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Common Causes of Ball Valve Failures and Solutions

Views: 0     Author: Site Editor     Publish Time: 2023-03-16      Origin: Site

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Most problems with ball valves are caused by improper installation of valve parts or incorrect installation of parts. The most common causes of ball valve problems are accumulation of dirt and water residue inside the valve, but also fluid spillage, stuck valves, decay, or even overheating, causing the valve to fail.

1. Fluid overflow sphere is blocked
The ball is clogged with solvent cement glue, which can cause the ball to stick inside the valve, preventing it from turning. When the ball seat is too tight, the valve will wear out quickly.

2. Wear and corrosion
During operation, wear occurs due to the frequent opening and closing of the valve. In addition, some valve parts will corrode, making the ball valve not work properly.

Due to the failure of these valves, these failures prevent users from using these valves to their fullest potential. Therefore, it is important to understand some of the common problems faced by ball valves and their solutions.

 

What are the solutions for the ball valve not working properly?

1. Unable to close the ball valve

main reason:
A ball valve that has been inactive for a long period of time may spill liquid (medium) when closed, especially if it has valve sealing problems. Sometimes, replacing a valve can be difficult, especially if a bad valve is installed too tightly.

solution:
To fix this, first, use a pair of pliers to tighten the fitting and watch to see if the leak stops.
If not, replace the seal inside the valve or buy a brand new valve.

 

2. The ball valve cannot be completely closed

main reason:
In some cases, the ball valve does not close completely, only partially, and it may be important to replace the seat or replace it with a reliable new valve. Not all seats can be replaced. Only those with six sides and corners or with a screwdriver slot can be disassembled.

solution:
Replace with a new valve.

(1) During valve replacement, make sure the water supply to the running line is shut off
(2) Make sure the pipe is cut and replace the previous valve with a metal saw
(3) Connect a new tube to the cut-off part
(4) Next, make sure the new ball valve is now in place
(5) Let the water flow and check for any loose connections or overflow

It is important to make sure that the problem of a half-open ball valve is resolved. It needs to be dealt with because a shut-off valve that is not fully closed cannot perform its duty under severe conditions, causing hazardous gaseous substances to spill or leaving water-filled areas.

 

3. Stuck ball valve

Ball valves are typically used as on-off valves, which means they should be fully open. They work by ensuring that the medium flows freely or is blocked.
Sometimes it may be critical to loosen the PVC ball valve to prevent it from obstructing the flow of fluid.

If the ball valve is stuck, follow these steps to resolve the problem:

Step 1: Manual Operation
(1) Turn off the water supply
(2) Turn the handle several times to loosen the valve to open and close the valve.
(3) Gently tap the valve body several times to release the spots between the valve body and the ball. Make sure the PVC valve is not subjected to rough impact; otherwise, it can crack easily.
(4) Gently shake the valve handle to repair the ball part and make it move.
(5) Remove the handle and use the pliers to turn the valve slightly to help it move freely. Reattach the handle to the valve with the help of screws.

If these steps don't work, continue to the next step:

Step 2: Apply Lubricant.
(1) Spray lubricant such as WD-40, which stands for Water Displacement, 40th formula. This way, the handle will enter the valve body, helping to remove rust and corrosive metal that cause the ball valve to seize.
(2) Let the valve stand for a while after spraying.
(3) Try opening and closing the valve by moving it back and forth.
(4) If it doesn't move, don't force it. Instead, lubricate it again and let it sit. Sometimes, you need to leave it for a long time.
(5) After several hours, hold the handle with a pipe wrench and turn the valve. If it loosens and moves, let the water flow and keep turning the ball valve to loosen it.
(6) If the ball valve is still stuck, replace the ball valve.

 

4. Ball valve leakage

Reasons for valve leakage during installation:

(1) Improper transportation and lifting will cause valve damage and cause valve leakage.
(2) Unresolved valve corrosion may cause the sealing surface to rupture, resulting in leakage of the ball valve.
(3) Unsafe installation location.
(4) Both ends of the valve are not blind installed.
(5) The absence of lubricant in the valve seat during installation will allow impurities such as rainwater and debris to enter the back of the valve seat.
There are burrs when soldering.
(6) An improperly installed valve in the half-open position may damage the ball and cause the valve to leak.
(7) Improper restraint during installation and misalignment of the valve stem drive with the assembly.
(8) Welding slag and other installation residues will leave traces on the sealing surface, causing leakage in the process

Reasons for valve leakage during operation:

(1) The most common reason for valve leakage during operation is that the operation management personnel lack correct maintenance methods.
(2) During normal operation, construction residues will leave traces on the sealing surface, causing leakage.
(3) Long-term inactivity of the ball and seat will cause them to lock and damage the sealing surface when the valve is opened and closed.
(4) When the ball valve is tilted two to three degrees, the ball valve will leak.
(5) Rust, dust and debris that accumulate between the connector and the valve stem can prevent the valve from seating, resulting in leaks.
(6) Universal actuators have their limitations. If it is left active for a long time, it will start to corrode. The limit bolt is loose, and the grease hardens, causing internal leakage.
(7) The valve position of the electric actuator is in the front, and leakage will also occur when it is not close to the wrong position.

What is the troubleshooting method for ball valve leakage?

(1) Check the valve restriction to determine if the overflow problem can be solved by modifying the restriction.
(2) Apply lubricant slowly to stop leakage. At the same time, pay attention to the changes of the pointer pressure gauge and check whether the air leakage continues.
(3) Sometimes leakage is caused by damage to the sealing surface. Therefore, it is recommended to use a valve cleaning fluid to clean the surfaces and seats.
(4) When you reapply lubricant from time to time, open and close the valve several times to release waste from the sealing surface and seat cavity.
(5) Check for leaks in the fully closed position. Apply enhanced sealant, if present.
(6) Make sure the valve cavity is vented, as it creates a large pressure differential, which helps in the sealing process.
(7) If there is still leakage, the valve should be completely replaced.

 

5. Worn O-rings

main reason:
The valve's O-rings wear over time because the ball is constantly being pushed against the ball.

solution:
This failure is normal. The only solution is to replace the old O-rings with new ones when the surface shows symptoms of wear. Additionally, reducing the intensity of fluid flow within the valve helps extend its life.

 

6. Actuator problems

main reason:
Determining the cause of this ball valve problem is important because repairing a ball valve actuator when the valve is faulty will waste time and money as some actuator problems are caused by valve problems.

So here are some common valve problems that can cause actuator problems:
(1) Weak stem
(2) a barrier
(3) Jam packing
(4) Excessive torque
(5) Solutions
(6) Put the system in manual mode and check whether it can be operated manually.
(7) In electric actuators, ensure that the applied voltage is not too high to reduce the risk of valve overheating.

 

 

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