Valv News

Industrial valve maintenance is the foundation of plant reliability. Valves are expected to operate for years under extreme pressure, temperature, and chemical conditions, but only when properly maintained. 

Industrial Valve Maintenance: An Overview

Different valve types (ball, slurry, coking, and check valves) each have unique maintenance requirements. Factors such as process media, pressure, temperature, and cycle frequency dictate maintenance intervals. For example, a valve in high-temperature slurry service demands more frequent inspection than one used in clean, low-pressure steam.

Common wear areas include the seat, seal, stem, and coating. Over time, exposure to process media and thermal cycling can lead to erosion, pitting, or galling. Recognizing these points of degradation early allows maintenance teams to plan corrective work before failure occurs.

Predictive vs. Preventive Maintenance

Predictive maintenance uses real-time data (like actuator cycle counts and torque readings) to identify when components are nearing wear limits. This data-driven approach reduces unplanned outages and helps prioritize maintenance efforts.

Preventive maintenance follows a structured schedule. For valves operating in severe service, inspections may be required quarterly or semi-annually. By combining predictive monitoring with preventive discipline, facilities can achieve maximum uptime with minimum cost.

Common Failure Modes & Warning Signs

Even the most durable valves will show signs of fatigue. Below are the most common issues and what they indicate:

• Seat wear and coating erosion: Early signs include minor leakage or increased torque during operation.
• Galling: Metal-to-metal contact leading to surface damage, often from improper lubrication or contamination.
• Corrosion: Caused by chemical attack or incompatible materials; visible as rust, pitting, or discoloration.
• Mechanical scoring: Resulting from debris or misalignment, leaving grooves on sealing surfaces.
• Leakage paths: Often caused by wear, misalignment, or improper reassembly after maintenance.

Root causes of these failures can include:

• Improper torque during installation
• Misalignment of valve components
• Contaminated process media or debris in the system

Warning signs to watch for:

• Unusual torque or actuator resistance
• Visible external leakage
• Deviation in flow performance or pressure control

Technicians should act quickly when these symptoms appear, as minor repairs can often prevent full rebuilds or replacements later.

Best Practices for Inspection & Cleaning

A structured inspection process is key. Start with external checks for leakage, corrosion, or actuator issues. Internally, examine seat and sealing surfaces for coating damage or debris. Clean with approved solvents or media that do not compromise coating integrity.

Recording inspection data (cycle counts, wear depth, and service time) creates a historical record that helps predict future maintenance needs. Plants that track and analyze this information reduce both downtime and cost over the long term.

Valve Maintenance Frequency Guide

Below is a reference table summarizing common maintenance tasks and recommended intervals based on service severity.