Tested & Proven 1/3 Developing tried and tested valve technologies

In this blog series, we dive into the world of valve testing from several different points of view. In this first instalment we look at the role of testing as a part of the development process of products and technologies.

Demand for proven performance

The story starts with the age-old dilemma of “who’s gonna be the fist to try it out”? A valve is almost without fail a mission-critical component of any process and pipeline it is a part of. As such, plant owners only want field-proven technologies attached to their valuable process. But while the core design of many of the valves used in industrial applications has stayed virtually unchanged for decades, it doesn’t mean there hasn’t been a great deal of development.

So, even if our valves haven’t fundamentally changed over time, they certainly have become better in terms of performance, reliability, durability, accuracy and many other parameters. We continuously explore possibilities to improve performance and reliability. We develop solutions such as Neles™ WearBlock™ to further enhance the high performance we are known for. This is where testing comes into the equation.

Digital and physical testing required

Whenever a new technology, design or material shows viable promise, we put it to the test. The first part of testing typically consists of modelling and simulations. We use digital tools to study new phenomena, simulate the performance of potential new component designs and material selections, and optimize designs. But we simply cannot put a new component, however small, into production without providing the proof that comes with actual physical, mechanical testing. Only then can we determine, document and prove real reliability in real environments and conditions.

Advanced simulation tools are used in the valve development phase.  

Only proven performance to market

All valves intended for market need to be tested for key performance factors such as tightness, torque and ability to withstand the needed pressures present in the environments they are intended for. For many valves, sustained performance in extreme temperatures is also an important requirement. This is why we also need to carry out extensive tests where valves are engulfed with fire for extended periods or cryogenically frozen before being tested for safety and performance. Testing designed to eliminate risks involved with fugitive emissions through the valve construction are also carried out on valves destined for market.

Fire tests are done according to industry or customer standards. A fire test simulates a fire in a plant or a factory and verifies that the valve stays tight enough to prevent internal or external leakage from expanding the size of the fire.

Cryo-testing ensures that the valves can operate safely and reliably in extreme low temperature conditions.

World-class in-house testing capabilities

Flow testing with real or equivalent flow media is an important part of the testing we carry out. We have most needed testing facilities on-site at our Valve Technology Centers where product development takes place as well. With R&D, production and testing on three continents, we are able to be run efficient processes from start to finish. We have the capabilities and facilities to carry out most needed test in-house.

Experience and insight creates trust

The ultimate reason for through testing is to create trust and peace-of-mind. Another thing that breeds trust is experience. This is something we have plenty of when it comes to product testing. Many of the dedicated professionals at our labs come with decades of experience and insight into valve manufacturing and testing. We have had dedicated R&D testing facilities in operation for more than 60 years. Type approval testing has been carried out since the first fire test and fugitive emission test standards were published in the 1980’s and 1990’s respectively.

Reinventing reliability every day

So, when we at Valmet say that we are bringing something new to market, you can rest assured that it is based on field-proven technology with decades of performance in real-world conditions under its belt. Any new performance enhancing attributes have also been thoroughly tested in both theory and practice before they ever make it to market. Our reputation has been built around reliability, and our testing capabilities and high internal standards are there to make sure this reputation remains.

Stay tuned

Keep your eyes out for the next instalments in the Tested & Proven -blog series where we will look more closely at the type testing and quality control of your valves by Valmet.