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Industrial or commercial valves are critical components in various industries. They regulate the flow of all kinds of liquids, gases, and other materials within pipelines. Most valve suppliers ensure that high-quality valves provide long-term performance, essential for operational efficiency, safety, and cost-effectiveness.
However, commercial valves can suffer from leaks, corrosion, wear, and failure without proper maintenance, leading to costly downtime and potential safety hazards. So, what do you do in such a situation? Ignoring this problem for a long time can significantly affect your productivity and efficiency.
With regular maintenance practices, proper lubrication, and scheduled inspections, you can actively extend the lifespan of industrial valves. Moreover, understanding best practices can play its part well, whether you work with a valve-supplying company or handle maintenance in-house. Let’s get started with common causes of valve failures!
Common Causes of Valve Failure
Commercial valves are basically mechanical devices used to regulate the flow of fluids, such as liquids and gases, through pipes and ducts. They are vital components of various industries, controlling the movement and direction of fluids to ensure the smooth operation of processes. However, sometimes, they malfunction due to numerous external and internal causes. The most frequent causes include:
Corrosion and Erosion
Valves often function in harsh environments, facing high temperatures, chemicals, and extreme pressure. Over time, exposure to these elements weakens the valve material, causing rust and surface damage. Corrosion can create leaks, reduce efficiency, and lead to complete valve failure if not maintained adequately with protective coatings and regular inspections.
Wear and Tear
Frequent use causes valve components to wear out, reducing their ability to control flow effectively. Moving parts like seals and gaskets may degrade, leading to leaks and pressure loss. Regular maintenance, timely part replacement, and lubrication help extend the valve’s lifespan and ensure smooth operation in industrial systems.
Improper Installation
Incorrect valve installation can result in misalignment, loose fittings, or improper sealing, causing leaks, pressure loss, or system inefficiencies. If valves are not correctly positioned, they may not function as intended, leading to early failure. Following manufacturer guidelines and using skilled professionals for installation ensures proper performance and long-term reliability.
Contaminants and Clogging
Dirt, debris, and buildup inside valves can block fluid flow, affecting performance and causing mechanical strain. Over time, clogging can lead to pressure fluctuations, reduced efficiency, and potential damage to valve components. Regular cleaning, proper filtration, and monitoring help prevent obstructions and maintain smooth, uninterrupted valve operation.
Extending Valve Lifespan Through Proper Care
Now you have learned What Valves Are & How Do They Work. Now, it is time to understand the basic maintenance routine to extend the life of these valves. To ensure the long-term performance of commercial valves, follow these essential maintenance steps:
Regular Inspections and Cleaning
Check valves often for leaks, rust, or wear. Clean off dirt, buildup, and residue using safe cleaning products. Look at seals and gaskets for damage and replace them if needed. Regular maintenance helps prevent breakdowns and keeps the valve working efficiently for a longer time.
Proper Lubrication
Use the right lubricant on moving parts to reduce friction and prevent damage. Each valve type needs specific lubrication, so follow the manufacturer’s instructions. Too much lubrication can attract dirt, causing problems. Applying the right amount ensures smooth operation and extends the valve’s lifespan.
Checking for Leaks
Test valves regularly under normal pressure to ensure they are sealed properly. If a leak is found, fix it immediately to prevent fluid loss and inefficiencies in the system. Quick action helps maintain smooth operations and prevents costly repairs or breakdowns.
Exercising the Valve
Open and close valves occasionally to stop them from getting stuck due to infrequent use. Automated valves should also be tested to make sure they respond correctly. This simple step helps keep valves in good working condition and prevents unexpected failures.
Proper Storage and Handling
Store extra valves in a clean, dry place, away from extreme heat or cold. Valves supplier can protect them from damage by keeping them in proper storage racks. Handling them with care prevents cracks, rust, or other issues that could affect their performance when put into use.
Tools and Equipment for Valve Maintenance
There are Different Types of Valves and Their Applications require unique maintenance routines. Ensuring proper valve maintenance requires the right tools and equipment. Some essential tools include:
- Valve wrenches and keys are used for removing, installing, and adjusting valves.
- Cleaning brushes and solvents help remove dirt and corrosion buildup.
- Lubricants and sealants enhance valve performance and extend lifespan.
- Testing and calibration devices ensure proper functionality through regular performance checks.
Using high-quality tools minimizes the risk of improper handling and enhances maintenance efficiency. A reliable Industrial valves supplier can guide you in choosing the right maintenance tools.
Troubleshooting Common Valve Issues
Since you know Which Industries Need High-Quality Valves. Understanding the basic troubleshooting can save you a lot of money and hassle. Typically, with regular maintenance, valve suppliers and users can experience problems. Below are solutions to common issues:
Leakage Issues
- Inspect seals and gaskets for cracks.
- Replace worn-out or damaged components.
- Check for loose fittings and tighten them where necessary.
Valve Sticking or Binding
- Clean internal components to remove dirt and debris.
- Ensure proper lubrication to reduce friction.
Noisy or Vibrating Valves
- Check for pressure fluctuations within the pipeline.
- Secure loose fittings and supports to reduce vibrations.
When to Service Industrial Valves?
Handling valves can be easy if you have purchased valves by considering all Key Factors When Buying Industrial Valves. However, commercial valves should be serviced depending on usage frequency, environmental conditions, and the type of fluids handled. However, general servicing guidelines include:
- Monthly checks for leaks, lubrication, and minor issues.
- Quarterly inspections for wear and corrosion.
- Annual maintenance for deep cleaning, pressure testing, and component replacement.
DIY vs. Professional Valve Maintenance
Since the latest trends in the valves industry are inclining towards sustainability, you should choose the servicing accordingly. While minor maintenance regimes such as cleaning and lubrication can be handled in-house, professional servicing is recommended for complex repairs and testing. A reliable valve supply company can provide expert support for specialized maintenance needs.
When to Call a Professional:
- Persistent leaks despite seal replacement.
- Unusual noise or vibration during valve operation.
- Pressure fluctuations affect performance.
- Primary component replacement or repairs.
Final Thoughts
Industrial and commercial valves are the backbone of many industries, regulating the flow of liquids and gases to maintain smooth operations. However, they can suffer from leaks, corrosion, and failures without proper maintenance, leading to costly downtime and safety risks. Valve supplier can increase their life through regular inspections, proper lubrication, and timely repairs are essential to extending their lifespan and ensuring efficiency.
Don’t let faulty valves slow down your operations. Permik Industrial provides high-quality valves and expert guidance to help you maintain peak performance. Whether you need premium valves or professional servicing, we have your solutions. Partner with our Industrial Supply Company for Reliable Valve Solutions
