Motor-operated valves (MOVs) play a crucial role in industrial settings, controlling the flow of liquids and gases in critical processes. However, these mechanical workhorses come with their own set of challenges that can disrupt operations if not properly managed. For technicians, addressing these issues is essential to maintain system reliability and efficiency. Let’s dive into the biggest problems MOVs face and how to tackle them.
1. Sticking or Binding
What Happens: Corrosion, dirt, or process can accumulate in the valve stem or seat, causing the valve to stick or bind during operation.
The Impact: This prevents smooth movement, potentially leading to motor overheating or failure.
The Fix: Regular maintenance, cleaning, and proper lubrication help keep the valve moving freely.
2. Inaccurate Positioning
What Happens: Miscalibration of position switches or feedback systems results in the valve not achieving the desired position.
The Impact: Inaccurate positioning disrupts flow control and may lead to process inefficiencies.
The Fix: Diagnostic tools are invaluable for verifying and calibrating positioners to ensure accurate operation.
3. Torque Settings Issues
What Happens: Incorrect torque settings or worn-out components like switches can cause operational problems.
The Impact: Improper torque can damage the valve or fail to achieve a tight seal.
The Fix: Periodic testing ensures torque settings are correctly aligned with the valve’s specifications.
4. Electrical or Motor Failures
What Happens: Electrical problems, such as insufficient voltage or faulty wiring, can affect the motor’s performance.
The Impact: The valve may fail to open or close as required, impacting process control.
The Fix: Regular electrical testing and motor inspections are critical to prevent failures.
5. Seal Leakage
What Happens: Seals degrade over time due to chemical exposure or regular wear and tear.
The Impact: Leaks can occur, leading to inefficiencies and potential safety hazards.
The Fix: Replace seals during routine maintenance to avoid unexpected failures.
6. Thermal Expansion
What Happens: Extreme temperature fluctuations can cause components to expand or contract, misaligning the valve body.
The Impact: Misaligned parts can bind the valve stem, affecting functionality.
The Fix: Use materials rated for thermal resilience and design systems to accommodate thermal expansion.
7. Diagnostic and Testing Difficulties
What Happens: Lack of proper diagnostic tools or expertise makes it hard to analyze MOV performance.
The Impact: Undetected issues can lead to unexpected downtime or catastrophic failure.
The Fix: Advanced diagnostic systems, such as SofTek’s Profiler, enable early detection and resolution of potential problems.
8. Actuator Problems
What Happens: Actuator components may wear out over time, or the actuator may not be properly sized for the valve.
The Impact: A poorly functioning actuator can fail to deliver the force needed to operate the valve.
The Fix: Ensure actuators are correctly sized during installation and perform regular inspections.
9. Over-Cycling
What Happens: Excessive opening and closing cycles, often due to poor control logic or process demands, wear out the valve.
The Impact: Over-cycling accelerates wear and shortens the valve’s lifespan.
The Fix: Optimize control systems to reduce unnecessary cycling.
10. Aging Infrastructure
What Happens: Older valves may not be designed to handle modern process demands or conditions.
The Impact: Aging valves are prone to failures and require more frequent maintenance, impacting operational efficiency.
The Fix: Retrofit or replace older valves with modern, more efficient designs.
Final Thoughts
MOVs are essential components in industrial systems, but they require careful maintenance and attention to function optimally. Understanding the common challenges they face helps technicians anticipate problems and implement solutions before they lead to costly downtime. From regular maintenance and proper calibration to leveraging advanced diagnostic tools like SofTek’s Profiler, taking a proactive approach ensures the longevity and reliability of your MOVs.
Have specific questions or need help with MOV diagnostics? Reach out to us to learn how our solutions can simplify your maintenance processes and improve performance.
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