Valves are essential components in industrial and commercial systems, controlling the flow of gases, liquids, or steam; however, like all mechanical parts, they are susceptible to faults that can disrupt performance and lead to costly downtime. Understanding the most common valve issues and their fixes can help avoid unnecessary repairs and maintain operational efficiency.
Pressure and temperature fluctuations
Operating valves outside their recommended temperature and pressure ranges can lead to failure. Excessive heat or sudden pressure spikes place stress on valve materials, causing seals to weaken or components to burn. In such cases, it is important to assess the operating conditions and either recalibrate the system or replace the damaged valve.
Wear and tear on valve seats
A frequent problem is the deterioration of the valve seat. This critical component helps seal the valve and ensure efficient system operation. Over time, exposure to high temperatures and repeated use can cause the seat to recede or degrade; when this happens, the valve may leak or lose pressure. The fix typically involves removing the worn seat and installing a replacement insert. Regular inspections are essential to catch early signs of wear and ensure your valve stock includes suitable replacements when needed.
Poor installation and maintenance
Incorrect installation remains one of the most preventable causes of valve failure, so following manufacturer guidelines and ensuring proper torque settings during assembly is vital. It is important to regularly check your valve stock to ensure it includes models suitable for the intended application.
Cavitation damage
Cavitation occurs when vapour bubbles form and collapse within the valve due to pressure imbalances, causing surface erosion and vibration. It is most common in control valves used in liquid flow applications. Fixes include selecting the correct valve type, using pressure-reducing valves in stages, or adjusting the valve’s elevation for improved thermal control.
Blockages from foreign debris
Pipelines contaminated with dirt, rust, or debris can impair valve function, especially in pneumatic or hydraulic systems. This may result in blockages or abrasion damage. A common solution is to remove and clean the affected valves.
