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Delivering for the dairy - greater milking efficiency with ERIKS and Spirax
Leaking control valves were leaving a dairy product manufacturer feeling pretty cheesed off. Fortunately, ERIKS were able to devise a solution that not only resolved the issue, but also helped the customer to milk even greater efficiency from their process.
Milking...
The control valves were part of a tubular heat exchange system, and had become worn over time. Because they were failing to close securely, there were knock-on effects on the system’s efficiency. Without effective and reliable closure, the heat exchange system tended to operate outside its set parameters, and water hammer was also occurring.
The customer came up with their own way to resolve the issue, but didn’t realise it would cause more problems than it would solve.
More valves, more problems
The customer’s idea was to install more valves: this time, actuated ball valves in front of the control valves. This would have helped the control valves to shut-off tightly, but it would also demand:
- reworked pipework to enable the valve installation
- additional control signals for the new valves
- increase compressed air consumption.
Instead of trying to rectify the problem with the existing control valves, ERIKS recommended replacing them with a completely different type of valve: the Spira-trol™ valve with a soft seat.
Set and forget
The Spira-trol™ valve is part of a range of 2-port single seat globe valves with cage retained seats.
Engineered to a highly flexible modular design, they are designed for steam and other industrial fluids, and can easily be adapted to most process requirements.
Once installed, commissioned and set, they can be safely left to get on with the job, with minimum maintenance.
By replacing the worn control valves with the Spira-trol™ valve with a soft seat, the customer would not only have valves with modulating capability, but also a watertight closure with no leaks.
Initially, the Spira-trol™ valves were installed at the two most critical points in the customer’s process, with a thermographic camera to monitor their operation.
Leak-free performance
After nine months of monitoring, the valves were still showing no signs of leakage. The customer was so impressed they installed eight more Spira-trol™ valves, replacing the modulating valves that had caused so many problems.
Three months later, the first two valves to be installed were opened up for inspection. The soft seats were found to be still in good condition and completely effective against leaks.
With a significant reduction in downtime and maintenance costs, along with improved process efficiency and reduced energy costs, the customer achieved payback in the first 12 months after installation, and realised an actual cost saving of £50,000.
For more information on Flow Control solutions and to get in touch with one of our ERIKS Pumps Specialists or Valve/Flow Control Engineers, please contact your local ERIKS Service Centre, who will be happy to discuss your options.
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