Tips for Reducing the Total Cost of Owning Valves
The two things that come to mind when talking about the total cost of owning valves are valve prices and regular maintenance – without a doubt, the most effective strategies for reducing valve costs. But in many cases, valve maintenance needs can increase over time, and spending money on maintenance can erode the initial savings made when purchasing the valve.
Low-cost valves often require more maintenance and therefore incur more costs in the long run. On the other hand, many expensive valves also have complex maintenance procedures that incur more costs.
These costs add up to huge sums in the case of large companies that have hundreds of valves.
So, the idea of cost savings should not end with the purchase and maintenance of valves. Focusing on reducing the total cost of owning a valve can open up many other avenues for reducing costs in the long run.
Consider these ways to reduce the total cost of owning valves
Choose the right valve size
We’ve previously covered the importance and use of each type of valve in water treatment plants. Oversized valves are sometimes deployed as an additional safety measure. Reports suggest that around 50% of valves tend to be oversized. Deploying oversized valves increases expenditure on purchase costs as well as on maintenance and operating fronts. It is best to avoid this.
Important article on: Maximizing the efficiency of greywater treatment equipment with the right valves
Reducing the need for maintenance
Regular maintenance of valves is of course an advantage. However, if the maintenance interval is short, it means that you have to spend time and money frequently checking and repairing the valves. Alternatively, you can take measures to make these intervals longer. For example, valves that operate in dusty environments are often fitted with dust protection modifications. This extends their life while reducing the need for maintenance.
Also read: Valve System Maintenance Guide: Preventive Measures and Scheduling Best Practices
Check Quality
In a globalized world, valves are sourced from far away places. It is difficult to monitor manufacturing and testing conditions. In such cases, ensure that the valve has key test certificates. We address customer concerns about traceability with effective solutions. Customers can now track the progress of their valves through the manufacturing and testing process and address their issues as soon as possible.
Consider valves that can switch roles
Valves are available in both custom and standard designs. Custom valves can provide better performance for specific applications. However, in rare circumstances, if the entire line has to be shut down, these valves also become useless. However, standard valves can be removed and deployed in new roles. Depending on the size and needs of their business, users should decide which valve to choose.
Ensure rapid repair and replacement
The ability to complete valve repairs quickly, or replace failed valves within a short period of time, reduces downtime. When selecting valves, look for valves that are easy to clean, repair, and can be replaced quickly. Finding a reliable valve supply partner can solve this problem. Sourcing all valves from a single supplier also ensures greater reliability and ease of maintenance in your network.
Optimize spare parts inventory
Ask your supplier to help you conduct a “criticality analysis” of your valve inventory. Based on equipment classifications, they can help you develop an inventory strategy that aims to minimize excess or unnecessary inventory while optimizing the impact of remaining inventory. This will ensure that the most critical components are readily available when they are needed. Critical assets (new or refurbished replacement valve assemblies) should be prepared so that downtime due to failure or damage is minimized through rapid replacement. For less critical spare parts, you can ask your valve supplier to maintain stocks at your local service center for purchase when you need them. This will reduce the inventory investment required.
Choose the right partner
The right supplier can help you make choices that will continually improve your operational performance and reduce costs. We at Water Care are proud to be that partner. We help you find the right solution for your application through a number of questions, which you will find below:
What media do you want to control?
The best place to start is with the media to be controlled, as this will affect the options available for valve material. After choosing the right type of valve, the correct construction material must be determined. If the media is corrosive, stainless steel is likely the best choice. However, for many common applications – providing cooling water to a machine for example – a brass ball valve or butterfly valve with polyamide coated discs is perfectly adequate. They also cost significantly less than stainless steel alternatives. By making smart choices, it is possible to offer the best quality and best price when choosing valves.
What operating pressure do you operate at?
The choice of operating pressure can have significant implications for cost and energy. All valves are clearly rated for pressure and there is a wide range available. For butterfly valves, PN16 is the most common nominal rating specified for general industrial applications – but this does not mean that it is the most efficient for your specific requirements. For example, if the process pump supplying media will only be supplying 4 bar, or if the valve is mounted on an open vessel outlet, there is the opportunity to choose lower media pressure ratings on the valve.
What is the best actuator technology?
The actuators come in There are four basic types: manual, electric, hydraulic or pneumatic. The final choice will be influenced by the number of valves you want to control and whether functions such as a safety option or adjustable speed are required. Pneumatic actuators are very simple in design compared to electric actuators, so they offer lower initial costs and maintenance. Pneumatic actuators can be very cost-effective for applications involving more than three or four valves – even if a dedicated source of compressed air is not available. The pneumatic solution generally offers a good range of features and good value.
What safety features are required?
A dual-acting pneumatic actuator meets the basic safety requirements in most applications because it will stop in its current position if the compressed air source is lost. It is actually the least expensive option because it requires fewer internal parts and can be smaller, providing a cost-effective alternative to a single-acting actuator. For safety-critical operations, such as transporting flammable gases or liquids that pose a risk of contamination, a single actuator offers enhanced safety.
Have you optimized your actuator selection based on your air network pressure?
Ensuring the compressed air network pressure is critical to sizing pneumatic actuators. Industrial applications typically use 5.5 or 6 bar systems as they are generally thought to be the most economical. However, if higher pressures are to be supplied, a smaller actuator can be specified, which means lower purchase costs and less energy wastage. If the plant is operating at lower pressures, a larger actuator is required to ensure safety is not compromised. In some circumstances, it may be more cost effective to install a local pressure booster to supply air to the actuator, rather than operating the entire system to deliver it at the actuator’s pressure rating. The downloadable process valve automation tool helps customers select the right actuator and valve set for each specific pressure from a range of suppliers and manufacturers.
Are there any other considerations?
Lubrication of moving parts is essential to ensure that pneumatic valves and actuators continue to perform at their optimum. Traditionally, this has entailed a constant maintenance requirement to check and top up lubricants; which not only has lifetime costs but also some associated environmental issues. Modern pneumatic systems for industrial applications now feature lifetime lubricants to provide trouble-free operation throughout their design life. The only challenge is remembering not to introduce any lubricants at all!
Read also:
Cost management in choosing the right valve for water treatment plant
