Image courtesy of Dow Terneuzen
Discover the importance of thorough valve inspection in maintaining process integrity and safety through the experience of Marc Simoëns, a veteran at Dow Benelux B.V..
By Iryna Mukha, Valve World
With over 39 years of experience with quality control and assurance, Mr Simoëns has extensive experience with valves and their applications, especially in the chemical industry. He has been working at Dow Terneuzen since 1985 and is now retiring after nearly four decades of service. The company specializes in a wide array of operations encompassing the production of petrochemicals, performance plastics, and specialty chemicals. At the heart of its operations lies a commitment to advancing sustainable practices, with a focus on delivering innovative solutions that drive efficiency across diverse industrial processes.
As a member of Dow Global Valve team, Marc is responsible for incoming quality control activities, performing shop inspections and quality audits at manufacturers and suppliers of valves, pipe, flanges, fittings, and PCE equipment. In this article, he shares his insight on valve inspection and its crucial role in delivering goods that are in compliance with the specifications and the applicable international standards.
Please tell us about your career background and current role.
“I started at an engineering company right after secondary school as an intern. I always wanted to be a technical draftsman, so when the opportunity to officially join Dow presented itself, I went for it. However, the company was looking for a quality control person, not a draftsman, as the department was started only three months before I got hired. Despite having no prior experience in QC, I started learning to do everything according to the US standards and, after a few months, I was able to start focusing more on inspecting components and tech.”
“In my current role, I serve as the focal point for quality assurance and control, overseeing a spectrum of critical components including piping, fittings, flanges, valves, control valves, castings, stud bolts & nuts, and other pressure-containing equipment-related parts. My responsibilities extend to conducting pre-inspection meetings and shop audits, ensuring that every facet of our installations meets the highest standards.”
“A significant aspect of my work involves performing meticulous incoming inspections on pipes, valves, and fittings (PVF) to guarantee the integrity and compliance of materials. Traceability is paramount in our industry, especially when dealing with a myriad of stainless steel alloys. With hundreds of variations, it’s crucial to avoid assumptions and meticulously verify materials to prevent discrepancies on-site. This attention to detail is pivotal for both new projects and maintenance, as I thoroughly inspect everything, starting from parts that have failed over time to find the root cause of the issue, all the way to the newly acquired components, ensuring they align with Dow Terneuzen’s stringent standards.”
Which aspect of your work has impressed you the most so far?
“Being entrusted with the inspection of materials originating from Europe, and even when shipped to the US, underscores the global reach and impact of my role. Additionally, I take part in expanding Dow Terneuzen’s approved company list, conducting audits to assess adherence to industry standards and practices. This involves evaluating the work of potential partners, ensuring they align with Dow’s stringent quality criteria. Notably, my responsibilities extend to collaborating with the Dow global valve team, where I contribute my expertise to a collective effort aimed at maintaining and enhancing the quality of our valve systems worldwide.”
“In instances where other Dow sites lack experience with specific valves, castings, or alloys, I leverage our global team’s expertise. This collaboration enables us to address challenges, share insights, and uphold the highest standards in quality across the diverse range of materials and components we encounter. Overall, my role embodies Dow Terneuzen’s commitment to excellence, precision, and global collaboration in the dynamic field of industrial processes and materials.”
“But there is also something that impressed me the most, in a kind of negative way. In spite of all the existing quality systems, we still have to perform inspections to be sure that we have reliable and safe equipment. Still after all these years, after all these quality systems that have been invented and implemented, we still have to perform thorough inspections. If everything worked according to the codes, if every quality and accreditation system worked the way it should, my job would not exist.”
What factors are key in the process of valve inspection?
“Valve inspection is a multifaceted endeavor that demands meticulous attention to detail and a comprehensive understanding of various standards and specifications. Unlike simpler components like fittings or pipes, valves present a myriad of complexities due to their diverse design requirements and functionalities. When inspecting a valve, we must navigate through an extensive checklist, covering approximately 35 checkpoints ranging from marking and finish to size and leakage testing.
This involves delving into different standards such as ASME, ASTM, MSSP, API, and other codes, as well as NDE codes, necessitating a high level of expertise and experience across all components involved in valve construction.” “Critical valves undergo rigorous shop inspections to ensure they meet stringent standards regarding functionality, hydrotesting, and seat testing.
“You get what you inspect, not what you expect.”
Failure of critical valves could lead to severe consequences such as plant breakdowns, underscoring the importance of thorough inspection protocols. While onsite retesting is feasible for smaller valves, larger critical valves require specialized equipment and testing facilities to mitigate risks effectively.”
“Ultimately, the key to effective valve inspection lies in proactive measures taken before installation. Choosing to test valves onsite upon receipt, while possible, may prove too late if discrepancies are detected post-delivery. Therefore, close coordination between internal stakeholders, clear specifications, and strategic decision-making regarding inspection locations are vital to ensuring compliance and mitigating risks associated with valve integrity.”
Which aspect of your work has challenged you the most?
“One of the most challenging aspects of my role is navigating the intricate process of coordinating valve inspection logistics amidst varying project demands and timelines. With critical valves scattered across different locations and often sourced from diverse manufacturers, ensuring timely and thorough inspection poses a significant challenge. Balancing the need for onsite testing with the practicalities of transporting valves to specialized facilities for comprehensive examination requires careful planning and effective communication between internal stakeholders.”
“Moreover, mitigating the risks associated with potential valve failures demands a proactive approach to quality assurance, often necessitating tough decisions regarding repair, replacement, or return of non-compliant components. The urgency of project timelines further compounds these challenges, as delays in inspection or remediation efforts can have far-reaching implications on overall project schedules and costs.”
“Despite these challenges, I find that effective teamwork and clear communication channels are instrumental in overcoming obstacles and ensuring the integrity and compliance of critical valves. By fostering strong partnerships between internal departments and external stakeholders, we can navigate complexities, mitigate risks, and uphold the highest standards of quality and safety in valve inspection processes.”
About this Featured Story
This Featured Story is an article from our Valve World Magazine, June 2024 issue. To read other featured stories and many more articles, subscribe to our print magazine. Available in both print and digital formats. DIGITAL MAGAZINE SUBSCRIPTIONS ARE NOW FREE.
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