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Reports from our field offices confirm that using replicator
parts is simply a bad idea.
n A natural gas power plant rebuilt several Fisher valves
using replicator seat rings, plugs, and cages. Within days,
the valves began to fail. Emerson’s Instrument & Valve
Services evaluated the replicator trim and determined that
incorrect materials had been used, heat treating was not
performed, tolerances were not met, and several essential
design features were not incorporated.
n A power utility plant faced problems with valve trim
failure on Fisher valves that had been rebuilt by another
firm. Emerson’s Instrument & Valve Services inspected the
valves in the field and discovered that the pin was 45° out
of alignment. Service vibration caused the groove pin to
work loose allowing the plug to separate from the stem.
n The operators of a co-generation plant replaced trim in
a Fisher valve that had been in service for four years. To
save initial costs they had a local machine shop manufacture
replacement trim. Within two months the replacement
valve trim failed in high pressure service causing expensive
downtime. The machine shop trim did not meet critical
original design specifications.
n A test of genuine Fisher and replicator valve gaskets
revealed that the Fisher gaskets were superior in meeting
compression requirements, thickness, density, and other
critical aspects that affect stack height and ability to seal.
In fact, the replicator spiral wound gasket broke during
testing at 44% of the Fisher compression requirement.
n A nuclear plant experienced leaks at the bonnet-to-body
joint of several Fisher valves. Emerson service technicians
found that original gaskets had been replaced with those
from a local vendor. The problem was resolved when the
valves were rebuilt with genuine Fisher gaskets.
Field reports.