101 Guide To Check Valve Problems And Troubleshooting

101 Guide To Check Valve Problems And Troubleshooting

Check valve failures are often due to improper installation techniques, insufficient maintenance practices, and inadequate research before application, among other factors. These failures can hinder the proper functioning of the valves, potentially damaging pipe systems, pumps, and well equipment.

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Check valves, also known as non-return valves, are essential devices that allow fluid to flow in one direction only. They are designed to prevent backflow in the systems to which they are applied. A failure of a check valve can lead to fluid flowing back into the well, which can have severe operational consequences.

To prevent check valve failures, proper installation, regular testing, and diligent maintenance are crucial. Recent advancements in monitoring technology allow for real-time assessments of valve performance, significantly enhancing maintenance strategies.

This post discusses how to test, install, and assemble check valves, while also highlighting common check valve failures, their symptoms, causes, and solutions.

Seat Closure Test (With Air)

The seat closure test uses air as the test fluid, conducted at an air pressure of 80 PSIG or higher. The testing times for different valve sizes are as follows:

Valve Sizes | Test Time
< 2 inches | 15 seconds
3 inches | 30 seconds

The maximum allowable leakage for metal-seated valves is 0.4 SCFH per inch of inlet size, while soft-seated valves must show no leakage.

Other Testing Methods

Lift-type and swing check valves can also undergo pressure tests. For lift check valves, the closure element's axis is perpendicular to the horizontal surface, while in swing check valves, the axis is nearly parallel to the surface.

The pressure test involves two components: the strength test for leakages in the valve body, and the sealing test for leakages around the sealing surface.

• Strength Test

The test fluid is introduced from the inlet, and the outlet is closed. The valve passes if there is no observable leakage from the valve body and cover.

• Sealing Test

The test fluid is introduced from the outlet, with the valve shut. The valve passes if there is no observable leakage from the sealing surface, gasket, and packing.

Common Check Valve Failures and How To Fix Them

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Even well-constructed check valves require careful use, regular testing, and maintenance to avoid problems. Neglecting these practices may lead to escalating issues that culminate in valve failure.

Pump check valve failures may arise from the accumulation of suspended particles, while well check valve failures often stem from using incompatible materials, leading to gradual deterioration of valve components. Thus, various modes of check valve failures exist due to differing functions, often caused by poor research, incorrect installation, and irregular maintenance.

Non-return valve failures can vary significantly as check valves come in different types and parts. Below are some common check valve failures:

Check Valve Failures

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Common check valve failures in pipe systems, wells, and pumps include:

Reverse Flow

Reverse flow occurs when water moves back from the outlet to the inlet area, indicating check valve failure. This backflow can be especially detrimental during discharge pump operations, as it may cause the impeller to rotate in the wrong direction, resulting in pump damage.

Causes of Check Valve Failures

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Alt text: Check Valve Operation

Troubleshooting check valve failures reveals several underlying causes, including:

• Incorrect installation, assembly, and maintenance practices

Improper handling during installation can lead to premature wear and tear, causing early-stage failures.

• High Temperatures

Elevated temperatures can cause the expansion of valve parts and degrade sealing integrity, resulting in leakages and potential valve failures.

• Low Fluid Pressure

Check valves function best under adequate pressure. Low fluid pressure can cause frequent opening and closing, leading to premature wear. Blocked or improperly sized pipelines can exacerbate these issues.

Symptoms, Preventive Measures, And Solutions

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Symptoms

Regularly identifying the symptoms of potential check valve failures can help in taking timely action. Symptoms include unusual noises, frequent cycling, and decreased system efficiency. Engaging in preventive maintenance, such as periodic inspections and real-time monitoring, helps mitigate such failures. Solutions often involve cleaning, replacing worn components, and ensuring proper installation and compatible material usage. Effective troubleshooting ensures longer valve life and optimal performance.

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