In the mining and metals industry, operational efficiency depends on the reliability and performance of equipment. However, an ore processing facility was experiencing recurring issues with a control valve whose leaks posed threats to both the productivity and safety of the plant.
A Faulty Valve Threatens Production
The 12-inch valve in place had a significant leak, creating a risk of emergency production shutdown. This unexpected stoppage would have not only resulted in a loss of production but also posed a major challenge regarding the availability of an emergency replacement 12-inch valve. Furthermore, there was a caustic burn risk due to the advanced wear of the valve.
Cautious Evaluation and Replacement
Initially, our client engaged our services for the onsite assembly of a valve and an actuator they had on hand. To prevent further issues, our team conducted a meticulous analysis of the actuator's force provided by the client. The calculations revealed that the actuator lacked the strength for the intended application. Our client had at their disposal a Fisher 1061 size 60 actuator, more suitable for the stringent usage constraints in their process. During assembly, it was discovered that the valve was not equipped with a seat, necessitating an urgent order for the missing part, leading to an installation delay.
Technical Expertise and Proactive Management
Our intervention highlighted the importance of technical expertise in managing industrial equipment. By identifying the lack of force in the initial actuator and the missing part, we avoided a costly unplanned production shutdown. The proposed solution included the use of a 12-inch V150 valve with a metal flat seat, suited to the specific needs of the site.
Significant Savings and Increased Reliability
The intervention avoided an unplanned production stoppage estimated at 8 hours, representing direct costs of $25,000 per hour, as well as associated costs for the overtime of three workers, amounting to $3,600. The total cost avoided thanks to our solution thus amounts to $203,600, demonstrating the significant impact of our expertise and proactive project management.
Through rigorous evaluation and strategic intervention, it is possible to avoid significant financial losses and ensure production continuity, while ensuring staff safety and environmental protection.