We see ball valves being used in plumbing, industrial, and commercial systems. However, the function of a ball valve is to handle the flow of liquids and gases. Their simple operation, functioning, and durability make them a favorite of everyone. Nonetheless, even the most long-lasting valve demands proper care and upkeep to work properly.
In this blog, we will talk about the significance of ball valve maintenance and useful practices to keep valves working at their best. Also, include practical advice on valve troubleshooting.
A ball valve uses a rotating ball with a ball in the center. This ball is also named a "bore". We use the handle by turning it in a specific direction. When it's done, the hole aligns with the pipe, and liquid passes by it. Then, the ball stops the flow, fully shutting off the valve. If we turn the handle of the valve 90 degrees, we will cease the flow completely.
• Valve Body: The major outer shell that houses all the internal components.
• Ball: The circular part inside which is turned on to handle the flow.
• Seats: Generally made of Teflon or a similar substance. They are pressed against the ball to tighten and prevent leaks.
• Stem: A rod that links the handle to the ball.
• Handle: Used to open or shut down the valve.
• Seals: Prevent leaks around the stem and links.
Learning about these components helps you understand what to examine during maintenance or problem-solving.
Ball valves are structured in a way that requires low upkeep. However, that does not mean they should not be considered. Usage, time, dirt, dust, corrosion, or wear can affect the performance of the valve. Issues such as leaking, difficult-to-turn handles, or complete failure can take place if the valve is not properly taken care of.
Regular ball valve maintenance offers many benefits, such as:
• Increases the longevity of the valve
• Prevents expensive breakdowns
• Enhances system operations
• Ensures safety and reliability
• Minimizes downtime in critical operations
Use the Valve in the Right Manner
Always use the valve when necessary. That is because not every valve is made for throttling or flow handling.
Select the Correct Material
Ball valves are available in materials like:
• Brass
• Stainless steel
• Carbon steel
• PVC
The correct material depends on the liquid type, pressure, and temperature of your system.
Do Not Tighten It Too Much
Extra-tightening the ball valve's connections or bolts can break the body or crush the internal seals. This may cause leaks or pre-valve-failure. Remember to use the right tools, like a torque wrench. Also, act upon the manufacturer's given torque settings during installation or repair.
Examine the Valve Frequently
Regular examining is the main part of effective ball valve upkeep. Seek indications of leakage, corrosion, or cracks around the stem, handle, and body. If you notice water presence in the valve surroundings when it's closed, consider a damaged seal or seat internally.
Operate the Valve Occasionally
It's wrong if a valve remains closed or open most of the time. In simple words, it should be turned on and off only sometimes. This secures the internal parts of your valve from sticking or becoming hard. This is applicable especially in dusty, dirty, or corrosive environments.
Clean it Regularly
Wipe the exterior of the valve using a wet cloth or suitable cleaning liquid if required. Secure the valve from catching dirt, oil, or grime buildup around its handle. Cleanliness is the secret of a valve staying durable and functioning better.
Some ball valves don't need oiling, especially those containing Teflon seats. Nonetheless, those valves that are used in impactful or industrial environments may take advantage of oiling to minimize friction, enhance sealing, and protect against corrosion.
However, it is recommended to use only those lubricants that are approved by the valve manufacturer. Besides, do not use petroleum-based greases. Why? Because they can harm the seals. They can only be used if they are specially recommended. When applying lubricants, only spread them over the stem and the ball area. Excessive lubricating can attract dust and dirt. So, avoid this practice.
Ball Valve Troubleshooting: Common Issues and Solutions
In spite of following the above-mentioned tips and taking care of your ball valve, it can come up with some problems. Therefore, following are some basic valve-troubleshooting practices to apply:
Rigid or Difficult-to-turn Handle
If you find the handle difficult to turn, the valve may be dry, dirty, or corroded. To get rid of this issue, clean the area around the stem and do some oiling on it. Nonetheless, if you see that the valve is still jammed, then the internal components of it need to be checked and replaced.
Leaking Valve
If you notice fluid leaks around the handle of the entire valve, it indicates that the packing or seals have come out. To tackle this problem, tighten the packing nut. If you see that the valve is still leaking, it means that it has cracks or the seats have been deformed. You know what that means? It means that it's time to buy a new valve.
No Flow When Valve is Open
If this is happening, there is a possibility that something is stuck inside the valve or the upstream system. That "Something" can be debris. Therefore, if this happens, remove the valve and clean it. Don't forget to examine the pipe for any possible blockages. Nonetheless, if the ball is corroded or damaged, it means you have to purchase a new valve.
Signs of Replacing Your Ball Valve
If nothing works, buy a new valve, but only if:
• The valve body is cracked
• The ball is heavily corroded or pitted
• Leaks continue after seal or seat replacement
However, if you don't want any hurdles in running your system flawlessly, purchase a new valve in any of these cases.
Reinstalling a Ball Valve after Maintenance
If you are reinstalling a ball valve, act upon these tips and tricks:
1. Make sure to clean all Components: Clean dust, grease, and debris from the valve and connection points.
2. Examine seals and gaskets: Check and buy new seals and gaskets if they seem to be dried out, cracked, or have come off.
3. Install the valve in the Right Position: Fix the valve in the correct position so that the flow is right.
4. Tighten bolts or fittings equally: Don't tighten them too much, and take the help of a torque wrench if possible.
5. Check the System: Turn on the system slowly and check for leaks before returning it to full operation.
• If you have extra ball valves, keep them in a dry and clean place.
• Keep them in their original packaging if it can happen.
• Do not place heavy items on them.
Before installing a stored valve, check properly if there are any signs of damage, rust, or broken seals.
Proper storage prevents valve failure even before the valve is ready to use.
• Always depressurize the system before touching the valve.
• Use the correct tools if you want to avoid harming valve components
• Discard old seals and lubricants
• Go through the manufacturer's instructions for particular upkeep requirements.
Follow these safety tips to safeguard both the valve and the people engaged with it.
If you take care of your ball valves, they will prevent system failure and expand safety.
Here, we are recalling the most useful tips:
• Always choose the correct valve material for your system
• Check and clean the valves on a regular basis
• Operate valves on a weekly basis to keep them functioning properly
• Do oiling on them if needed
• When you are installing a ball valve, do not tighten them too much
• Have the knowledge of when to fix and when to buy a new one
Ball valves are reliable; nonetheless, they still need care and attention. Therefore, if you take care of them properly, they will serve you the best. Whether you are running a factory, a commercial building, or a home system, applying these ball valve maintenance and valve troubleshooting tips will keep everything running flawlessly.
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