Why is my control valve leaking? Four signs to look out for

Any complex system is only as strong as its weakest point. All too often in pipework, it’s a leaking control valve that is cause for concern. Even a small leak can lead to inefficient flow and unplanned downtime, which both result in financial loss. Leaks can also be a health and safety issue if your system handles volatile media like hydrogen.

The nature of control valves, which are typically not designed for tight shutoff, can make it difficult to identify leaks. However, if you’ve had issues controlling your process variables recently, it could indicate that you need to repair or replace your control valves. The first step for the end user is determining the acceptable leakage rate that the valve can have using the ANSI FCI 70-2 standard. Most control valves are rated Class III or Class IV, with Class V and Class VI reserved for tighter shutoff requirements. Here are four red flags you can look out for, and one step you can take to avoid leaks in the first place.

1. Visible damage and wear and tear

Over time, control valve parts such as the actuator, plug, trim or packing can lose integrity. During inspections, you’ll want to look out for cracks, corrosion and other signs of wear. You can also consider wear and tear when you specify your control valve. Selecting the right materials and configuration for your application will prolong the valve’s lifespan.

At Trimteck, our OpGL valves are designed with fewer components and are built from durable materials. This results in rugged construction and a much longer mean time between stops (MTBS)—up to six million cycles.

2. Incorrect valve size

An oversized valve can reduce flow pressure, leading to poor control, unstable operation, and increased wear. On the other side of the coin, an undersized valve may be forced to operate too close to its maximum capacity. This leads to excessive pressure, potential damage, and reduced lifespan. Choosing the right valve size from the start is an often overlooked aspect of correct valve operation.

3. Abnormal noise and vibration

Unexpected noises or unusual vibrations can indicate internal damage, blockages, turbulent flow, or cavitation. They can be an early warning sign that leaks are on the horizon, and can increase stress on the rest of your piping system. This can lead to the weakening of joints or connections elsewhere.

Regular inspections can mitigate risks before they significantly impact your service. But prevention is always better than cure, and choosing robust valves designed for your application can reduce unplanned downtime later on.

4. Erratic valve behavior

Erratic performance, such as inconsistent response times, incomplete shutoff, difficulty in maintaining set points, or unexpected pressure fluctuations are warning signs of damage. Your valve may be suffering from corrosion or cavitation that could lead to leaks. Choosing valves that are easy to maintain, appropriate for your application, and made with materials that ensure a longer lifespan can save you time and money.

Trimteck valve components are always made from materials that are the best fit for the application. From graphite to zirconium, carbon steel to Monel and titanium, our valves are built to last in the most challenging of environments.

Choosing the right valve

Preventing most control valve leaks comes down to two key factors: regular inspections and specifying the right valve for your process control system. The latter sounds obvious, but buying off-the-shelf solutions often means making compromises in design, configuration, or materials.

At Trimteck, we precision-engineer custom specialty control valves for every industry, from aerospace to food and beverage. With over 20 years of experience, we’ve likely worked with process control challenges like yours before. But, you can still expect a personalized service and control valves built for your unique system requirements. To discover how we could help you minimize leaks and optimize your output, get in touch with one of our expert Sales Engineers.