If there is any reason at all to make an operations manual, valve knowledge is first and foremost. It’s so important that if you were to disregard any of the posts in this series and decide that setting a baseline or writing an operations manual isn’t for you, this section still applies to every facility.
I was working at a resort with a customer on a new install. The small pool was drained. We finished the installation and started to refill it. The operator knew which valves needed to be open or closed from memory. As we were waiting for the pool to fill, we filled that time with training. An hour goes by, and the pool is maybe a quarter full. It’s already about 9 PM. I asked the operator if it’s normal for it to be this slow and he says yes. We waited another couple of hours until finally it was filled to the skimmers and we could turn it on. I shrugged it off, sometimes pool fills are slow. Sometimes they take days if it’s a large pool. The next day I’m talking with some of the other operators and managers and they asked why we left a drain valve partially open. It had taken so long to fill the pool because it was draining at the same time!
This could have been avoided with an operations manual listing all valve positions.
Tagging valves can be done a variety of ways. From the old redneck sharpie trick to a metal tag to following strict standards set by ANSI or OSHA. This post will recommend a specific simple method that numbers the valves which corresponds to a section in an operations manual.
The Tagging
- Expansion Buffering: Don’t start with 01! Always leave a gap of 2-5 numbers between valves or groups. So for the first valve, start with 06. This allows for changes to be made later without breaking the numbering logic.
- Number the valves starting with the very first one in the system, which is probably on the suction side of the pump.
- From there, progress down the line, numbering each valve and valve set you come to. A “group” of valves would be something like a heater. A heater is typically 3 valves, one bypass and two isolation.
- Use high quality metal tags that will stand the test of time. Using cheap tags may mean they are unreadable in less than 5 years. Brass, usually. Stamped brass Brady Tags are a common choice.
Tag every single valve. Do not skip any. If you want to tag items that are not valves, that’s fine! It’s all part of the system and can be included in the operations manual. An example of this is a check valve or strainer. It’s not a valve, but it is something that you may want to tag and include in the same section of the operations manual.
The Data Collection and Entry
This is the hard part. You’ve tagged all the valves, but what to do next? Interview staff, and anyone who knows that specific system. You may want to consider bringing in a professional who can explain the valves in detail. Each valve should include, at a minimum:
- A general description of the valve: Its name and purpose. What does it do, why does it exist?
- Operational valve position: Should it be left at 50%? Closed? Open? This would be the baseline! Where is the valve during normal operation?
- Valve operation: When should it be handled? Never without supervision? During backwashing is it closed? When heater is isolated is it open? What operations require interacting with this valve.
Lastly, once the valves are tagged, they can be included in operator procedures. For example, written instructions can be created for backwashing using the valve tags. Close Valve 09, Open Valve 10, etc.
Every effort should be made to document every valve. Any valve not documented is a weakness that could come back to haunt a facility.
Once this project is completed, never again will the question “What does this valve do?” be a headscratcher. The answer is now “Let’s check the book”.
It cannot be overstated. It is a critical part of creating and maintaining a baseline. If the larger project of baselines and full operations manuals cannot be tackled, focus on this and just call it the “valve book”.
You might also like:
Establishing a Baseline in the Pump Room: Part One
Establishing a Baseline in the Pump Room: The Series Introduction