Valve diagnostic services for Dow Corning

After extensive evaluation trials, Dow Corning has signed a three-year contract with Emerson for the supply of control valve monitoring services using AMS ValveLink and FlowScanner software.

As the largest Dow Corning manufacturing plant for silicon-based products globally, production continuity is crucial for the company and its customers.

Emerson service personnel will be applying advanced diagnostic tools such as AMS ValveLink and FlowScanner control valve diagnostics.

Two trials have proved to Dow Corning that this diagnostics approach leads to increased efficiency and savings in maintenance costs.

In the first trial, on a relatively new section of plant, the Emerson FlowScanner software showed that of the 26 control valves that would normally have been removed for overhaul, 22 of them required a minor adjustment or no work at all.

It was only necessary to remove four valves from the line for repair.

In this trial, the control valve diagnostic checks saved 73% of the cost over the traditional methods of valve maintenance.

In the second year, an older section of plant was inspected.

Two thirds of the valves were found to be operating normally, and only 10 out of 31 valves were removed for overhaul.

This represented a 55% cost saving.

Statistical analysis has shown, with a 95% certainty, that there has been no change in valve failure rates following the adoption of this strategy.

Lee Hookem, Reliability Engineer at Dow Corning, conducted the trial evaluation and commented: "We wanted to introduce predictive maintenance, rather than dismantling and repairing all control valves on a scheduled basis.

Cost savings arise by reducing the number of lines that need breaking and the control valves then lifted off the plant for overhaul.

In addition the FlowScanner surveys identified I/P converter and valve positioner faults that could be fixed in situ.

These minor faults may not have been picked up under our traditional maintenance regime.

The contract for use of ValveLink software, and maintenance using Emerson personnel, will extend these savings across all control valves on the site".

Peter Ball, UK Valves Sales Director for Emerson commented: "The AMS ValveLink monitoring and diagnostic service is a powerful tool in identifying wear in valves, or poor performance in a control loop.

Savings come from both knowing which valves and loops need attention, and which ones are running fine and should be left alone.

We take pride in the combined performance of our technology and our experienced team of site consultants and analysis staff as they deliver on key performance indicators, that will produce significant savings for Dow Corning".

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