150, fax +358 20 483 151
North America
44 Bowditch Drive, P.O. Box 8044Shrewsbury, Massachusetts, 01545, USA
Tel. +1 508 852 0200, fax +1 508 852 8172
South America
Av. Independência, 2500-Iporanga18087-101, Sorocaba-São Paulo, Brazil
Tel. +55 15 2102 9700, fax +55 15 2102 9748/49
Asia Pacific
20 Kallang Avenue, Lobby B,#06-00 PICO Creative CentreSingapore 339411, Singapore
Tel. +65 6511 1011, fax +65 6250 0830
China
19/F, the Exchange Beijing, No. 118Jianguo Lu Yi, Chaiyang Dist100022 Beijing, China
Tel. +86-10-6566-6600, fax +86-10-6566-2575
Middle East
Roundabout 8Unit AB-07, P.O. Box 17175Jebel Ali Freezone, Dubai, United Arab Emirates
Tel. +971 4 883 6974, fax +971 4 883 6836
For further information please contactone of our regional offices or visit ourweb site www.metso.com/valves
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