Common Valve Failures and How to Prevent Them

In critical industries like chemical processing, pharmaceuticals, oil and gas, and water treatment, selecting the right ball valve manufacturer is crucial for ensuring operational safety, efficiency, and durability. The growing demand for high-quality ball valves has made India a global hub for valve manufacturing. From pneumatically actuated ball valves to full-flow ball valves, Indian manufacturers offer world-class flow control solutions.

Common Causes of Valve Failures

Corrosion and Erosion

When materials and fluids interact with each other over time, corrosion and erosion take place, which weakens the structure of pipes and valves and creates damage. Harsh chemicals and high-pressure fluids can speed up this process and cause material degradation in industries like chemical and oil, and gas. To reduce expensive maintenance costs, regularly inspecting materials is crucial for preventing damage and guaranteeing that pipes and valves stay strong and effective.

Cavitation

Cavitation occurs when sudden pressure changes cause vapor bubbles in a fluid. These bubbles have the potential to burst and seriously harm the valve parts. Cavitation can cause valves to pit, vibrate, and eventually break in industries like power generation and water treatment, which reduces system efficiency. Maintaining important machinery and ensuring smooth operations help reduce cavitation.

Valve Seat Wear

A common problem is valve seat wear, in which the valve seat's surface deteriorates with time, resulting in leaks and pressure loss. Degradation of the valve seat could compromise the safety and quality of products in industries where accuracy is essential, such as food and beverage, and pharmaceutical. The integrity and effectiveness of the system are maintained by tight seals and leak control provided by routine maintenance and quick valve seat replacements.

Improper Installation and Operation

From leaks to complete valve breakdowns, improper valve installation and operation can result in a variety of operating issues. This can cause major downtime and repair costs in regular industrial settings by interfering with production processes. Preventing these problems and preserving efficient operations need careful installation, employee training, and following to manufacturer's guidelines.

Signs of Valve Failure to Watch Out For

Inconsistent pressure or flow

Inconsistent pressure or flow always indicates some type of issue with the valve, such as blockage, wear and tear, or improper valve function. This can disturb the functionality of the valve, affecting the overall process

Leaking or Dripping

Common indicators of valve failure include leaks or drips, which are usually caused by worn seals, damaged valve seats, or poor installation. Leaks can result in operational inefficiencies, safety hazards, and environmental harm in addition to resource waste. These problems can be avoided and system integrity maintained with regular upkeep and valve replacements.

Unusual Noise or Vibration

Unusual vibration or loudness may be a sign of cavitation or valve failure brought on by vibration. When pressure decreases, cavitation takes place, resulting in vapor bubbles that violently collapse and harm valve parts. Poor valve installation or sizing could lead to vibration-induced failure. Early detection of these problems by sound and vibration monitoring can help avoid serious damage and system failures.

Frequent System Shutdowns

Valve problems may be the direct cause of frequent system shutdowns. Random interruptions may result from malfunctioning valves that disrupt flow, reduce pressure, or even cause a safety risk. Continuous system operation is ensured by routine maintenance and rapid valve replacements, which boost productivity and decrease downtime.

Preventive Measures to Avoid Valve Failures

Regular Inspection and Maintenance

For valves to function properly, routine maintenance and inspection are essential. Checking for leaks, keeping an eye on flow and pressure, lubricating moving parts, and examining seals and valve seats are all examples of best practices. By planning routine maintenance and replacing worn parts as soon as possible, potential issues can be found before they become serious, which lowers maintenance expenses and downtime.

Proper Valve Selection

For long-term performance, choosing the appropriate valve for each application is essential. It is necessary to take into account variables such as fluid type, pressure, temperature, and flow needs. Proper valve selection ensures optimal performance and safety in severe environments such as chemical, pharmaceutical, and oil and gas industries by preventing early wear, corrosion, and operational failures.

Automated Valve Monitoring Systems

The tracking of valve health has been transformed by automated valve monitoring systems as a result of the growth of the Internet of Things. By identifying problems like leaks, pressure changes, or wear, these systems offer real-time data on valve functioning. In sectors like water treatment and power generation, early detection is crucial because it enables proactive maintenance, which reduces downtime and maximizes operational efficiency.

Training for Operators

The performance of valves depends on their placement and operation. By instructing operators how to operate valves properly, identify failure indicators, and stick to the installation instructions, there is a lower chance of human error, and system functionality is guaranteed. Skilled operators can effectively operate valves, avoiding problems and increasing the equipment's life.

Unison Valve Products to Prevent Failures

Automatic ball valves

Automatic ball valves use a rotating spherical ball to control the flow of fluids, making them ideal for quick shut-off applications.

• Common Failures:

  • Leaks: Over time, the seals can wear out, leading to leaks.

  • Blockages: Dirt or debris may get stuck, causing the valve to malfunction.
    

• Solution:

  • Regularly clean the valve to avoid dirt buildup.

  • Ensure seals are properly maintained and replaced when worn to prevent leaks.

Automated systems can help monitor performance and catch issues early.

Butterfly Valves

 Butterfly valves are compact and efficient, using a rotating disk to control flow in high-pressure applications.

• Common Failures:

  • Sealing Issues: Worn seals can cause leaks.

  • Pressure Loss: If not properly designed, they may struggle to handle high-pressure systems.
    

• Solution:

  • Use the right materials for seals to match the fluid and pressure conditions.

  • Regularly inspect the disk and sealing areas for wear, replacing seals when needed.

Ensure the valve is rated for the pressures it will handle to avoid failures.

Gate Valves

Gate valves are designed for a tight seal and work by lifting or lowering a gate to control the flow of liquids and gases.

• Common Failures:

  • Leakage: Over time, seals and valve seats can degrade.

  • Difficulty in Operation: Buildup of debris can make the gate hard to move.
    

• Solution:

  • Lubricate and clean valves regularly to keep them functioning smoothly.

  • Replace seals and valve seats as part of regular maintenance to prevent leaks.

For harsh environments, consider using corrosion-resistant materials to extend valve life.

Globe Valves

Globe valves are perfect for regulating flow in pipelines and provide fine control over fluid movement.

• Common Failures:

  • Flow Issues: Worn valve seats or disks can lead to inconsistent flow.

  • Sticking: Buildup of minerals or other debris can cause the valve to stick.
    

• Solution:

  • Inspect and replace worn valve seats and disks regularly to ensure smooth operation.

  • Clean the valve often to prevent mineral deposits and debris buildup.

Choose the right materials for your specific fluids to minimize wear.

Check Valves

Check valves ensure that fluids only flow in one direction, protecting critical components like pumps from damage and contamination.

• Common Failures:

  • Backflow: A faulty check valve can allow fluid to flow the wrong way.

  • Leaking: Poor sealing or damage can cause leaks.
    

• Solution:

  • Install pressure-relief systems to prevent issues with backflow.

  • Regularly check and replace seals and valve seats to avoid leakage.

  • Opt for materials resistant to corrosion and wear for longer-lasting performance.
    

Conclusion

Proper valve selection, fast repairs, and regular checks help your equipment last longer, avoid frequent issues, and save downtime. Whether it's fixing leaks, controlling pressure, or boosting flow control, taking care of your valves can ultimately result in major cost savings.

Explore Unison's range of high-quality valves manufactured for optimal efficiency and reliability. Invest in the correct solutions now to prevent costly failures and keep your systems running smoothly.

FAQ Section

Q1: What are the most common valve failures in industrial applications? 

Ans: Common valve failures include corrosion, cavitation, seat wear, and improper installation, leading to leaks, inconsistent flow, and pressure loss.

Q2: How can I prevent valve failures in food processing plants? 

Ans: Regular valve inspections, proper valve selection, and ensuring valves meet hygiene standards (like FDA compliance) are essential for preventing failures in the food industry.

Q3: What’s the impact of cavitation on valve performance? 

Ans: Cavitation occurs when vapor bubbles collapse inside the valve, causing shock waves that damage valve components, leading to erosion, leakage, and system failure.

Q4: How do I select the right valve for my industrial system?

 Ans: Proper valve selection depends on the application, pressure, temperature, and material compatibility. Consult with valve manufacturers like Unison Valves for customized solutions based on your specific needs.

Q5: How often should industrial valves be inspected to prevent failures? 

Ans: Valve inspections should be done regularly, especially in critical industries. High-risk industries like oil and gas may require more frequent checks, whereas others may schedule inspections based on usage.