In the UAE, there are many reasons to use a globe valve instead of less common valve designs (like gate or butterfly valves) for flow regulation in industrial processes. Whether it's a manufacturing facility or an oil refinery, every component of the process is critical to achieving maximum efficiency. Unfortunately, though small in footprint, failures of globe valves can lead to very large disruptions of operations.

This post will detail a realistic example of how a globe valve failure caused an entire production line to stop. This post will also provide valuable insight into the importance of the globe valve, some preventive methods that industries in the UAE can take to avoid future problems caused by valve failures, and the need for all industries operating in the UAE to consider and maintain their valves with the same frequency and importance that they place on other critical components of the production system.

What is a Globe Valve and Why is it Critical?

A globe valve, or regulating valve, is a very common type of valve that can be used in a variety of applications for regulating the flow of fluids through pipelines. Due to its ability to regulate the flow of the fluid to a very precise extent, it is ideal for use in various industries, as well as for utilities and aftermarket applications (e.g., oil/gas extraction, potable water treatment, chemical processing, etc.). Given that these industries are the backbone of the UAE economy, it is easy to see why the globe valve is so important.

Some of the numerous advantages of the globe valve include:

• Excellent throttling capabilities

• Reliable sealing capabilities; and

• They can accommodate very high-pressure conditions.

Unfortunately, all of the benefits of a globe valve become a liability when the valve fails.

The Incident: A Small Issue, Big Impact.

A manufacturing company in the United Arab Emirates had a production line that processes industrial fluids that stopped working. It appeared to be a small problem – a pressure imbalance in the pipeline.

What Occurred?

Upon investigation, the engineers found that the globe valve had failed due to damage to the internal seat of the valve. This failure was responsible for:

• Pressure fluctuations

• Inconsistent Regulation of Flow

• Leakage within the system

As a result of all of these failures, the entire production line was shut down within a few hours to prevent additional damage.

The Domino Effect on Production

The failure of one valve may seem like no big deal, but when it happens in a network of many valves, it will cause a ripple effect. 

1. Production Downtime

In this situation, a failure of the globe valve caused downtime for over 36 hours at the facility. This led to 

• missed production targets

• delayed shipments

• contract penalties

According to industry sources, unplanned downtime in the manufacturing industry can cost as much as $260,000 per hour, depending on the size of the operation.

2. Equipment Damage

The failed globe valve created pressure surges that caused damage to many things in the facility, such as the following:

• pumps

• heat exchangers

• pipeline joints

The cost of repairing all of this damage is separate from the cost incurred by replacing the valve itself.

3. Safety Risks

The failure of a valve in an industry that is handling hazardous fluids can create a serious safety concern. Failure to contain a leak of hazardous fluid can lead to

• leakage of a hazardous chemical

• an increased risk of an accident

• environmental hazards

Finally, in the UAE, a failed valve can lead to significant legal ramifications as well as regulatory compliance violations since the UAE has some of the strictest standards in the world for regulatory compliance.

Root Cause Analysis: Why Did the Globe Valve Fail?

The valve has been thoroughly examined to identify root causes of why it failed. The following issues have been identified:

Inadequate Maintenance Procedures

The globe valve was not maintained for over a year, so it was not inspected regularly, which contributed to undetected wear and tear on the valve.

Poor Material Quality

The globe valve installed at the site did not meet the requirements for manufacturing asbestos for high-pressure applications.

Improper Installation

During installation, the valve was not aligned properly with the pipes, which caused improper stress distribution across the valve seat, resulting in a premature failure of the valve.

Lessons Learned by UAE Industries

This incident provides important information for other businesses that operate under high-demand conditions.

1. Make an Investment in Quality Globe Valves

While it may be possible to select non-high-quality or non-high-standard products that are inexpensive at the time of purchase, in the long run, this will result in significantly greater costs for your business in terms of replacement parts/repair costs.

2. Practise Preventative Maintenance

By establishing a proactive plan of preventative maintenance that includes planned inspection frequencies and a tracking system for recorded inspections, the end-user will be able to identify early indicators of the following:

• Corrosion

• Seat Failure/Seat Damage

• Leakage

3. Train Technical Personnel

Training for technical personnel should provide the skill level necessary to identify the problem and resolve the issues identified before they become problems, and training should include the following:

• Proper techniques for the installation of the globe valves

• Procedure for performing routine diagnostics

• Emergency response procedure

4. Use Smart/IoT-based Monitoring Systems

Many of the new UAE facilities are implementing IoT-based smart monitoring systems. These types of systems will do the following:lp to:

• Identify potential anomalies due to instantaneous pressure.

• Send alerts to operators immediately

• Prevent failure of the system due to catastrophic events

UAE's Industrial Sector: Why It’s Important

The industrial sector of the United Arab Emirates is faced with extreme operating environments. These conditions include:

• Extremely high humid & dry temperatures

• Dust and sand hazards

• Constantly operating under high-load conditions

These elements put a greater risk on component failure and make having an effective maintenance strategy and building a robust system even more important.

Closing Thoughts

The recent globe valve failure (as discussed in this post) serves as an important example of how small items can create large consequences. Because many businesses in the UAE operate in a ‘fast-paced’ environment where operational efficiency (or lack thereof) greatly affects their profitability, ignoring routine maintenance or using substandard components can be an expensive choice. Furthermore, one failure may not be isolated. It has the potential to cause failures throughout the entire system, disrupt the workflow, and harm the facility's ability to produce necessary goods and/or services. 

If you have any globe valves in your plant, now is the time to take a proactive approach! Start with conducting an audit of your existing valve systems (looking for potential weaknesses and signs of wear); upgrading to premium-quality valves (therefore providing your plant with superior valve durability and performance); and carrying out a structured preventive maintenance programme (which will allow you to identify problems before they become full-blown failures).