Case Study: The Importance of Proper Check Valve Installation and Its Impact on Facility Operations

Pumping systems are the lifeblood of many industrial operations. However, like any complex system, a single point of failure can result in costly downtime and maintenance. One such critical component in these systems is the check valve. This case study focuses on the implications of poor check valve installation in a facility with a compact footprint and the lessons learned in minimizing the total cost of ownership.

The Challenge: A Compact Footprint Facility

In a particular installation, the facility had an extremely compact layout. Due to space constraints, the check valve was installed immediately after the pump and increaser, leaving little pipe length distance between the components. This resulted in the high-velocity pump discharge focusing a jet of water directly at the check valve’s disc and pin connections.

Issues

• Premature wear on valve components.
• Improper seating of the disc.

Cost of Ownership

The total cost of ownership for a check valve extends beyond the initial purchase price. It includes:

• Initial Cost: The upfront price of the check valve.
• Operating Cost: The ongoing expenses related to energy usage and efficiency.
• Maintenance Cost: Regular and unexpected maintenance activities.

An inexpensive check valve might seem cost-effective initially but can end up costing significantly more due to unscheduled maintenance and downtime.

Field Experience

Problems Encountered

1. Proximity to Pumps and Increasers: Check valves often fail prematurely when installed too close to pumps and increasers.
2. Oversized Discharge Pipes: Design plans frequently oversize discharge pipes for future expansion, requiring extreme reducers to fit current pump sizes.

Both these factors lead to turbulent flow, wearing out the disc and pin connections, and causing premature check valve failure.

Solutions Implemented

1. Re-calculating Pipe Distance: For existing facilities, the check valve was moved further away from the pump to achieve more laminar flow. The recommended distance is at least five pipe diameters.
2. Check Valve Redesign: If there are spatial limitations, an alternative style of check valve that can withstand turbulent flow is considered.
3. Proper Sizing: The check valve was appropriately sized for the process conditions, avoiding the use of extreme increasers wherever possible.

Keys to Successful Check Valve Performance

1. Request a Surge Investigation: Always consult with the valve manufacturer to determine whether your process conditions require a check valve or a different type of control valve.
2. Consider Total Cost of Ownership: Evaluate not just the initial costs but also operational and maintenance costs over the valve's lifecycle.
3. Valve Selection and Sizing: Proper valve selection, sizing, and installation are crucial for optimal performance and longevity.
4. Design Phase Planning: All of these should ideally be determined during the design phase to avoid operational issues later.

Check valves are more than a mere component in a complex system; they are integral to the system’s success. Incorrect sizing, placement, and poor understanding of the total cost of ownership can result in significant financial and operational setbacks. This case study serves as a lesson and guide for facility managers, engineers, and decision-makers in optimizing check valve performance.

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