04 September 2024 World

Replace Butterfly Valve on A Live System


Butterfly valves are essential components in various industries and are responsible for regulating the flow of liquids and gases through pipelines. However, these valves can face challenges over time due to exposure to harsh chemicals and high temperatures, leading to erosion or corrosion that can impair their performance and create safety risks. Recognizing the signs that a butterfly valve needs replacement is vital for maintaining optimal valve function and avoiding costly downtime or potential hazards.

Traditionally, replacing a butterfly valve required draining the relevant section of piping and taking the system out of operation. However, this is no longer necessary with the introduction of the AOGV replacement system. This innovative solution is gaining popularity as it allows for efficient valve replacement without disrupting system operation.

Retracting and installing Butterfly valves in live piping systems using the AOGV method is a tried and tested, robust alternative to traditional methods. There is no need to drain or restart the processing system or do a full shutdown. The AOGV is installed over the wafer-type Butterfly valve, sealing on the pipe flanges as normal for this method.

The AOGV system for Butterfly valves handles the valves and the raised face sealing surface with care. The old valve is floated out from the piping system flanges on an integrated transportation trolley, not touching the flange sealing surface. The steps are then reversed. The new valve is floated in, positioned accurately and re-installed in the piping system. The system is fully operational upon completion, with the original pipe and the new valve requiring no additional fittings.

The first planned operation for the second-generation AOGV now in use, replaced an isolation valve on a firewater main ring without taking the firewater system down. In another case, six Butterfly valves at one plant were planned for replacement using an AOGV. This significantly simplified the replacement process compared to the previous method, which included shutting the system down and moving lots of pipework.

As demonstrated by recent successful operations, the AOGV system ensures timely replacement of butterfly valves without disrupting process operations. Today, it stands out as a reliable and effective alternative to traditional methods that require system shutdowns.