How to Troubleshoot and Maintain Gate Valves

Industrial operations have to be consistent and free of massive flaws. To maintain high consistency in performance, operators have to ensure that gate valves are in good form. A tiny error in the function of a valve can lead to a massive impact on the overall valve and piping system in industrial and commercial sectors. Therefore, industries focus on valve troubleshooting at the right time by maintaining inspection schedules. Both inspection and maintenance are performed together to prolong the top performance of gate valves. They ensure there is no risk of leakage, contamination, or collapse in them. To address these risks, they have to monitor valves. All they have to do to avoid the problems below is follow a strict inspection schedule and consistent maintenance.

Seat Leakage

Seat leakage problem is very common in gate valves, which needs the most attention. Seats get debris around them, which leads to leakage. If you notice anything like that, just disassemble the valve and clean the seat. If the valve still leaks, inspect the packing. Open and close the valve multiple times to see if the problem is with the seat or the packing. Then you can replace either component. 

Valve Stem Leakage

If the problem is in the gate or stem, tighten them to stop leakage. You need to tighten the packing nut to prevent any further leakage. In gate valve maintenance, sometimes the problem can be resolved simply by tightening the nuts. If it doesn’t work, try replacing the packing material. Then test the valve again. The problem will go away either by tightening the stem or replacing the packing.

Jammed or Hard to Move

Usually, it happens when there is debris inside the handle or in other components. Disassemble the valve and remove debris from it. Once you clean it, apply lubricant inside it. It will loosen it up a bit. If the valve remains hard to open or close, replace the worn parts. Sometimes corrosion is the problem, which damages the metal components. 

Damaged Stem

When you do lubrication and cleaning, but the valve still faces problems, it could be something else. Inspect the stem to see if it is damaged. If it is damaged, replace it or replace the whole valve. If the stem is not completely damaged and can continue to perform, you can try to carry on. It will be a cost-effective way to tighten the nuts and stems.

Closure Problems

Sometimes the gate valve fails to close completely. Its closing process faces problems because of the accumulated debris inside it. Clean the valve’s handle and stem areas properly, and then lubricate them if required. Then there will be smooth opening and closing operations. 

Essential Gate Valve Tests 

Industries have to perform some essential tests to make sure gate valves are in good form. These tests are simple and provide positive outcomes. To make sure your gate valves are in reliable condition, here are some tests to conduct.

Hydrostatic Testing

It is a water-based test in which high-pressure water is passed through the valve. When high-pressure water is passed, the other side of the valve is closed, and the pressure remains there for a few seconds. During this process, the leakage is inspected. If the valve doesn’t show any sign of leakage, it passes the test.

Pneumatic Testing

The second type of test is a pneumatic test, which is conducted in gate valves where water can not be used. Some valves have a risk of contamination, which is why a pneumatic test is used. Professionals conduct it by supplying high-pressure gas to test the leakage. Everything is almost the same, but instead of water, gas is used.

Back-Seat Testing

Then the third test is the back-seat test. It helps in inspecting the performance and stability of the back seat. It helps to detect stem leakage. During the process, the packing gland is removed, and then the pressure is applied. The stem and packing grand region are inspected under high but bearable water pressure. 

Gate Valve Maintenance Tips

Here are some maintenance tips that can help users keep the performance of gate valves optimum. In industries, operators have to follow these processes to ensure the consistent performance of all valves. If they don’t perform these maintenance activities, there will be problems with the flow rate and valve handling.

Tighten the Nut

Since liquid and gas pass through gate valves, they affect every component inside them. Therefore, make sure you tighten their nuts periodically to keep the performance consistent. 

Lubricate the Valve

Keep the valves lubricated to prevent jamming and corrosion inside them. Follow a schedule to lubricate the valves consistently. It will avoid under- and over-lubrication. There will be no risk of corrosion either. 

Clean and Remove the Debris

Debris can reduce the efficiency of gate valves. Therefore, you need to disassemble gate valves periodically to clean debris inside them. This debris can also cause corrosion, which will further damage the valves. So, keep the valves clean to have optimum performance from them.

Inspect the Performance 

Perform semi-annual or annual tests on all the gate valves to inspect the performance level. Your overall valve system can be affected if you fail to conduct quality tests once a year, especially if the usage level is very high.  

Visual Inspection for Corrosion and Erosion

If you notice any corrosion or erosion on valves, lubricate them. Also, inspect visual damage on them, which includes worn-out components like handles and the base.

Conclusion

Gate valves are among the most essential valves in industrial, commercial, and even residential sectors. Since it is about troubleshooting common faults in them, we covered everything possible in this blog. From jammed handles to leakage problems, all these issues lead to a reduction in performance. Then the business has to bear the cost because material waste occurs in these valve issues. To address these problems, industrial operators have to perform several tests and maintenance. Then they expect consistent performance from them.