Troubleshooting Valve Actuators: Common Issues and Fixes

The valve system consists of various kinds of components, and actuators are one of them. When it comes to automation, actuators work like the backbone. They ensure the valves are working in the designed way at a specific speed. Then we all know that everything faces issues after some time, which could be for any reason. The automatic valve system starts having problems in different forms. It could be low torque, motor failure, excessive vibrations, and the list goes on. The actuator troubleshooting helps identify the actual issue. Until the issue is found, one can’t proceed to a resolution. Many industrial and commercial users face similar problems, and we bring their solutions for you.

Failure to Start/Motor Not Working

It is a common problem in the actuator valves. If they fail to start, there is a problem with their motors. It happens because of a blown fuse inside the actuator. High voltage or excess load could damage the fuse, and the result is failure in the starting process. Besides, there could be a problem with the drive nut. If it is broken or misaligned, the actuator can not move the valve. 

Solution

You need to do actuator troubleshooting by checking the voltage if you use an electric actuator. The voltage range must be compatible, and the fuse must be replaced. Once you do that, the actuator will start working. It is a part of valve maintenance, which also includes the drive nut’s alignment. Make sure you know that all the components connected to the actuator are working and fine.

Valve Doesn’t Open or Close

The valve seems to be jammed or blocked. The actuator might be working, but it can’t open or close the valve. Whether you use hydraulic, electric, or pneumatic actuators, this problem might occur with both. The problem could be with the actuator or with the valve’s mechanism.  

Solution

Check the air pilot pressure because it must be less than the system’s operating pressure. It should be at 90 psi or 6 bars. Besides, check if there is binding in the valve mechanisms, and lubricate the jammed parts. It is a part of valve maintenance because some components could be jammed by corrosion. 

Excessive Vibrations and Noises

If the valve actuators are making too many vibrations and noises, it means there is a problem inside them. You will feel something strange in them because they will be overheating, too. It happens when there is too much packing, because the components can’t get enough room for basic functions. It also happens when the seals have worn and need replacement. Besides, there is an increased thrust in the actuator, which is causing a load on the valve. 

Solution

You need to do valve maintenance by replacing the damaged packaging. Also, do not overtighten it when closing it back. Adjust the thrust of the actuator that meets the valve’s requirements. Then you will feel that the valves and actuators are not making any noise or vibrations.

Mechanical Jamming Due to Rust

Valve actuators can get mechanical jamming because of moisture. The corrosion could reach the components when the environment is moist. Slowly, the components start to lose their efficiency. When layers of rust occur inside the valve actuators, they get frequent jamming. 

Solution

The solution to this mechanical jamming is lubrication. You need to lubricate the rusted components of the actuator in periodic valve maintenance. It is a mandatory step, and every valve actuator that is near moist conditions desperately needs lubrication. 

Misalignment in Valve and Actuator 

After some time, valves and actuators face misalignment issues. Due to vibrations and frequent operations, they face this alignment problem. As a result, their performance and operational speed drop. It happens when the actuator fails to coordinate with the valve’s components.

Solution

Replace the damaged components and seals. Then realign the components that connect the valve and actuator. Do correct calibration for the optimum movement of each component.

Inconsistent Movement and Low Torque

Low torque and inconsistent movement of the actuator and valve are other common problems. People notice this problem when the actuator fails to maintain a constant speed in operations. The reason behind this is the blocked actuator filter. Also, there is air in the hydraulic actuator or a low fluid issue. These are the reasons behind low torque. Then there is another problem, which is with the motor. Technical issues like damaged wiring could cause this issue. Even contamination can reduce the movement and torque. 

Solution

What you need to do in actuator troubleshooting and valve maintenance is motor inspection. It needs to be repaired or replaced. Then the blocked actuator filter needs your attention. Inspect it if it needs to be realigned or replaced. Clean the motor to remove contamination, if there is any. Repair the motor, and test the torque after that.

Not Returning to the Fail-Safe Position

If the valve is not returning to its safe position, there is a problem with its return spring. There is a broken return spring inside the actuator housing, which is not letting the valve reach its fail-safe position. 

Solution

What you need to do is replace that return spring to restore the lost performance. Once you replace the return spring, the actuator will be able to bring the valve back to its fail-safe position efficiently. 

Signal Disruption

Then there is another issue, which is signal disruption in the actuator. That means there will be inconsistent operations and sudden changes in the results. It will appear like the actuator is not working in its right way at all. The problem is the faulty wiring inside it.

Solution 

You will have to do some tests, repair wiring, and calibrate it. Inspect the problem in the wiring by testing each wire to determine if it is sending the signal perfectly or not. The wires that are not working well need repair or replacement. 

Conclusion

There are still many common issues that take place inside the valve actuators. We highlighted some of them along with their solutions. To avoid these problems, you should do timely actuator troubleshooting and valve maintenance. Then you will be able to work proactively against any sudden damage. On an industrial level, a chain of actuators is installed for large-scale operations. They often face issues, and technicians have to ensure timely replacement to keep the performance consistent.