The Complete Handbook for Maintaining and Repairing Industrial Valves

industrial valve repair maintenance

A Valve is a mechanical device that is used in various industrial processes, including oil and gas production, chemical manufacturing, and water treatment. It helps to regulate fluid and gas flow in pipelines and can be manual or automated. Valve maintenance is crucial for its proper functioning and longevity, preventing valve failure and reducing energy consumption and environmental impact. It can be in various sizes, shapes, and materials.

Repair and Maintenance of Gate Valve

Before starting the repair and maintenance, which ensures the system is relieved of the pressure to avoid injuries, losses, and environmental damage. 

Valve lapping: Use a lapping machine to smooth out the valve seat and disc to enhance a tight seal when the valve closes. Using the valve for a long period leads to the formation of scales on the valve, which then interferes with disc closure and thus, fluid leakage. Also, the build-up of these scales reduces fluid pressure. 

Lubrication: Lubrication of the gate valve stem threads and stem nut reduces friction and wear and makes it easy to open/close. Use a grease gun to do the lubrication. 

Valve packing should be adjusted monthly or as advised by the manufacturer.

Cleaning: open the gate valve bonnet component and clean the valve seat, disc, and entry and exit ports to prevent fluid blockage. 

Replace the disc (components that close fluid flow) if it does not stop the fluid flow effectively. Replacement of the disc would involve opening the valve bonnet to access the valve interior.

Troubleshooting Gate Valve

Leakage through the valve-pipe connection. 

1.  Worn-out seals/gasket. Replace the seals/gasket. 

2.  Loose connection of bolts and nuts. Tighten the bolts and nuts. 

3.  Excess fluid pressure. Make sure that the fluid pressure is at the maximum that the gate valve manufacturer. Trust Cair Euro Automation, we are the leading Valve Manufacturer in Ahmedabad, India. 

Leakage through the bonnet-body connection.

1.  Loose bolts and nuts, tighten the bolts and nuts. 

2. Worn-out seals/gaskets. Replace the gaskets/seals. 

The valve is hard to operate.

  1. Blocking materials are found in the valve or on the valve stem. Take the valve apart and get rid of those items.
  2. A bend on the valve stem. Replace the stem. 
  3. Extremely tight packing. Loosen the packing

No fluid flows through the valve: 

  1. The valve is blocked. Take the valve apart and clean it of any foreign objects. 
  2. Worn-out gate. Replace the gate.

Repair and Maintenance of Globe Valve

  • Valve grinding: Perform Valve grinding regularly to help realize a dense, flat surface. A grinding machine is used to carry out the grinding process. Perfect and tight seals are made possible by this method, which helps to smooth seats and seals.
  • To minimize wear and improve smooth operation without requiring a lot of torque to open or shut, lubricate the valve stem regularly.
  • Open the globe valve bonnet and clean off scales or residue accumulating inside the bonnet and valve body to prevent blockage. Take advantage of this opportunity to examine the valve seat and disc and replace them if necessary.
  • To prevent leaks, replace the gland packing as advised by the globe valve manufacturer or after a specific amount of use. 
  • Remove the globe valve and inspect and replace the seals and O-rings. 
  • The pipe-body connections and the bonnet’s worn-out bolts and nuts should be replaced.
  • To minimize leaks and, therefore, fluid losses and environmental harm, new bolts and nuts will guarantee secure connections.
  • Use cleaning products to remove any buildup on the valve body.

Repair and Maintenance of Safety Valve

  • To improve the valve’s sensitivity and dependability, calibrate it regularly. 
  • Ensuring the valve is within the necessary set pressure requires calibration. Grease and grime should be cleaned off the valve body. 
  • To stop the safety valve’s hefty hammer from being repositioned or coming loose, make sure the lead seal is in place.
  •  To improve the flawless and tight seal, lap the valve disc and seat. 
  • If the valve spring corrodes from being exposed to dirt, salty water, or industrial chemicals, replace it. 
  • In addition to weakening the spring, corrosion can cause misaligned pressure readings when the valve is adjusted.

Troubleshooting Safety Valve

  • Leakage through the bushing
    1. Tighten the bushing. Replace the bushing.
    2. Dirt on the sealing surface. Open the valve and wash away the dirt.
    3. Damaged sealing surface. Replace the seal or repair it by Lapping.
  • Inflexible opening/closing
    1. Improperly positioned adjusting ring. modifying the “adjusting ring” by the protocol. 
    2. Moving parts jammed. inspect the internal parts of the valve for dirt, corrosion, impurities, and improper assembly that may cause this problem and repair it as necessary. Safety valve chatter
    3. High fluid discharge capacity. Use a higher-rated safety valve or the safety valve specified by the manufacturer for the discharge capacity. The diameter of the inlet pipe is inadequate. Either increase the intake diameter or lower the resistance of the inlet pipe.
    4. High resistance on the discharge pipe. Lower the discharge pipe resistance.

Repair and Maintenance of Check Valve

  • Perform grinding operation on the valve seat to remove any large or small defect that may impair perfect valve closure.
  • Lubrication. Lubricate the moving disc hinge pin to reduce friction, and wear and enhance effectiveness when closing/opening for fluid flow.
  • Once a specific amount of use has passed, check and replace the gasket. Because of the pressure from the body-bonnet connection nuts, the gasket deteriorates with prolonged usage. 
  • Lap the valve seat or replace it. Leakage or backflow will happen if the seat, which aids in creating a tight seal between the body and the disc, is worn out or destroyed.
  • Tighten the bolts connecting the body and the bonnet to prevent fluid leakage.
  • Tighten bolts connecting the valve to the pipe to prevent fluid leakage at the joint.

Troubleshooting Check Valve

  • The valve disk does not open.
    • The valve was installed in the wrong direction. Install the valve such that the fluid flow matches the arrow indicated on the valve body or according to the valve manufacturer’s instructions.
    • The suction pressure is low. To provide a greater force capable of pushing the valve disc to open, increase the flow pressure of the fluid. The valve downstream is shut off. 
    • Turn on the downstream valve. Inverse fluid flow There’s an opening in the disk. If any foreign objects are preventing the disc from returning to the valve seat, open the valve and remove them. worn-out valve seat. 
    • Lap or replace the valve seat. 
    • Broken objects on the valve seat. Take off the bonnet and clear the particles to open the valve. 
    • Fluid seepage worn-down gasket. Put the gasket back. 
    • Loose connection. Fasten the bolts and nuts that secure the valve body to the bonnet, as well as the body to the pipe. However, avoid excessive tightening as it damages the valve gasket, bolts, nuts, and valve flanges.
  • The valve vibrates while in use.

Repair and Maintenance of Ball Valve

  • Check the tightness of bolts and nuts, and if loose, tighten them. Tighten the bolts to attain the torque recommended by the manufacturer. Excess torque will damage the bolts, nuts, and valve flanges. Cair Euro Automation is one of the leading Ball Valve Manufacturers in Ahmedabad, India. We are also well-known for manufacturing Electric Actuators.  
  • Lubrication. Lubricate the valve frequently to prevent abrasion wear on the ball when it closes/opens. Lubrication also enhances the smooth and easier operation of the valve and improves seal effectiveness.
  • Grind the valve ball and seat regularly. Grinding will help smooth the ball and seat for a tight seal when the valve closes.
  • Open the valve and inspect the valve interior. Replace or Lap the ball valve and/or seat if worn out or damaged. Also, clean the valve interior of materials sticking on the valve body.
  • Inspect and replace seals and gaskets if they are worn out or damaged.

Troubleshooting Ball Valves

  • The ball valve is hard to operate.
    • Solids clogged in the valve. Open the valve bonnet and clean off the solids.
    • Corrosion inside the valve. Clean off corrosion scales inside the valve.
  • External fluid leakage
    • Loose connection between the valve and the pipe. Tighten the bolts and nuts to the torque recommended by the valve manufacturer.
    • Loose connection between the body and the bonnet. Tighten the bolts and nuts.
    • Worn-out gasket. Replace the gasket.
    • Excess fluid pressure. Ensure the fluid pressure level is as recommended by the valve manufacturer.
  • Internal fluid leakage
    • Damaged seat. Replace or Lap the valve seat.
    • Debris is stuck on the valve seat. Open the valve and clean off the dirt.
  • The valve is hard to open/close.
    • Foreign materials are stuck in the valve. Open the valve and remove such materials.
  • Noisy operation
    • High fluid velocity. Reduce the fluid velocity.
    • Wrong valve sizing. Replace the valve with a higher-rated valve.
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