When the Wrong Valve Gets Installed — How Targeted Modifications Can Restore Process Reliability

It’s an unfortunate but common reality across many plants:

After commissioning, critical equipment is sometimes found to be unsuitable for its actual operational environment.

One of the most frequent examples we encounter at BIA Engineering Ltd is valves.

Valves that:

• Were selected based on original design assumptions that have since changed

• Are technically correct “on paper,” but perform poorly under real-world process conditions

• No longer match plant requirements due to increased throughput or revised operating strategies

The result?

Erratic process behaviour, control instability, premature equipment wear, and frustrated operations staff.

Real-World Example

In one recent project, a plant’s throughput had increased significantly since original commissioning.

A particular control valve — originally fit for purpose — now struggled to maintain stable flow under the new operating profile.

Operators were battling:

• Unstable control loops

• Frequent alarms

• Inconsistent product quality

Rather than recommending costly valve replacement and associated downtime, we worked with the client to implement targeted modifications and control system adjustments to restore stable operation.

Our solution included:

• Re-characterising the valve’s control profile to better match process needs

• Implementing smart control sequencing to compensate for valve limitations

• Providing clear operating guides to plant staff for managing this section of the process

• Building in alarms and indicators to flag when operating conditions moved outside the valve’s effective range

The result?

Stable, reliable control — without the need for major capital expenditure or disruptive plant works.

Why This Approach Matters

In many cases, replacing a valve is not practical:

• Lead times for specialist valves can be long

• Installation can require significant plant downtime

• Associated piping and control modifications can add complexity and cost

Yet doing nothing is not an option — unreliable process behaviour creates ongoing risk.

Our philosophy at BIA Engineering Ltd is simple:

• Identify what can be improved now

• Apply targeted interventions that restore stability

• Help the plant operate reliably until a longer-term solution (if required) is feasible

Engineering solutions beyond expectations means not just spotting the problem — but delivering practical, cost-effective fixes that improve plant performance today.

If your plant is fighting against problematic valve behaviour or legacy equipment mismatches, we can help you bring those systems back under control.