The use of highly agrosive and corrosive chemicals under high pressure has made maintaining safety, reliability and efficiency in industrial plants very challenging. Even the smallest of valve malfunctions can lead to, safety and economic disasters such as unplanned downtimes and huge catastrophic events. In this case, we review how outstanding the operational safety, maintenance efficiency and long term performance of chemical processing plants is from using PTFE lined ball valve and PFA lined ball valves.
The Case Risks Associated with Processing Chemicals
Conventional metal valves of all types are subject to the growing risks of acid solvents and other aggressive fluids through valving; this is done through some of the worst consequences associated with aggressive and corrosive fluids. Protection through coating of some valves reduces but, does not eliminate risks of highly corrosive scaling and wearing. Loss resulting Leakage of aggressive valves pose significant dangers to the maintenance downtime which is largely spent in the following fears:
- Safety concerns
- Unreliable plants
The reason this case has become more and more frequent is due to the underlying problem of corroding valves which lead to minor leaks. Though major disasters have not been recorded, the problem with the rising number of frequent repairs and unplanned downtimes has become more and more pressing.
The Solution Using Lined Valves
To solve the problem, the plant chose to introduce a series of lined valves with corrosion resistant valves features and durability. Unlike normal valves, these possess linings of protective PTFE of PFA that encapsulate a non-reactive barrier to the fluid and the valve body.
The major installations consisted of:
- PTFE lined ball valve units within the high transfer line of acids
- PFA lined ball valves within the handling systems of solvents
- Miscellaneous chemical valve and pipes for systems of dosing and mixing
By deploying these advanced valves that were resistant to corrosion, the facility made sure that even the most corrosive fluids would not corrode the surface of the valve, thus minimizing any leakage and improving facility plant reliability.
Why the PTFE Lined Ball Valve Was Selected
PTFE (Polytetrafluoroethylene) is highly appreciated for being inert to most chemicals and stable within a wide range of temperatures. The PTFE lined ball valve was selected for acids and for fluids that are highly acidic such as Hydrochloric and Sulfuric acids because:
- It is resistant to virtually all corrosive chemicals
- It operates across a wide range of temperatures
- It provides a tight shut off thus reducing the leakage issues
This solved the problem of rampant corrosion on the steel valves and prolonged operational life while reducing the frequency of replacements needed.
Gains of PFA Lined Ball Valves in Solvent Systems
The facility decision for PFA lined ball valves was to deal with the solvent lines. PFA (Perfluoroalkoxy) has much in common with PTFE in terms of corrosion resistance but has greater mechanical strength and flexibility. The benefits noted are:
- Decrease in permeation of aggressive solvents
- Increase in resistance to mechanical stress
- Decrease in maintenance intervals due to reduction in downtime
These valves were critical in ensuring that the handling of solvents was safe and reliable with protection against the consequences of valve failure.
Contribution of Corrosion Resistant Valves to Safety
Operational safety changes were profound with the addition of corrosion resistant valves. The plant was able to mitigate the:
- Suppress routine emergency valve repair
- Chemicals exposure to the employees
- Cross contamination in the product lines
- Industrial safety regulation compliance
The study shows that such investment in lined valves simply lowered the operational risks and maintenance costs.
Importance of Maintaining Industrial Safety Valve Maintenance
As the new lined valves offered unmatched durability, the factory industrialized the industrial safety valve maintenance program as well. Preventive inspections on safety valves were diuretic which ensured:
- The primary walls of mechanical wear were captured early.
- There was acceptance of the security of the internal linings.
- The cleanings heads the eliminations of scaling debenture.
This systemº of working, ensured peeps bolts and other safety system valves on the systems which would risk unexpected failures, further strenthening the plant reliability.
Results A Reliable Plant
After the completion of the lined valves, the factory saw gains of:
- 60% less valve failure related downtimes
- 40% less maintenance work
- No valve leak related safety incidents
- The lined valves were serviced for a longer time
- The reduced frequency of replacements were there fort
The implementation of the PTFE lined ball valve and the PFA lined ball valves ensured safety. These led to far less disruption in operational flow resulting in increased profitability.
The Case Study Takeaways
This case study strongly brings to the front, PTFE lined ball valve and PFA lined ball valves are made for extreme conditions with severe chemical corrosion.
To maintain operational efficiency, combining advanced valve technology with regular industrial safety valve maintenance is critical.
The proven performance of lined valves is an answer to the challenge of balancing safety, plant reliability, and cost.
Discover our Lined Valves which are focused on safety and reliability in extreme conditions.
Frequently Asked Questions
- Why do customers use coated valves?
The principal reasons are to improve plant safety, put off upkeep charges, enlarge valve lifespan, and halt corrosion. - What is the distinction between a PTFE lined ball valve and a PFA lined ball valves?
The PTFE lined ball valve is more chemically resistant and gives a broader range of temperatures, whilst PFA lined ball valves are higher in electricity and flex around solvents. - Do lined valves increase plant reliability?
Definitely, lined valves improve plant reliability by minimizing leakage, downtime, and safetly risks. - Why is maintenance of safety valves something to consider, even with lined valves?
Unscheduled failure is possible due to loss of lining, loss of mechanical efficiency, and failure to maintain integral wane. - Are lined valves suitable for all chemical valve applications?
Yes, these valves are widely used in environments with aggressive, in addition to solvents and acids, where corrosion resistance is highly needed.