Critical Valve Maintenance for Petroleum Coke Processing

Coking plant that uses industrial valve maintenance
Industrial valve maintenance ensures that ball valves used for petroleum coke processing can operate as efficiently as possible.

Petroleum coke is a byproduct of refining crude oil and has become a valuable commodity in the energy industry. Due to its extremely high temperatures, coking is one of the most severe processes in the refining industry. That’s why it is critical to maintain the industrial valves that are integral to this processing. Without proper maintenance, the harsh operational conditions can cause the valves to malfunction, leading to unexpected shutdowns.

To maximize profitability while minimizing risk, it is essential to understand the valve maintenance requirements for coke processing. For expert industrial valve maintenance repair services, count on Southern Valve Service. With our help, you can maintain efficient and safe coking operations in your refinery.

Valve Requirements for Petroleum Coke Processing

There are two primary methods for processing petroleum coke: delayed coking and fluid coking. Delayed coking involves heating the coke to high temperatures for an extended period, which breaks down the complex hydrocarbons into simpler molecules. Fluid coking uses a fluidized bed to suspend the coke particles in a stream of hot gas, creating a more uniform and high-quality product. The decision on which method to use depends on the type of crude oil being processed and the desired output. 

The petroleum coke industry has been growing rapidly in recent years, leading to an increased need for high-quality valves that can meet the demanding coking process. Valve requirements for petroleum coke processing can be complex and demanding. Based on its capacity, each drum in the coking process may use up to 12 valves. These valves must be able to withstand high temperatures and pressures, in addition to resisting corrosion and abrasion from the harsh processing environment. 

Selecting the right valve for petroleum coke applications will directly impact plant efficiency and productivity. Various types of valves can be used to control the flow of liquids and gases in the production process. However, the most common one is the ball valve. This type of valve operates with a rotating sphere, which has a hole running through its center. When the ball is rotated, the hole opens or closes, allowing or restricting the flow of liquid or gas. Ball valves are preferred in the petroleum coke industry for their durability, reliability, and ability to withstand high pressure and temperature. 

Prevent Valve Failure with Regular Maintenance and Critical Repair

If coke processing valves are not maintained, they can fail, which can lead to costly repairs. If the valve reacts with the material flowing through it, it could corrode. It could also become eroded inside due to the high-speed flow and abrasive nature of petroleum coke particles.

Without regular maintenance, valves can allow heavy residuum to creep into the seat or stem areas over time. As the valve becomes jammed up, it causes the valve to move more slowly or to seize up, increasing cycling time and reducing production efficiency. It may even force a shutdown of the entire operation. 

To mitigate these causes of failure, valve inspections, cleaning, and servicing is crucial. Key components to examine include the valve body, ball, seats, stem, and seals. Proper maintenance of ball valves in petroleum coke processing can lead to increased productivity, reduced downtime, and enhanced safety.

Scope of Work for Industrial Ball Valve Repair

Daily use and exposure to harsh chemicals and high temperatures can take a toll on ball valves, leading to leaks and malfunctions that can severely impact production. Industrial valve repair ensures that these valves are in fully operational condition, ready to handle the demanding conditions of petroleum coke processing. 

A generic scope of work for coker ball valve repair usually includes:

  1. Decontamination
  2. Disassembly
  3. Sandblasting
  4. Inspection
  5. Machining 
  6. Polishing
  7. Lapping
  8. Replacement of fasteners
  9. Tapping of bolt holes
  10. New packing and gaskets
  11. Repairing gear/actuator
  12. Assembly
  13. Testing

With the right repair services, refineries can keep their coking valves working at optimal performance levels and maximize output in this critical industry.

Reliable Maintenance Services for Industrial Valves – Southern Valve Service

By opting to repair valves instead of replacing them, refineries can significantly reduce their expenses and extend the lifespan of their equipment. This not only saves money but also helps to minimize downtime, ensuring that production can continue without major disruptions. 

The expertise of our repair technicians ensures that your valves are restored to optimal performance, guaranteeing smooth and reliable operation. Consider the benefits of valve repair when it comes to maintaining a cost-efficient and sustainable coking operation—contact our team for a quote today so we can assist you in keeping your production process running smoothly and efficiently.