Control Valve Servicing & Repair

In-House Control Valve Servicing

For complex repairs or upgrades that are impractical on-site, our in-house control valve servicing provides a comprehensive solution. Within our facility, we inspect, test, maintain, and repair control valves using specialised equipment and the expertise of our skilled engineers.

We also utilise advanced 3D modelling with SolidWorks and a state-of-the-art IEC-compliant valve sizing program to analyse and determine the suitability of control valve applications against existing process conditions. This enables us to recommend, design, and manufacture trim sets tailored to specific process requirements. Where size and design allow, we can upgrade valve trims to more advanced solutions, such as multiple cages or multi-turn disk stack configurations, ensuring optimal performance.

We can turn up to 36 inches, mill, drill, and slot components as required in the manufacture of trims, shafts, and interface components. The assembly shop is well-equipped with all the necessary hand tools, power tools, and a full range of inspection instruments, including a valve test rig and test flanges for large, heavy-rated valves up to 24 inches. Our facility has a lifting capability of up to 8 tons, a spray booth, and both TIG and MIG welding facilities.

• Complete disassembly, inspection, and detailed reporting
• High-efficiency overhaul service for standard control valves
• Comprehensive body, bonnet, and trim repairs for control valves
• Restoration services, including shot blasting, painting, and refinishing to specification
• Heat treatment and material hardening for control valve components
• Stellite #6 overlay and precision machining for control valve trim

On-Site Control Valve Servicing and Repair

At Valve Solutions, we offer on-site control valve servicing, repair, and refurbishment. This service eliminates the need to transport valves to our workshop, significantly reducing downtime by allowing engineers to address issues without interrupting operations. On-site servicing enables our engineers to assess valves in their specific operational environment, ensuring repairs are accurate and tailored to the valve’s unique conditions.

During on-site shutdown repairs, our experienced valve technicians, supported by our trained engineers, can analyse the damage, review process conditions, and re-size or re-engineer the valve to ensure the best solution is implemented. This process can be applied to both our own valves and those of other manufacturers. A key aspect of any valve performance review is ensuring the actuator maintains authority over the process across the full range of operating conditions. For some flow applications, both compressible and incompressible—actuator stiffness is crucial to achieving a stable control environment.

We can re-fit actuators both piston or spring diaphragm up to 300 sq. in, available in single or double-acting configurations for the piston type, with spring fail-safe or volume tanks as needed. Additionally, a full range of accessories can be fitted to optimise operation, with mounting options that include plate-mounted or box-enclosed setups.

All of our technicians are Swagelok-trained, ensuring neat and sound installation practices throughout the process.

• On-location machining, lapping, and reconditioning of valve seats
• Troubleshooting and fault diagnosis for control valves at the site
• Identification and rectification of control valve performance issues

Control Valve Maintenance Plan

Control valve maintenance plans are a proactive approach that ensures a control valve operates efficiently, extends its lifespan, and reduces the risk of major failures or breakdowns occurring. These regular inspections allow small issues to be addressed like corrosion, wear and tear, leaks to be detected, and components to be replaced if necessary. We offer planned maintenance contracts, which are a part of a preventive maintenance scheme, and controlled and managed by Valve Solutions and /or the customer.

• Full project support for control valve maintenance during planned outages
• Management and coordination of control valve maintenance projects
• Detailed reporting covering the entire inspection and servicing process
• Expert support for corrective actions and resolving control valve performance issues

Emergency Control Valve Servicing

Emergency control valve servicing is the rapid response and repair of control valves that have unexpectedly failed. This urgent service is typically important for valves in industries like oil & gas, chemicals, power generation, and water, where a brief loss of valve functionality can cause significant disruption.

At Valve Solutions, we offer emergency on-site control valve servicing where our team of specialist engineers will attend the site, quickly and thoroughly assess the valve, and immediately repair any operational problems.

• Rapid response service for urgent control valve issues
• Emergency machining services for trim components and valve parts
• Fast-tracked manufacturing of replacement control valve trim components
• Urgent sourcing and supply of critical control valve trim materials

Actuator Repair, Servicing & Maintenance

Actuator maintenance, servicing, and repairs are essential to keep valve systems operating efficiently. The process involves inspecting and diagnosing issues, repairing or replacing faulty or damaged parts, and routine checks.

An initial assessment is undertaken once the actuator arrives at our workshop. This typically includes specific testing to determine its need for repair or overhaul. Following this, a complete strip down and inspection of the actuator and its components is undertaken to check the condition. A detailed report and recommendations of the work proposed will then be submitted to the customer alongside a quotation. The work will then be undertaken with new parts fitted where required, the actuator reassembled, and further testing to ensure it is fit to return to service. The customer will also receive all necessary paperwork that has been completed against the refurbishment /overhaul.

• Full refurbishment and overhaul of control valve actuators and instrumentation
• Servicing and troubleshooting for pneumatic piston actuators
• Servicing and troubleshooting for pneumatic diaphragm actuators
• Overhaul, servicing, and troubleshooting of manual override systems for actuators
• Inspection, calibration, servicing, and troubleshooting of all control valve positioners
• Loop testing, calibration, and fine-tuning of control valve instruments

How Long Does It Take To Repair A Control Valve?

The time it takes to repair a control valve varies depending on several factors, including the type of valve, the nature of the issue, the complexity of the repair, and the resources available on-site.

That being said, at Valve Solutions, we pride ourselves on our rapid response times which beat industry leaders. We can provide emergency turnaround times for control valve issues, immediate access to control valve machining including trim components, and extensive engineering support.

Valve Solutions 3 Step Process:

1. Once the valve arrives at the site, an initial assessment of the valve and its components is undertaken, to inspect its condition. This will determine whether the valve needs to be repaired or overhauled, and a detailed report with recommendations of the work proposed is then submitted to the customer.
2. Once the customer approves the detailed quotation, our highly skilled engineers will begin the repair and maintenance work on the valve. This can include further testing, the replacement of parts, and reassembling the valve to ensure it is fit to return to service.
3. The valve will then be returned to the customer, accompanied by all the necessary paperwork completed against the refurbishment /overhaul.

Valve Servicing FAQ:

Why is valve repair and maintenance important?

Regular servicing and repairs of a control valve are crucial to ensure the reliability and efficiency of the valve’s operations. Routine maintenance improves safety, prevents unexpected breakdowns, and extends the lifespan of valves.

What is the lifespan of a control valve?

A control valve’s lifespan varies depending on several factors including the type of valve, its usage, the operating conditions, and whether it receives regular maintenance. However, control valves can typically last from 5 to 20 years, with regular servicing and repairs allowing a valve’s lifespan to be significantly extended.

How often should valves be serviced?

While the frequency of valve servicing depends on the type of valve and its operating conditions, in general, valves should be inspected and serviced at least once every 2 years as part of a routine preventative maintenance schedule. Valves used in high-demand or hazardous environments should be serviced more regularly to ensure safety and functionality.

What signs indicate a valve needs to be repaired?

Some telltale signs that a control valve requires repairing include leaking or dripping, reduced performance, unusual noise or vibrations, poor regulation, and visible corrosion or wear on valve components.

What is the difference between valve repair and maintenance?

The repairing of a valve involves fixing or replacing parts that are broken, damaged, or malfunctioning. Differently, valve maintenance includes the regular upkeep of inspections, cleaning, and adjustments, to ensure the valve continues to operate properly and prevents any major issues with the valve.

What happens during a valve overhaul?

An overhaul involves disassembling the valve, a thorough cleaning process, and a comprehensive inspection to identify any worn or broken parts, alongside repairs and replacements being made. The valve will then be reassembled and tested to ensure it meets its original specifications.