Commercial gas systems are integral to all commercial construction companies‘ safe and efficient operation, from manufacturing plants to large-scale food service operations. Malfunctions in key components of these systems, such as piping, pressure-reducing valves, and hot taps, can lead to severe consequences. For instance, the failure of pressure-reducing valves or regulator stations can lead to over-pressurization, which increases the risk of explosions and fires. Similarly, faults in polyethylene plastic pipes or steel piping can result in gas leaks, contributing to hazardous situations and significant methane emissions. 

In the United States alone, malfunctions in commercial gas systems cause potential hazards like fires, which cost businesses billions in damages each year. It is crucial to opt for commercial gas systems repair promptly to protect yourself, your workers, and your business from such tragedies. Let’s discuss the causes that indicate repair needs and effective solutions.

Key Components in Gas Systems: Causes of Malfunction and Repair Solution

Let’s explain in detail the reasons that cause the key components to deteriorate and eventually malfunction over time.

A) Polyethylene Plastic Pipes

Polyethylene plastic pipes are extensively utilized in gas distribution networks for their highly resistant nature and ease of installation. They guarantee dependable gas delivery, reducing maintenance requirements and operational interruptions, thus ensuring the safety and efficiency of commercial gas distribution systems. Despite their flexibility and durability, these pipes can experience malfunctions due to various factors:

  • External forces such as digging or construction activities can cause pipes to crack and break.
  • Exposure to certain chemicals or substances in the soil or environment can degrade the material over time.
  • Temperature fluctuation can lead to the expansion or contraction of the pipes, potentially causing leaks.

Repairing Solution

Welding is essential for maintaining the integrity of both plastic and steel pipelines. Welding plastic/steel pipes ensures secure and leak-proof joints, which is critical for safe gas transport. 

B) Steel Piping

These are commonly used for transporting gas over long distances. Due to their ability to withstand high pressure and extreme conditions, these pipes ensure risk-free operation. Besides its amazing properties, steel piping, over time can experience malfunctioning. Below are the top reasons behind this:

  • Over time, pipes cause rust and corrosion due to exposure to moisture & gasses.
  • Rapid changes in gas pressure can stress steel pipes and cause potential failures.
  • Poor welding during installation or maintenance.

Repairing Solution

Cathodic protection is a crucial technique for preventing corrosion in steel pipelines. It involves applying a low-voltage electrical current to the pipeline, which counteracts the natural electrochemical reactions that cause corrosion. 

C) Regulator Stations

The regulator station plays a crucial role in industrial gas systems as it helps maintain the gas pressure level. Therefore, its malfunctions lead to severe consequences. Have a look at the top factors that cause it:

  • Components within the regulator station, such as diaphragms or springs, can wear out over time, affecting pressure regulation.
  • Dust, dirt, or debris can enter the regulator station, impairing its functionality.
  • Improper installation or adjustment can lead to incorrect pressure settings or operational issues.

Repairing Solution

In a regulator station, the repair process for commercial gas systems begins with isolating and shutting down the station to ensure safety during maintenance. Technicians then disassemble the station to inspect components such as diaphragms, springs, and valves for wear or damage. Cleaning out dust, dirt, or debris that may have accumulated inside the station is crucial to restoring optimal functionality. Proper reassembly and calibration follow, ensuring that pressure settings are correct and that the station operates smoothly without leaks or pressure fluctuations. 

D) Pressure Reducing Valves

It is a vital component in industrial gas systems that converts high pressures from sources like gas wellheads or transportation networks into safer levels for various applications. PRVs ensure consistent outlet pressures despite fluctuations upstream. However, malfunctions can arise from numerous factors, including:

  • Internal components like seals or springs can degrade over time, affecting valve operation.
  • Debris or sediment buildup within the valve can restrict flow or cause irregular pressure regulation.
  • Variations in temperatures can affect the performance of materials within the valve, leading to inefficiencies or failures.

 Repairing Solution 

A common repair solution for pressure-reducing valves (PRVs) is replacing internal components such as seals, springs, and diaphragms. This process involves shutting down the system to safely access the valve and carefully dismantling it to inspect, clean, or replace the affected parts. Once reassembled, the valve is tested to ensure proper functionality and pressure regulation.

E) Master Meter Systems

It’s a meter system that measures the total gas usage for a commercial property. When the master meter system isn’t working correctly—it can lead to issues such as inaccurate measurement and billing issues. Also, hazardous situations like gas leaks might arise if not treated on time. The reasons behind it’s improper working can be:

  • Incorrect calibration or drift over time can lead to inaccurate gas usage readings.
  • Sensors or electronic components within the master meter system can fail, leading to inaccurate measurements.
  • Exposure to moisture, temperature extremes, or contaminants can affect electronic components or mechanical parts.

Repairing Solution

Master Meter Systems require precise calibration and, if necessary, sensor replacement to maintain accurate gas usage measurements. The repair process starts with temporarily halting the gas flow to work on the meter safely. Specialized equipment is used to recalibrate the meter, and if sensors are found to be faulty or degraded, they are replaced. 

F) Hot Taps

Hot taps are used to connect new pipelines to existing ones without interrupting service. In this key component of the commercial gas system, malfunctions can arise from:

  • Incorrect drilling techniques or equipment failure during the hot tap process can cause leaks or damage to the pipeline.
  • Compatibility issues between the tapping equipment and pipeline material can lead to mechanical stress or leaks.
  • Failure to adhere to safety protocols during hot tapping can lead to accidents or operational disruptions.

Repairing Solution

The technique often involves replacing the tapping sleeve or valve for Hot Taps. The process begins with preparing the existing pipeline ensuring it is properly secured. If the old sleeve malfunctions, it is removed and replaced with a new tapping sleeve around the pipeline. 

Sometimes, repairing a component may not be feasible due to extensive damage or wear. In such cases, component replacement is necessary. This involves replacing faulty parts such as pressure-reducing valves, regulator stations, or master meter systems with new, high-quality components. 

How to Ensure Uninterrupted Operations During Repairs and New Parts Installation

The technique of bypassing is employed to maintain uninterrupted service and ensure worker safety during repair and new parts installation processes. Bypassing redirects gas flow away from the component undergoing maintenance, allowing other system parts to operate normally without disruption. For example, during the repair of a pressure-reducing valve (PRV) or regulator station, bypassing enables gas to circumvent the faulty component, thus maintaining consistent pressure levels across the system.

Also, it provides a safe and controlled environment for technicians to access repaired or replaced components. This method mitigates risks such as gas leaks or pressure fluctuations that could arise by avoiding complete system shutdowns. This critical technique supports the reliability and safety of industrial gas systems by ensuring continuous gas supply during maintenance activities.

If you observe any malfunction in your commercial gas system’s key components, timely repairs are paramount to avoid escalating issues. Choose trusted commercial utility contractors who prioritize adherence to building codes in commercial construction and possess proven expertise in resolving such concerns.

Conclusion

Contact Dub-L-EE if you need any of these commercial gas systems repair or replacement.  As one of the most reliable commercial utility contractors in Albuquerque, we have been in the industry since 2012 and are committed to delivering quality work. Alternatively, you can view our portfolio to see that our professionals follow best practices throughout the entire process.