In every industrial and mechanical system, valves are important parts that control the flow of liquids and gases in a system under various conditions. Even the most robust valves develop problems with time, which become inefficient and create leaks that result in costly system downtimes. Hence, learning how to recognize and solve some of the common valve problems helps increase system reliability and prolong the equipment.
Every industrial plant, large or small, and every water distribution system, need to know the safety and operational performance required in this field.
Problems with valves are most often the result of a combination of factors. These can consist of mechanical failure, upkeep problems, and in some instances corrosion. Certain conditions, which include high temperatures, fluctuating stress, and aggressive chemicals in the environment, can get worse issues.
Some specific issues are:
- Dirt and debris accumulation in the valve
- Sealing parts that are corroded or excessively worn
- Actuators that are misaligned, out of calibration, or both
- Lubrication that is insufficient, absent, or overly performed in the system
- Inapplicable materials that are corrosive liquids
Having a coherent and effective valve maintenance strategy will solve many of these problems and will prevent a valve failure.
1. Leakage in Valve Systems
Leakage in valve assemblies comprising several components is one of the most common problems that one can encounter in industrial applications of valves. Such leaks can lead to safety problems, loss of products, and release of gases or fluids into the environment.
Causes include:
- Seals and O-rings that are worn out and can no longer hold.
- Valve seats that are corroded, pitted, or attacked in other ways.
- Packing glands that are loose.
- Flanges that have been tightened improperly.
Steps to Troubleshoot:
- Inspect the seals and replace the worn ones.
- Packing nuts should be tightened evenly and to a sensible amount to avoid uneven pressure.
- Valve seats should be cleaned in a thorough manner.
- If valves are in a highly corrosive environment, consider leak-proof valves having PFA or PTFE lining (see PFA Lined Discharge Ball Valve).
Promptly tackling leakage in valve systems helps control the loss of fluid and improves safety in operations.
2. Stuck Valve
A stuck valve is a problem that is common and one that can either limit or totally stop the flow of liquid or gas. The problem is most frequently triggered by the valve being idle for a long time, and the accumulation of debris or rust that builds up on the valve stems.
Suggested Troubleshooting Steps:
- Tap the valve body gently to release the internal parts.
- If the tap approach fails, then the parts should be disassembled and cleaned, and the appropriate working anti-friction compound should be applied.
- Lubricating the valve should reduce friction.
- For valves that are mechanically operated, the actuator has to be checked for calibration as well as the power supply.
- The valve should be operated even during system downtimes to reduce the likelihood of seizing. This is a part of preventive valve maintenance.
3. Repairing and Troubleshooting Sprinkler System Valves
When dealing with fire protection and water distribution systems, the repair and maintenance of sprinkler valve systems is something that cannot be overlooked. It might be the following when a sprinkler system is malfunctioning:
- A solenoid or diaphragm might be stuck or frozen
- Filters may be blocked, or inlet ports may be clogged
- Actuators may be faulty electrically
Solutions:
- Deactivate the main water supply, and depressurize the system
- Extract the valve cover and wash the inner components
- Diaphragms and solenoids that are worn out should be changed
- Actuators must be smooth and verified for proper calibration
False activations and no activations during emergencies can be avoided with the help of routine system testing. For more valve solutions, check Elite Flow Control USA’s Valve Products.
4. Analysis of a Valve Failure
When a breakdown occurs repeatedly, performing a valve failure analysis becomes crucial to understanding the root cause. Valve failure analysis helps engineers understand the cause of the failure rather than just the symptoms.
Types of failure to review:
- Valve bodies, internal erosion, or corrosion
- Cracking or fatigue failing
- Deformation caused by over-tightening
- Mechanical stress caused by poorly calibrated actuators
The understanding of a valve’s failure is very important when it comes to future reliability and designs. This is especially true for chemical and gas plants. They depend on valve failure analysis to enhance equipment reliability and minimize downtime.
Actuator Calibration Significance
An actuator enables automated operation of a valve. If it is not properly set, it may cause a failure of a valve to open or close and lead to problems such as leakage in valve, improper pressure balance, or mechanical failure.
The actuator calibration procedure involves:
- Identifying and confirming correct valve position feedback signals.
- Matching the system pressure to the actuator torque limit.
- Testing the system open and close cycles under operating load.
- Completing calibration data and recording it in the maintenance log.
Routine actuator calibration prevents discrepancies in control signals and instability in the process.
Preventive Maintenance on Valves
Scheduled and properly documented valve maintenance provides the highest increase in the longevity of equipment and the lowest likelihood of failure. Most equipment is highly reliable and will perform as expected; however, all equipment will fail someday and will need maintenance or repair.
Maintenance procedures on valves include:
- Cleaning and maintenance of valves
- Automating the maintenance of valves
- Regular valve failure analysis
The maintenance of all equipment and proper documentation will provide assurance the equipment will function as expected during its predicted service life.
Concluding Maintenance
The various repairs on valves such as sprinkler valve repair, servicing a stuck valve, or repairing a leaking valve, all need to be documented. Reasonable and properly scheduled valve maintenance will provide the lowest risk of failure and ensure safety. It will also reduce the risk associated with a significant service interruption.
Analyzing the reasons of valve Problems, accurately performing actuator calibration, and gazing protection schedules will enhance equipment toughness and operational efficiency whilst reducing luxurious system downtimes.
In actively used industrial settings where precision and dependability are the most vital requirements the maintenance of all types of valves represents the most beneficial and rewarding investment possible.
Troubleshooting Valve Problem FAQs
What are the most common valve troubles?
Corrosion, particles accumulation, and worn seals are the predominate issues resulting in leakage or valve failure.
How do you restoration a stuck valve?
Clean the valve, upload lubricant, and verify actuator calibration inside the case of automatic structures.
Why is valve maintenance important?
To assure a smooth flow of liquid or gas and to extend its service life, valve maintenance and leak avoidance are vital.
What causes leakage in valve systems?
Corroded seals and improperly fitted systems are the main causes of leakage in valve systems
How regularly have to actuator calibration be done?
The calibration and purposeful assessments of actuators have to be carried out at least every six to 12 months, primarily based on operational conditions and frequency of use.