Client Requirements
Our customer experienced a valve actuator failure in their plant and found this failure was caused by water leaking through a valve gland into the actuator. The plant faced two main challenges:
- Material mismatch: All line equipment was super duplex stainless steel, but valve stems were SS316, prone to corrosion.
- Cost constraints: Replacing all 100+ valve stems with higher-grade material would be expensive. The client needed a cost-effective trial solution to determine if leaks were isolated or systemic before committing to a full replacement program.
Our Solution
BEP Flow Solutions manufactured custom plastic spacers to sit precisely between the valve and actuator as per customer design. Key design features included:
- Uniform spacing: Created a visible leak path to detect gland leakage externally.
- Bright, easy-to-inspect design: Yellow color and protruding tab allowed inspectors to confirm spacer placement and quickly identify leaks.
- Lightweight polymer construction: Allowed fast, repeatable installation during scheduled shutdowns.
Outcome
- Cost-effective: Offered a low-cost alternative to full valve stem replacement.
- Trial approach enabled: Allowed testing across 100+ valves to identify hidden leaks before committing to upgrades.
- Quick and repeatable installation: Minimal impact on shutdown schedules.
- Early success: Initial deployment shows strong potential as a proactive leak detection method.
Client Impact
The client avoided immediate capital expenditure while gaining a practical tool to monitor and prevent leaks. This proactive solution reduces the risk of future actuator failures and extends the operational life of existing equipment.
Takeaway
No problem is too small or too sneaky for BEP Flow Solutions. We pride ourselves on delivering practical, proactive solutions that put client satisfaction first.
