Valve failures are serious problems that cause disruption and operational loss. They can arise from a number of factors and can largely be reduced with the right preventive maintenance strategy. Here are the ten most common causes of valve failure:
- Wrong selection. Choosing a valve that does not match the application requirements is one of the leading causes of failure. A valve unsuited to the pressure, temperature or medium leads to performance problems and early wear.
- Insufficient or incorrect maintenance. Skipping regular maintenance, or applying the wrong technique, results in sealing problems and restricted movement.
- Corrosion. Corrosion occurs when the valve material does not suit the environment. It is especially common in the marine and chemical industries and shortens valve life.
- Ingress of foreign matter. Sediment and solid particles collecting inside the valve scratch the seat face and prevent tight closure. A strainer on the line reduces this risk.
- Overpressure. Operating above the design pressure leaves permanent damage on the body and the sealing elements.
- Cavitation and erosion. High flow velocity and sudden pressure drop cause material loss on disc and seat surfaces.
- Incorrect installation. Connecting against the flow direction, uneven tightening of flange bolts and pipe strain all stress the valve.
- Gasket and packing fatigue. Thermal cycling hardens sealing elements over time; planned replacement is needed.
- Excessive cycling. A valve operated far more frequently than designed suffers early fatigue in the stem, seat and actuator connections.
- Long periods without movement. Stems seize on valves left unused for months. Turning them a few turns periodically prevents this.
Most of these failures can be avoided with correct valve selection, a regular maintenance plan and suitable material choice. Contact our team for help selecting the right valve for your application.