safety valve repair pricelist

The high pressure safety valve, or oil relief valve, is located near the oil pump. When the oil is thick and cold, the oil pressure forces down the valves against the spring tension, allowing the oil to go to the engine bearings. Then, it returns it to the crankcase. The oil pressure valve makes sure that the oil pressure is consistent at all the bearings, regardless of the speed of the engine. At high engine speed, the excess oil escapes so that power isn’t lost by the driving the oil pump.

If you suspect any damage at all to the high pressure safety valve, you should get it checked immediately. One of our expert mechanics can help you diagnose the problem and determine if a replacement is warranted.

If the high pressure safety valves fail, that could result in a leaking or cracked oil cooler. If that happens, the oil pressure valves will have to be removed and examined, and that could be a very expensive procedure. If a valve ends up being stuck, excessive oil pressure can result, and there could be serious damage to the engine. Work with one of our expert mechanics if you discover any of the symptoms we have described above.

6. Calculate sparepart costs (if any), service cost pr. hour (if any) times number of services per time periode (once a year minimum for functional test, repairs and service cost more seldom?)for each single valve to get total cost.

As your full-service partner, we offer setting and testing services to verify valve performance and validate conformance with stringent ASME and military specifications. This certification testing provides an extra layer of safety and ensures added confidence and peace of mind.

At our state-of-the-art test facilities in California and Virginia, we can conduct functional testing on all types and sizes of pressure relief valves. Please contact us to discuss your specific testing requirements. Our capabilities include but are not limited to:

Air service relief valves in accordance with ASME Section VIII, MIL-V-22549, MIL-V-20065C and ASTM F1508. Sizes 1/4″ – 8″, Pressures 3 PSIG – 6000 PSIG

Liquid service relief valves in accordance with ASME Section VIII, MIL-V-24332, MIL-V-20065C and ASTM F1508. Sizes 1/4″ – 8″, Pressures 3 PSIG – 1500 PSIG

Steam service relief valves in accordance with ASME Section I and Section VIII, ASTM F 1508 and MIL-V-20065, Revisions C & D. Sizes 1/4″ – 8″, Pressures 3 PSIG – 2000 PSIG

Dante Valve offers valve repair services for its commercial/industrial valves. The following repair guidelines have been implemented as of May 1, 2019:

Valves with a new purchase value of $600 or less are not economically feasible to repair. In this situation, customers will be offered a new valve, rather than a repair.

The valve to be repaired will be evaluated for warranty repair. If found to be a warranty repair, the valve will be repaired at no cost to the customer. If found not to be a warranty repair, the valve will be evaluated for repair or returned to the customer.

Repair evaluations will be billed at our standard hourly rate. If the customer chooses to have Dante Valve complete the repair work, the evaluation charge will be waived.

To ensure that pressure relief valves relieve and flow properly, the ASME and the National Board of Pressure Vessel Inspectors certify all assembly programs, testing facilities, and even technicians under the VR Valve Repair program. Dante Valve is proud of our VR program certification and our ability to offer VR valve repair at our California location.

Accreditation under the National Board’s VR program ensures the quality of all valve repairs, the authenticity of materials, and the completion of work in accordance with established quality protocols. All VR valve repairs receive the VR stamp upon repair completion.

A lot of times we go into outage meetings an look at the budget for Safety & Relief Valves, PRV Valves, Control Valves, or any other valves that we have and wonder why our costs are so high and the budget has burst. We look to our suppliers for advice, but they recommend buying a new valve. They then tell us that they can throw out the old one and scrap it and sell us a new one that costs thousands of dollars. No matter where you live it’s the same way. Every year we see new reasons they tell us to replace the valve and spend thousands of dollars on new valves. We see more money go flying out the window! We put a lot of trust in the valve companies to lead us in the right direction, but we find that we could have just repaired the valve and saved the company money. Now is the time to change and show the cost savings at the outage meetings. The cost of repairing a valve is so low that when you look at a 40 thousand dollars replacement to an 800 dollar repair it’s no brainer. How you say because that’s how valve companies have worked for years. That’s where they make their profit by moving the percentage line of 60% its cheaper to go new. But what they forget is we can repair that valve by not scraping it but repairing the valve, an saving thousands on our budget!

Alright here’s the good stuff we recognize the high cost of valve replacement, and more importantly the economics of valve refurbishment and repairs. Our abilities to repair your valves to OEM specifications, API, TSSA, and National Board standards, plus with 40 years of repairing valves tells you we don’t mess around when you need your Safety & Relief Valves, and all other valves to ASME certifications - Sec I & VIII National Board "VR" Certifications API Testing standards & capabilities quickly economicaly.

These valves protect and control some of a plant’s most essential and costly equipment, such as Power Plants, Cogen Plants, Wastewater Treatment Plants, Chemical Plants, Oil Rigs throughout North America, Rubber Plants, Steel Plants, Gas & Steam turbines, Compressors and Pumps, Mining Coal or other Minerals. and Paper Mills throughout Canada, and USA. Your valves need planned maintenance or significant refurbishment, that we can help you ensure that they are running effectively. We offer a comprehensive range of servicing options across our full range of valves, trims and equipment. We have the facilities, expertise and flexibility to ensure that your valves are maintained safely, effectively and promptly. All Makes Safety & Relief Valve, all models of other valves. ASME certifications - Sec I & VIII National Board "VR" Certifications API Testing standards & capabilities. Obsolete valve parts Reverse Engineering Boring, Milling, Turning, Grinding, Honing and Lapping. Weld Overlays, and Cobalt-based Hard Facing. Valves serviced and maintained on a regular basis by our specially designed grinding, testing and lubrication equipment can benefit from extended valve life of three to five times.

Although single valves or small batches of valves are repaired for major process and power plants all the time, the greatest influx in the business today comes from dedicated periods of plant maintenance. These intervals are called outages, shutdowns or turnarounds.

During a turnaround, the valve repair company only has so many days and hours to repair valves and bring them back to working condition in accordance with the original design specification or repair standard. This situation could be compared to TV cooking shows where the contestants only have so many minutes to effectively create a well-prepared, succulent dish.

To further that analogy, the TV chefs, at the beginning of the show, often don’t know the ingredients they’ll have. Similarly, a repair company often doesn’t know what valves must be repaired or what condition they’re in until repair personnel come through the door, and the equipment has been inspected. All these repair unknowns mean that accurate pricing is important, both for the service company to cover its costs and make a profit, and for the owner/end user to justify the cost of the repair.

To use a second analogy, a repair procedure is a lot like a visit to the doctor. The ailing person might be feeling a bit fatigued or have some recurring pain. Sometimes the problem will be obvious, and a prescription or treatment will be ordered right away. Sometimes, however, additional investigation is needed so tests are administered to determine what to fix and how. This is similar to the process involved in valve repair.

TCO is probably the most important consideration in the repair/no-repair decision-making process. However essential variables in the TCO equation have changed significantly in the last 20−25 years. Today, many of the valves that would have been fixed two decades ago are not repaired; instead, they are just replaced. This is because the cost of a new valve from a low-cost manufacturing location such as India or China is lower than the cost of basic refurbishing.

Furthermore, before Y2K, valve service companies were regularly repairing 2–6-inch, Class 150 and 300 gate valves. In fact, some facilities had assembly-line refurbishment operations for small cast steel valves that reduced the cost of repair for these valves because of economy of scale.

But labor rates for trained valve technicians have risen significantly over the last two decades as the workforce aged. This, plus the requirement to repair valves to tighter specifications such as American Petroleum Institute (API) RP621 valve repair standard, have raised the total cost of valve repair.

What this means is that the line between an economically repairable valve or a decision to replace with a new valve has seen a distinctive rise in size and pressure classes. Today, many refiners will not even consider repairing Class 150 cast-steel valves less than nominal pipe size (NPS) 12. Other refiners bump up the repair threshold to NPS 20. In Class 300, the economical-to-repair size limit drops to around NPS 10 for cast-steel-bodied valves. It drops even lower for valves in Class 600 and above.

So far, we’re talking about commodity gate, globe and check valves, which make up the bulk of refinery and process plant valve populations. But what about more expensive and more exotic valves? When the body material becomes chrome/moly or stainless steel, the repair/no-repair threshold drops significantly. Here, an NPS 6-inch Class 150 in CF8M (cast 316ss) material becomes cost effective to repair. However, as the austenitic stainless steels (300 series) become more commoditized, that go/no-go repair threshold continues climbing up just as the plain carbon steel plot line did years ago.

Most owner/end users have some valves in their facilities that are more critical than others. These valves may see much higher pressures, be larger in size, be motor-operated or convey hazardous or lethal media. The TCO formula for these critical valves is a bit different. They must be maintained at a higher level than the commodity valves so proper repair is even more important. Oftentimes, additional nondestructive evaluation is called for, and special testing is required. These valves almost always take more expertise, technology and time to repair. This translates into higher repair cost.

Sometimes a new critical valve is available and the owner/end user has to decide whether or not to issue a purchase order for the repair or order new equipment. A rule of thumb for this decision is that if the cost of repair exceeds about 60−65% of the cost of the new valve, then a new valve is ordered.

Replacement with new equipment is not always an option, however, because these valves are often special-order, highly engineered valves with long lead times. In those cases, the decision becomes easy: The valve is repaired. In some cases, repair of specialized valves can cost more than a replacement valve would cost. Another factor in deciding whether or not to repair is the robustness of the original valve compared to the perceived robustness of a new replacement valve.

Unless a defect or problem is a painfully obvious one such as a casting leak through the side of the valve body, an investigation must be made first. This repair investigation is called tear down and inspection (TDI). TDI is where the problems are discovered, and the diagnosis is made. Most valve repair operations of critical valves begin with TDI, while in some cases, the owner may not ask for an initial TDI. TDI is almost always a separate billable item to cover the repair company’s costs for the inspection in case the valve is scrapped and no additional repair work is performed. Usually, the initial purchase order to a valve service company is just for the initial TDI.

TDI involves complete disassembly of the valve and examination of all the component parts. In some cases, a pretest is performed before the disassembly process. Once the valve is disassembled, any corroded or discolored parts are blasted or chemically cleaned to get the parts down to bare metal so that a careful inspection can be made. The visual inspection is augmented by measurement of key components. Sometimes additional nondestructive evaluations such as dye penetrant (PT), magnetic particle (MT), positive material inspection (PMI) or radiography (RT) are performed.

With all the parts’ inspections completed, the repair facility can prepare a scope of work and give an expected repair price, which includes the purchase of new parts, if they are available. The valve owner will then make the decision to repair or replace.

Although we’ve been talking about linear valves and check valves so far in this article, the process for quarter-turn valves has some similarities but also some differences.

For soft-seated ball valves, it’s vital to procure exact OEM replacement soft goods if they are available. By going back with the original OEM seals, tolerances can be maintained, and proper operation is better assured. This also ensures that during the valve’s next turnaround, OEM replacement parts will still fit. The cost of OEM parts is usually higher, but they should be the choice when available from the OEM. Parts are usually billed on a cost-plus-20% or so basis.

Metal-seated ball valves are slightly more difficult and potentially costly to repair because of the non-resilient nature of their seats and less-forgiving finishes and tolerances. For this reason, some of the severe-service ball valve manufacturers provide their own repair services. While OEM repair can be an excellent choice because of the direct access to OEM engineering and parts, possible drawbacks also exist, depending upon the situation and repair capabilities of the OEM.

These include: 1) The owner/end user usually prefers to minimize the number of purchase orders issued for valve repair on a turnaround, and sending every valve back to the OEM for repair involves cumbersome paperwork, and 2) OEM repair operations sometimes compete with production work, especially when machining or welding is involved, so valve repair work is sometimes pushed aside for project work.

High-performance butterfly valves see a greater percentage of OEM repair. The angles and tolerances of these valves are critical and usually, the OEM has the benefit of special jigs and fixtures that can make repair of the valves quicker and more economical.

Other valve types that favor OEM repair (or at least very strong OEM/repair facility relationships) are control valves. In general, they do not even fall under the same plant umbrella as block valves do. The control valves, with their critical regulating function to perform, are usually handled by the instrumentation group in the plant. The coordination of their repair falls under their responsibility as well. Since the control valves are more than final control elements, the repair facility needs to have an excellent understanding of the actuator, positioner and control system with which the valve interfaces, which is why OEM repair facilities see a much greater percentage of these valves during outages.

Repairing pressure relief valves (PRVs) is a special case. Since these valves perform a critical safety-related function in the plant, repairing them is heavily scrutinized by governmental agencies, the valve manufacturer and the owner/end user. There are strict rules established by the American Society of Mechanical Engineers (ASME) National Board (NB), that describe in detail repair procedures to be followed. Included in these requirements is the insistence on OEM replacement parts if the valve is to be restamped.

Since PRVs are repaired on regular schedules and they generally are not operated frequently, their repair costs can usually be estimated fairly accurately ahead of time. The repair process normally involves a pretest, followed by the typical TDI, and measurement and inspection of key components. The machining of parts and especially welding of any component is tightly controlled by the repair section of the NB code. Following repair and/or parts replacement, the PRV must pass a tight test procedure that ensures the valve will function as required.

Process plants and refineries also have large and unusual special-purpose valves that have to be repaired periodically. Giant, high-temperature flue gas and catalyst slide valves, which can weigh 20 tons or more, are examples of these types of valves. The repair of valves this large must be accomplished by field service (in-line) repair. Any in-line valve repair is going to be more expensive because of the logistics involved.

Other valves that are almost always repaired in place include virtually all welded-in valves. In-line valve repair is usually performed on critical butt­weld-end power plant valves. Any machining, lapping or welding equipment must be portable to be brought to the jobsite and transported to the valve in need of repair. Just the handling of the equipment can require the creation of special temporary scaffolding as well as the availability of cranes and lifts. Normally, all equipment brought to the jobsite for field service repair is billed to the customer on a per-day basis.

The most dangerous and expensive field service valve repair occurs in nuclear power plants. Personnel performing this work are the cream of the valve repair crop because any mistake made during repair can be deadly. Needless to say, the rates for field service repair in nuclear facilities are very high.

One of the biggest issues valve repair companies face is the balance of manpower. A company may participate in six to eight major repair turnarounds a year, plus a number of smaller repair jobs. A large valve repair turnaround can require two or three shifts of straight, 24-hours-a-day work until all the valves are repaired. These types of jobs require many highly qualified technicians to man the multiple shifts. An issue comes up when there are no turnarounds in house and the number of random repair jobs is low, a situation that leaves many highly paid personnel sweeping the floor or doing other non-billable work.

Because of the up-and-down monthly business cycles in valve repair, assessing the financial viability of a repair company has to take into account a 12-month business cycle, as some months can be very profitable, while others can be stained with red ink.

Some repair jobs require techniques or processes that are above and beyond the normal daily routine. These include the qualification of very specific welding procedures. A good repair facility working on linear and quarter-turn valves will probably have 100 to 150 welding procedures qualified in accordance with the requirements of the ASME Boiler and Pressure Vessel Code. However, it is not unusual for an end user to request special welding procedures that exceed the requirements of Section IX of the boiler code. These procedures are usually processed on a hot-rush basis, with the cost for these special procedures added to the invoice.

A logistical and economic advantage for repair facilities is having vertical integration. Not having to send components out for special processes such as welding, nondestructive evaluation and heat treatment can save the customer both time and money.

It is rare for a customer in the oil and gas industry to ask a valve service firm to just repair a valve. Specific criteria and procedures are created that need to be followed. While some companies have their own repair standards, many reference the appropriate and available API repair documents.

API’s RP621 refinery valve repair document is thorough. It requires numerous examinations and inspections of valve components. In addition to the inspection phase, all repair activities must be documented in detail on forms submitted to the owner/end user following the repair process. This equates to much paperwork or a thorough enterprise resource planning (ERP) system to digitally document all repair activities, including inspection and test reports. All of these inspections and documentation take time. This is why the thorough repairs in accordance with RP621 cost a lot more than a cursory “clean up and retest” repair.

While the API RP621 document is specified for gate, globe and check valves, currently no repair standard exists for quarter-turn refinery valves. The API refinery valve group has considered creating such a document and could begin work on it in the next few years.

On the midstream side of the oil and gas industry, API has a repair document for valves built in accordance with the API 6D Pipeline Valves design standard. This document is API 6DR, Repair of Pipeline Valves. Repairing valves to this standard is also going to cost more because of the repair details and documentation requirements.

Most valve repair is focused primarily on the refining, petrochemical, chemical and power industries because of the harsh operating conditions that valves in these services see. However, valves in water service require repair from time to time, although not as often as process industry or power valves. Waterworks valves that see the most repair activity include large outer diameter gate, ball and butterfly valves as well as valves in dams and hydro-electric facilities. Since most of these valves are difficult to remove, they are repaired in place and dictate the higher in-line repair pricing.

It would be great if all repairs could be quoted at a set price before the valves are inspected, but many factors go into the costs and pricing of fixing a valve. While set pricing is occasionally done, these ahead-of-time, no-inspection-basis price quotes are necessarily high to cover all possible contingencies.

Performing valve repair that is both profitable for the service facility and economical for the owner/end user is the goal for every repair job. At the end of the day or the end of the turnaround, the objective is to have customers that are confident they received value for their repair dollars and a repair company that was able to make a reasonable profit on its labors.

GREG JOHNSON is president of United Valve (www.unitedvalve.com). He is a contributing editor to VALVE Magazine and a current Valve Repair Council board member. He also serves as chairman of the VMA Communications Committee, is a founding member of the VMA Education & Training Committee and is past president of the Manufacturers Standardization Society. Reach him at greg1950@unitedvalve.com.

When planning a check valve installation, the primary goal is to achieve a valve and piping system that offers the longest service life at the lowest cost.

Shipment: All products and/or services covered by the quotation are sold F.O.B. either our plant in Linden, NJ or the manufacturer"s plant for the parts and/or valves required, unless otherwise indicated. The risk of loss or damage in transit will be upon the purchaser. The products will be prepared for shipment in a manner prescribed by us or the manufacturer and shipped by any public carrier which we deem satisfactory, unless the purchaser provides other specific shipping instructions when placing orders. Any date provided by us for completion of work or for shipment is intended as an estimate only and is not to be deemed a term of the quotation. Shipping charges shall be pre-paid and billed at the time of shipment.

Warranties and Limitations: We warrant only that our products will conform to their description herein and that at the time of sale our products will be free from defects on workmanship and material. The name and reputation of Certified Valve Repair stands prudently behind every valve or piece of equipment we recondition. We are valve repair specialists, if at any time, in any way, a valve or piece of equipment that we have repaired fails to provide complete satisfaction, please bring the matter to our attention. Every repaired valve, pump, instrument, or equipment when used in accordance with the manufacturer and our recommendations is guaranteed to be free from defective workmanship and material. We will repair or replace without charge, F.O.B. our plant any repaired unit which our own examination proves to be defective within a period stated by our firm at the time of delivery. We assume no responsibility for incidental damage or expense. Authorization is required before returned articles will be accepted.

Choosing remanufactured safety and relief valves is a smart alternative for saving money and minimizing down time. It makes good sense for the majority of industrial uses because they are:

How much time and money have you lost because of price, availability and delivery times associated with new safety valves? Get production back up to speed affordably and confidently with remanufactured valves.

If a remanufactured valve doesn’t meet your expectations for any reason, within 5 days of receipt and prior to installation, return it for full credit plus shipping and return freight costs.

Your pressure relief valves are the most important pieces of safety equipment in your facility or along your pipelinesystem. There’s no margin for error. Your PRVs need to work — every time. So how do you know when you can get by with a repair, or when it’s time to replace them?

In many cases, regular valve testing and repair isn’t optional. It’s mandatory. But how do you know if it’s time for a replacement? Here are three times you need to think about repairing or replacing your pressure relief valves.

Pressure relief valves are designed to open to relieve pressure in your system and then close again. In a clean environment, they may be able to open and close multiple times with no problems. But, in some cases, when a valve opens, debriscan get into the valve seat, which can prevent the valve from returning to its originalclosed position.

In some locations and industries, regulations govern how long valves are allowed to be in operation before they need to be repaired or replaced. For example, your state inspector may require that your valves be completely disassembled, inspected, repaired, and tested every five years. In extreme cases, such as if a valve is frozen, the local jurisdiction will mandate replacement.

For smaller valves and applications, you can test your valve by lifting the test lever. Note, though, thatyou shouldn’t do this too often, only about once a year.ASME UG136A Section 3 requires valves have at a minimum of 75% operating pressure versus the set pressure of the valve for hand lifting to be performed.

For larger valves and applications, you can send them to us for testing or we can visit your facility and test them online through ourElectronic Valve Testing (EVT) services.

The service and application a valve is used for affects its longevity. A valve used for clean service, such as steam, can last a long time — easily 20 years if it isn’t operated too close to the set point and gets the right preventative maintenance program. On the other hand, a valve that used for acid service, operated too close to the set point, or exposed to dirt or debris in the system will need to be replaced more often — such as every 10 years.

Our technicians are factory-trained to repair and recertify valves back to their OEM specifications. But is that the best course of action? Or should you just replace them?

In general, we recommend repairing your valves when possible to get the most out of your investment. However, sometimes, replacement is simply more cost-effective than repair.

In either case, it will certainly cost less to replace the valve than to pay for any damage you might incur from keeping it in service past its prime!

In general, it’s difficult to impossible to say exactly how long your pressure relief valves will last. It depends on several factors, including the service, the system, and how the valves are operated. The best way to both keep your valves operating correctly and identify when they need to be replaced is to put them on a regular preventative maintenance program, ideally supported by a valve management software like ValvKeep.

At Allied Valve, your safety is our first priority. Our pressure relief valve repair services can keep your valves working at their highest levels of performance.Learn more about what we can do for you.

1-800-223-7019. Work must be done by a Safety Valve referred contractor to be covered sodo NOT call a contractor directly or your claim will not be covered.

We do not cover the opening or closing of walls to gain access to pipes. Opening of walls to allow access to pipes is Your responsibility. You are responsible for closing the wall after the repair is complete. Check your homeowners insurance policy; it may cover the cost of handling lead paint and/or closing the wall.

No. The customer is responsible for making the area of the repair accessible. Therefore, the customer must move or remove any obstructions before work can begin.

All leaking internal clean water pipes (hot or cold), fittings and valves from the point the supply enters the house up to and including the shut-off valve before each fixture

Trusting our experience, our customers asked for a fast, accurate way to replace and/or manufacture valve parts. Our team listened to their needs, then looked for solutions, and we responded. Our cutting-edge, exclusive Millennium Power Services Virtual Valve & Parts Program (MPS-VP2) has been developed to fill those needs.

The Millennium Power Services Virtual Valve & Parts Program brings an exciting new dimension to the way parts repair and manufacturing is done. In addition, it saves time and money.

TrimKit is an innovative program for valve parts replacement that offers considerable time-saving, cost-effective and peace-of-mind when time is of the essence. This ensures that Millennium Power Services can be the only vendor needed for valve parts and a wide range of related consumables.

The way TrimKit works starts with establishing whether Millennium Power Services will manufacture or refurbish the valve parts. We then ship it back along with TrimKit: a protective case containing pistons, gaskets, seals, packing—whatever meets the valve’s exact specs for complete reinstallation.

TrimKit reduces cost of ownership and increases your valve parts’ life. Once replacement is complete, old parts are packed into the protective TrimKit case, then shipped back to Millennium Power Services. Once received, we proceed to refurbish and/or replaces parts and replenish all soft goods. Full reports are included and root cause analysis is done on valve wear and/or failures. Checklists are also included for added verification for a complete solution that will give you peace of mind.

At Millennium, we scan and gather information with utmost precision. But our attention to detail doesn’t stop there. Using our precision BOSSFM20 fiber laser marker, we code, mark, and engrave each valve part with specific information.

Extreme Force Valve has the authority to use the VR Stamp. Our accepted quality system meets the standards established by the National Board. Our VR Stamp signifies that our quality system complies with the boards requirements for proper repair of ASME code section I and VIII valves that have been NB capacity tested

The T/O mark signifies that our valves meet all the requirements for in service testing and certifications of pressure relief valves, providing they pass all testing required and no repairs are needed. Only minor set pressure adjustments are allowed. There is no need to disassemble a valve that operates properly.