Valve management service provides production reliability for maintenance shutdowns at Outokumpu’s steel plant

At the steel plant, regular shutdowns in particular require a large amount of resources, so their optimal use and allocation are important. Outokumpu selected Valmet as the supplier when it set out to further develop its valve maintenance. “We were looking for a turnkey valve maintenance service,” Rovanen says. From this starting point, Outokumpu and Valmet began to build a model that made it possible to:

1. Reduce the valve inventory value
2. Harmonize an extensive product selection
3. Reduce capital tied up in valves and their spare parts

“Our initial goal was to reduce the capital tied up in valves and spare parts. We were also seeking harmonization between various valve suppliers, and Valmet had an available solution. In addition, we wanted to standardize complex products. We trusted Valmet’s flow control expertise in these,” Korteniemi explains.

In the valve management service, all work is carried out safely and cost effectively, in a controlled manner according to plan. All completed work is reported. This comprehensive service is based on Valmet’s strong flow control expertise and experience.

The service includes a cost estimate for the shutdown and a personnel resource estimate for the valves. Valmet’s flow control experts review all the valves and plan the work at the plant in advance, two months before the beginning of the shutdown. “We reviewed the valve positions together, checked the valve plates or cards, and prepared a lifting plan. In other words, all the key preparations, as well as a plan for the order in which the valves were to be dismantled, were made well in advance,” says Rovanen. Shutdown planning also takes into account updating the equipment, which makes it possible to determine the time and extent of future maintenance needs more precisely.

All proactive work reduces the amount of work needed during the shutdown, and careful planning enables the work to be carried out safely and efficiently during normal working hours. This also makes it possible to acquire the spare parts in good time. In addition, the exact number of employees needed for the shutdown can be determined. “We did as much as possible in advance,” Rovanen explains.

Valmet plays an important role in ensuring successful annual shutdowns. “We’ve stayed on schedule, and the work has been done successfully and safely,” says Rovanen.

The valve management service ensures that the right valves are serviced at the right time. This also ensures that the plant has the right valves for the right places, as well as cost control. “The service model by Valmet flow control has made our work easier. The mutual exchange of information has also improved,” Rovanen says.

“I have only positive things to say about the valve management service. A large number of valves were reviewed during the shutdown, and practically no input was needed from me. The shutdown ran smoothly in the background, and there was no negative feedback. Everyone praised each other. This service saves a lot of working time,” Rovanen explains. “Above all, the maintenance and management service provided by Valmet has improved predictability. When things are done proactively and systematically, costs can be kept in check, and cost savings can be achieved,” says Korteniemi.

Although inventory values have decreased, response times have improved. The service level has remained unchanged, even improved. “We cooperate closely. Valmet knows our maintenance staff, which enables us to further develop our cooperation.”