Identifying, Correcting, and Preventing

Boiler Valve Failure

143 McDonough Parkway, McDonough, GA 30253
www.boilersupplies.com (800) 780-3776 pg.2
Introduction: Boiler Valve Failure and Prevention

Boiler breakdowns and failures can be both
dangerous and expensive. If a boiler is not
maintained and inspected regularly and properly,
it can lead to serious problems, ranging from burns
and explosions to toxic chemical exposure and res.
Furthermore, the failure of a boiler can cost
thousands of dollars as a result of downtime,
costly repairs, property damage, and workers
compensation.
Within a boiler, the valves are critical parts
responsible for its opertion and its safety. When
valves are damaged or broken, money, safety, and efciency are at risk. Of course, the opposite is true; properly
working valves keep the boiler in good working order.
Regular maintenance and inspection of valves ensures minimum investment of time and resources, and maximum
functionality, especially when compared to what failing valves can mean for a business.
In this guide, we will identify the most common types of boiler valve issues and failure, and the ways to avoid them,
as well as the ways to increase the lifespan of your valves.
143 McDonough Parkway, McDonough, GA 30253
www.boilersupplies.com (800) 780-3776 pg.3
Common Boiler Valve Problems

The most common boiler valve problems occur when valves are not maintained and inspected regularly and
correctly; valves get damaged or broken most often due to corrosion, wear, and contamination. Regular
maintenance helps prevent this.
Furthermore, the lifespan and functionality of a boiler valve is affected by the quality of maintenance and repairs,
as well as the overall quality of the valve itself. Without qualied, effective maintenance and/or repair, and with the
stress of the three aforementioned factors, the following specic problems can happen to valves:

1) Bending
4) Rust
Now lets take a further look at what leads to these problems.

Improper Maintenance
For these purposes, maintenance can be dened as cleaning, replacing, remachining, general repair, and
inspection. When this is not done correctly or often enough, the valves relieving capacity can be affected.
Operationally, leakage can occur, as well as simmering, causing burning. This then leads to other frequent problems,
such as rusta result of leakage.
In fact, a leaking valve is frequently the cause of the other problems. When a valve leaks, lost water or steam will be
compensated from outside moisture. This moisture will often contain impurities/contaminates, leading to failure, and
will cause higher or improper metal temperatures, leading to burning, as well as to overall failure.
Mishandling or improper reassembly can lead to deformity of a part, in which case, bending might be seen. If boilers
and their parts arent checked often enough, the boiler can run too hot, which can again lead to valve burning.
Furthermore, inspection/maintenance must include proper insulation of supply or return lines, especially in cold
environments. Without this, freezing is possible.

Improper Workmanship
Oftentimes, a valve is only as good as its original design. Poor workmanship, ranging from improper preparation of
seating surfaces to inadequate welding and incorrect assembly can and often will lead to leakage, again a cause of
overall failure.
Valves must also be thoroughly tested by both the manufacturer and anyone performing repairs.
Correct inspection and maintenance of your boiler valves means a) a high quality valve will live up to its potential
and remain high quality, and b) deciencies or poor workmanship will be caught, and valves can be repaired or
replaced with effective ones.
2) Burning
5) Freezing
3) Leaking
6) Failure, especially if motorized
143 McDonough Parkway, McDonough, GA 30253
www.boilersupplies.com (800) 780-3776 pg.4
Avoiding Problems and Increasing Valve Longevity

As problematic as these issues can bealong with how catastrophic they can bethere are simple steps that can be
taken to avoid them, ensuring you get the most out of these critical boiler parts.
These steps are twofold:

1) Buy High Quality Valves
This can seem self explanatory, but many people often choose to buy the least expensive valves, or simply dont
know how to differentiate between a good and a bad one. In the case of the former, it cannot be overstated that
purchasing a valve simply based on the lowest price can become a major problem.
Boilers are a very substantial investment, and when choosing the right valves, a poor quality product can ruin an
otherwise good and expensive piece of machinery. When you compare the relative cost of a high quality valve to
the cost of valve and boiler failure, its evident that spending money on a good valve will save money in the end.

Of course, there are plenty of good valves that are also cost-effective. The key is to nd a valve manufacturer or
distributor with experience and knowledge. They will not only provide you with the best valves, but also with the right
ones for your application. If you dont know which valve is the best for you, a qualied expert can guide you.

2) Regular Maintenance/Inspection for Wear and Tear
Considering wear and tear are some of the leading causes of valve failure, this is what you want a qualied
individual to be looking for, and doing so regularly.
First and foremost, various maintenance tasks should be performed on a monthly, semi-annual, and annual basis.
Secondly, keeping a maintenance log will keep track of all ndings and ensure timely repairs, if necessary.
Qualied inspectors will check the pressure surge; when it exceeds maximum operating pressure, wear and tear will
occur and over time, failure will become much more likely. They will also look for the numerous factors that contribute
to the issues as previously discussed. For example, they can be sure the boiler is not running too hot, which will burn
a valve.
Furthermore, having a qualied technician perform regular maintenance, one who is familiar with valve operation,
design, maintenance, and repair, means they will know what to look for, no matter how small. They will also be
well aware of all standards that are directly related to valve repair, as set forth by the National Board of Boiler and
Pressure Vessel Inspectors.
If you do not have access to a qualied technician, contact the company from which you purchased your quality
boiler valve.
143 McDonough Parkway, McDonough, GA 30253
www.boilersupplies.com (800) 780-3776 pg.5
Conclusion

A boiler is an invaluable, complex piece of
machinery, one made up of many parts. If one part is
improperly designed or maintained, the entire boiler
is in jeopardy. Loss of efciency, time, and money
occur as a result, and of course, numerous safety
repercussions, which must be avoided at all costs.

Boiler Supplies is a distributor of the highest quality
valves available, with extensive knowledge of
and experience in the industry. We can guide you
to the right products and maintenance for your
needs. Contact us at 800-780-3776 or www.
boilersupplies.com with any questions.