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Classification of Failures
Pipeline valve failures can be divided into several categories:
- Mechanical damage — includes wear, corrosion, destruction of seals and gaskets.
- Electrical failures — apply to motor-operated valves where issues may occur with the motor, wiring, or control electronics.
- Hydraulic problems — associated with leaks, blockages, or improper valve operation.
Complete and Partial Failures
A valve failure means the breakdown of one or more of its components.
These failures may be complete — when further operation is impossible until the issue is resolved — or partial, when operation is limited but still possible.
Complete failures include
Shut-off valves
- Inability to move the closing element between “Open” and “Closed” positions
- Leakage through the shut-off element making operation impossible
- Leakage through external seals (packing, flanges) or through the body (fistulas), creating a hazard to personnel and causing irreversible equipment wear
Safety valves
- Failure to actuate when pressure exceeds limits
- Need for forced closing when pressure decreases to acceptable levels
- Leakage through the shut-off element or external seals threatening safety and damaging equipment
Control valves
- Failures preventing adjustment of system parameters due to mismatch of control characteristics
- Inability to move the regulating element
- Leakage through external seals or body posing danger to personnel
Partial failures include
Shut-off and safety valves
- Leakage through the shut-off element reducing efficiency but not stopping operation
Control valves
- Malfunctions causing partial deviation of controlled parameters
- Reduced efficiency due to poor smoothness of operation
- Increased clearances in actuator connections
- Incorrect selection of control elements or seat depending on water consumption
Faults and Troubleshooting Methods
| Fault | Symptoms | Solution |
| Seal wear | Leakage, pressure drop in system | Replace seals, inspect and replace damaged parts |
| Corrosion | Metal discoloration, rust | Cleaning, anti-corrosion treatment, replacement of damaged sections |
| Blockage | Reduced capacity, vibration | System cleaning, flushing, installation of filters |
| Actuator malfunction | No response to control, abnormal sounds | Electrical diagnostics, repair or replacement of motor/controllers |
| Valve damage | Incomplete closing/opening, leaks | Repair or replacement of valves, mechanism adjustment |
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