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Do you have pressure relief valves with inlet pressure losses greater than 3% of the valve set pressure? Do you have over sized pressure relief valves causing valve chatter? Did you know a restricted lift pressure relief valve could solve these common problems?

API 526 Table 1 shows a 21% to 78% increase in effective orifice area from one selected orifice to the next lettered orifice. In some applications, the user may require an orifice somewhere in between so that the resulting rated capacity is lower. This reduction in rated capacity can be achieved by restricting the lift. A restricted lift pressure relief valve has a reduced flow area (reduced effective orifice area), resulting in a lower rated capacity for the valve. A lower rated capacity, based on the reduced lift, will lower the inlet and outlet piping pressure losses and reduce the acoustic effects. API 520 Part 2, Sixth Edition, paragraph 7.3.7.5 also recommends restricting the valve lift to address high inlet pressure losses.

Consolidated offers the 1900 Series API 526 pressure relief valve with a restricted lift option for orifices F-W under National Board capacity certification number 18223. This certification was granted by compliance to ASME B&PVC Section VIII, paragraph UG-131(e)(1). This option is available for all compressible media (gases and steam) applications for both new valves and repair valves.

ASME B&PVC Section VIII, paragraph UG-136(a)(11) gives the requirements that must be met for restricted lift applications which states valves shall not have their lifts restricted to a value less than 30% of full rated lift, or 0.080 in. (2 mm). Paragraph UG-133(h) states that when sizing and selecting valves, the restricted lift nameplate capacity shall be determined by multiplying the capacity at full rated lift as defines in UG-131(e)(3) by the ratio of the restricted lift to the full rated lift. Paragraph UG-136(c)(4)(b)(5) gives the requirements that an ASME Assembler must meet to supply restricted lift valves.

A VR stamp holder is not required by NB-23 (NBIC Part 3) to have ASME restricted lift capacity certification when performing lift restriction as part of a repair.

The nameplate on restricted lift relief devices shall be stamped to identify the reduced lift value and the rated capacity based on that reduced lift value.Restricted lift pressure relief valves may be specified by providing the manufacturer with a required restricted capacity. The manufacturer shall determine the lift that will provide a restricted rated capacity that meets the required capacity. Prior to making a final selection the purchaser shall confirm that the restricted lift relief device meets the design requirements. Note that valves restricted under a VR repair will have the rated restricted capacity and the restricted lift value listed on the repair nameplate.

SRVSpeQ has the restricted lift option included and requires the percentage restriction to be inputted. The valve configuration code will have an “RL” included at the end.
Lift restriction is accomplished by installing a limit washer between the guide and disc holder as shown in the figure. The limit washer is cut to the appropriate length based on the lift required.

Contact Setpoint Integrated Solutions,   1-800-256-7373 for all of your relief valve needs from Service to New Assembly.

*Adapted from Matt E Byers, Sr. Product Manager,                                                               Consolidated Valves, Baker Hughes, a GE company

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Many process applications require specific materials and characteristics to meet industry standards for Severe Service. In this post we will review common severe service applications*.

ASME’s Category M Service Dangerous fluid service is defined in ASME B31.3, Process Piping and is called Category M Service.

•   A fluid service in which the potential for personal exposure is judged to be significant and in which a single exposure to a very small quantity of toxic fluid, caused by leakage, could produce irreversible harm to persons on breathing or bodily contact, even when prompt restorative measures are taken.

There are also other interpretations, as some end-users define dangerous fluids as:

•  Toxic materials such as:
  • Phenol, Hydrogen Sulfide and Chlorine
• Highly corrosive materials such as acids and caustic
  • Ex. HF Alkylation service is considered a critical service. It is an acid that vaporizes at 67 degrees F and is very corrosive. One drop can eat through your skin and the vapors will destroy your lungs.
• Flammable materials, including light hydrocarbons
• Boiler feed-water and steam requiring class 300 ratings and higher
• Oxygen in concentrations greater than 35%

Other factors determining critical service are difficulty in the sealability of some medias, as well as high-temperature applications.  Includes mining and slurries  Very high temperature media are also considered critical service applications. Flue gas or catalyst injection.

Some common critical service applications:

• Application: Nuclear                       Why Critical Service?: Oxygen
• Application: Hydrogen                    Why Critical Service?: Highly Corrosive
• Application: Hydrogen Sulfide     Why Critical Service? : Emergency Shutdown
• Application: Chlorine                       Why Critical Service?: Flammable Fluids

Nuclear Applications

Nuclear electric generation plants are considered a critical service application due to the risk of equipment failure that could lead to exposure from radiation escaping containment. This application has very strict valve standards, codes and guidelines. Such as:

• Near perfect casting requirements
• Extremely tight quality requirements for nuclear valve manufacturers
• Repair requiring ASME certification N – Stamp

Hydrogen Applications

Maintaining containment of gases, such as hydrogen, has an impact on materials and safety to keep personnel safe.

• Very small molecule size of hydrogen requires forgings or high quality castings
• Hydogren gas is highly inflammable
• Hydrogren corrosion can be an issue
• Governed by ASME B31.12-2008.

Hydrogen Sulfide Applications

Sour gas, or hydrogen sulfide is another application that can be hazardous to your health in certain concentrations. This sour gas can be found in some crude oils, from the well through the refining stages.

• Prolonged low-level exposure destroys sense of smell
• High ppm concentrations have no odor
• Levels about 100 ppm are dangerous to life and health
• H2S is highly corrosive
• Valve Material specifications are covered by NACE international standards
  • MRO 175 Upstream applications
  • MRO 103 Downstream Refining applications

Chlorine Applications

Chlorine is another corrosive application where materials and proper equipment are crucial for public safety.

• Lethal in concentrations of 35-50 ppm
• Chlorine Institute issues guidelines for valves in chlorine service including those used on railroad tank cars

Oxygen Applications

Oxygen in itself is not dangerous, but when in service with other flammable material it can become dangerous.

• Supports combustion
• Makes any flammable material burn intensely
  • Can cause combustion hot enough to melt metals
• Valves in Oxygen service must be completely free of all oils and grease
• Oxygen Service Standards and Specifications are provided by:
  • Compressed Gas Association (CGA)
  • National Fire Protection Association (NFPA)
  • ASTM International

Highly Corrosive Media Applications

Primarily acids and caustics,  highly corrosive media presents its own challenges within applications. If the wrong material is chosen for corrosive service, some corrosives can eat though the base metal in a matter of hours. Therefore, proper material selection throughout the entire assembly is key. Valve Trims are often more susceptible to corrosion with the addition of velocity-based erosion.

Emergency Shutdown Valves (ESV)  or Emergency Isolation Valves (EIV)

Many critical pant applications utilize ESV or EIV valves. These valves must always work when required, and are usually a block valve that can be closed either by hand or automated.  ESVs are a requirement at all intervals in flammable service transport pipelines.

Flammable Fluid Applications 

All flammable fluids are normally considered a critical service applications. All hydrocarbons are flammable fluids. As a result the most common concern is leakage pasted a closed valve, sometimes do to corrosion or erosion. Research into flammable fluid control has led the way fro new valve designs.

With a variety of different packages to choose from, Setpoint Integrated Solutions has the appropriate specifications to meet your needs. Contact us today

*This post was adapted from content created by VMA at their Valve Basics Course, found here

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Setpoint Integrated Solutions was honored Wednesday, October 11, 2017 at the Baton Rouge Business Report’s Top 100 Private Companies Luncheon.

Since its inception in 1982, the Greater Baton Rouge Business Report has been committed to delivering accurate, honest and in-depth coverage of the Baton Rouge business scene. After many years and hundreds of issues, this publication not only continues its mission, but also has exceeded expectations by becoming a true partner to business and the community.

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There are many choices of Quarter-Turn Isolation Valves within the industry, such as Plug Valves, Ball Valves, and Butterfly Valves.  This post will  focus on Plug Valves and their characteristics.*

• In the quarter-turn family, opens and closes with 90-degree rotary turn
• Used for on-off and regulating flow
• Lubricated and non-lubricated types
• Available in many different materials

Plug valves have been in use for quite some time, they are  the oldest design of the quarter-turn isolation valves. They contain three basic components, of a body, a plug, and a cover.  The plug can be round, rectangular, tapered, or cylindrical, features a passage through which the media can flow, and this media flow will be controlled by turning the plug 90°, hence the term Quarter-Turn.

The on-off rotary turns will allow for isolation  and for regulating flow.

While plug valves are useful in many applications, they are particularly easily adapted to multi-port construction. As a result, three and four way plug valves are commonly used in the chemical processing industry. An advantage of this is the elimination of fittings or multiple straightway valves with one multi-port valve.

Plug Valves can be classified into two types:

• Lubricated
• Non-Lubricated

Lubricated Plug Valves

Lubricated Plug Valves allow lubrication to be injected in a fitting under pressure through grooves in the plug or body to prevent fluid leakage between the plug face, and the valve body.  The reduced friction from the lubricant also enhances easy and quick operation of the valve.  The lubricated plug valve seals only against the downstream seat, and when properly lubricated is often the most leak-free seal available. Temperature limits will be based on the lubricant used within the valve, and the pressure drop should be fairly low due to the flow path being streamlined.

Lubricated Plug Valves are often used in handling hydrocarbons, corrosive fluids, and slurries.

Non-Lubricated Plug Valves

Non-Lubricated Plug Valves have multiple different subgroups, comprised of Lift, Sleeved, Lined, Eccentric, and Offset Eccentric.

Lift type non-lubricated valves are designed so that the stem first lifts the plug off the seating surface and then rotates the plug into the open position. This is useful in extending the life of the plug as it is not being drawn against the seating surface during stroking. After rotating the plug to the closed position the handwheel will continue to need to be rotated until the plug is properly in position against the seat. The mechanical seal on both the upstream and downstream sides of the valve in the closed position allows this type of plug valve to be used as a double block and bleed.  This feature allows the center section to bleed or clear any debris within the valve if it is has been equipped with a bottom access plate.

Sleeve lined plug valves are similar to a conventional plug valve, but it uses a fluorocarbon sleeve locked in place surrounding the tapered plug maintaining a  continuous seal. THe sleeve supplies the lubricity needed to cycle the valve, giving it characteristics of quick open and close, maintenance free performance, non-stick, and an extended life.

A lined plug valve is the same as a sleeved plug except that the body and plug are completely plastic or teflon lined and this isolates the valve body from the media. Usually made with a body of Ductile Iron, which is sufficient due to low temperature and pressure used in chemical applications.  Having the valve body isolated offers a less expensive alternative to special alloys. The limits on a plastic lined or sleeved plug valve is that it has a limited operating temperature, usually no more than 400 degrees F.  These valves tend to be found in highly corrosive applications, pharmaceutical, and food / beverage applications.

Finally, the eccentric type of non-lubricated plug valves is similar to a conventional plug, with half of the plug being removed. As the plug  rotates it is moved away from the seat, so that the plug is completely out of the media flow path when fully open.

Setpoint Integrated Solutions has a variety of Plug Valves to choose from, as we are distribution partners of top tier OEM Flowserve Durco.

*This information was adapted from content created by the Valve Manufacturers Association for Valve Basics, details found here.

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What Seven Factors Separate Valve Service Shops?*

1. OEM Authorized
2. Asset Management Tools
3. Certified Technicians
4. Diagnostic Capabilities
5. Access to OEM Inventory
6. Technological Expertise
7. Facilities

Together these seven factors determine the quality of your valve service at the many options within the marketplace.  As companies increasingly turn to outside vendors, such as Setpoint Integrated Solutions, to manage their valve population, it is necessary to understand all the factors that can affect the quality of maintenance and repair.

Factor 1: OEM Authorized Repair

One territory can have dozens of firms that offer valve maintenance and repair services. All of these firms are not created equally.  Often times the experience can be described as:

” Valves coming back from the repair shop looked great. Testing, however, told a different story. Many of the valves have not been repaired correctly and are not performing to OEM requirements.”

This usually results in higher maintenance costs and/or lost production. It also can mean compromised product quality and unnecessary safety risks. In order to ensure repeatable quality and minimize these safety risks, working with OEM Authroized Repair Facilities is integral.

To diagnose control and line valves, the shop should have a unit that can compare current valve data to “Day One” baseline data.Most valve OEMs have a list of authorized service providers. No one is required to choose one of these providers, but the credential of being listed as authorized is one sign of a quality shop.

To become an authorized service provider, a shop must meet specific criteria the OEM sets in areas such as integrity, safety and environmental compliance. Plus, the team is required to complete the OEM’s training program. Usually, OEMs hold certified shops to high standards when it comes to facilities, equipment and personnel. Knowing that a service provider meets these criteria, however, gives companies added confidence that they are dealing with a reputable shop.

OEMs regularly audit their authorized service providers to ensure they are meeting the necessary performance standards. While ISO 9000 is a good standard to be followed, it is not a valve operating guideline. When it comes to valve assembly/testing and repair, the OEM is the body best equipped to conduct the detailed review necessary and is willing to share audit reports.

Additionally, OEM-authorized service providers have access to important details regarding the properties, construction and workings of a specific valve or part. This is because OEMs build their products to rigorous specifications. While it’s true that a valve or part can be re-engineered, only the OEM knows the original specs with certainty.

An OEM-authorized service provider also receives extensive product training from the OEM and can consult with the OEM’s engineers to diagnose problems. An authorized shop will use OEM parts, rather than re-engineered parts, helping to ensure that the valve performs as expected.

Finally, not using an OEM-authorized service provider may void the manufacturer’s warranty.

Setpoint Integrated Solutions is an OEM-authorized service provider. Specific certifications held across our branch locations are:  Masoneilan Authorized Repair Center (MARC), Consolidated Green Tag Center (GTC), Groth Authorized Repair Dealer (GARD), Flowserve Black Tie Authorized Repair House, Valve Automation and Control Repair Facility. Details found here.

Factor 2: Asset Management Tools

A significant differentiator between valve service shops today is the ability to provide asset management tools. These tools put valve records—including repair data, repair records, test documentation, wiring diagrams and “before” and “after” photos”—in a single, easy to use, accessible database. The customer owns the data and can access that information 24 hours a day.

This added capability can simplify record-keeping for inspections and make it easier to meet reporting requirements. But asset management tools can be so much more than just a document management tool—they can be a plant manager’s best friend. Some, for example, provide analysis features and can assist in detecting trends for repairs, some manage inventory for optimization, others provide features such as “turn-around management” clouds where one can drag and drop valves for planning a turnaround. Others help with diagnostics and provide recommended solutions for resolving issues.

Setpoint Integrated Solutions, in collaboration with Baker Hughes, a GE Company, utilizes ValvKeep for all the valves it touches. ValvKeep tracks each repair event for each valve that goes through our shops. This information is then used, similar to a medical record, to track the health of the valve throughout its lifetime. More information found here.

Factor 3: Certified Technicians

When a person chooses a physician, he or she is likely to consider degree of education, specialized training and other credentials. The same criteria should apply when choosing a valve service partner. Those choosing should ask to see a firm’s training certificates; and find out whether the technicians are trained in the latest OEM standards, as well as ­relevant standards from organizations such as the American Society of Mechanical Engineers. They also should ask whether the technicians’ certificates are up-to-date because training is not a one-time task, but a continuous process.

With more than 200 certified and nationally accredited technicians, Setpoint Integrated Solutions stands ready to serve your needs through process repair services. Setpoint I.S. is committed to the highest standard of safety and quality assurance.

Factor 4: Diagnostic Capability

To diagnose pressure relief valves, technicians should have electronic valve testers that can test a valve in-situ.Today, when your car has an odd noise, your mechanic uses computer-based tools to diagnose the problem. A solid valve service provider will have similar tools in its collection.

For example, a technician working with pressure-relief valves should have electronic valve testers that can test a valve in-line and in production (in-situ). For control and line valves, technicians should have a diagnostic unit that can compare current valve data to “Day One” baseline data. With a significant number of analog positioners still in use, such devices can help remove the guesswork from assessing valve health.

Setpoint Integrated Solutions Technicians are OEM certified and highly trained. Their use of diagnostic tools save you time and money by making the right repair the first time.

Factor 5: Access to OEM Inventory

A good service provider has OEM valves and parts in stock and can quickly configure, assemble and test a replacement valve.Even the best technician cannot get a process running again without the necessary parts, replacement valves and other devices. When something is needed to get that process going, the best providers of maintenance and repair services will simply pull from their well-stocked shelves the necessary OEM parts, valves, positioners, etc.

Certainly, it is impossible for a service provider to have every SKU in its warehouse. But affiliation with a network of service facilities can provide access to millions of dollars of inventory that can be on hand in days, and sometimes even hours. A prospective service provider needs to belong to such a network.

Setpoint Integrated Solutions carries significant inventory for all of the OEM partners that  it represents.

Factor 6: Technological Expertise

A growing number of facilities are adopting digital technologies such as wireless communication, valve diagnostics, the HART Protocol, the FOUNDATION fieldbus and PROFIBUS. A strong service provider will have a “digital champion” on staff or accessible who can guide users and who has the technical expertise to advise on when to upgrade to digital technology.

Setpoint Integrated Solutions focuses on providing best in class technological expertise through the aforementioned protocols as well as the use of other systems such as  ValvKeep, VavleAware, and Valve Vue.

Factor 7: The Facilities

Visit a prospective service provider’s facility. Take note of whether the shop is neat, clean and well-lit. Organization is strongly correlated to quality. This photo shows the DMC–Carter Chambers facility in LaPorte, Texas.A tour of a prospective service provider’s facility can reveal much. Such a tour should include stops at areas in the shop for sandblasting, machining, welding and painting. Take note of whether the shop is neat, clean and well-lit; organization of that shop is closely correlated to quality. After all, would anyone hire an accountant whose office was wall-to-wall stacks of paper? As an added benefit, some providers also have onsite facilities where they offer training for their customers.

State-of-the-Art Facilities: Setpoint I.S. features more than 400 employees and encompasses more than 425,000 sq. ft. of repair and distribution facilities across 13 strategic Gulf South locations. We’ve invested in the latest technologies and equipment to ensure our customers receive the best service available.

Choosing a valve service provider requires time and effort. But given the importance of valves to any process facility’s performance, the ­decision cannot be taken lightly. The key is: Do your homework; it will be time well spent.

Setpoint Integrated Solutions stands ready to assist in all your valve service and valve repair needs. Contact us today.

*This Content was adapted from an article by Gary Ostrowksi for Valvemagazine.com found here.

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Setpoint Integrated Solutions is currently in motion helping in any way we can with the recovery efforts from Hurricane Harvey.   We can be reached 24/7 on our Emergency Hotline: 877-906-4790

Our team has been as impacted as you, our customers, and we are all in this together. Based on our previous experience in recovery management,  we offer guidance to minimize downtime, so you can get back up and running in no time.

To expedite your valve and instrument recovery, click here.

This Recovery Management  document features multiple items to review as you are underway in the recovery process. Items such as:

• Make a visual inspection and assessment
• Inspect for possible damage, details on PDF, above.
• Identify what can be repaired v. what can be replaced.
• Take photos to capture Tag Number, Serial Number, Valve Orientation, and  other pertinent information.
• Verify on site assets and inventory listings
• Define Priorities and Urgent Needs

Through the use of your sites’ data in ValvKeep®, we can maximize these efforts and assist you in getting back up and running.

When dealing particularly with Motor-Operated Valve (MOV) Repair In House & In the Field, click here.

Setpoint Integrated Solutions provides you with:

• Access to over 40 Senior Level MOV Technicians
• Ability to fully function test every repaired MOV
• On hand inventory and parts to support site needs.

As we continue to help our customers getting back up and running, we stand ready to assist with our experience and guidance in recovery management

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Consolidated’s Certified Green Tag Centers (GTC*) are the industry standard.  Each GTC location is staffed with highly qualified technicians who are skilled in delivering exceptional support and technical expertise. Plus,  GTC operations are equipped with machine tools and inspection facilities as well as assembly, paint and test equipment—all backed by Baker Hughes for the assurance of quality.

Each GTC  provides an extensive range of services, including, but not limited to:

• Commissioning
• Mechanical Inspection
• Valve Repair
• Shut Down Planning
• Onsite Repairs
• Troubleshooting
• OEM Parts
• Retrofits
• Compliance Management
• Asset Management
• Predictive Maintenance
• Training Classes
• Site Surveys
• Onsite Inventory

Globally recognized and in compliance with ISO 9000 standards, you can be sure when you see the GTC emblem that you have hired the right resource to handle your critical needs.

As the world’s largest Consolidated channel partner for Baker Hughes, Setpoint Integrated Solutions has  10 Green Tag Centers (GTC) and years of experience in repairing Consolidated Valves with Consolidated OEM parts.  Call Setpoint Integrated Solutions today to ensure that you increase performance, extend service life, and protect your investment with OEM certified parts and service on your Consolidated valves.

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When choosing a sight flow indicator, there are questions that need to be asked regarding the design and performance of the sight flow indicator for the given application.

Some of the most important are:

• Does the sight flow indicator maximize your production?
• Do the threads within the sight flow indicator gall?
• How high is the pressure rating on the sight flow indicator?
• Does the sight flow indicator maximize your view?

The answers to these questions should lead you toward choosing the most appropriate sight flow indicator available for the given application. One of the sight flow indicators that Setpoint Integrated Solutions represents is the Hygienic Sight Flow Indicator, by Jacoby Tarbox, a product of Clark-Reliance, and can answer all of these questions, because cleanability matters.  With this product you can achieve controlled intrusion meeting ASME-BPE’s strictest requirements by employing ASME BPE dimensions and design principles,  precision-bore borosilicate glass, and tightly tolerance EHEDG inspired O-ring capture.

The T100-Hy-Sight hygienic sight flow indicator sets itself apart from other sight flow indicators because it does maximize your production by shortening cleaning cycles and preventing product loss.

It also features ACME No-Gall Threads for easy maintenance and eliminates the potential for cross-threading.  It has a positive stop design that eliminates over-compression of O-Ring into tube bore and it has no exposed threads to trap debris.

The Jacoby-Tarbox Hy-Sight has the highest safety factor versus system design pressure and replaces bulls-eye units improving the cleanability while saving space and cost.

Finally, the Hy-Sight and Full View Hy-Sight options maximize your view while providing maximum process visibility and allowing you to see unique ,”must see” process conditions.

*Information and video adapted from here.