Tork Systems has gained its strong reputation in the Ship Repair community with our fast responses and excellent products in new valve sales. With our Valve Overhaul capabilities, we bring the same passion and expertise to extending the service life of previously installed shipboard valves – just another way we Get Ship Done.  
 
What is Valve Overhaul?
Valve overhaul or repair is the proactive maintenance of a valve, aimed at extending its usable lifespan or enhancing performance. Over time, valves experience wear and tear due to factors such as corrosion, erosion, and mechanical stress.
This is especially true of valves used on ships. Deterioration from corrosive fluids like salt water or buildup from sea life or plants can lead to leaks, inefficiencies, and ultimately, operational disruptions. By conducting regular overhauls, vessel operators can address potential issues before they escalate, thus ensuring operational continuity and safety.

How are Valves Overhauled?
Valve overhaul typically involves inspection, disassembly, repair, and testing. Every valve is different and will have different needs that can only be addressed after the valve has been opened up. That being said, each valve type (ex: gate valves) will have a typical overhaul process and list of parts to be renewed.
Here's a general overview of the process:

1. Inspection: The valve is thoroughly inspected to identify any visible damage, wear, or corrosion. This includes examining the valve body, seats, seals, stems, and actuators.
2. Disassembly: The valve is disassembled, and individual components are inspected more closely. This allows technicians to assess the condition of internal parts and determine the extent of any necessary repairs or replacements.
3. Cleaning and Refurbishment: Components are cleaned to remove contaminants such as dirt, debris, and rust. Depending on the condition, parts may undergo refurbishment processes such as machining, regrinding, or coating application to restore their integrity.
4. Replacement of Wear Parts: Components that have reached the end of their service life, such as seals, gaskets, and bearings, are replaced with new ones to ensure optimal performance and reliability.
5. Reassembly: Once cleaned and refurbished, the valve is reassembled according to manufacturer specifications, taking care to lubricate moving parts and apply sealants as necessary.
6. Testing and Calibration: The overhauled valve undergoes rigorous testing to verify its functionality, integrity, and performance. This may include pressure testing, leak testing, and functional testing to ensure compliance with operational requirements.
7. Documentation: Comprehensive documentation of the overhaul process, including inspection reports, repair records, and testing results, is maintained for future reference and compliance purposes.

Marine Valves and Shipboard Applications:
In maritime environments, valves play a critical role in various shipboard systems, including propulsion, ballasting, cargo handling, and fire suppression. Marine valves are subjected to unique challenges such as exposure to saltwater, high pressure differentials, and constant vibration. Consequently, regular overhaul and maintenance are essential to uphold safety standards and prevent operational disruptions at sea.
Common types of valves found in shipboard applications include:

1. Gate Valves: Used for on/off control in pipelines carrying water, fuel, or other fluids.
2. Ball Valves: Employed for quick and reliable shutoff in systems requiring frequent operation.
3. Globe Valves: Utilized for throttling and flow regulation in pipelines with varying flow rates.
4. Check Valves: Prevent backflow in piping systems to maintain directional flow and prevent contamination.

How much does it cost to repair a valve?
Deciding to repair or replace an existing valve depends on several factors. Price is often first among these.
The cost to overhaul a valve is tied to the size and type of valve, as well as its condition. Smaller valves, typically 2-inch and below, are usually replaced with new valves. This is because the cost to repair these smaller valves is usually more than the cost to replace them. Smaller valves are also harder to service because there’s less material to work with.  
Larger valves are usually repaired. Overhaul is considerably less expensive than replacement. More importantly for the working boats we serve, repairing a valve is usually the fastest way to get the vessel off the docks and back into the water. When certain larger valves take upwards of a year to make and deliver, we can often overhaul large marine valves in a matter of days.

For marine estimators, the prevailing logic is to use 75% of the cost of a new valve. This will cover the vast majority of repairs needed. Most valves will simply need a basic overhaul, like replacing resilient parts. If your valve is in particularly bad shape, though, it might need more expensive or longer-lead components, like a new stem, disc or wedge.
 
Given the critical nature of marine operations, shipowners and operators must adhere to strict maintenance schedules and regulatory requirements. Valve overhaul is a vital component of this maintenance regimen, ensuring that valves remain in optimal condition to support the safe and efficient operation of vessels.
In conclusion, valve overhaul is a proactive maintenance practice that is indispensable for ensuring the reliability, safety, and efficiency of industrial and marine systems. By adhering to established overhaul procedures and leveraging advanced technologies, organizations can mitigate risks, extend equipment lifespan, and optimize operational performance. In the maritime sector, where reliability is paramount, regular valve overhaul is not just a best practice but a fundamental requirement for safeguarding lives, assets, and the environment amidst the challenges of the open sea.
Top of Form