Faucet and Valve Maintenance Checklist

Many industries rely heavily on valves and faucets. Industrial fluid systems, water heaters, and almost all plumbing fixtures depend on valves to control the flow of liquids and sometimes air. Proper faucet and preventative valve maintenance is a crucial element of any boiler maintenance checklist and many other facility maintenance plans to ensure safety and the reliable flow of liquids.

Introduction to Valve Maintenance

A valve is a device that regulates the flow of liquid or gas through pipes. It’s used for a variety of applications, from industrial chillers to tanker trucks. A faucet is a valve that regulates the flow and release of a fluid, usually water. Industrial valves play a critical role in controlling the flow and output of fluids and gases in many production processes and internal systems. 

Types of Valves

When performing a valve maintenance routine, it’s helpful to know the common kinds of valves you might encounter in a commercial or industrial facility. 

Gate Valves

The most common type of valve, a gate valve, uses a linear stopper that opens and closes, like a fence gate, to hold back or release water.

Globe Valves

A globe valve works using a disc stopper that raises or lowers as the valve handle is turned. When the valve disc is at its lowest, it stops all fluid flow. At the disc’s highest point, water output reaches its maximum flow.

Check Valves

Check valves use a ball, disc, or diaphragm that is on a spring or is free-floating. As the minimum downstream pressure hits the stopping mechanism, the valve opens. The valve closes and seals once the pressure reduces to below the minimum, or “cracking” pressure.

Ball Valves

A ball valve uses a ball stopper. The ball contains a hole that lines up with the media flow when open. When closed, the ball’s solid side blocks the gas or liquid flow. Ball valves often contain a valve cavity relief mechanism to allow excess pressure to escape without losing material. Proper ball valve maintenance is important.

Butterfly Valves

A butterfly valve uses a pivoting disc to regulate flow. When closed, the disc sits within the valve body, perpendicular to the media flow. The valve is open when the disc is fully or partially parallel to the pipe’s interior.

Pressure Relief Valves

A pressure relief valve is a safety device that uses a ball, disc, or diaphragm attached to a spring. When upstream pressure exceeds the spring’s tension, the valve opens to release excess pressure from within the media enclosure.

Common Problems in Valve Maintenance

Proper routine maintenance is vital for keeping valves working correctly and increasing valve life expectancy. Foregoing or delaying valve maintenance can result in several common issues, such as those listed below. 

Leaking Valves

Improperly installed valves or worn components often result in leaks. Depending on the medium, leaking valves can wear out seals and other valve components, as well as potentially damage the area around the leak. 

Stuck Valves

Stuck valves are the bane of any production that relies on fluid control. Corrosion, accumulated debris, and inadequate lubrication are the most common reasons a valve might stick.

Corroded Valves

Corrosion weakens valve components and sealing surfaces. Leaking, sticking, and valve failure are the most commonly encountered outcomes when valve corrosion is left unaddressed.

Overheating

Overheating can cause the valve body to expand and not seal properly. Excessive fluid temperatures, inadequate cooling, and thermal expansion can overheat a valve. 

Valve Maintenance Checklist

Proper valve maintenance is key to reliable and efficient flow control. Design a preventive maintenance checklist that includes all flow control mechanisms to ensure all necessary maintenance tasks are performed effectively. An effective faucet and valve maintenance checklist should contain these items.

If you’re looking into valve maintenance for water heaters, you may find ServiceChannel’s insights on water heater preventative maintenance helpful.

1. Check Tub/Shower Valves for Leak

Inspect shower, tub, and basin valves for signs of fluid leaks, such as drips, to prevent material waste and damage to the area around the valve. Industrial liquid leak detectors can help identify leaks ahead of inspections. 

2. Inspect for Corrosion

Inspect all valves for signs of rust, corrosion, and wear on visible surfaces. When possible, examine the valve’s internal components, such as valve seats, stems, and stopping mechanisms. Corrosion can lead to a valve leak. This can be especially problematic in the case of a potential chemical leak at an industrial facility.

3. Verify Faucet Aerators and Showerheads

Mineral deposits and debris caught in faucet aerators can impact fluid flow and cause unwanted splashing. Inspect and clean shower and faucet aerators that show signs of buildup.

4. Test Drain Functionality

Clogged drains can back up and cause structural damage to facilities and homes. Test all facility drains to ensure they function correctly and have no clogs. 

5. Apply Lubricant

Lubricate all moving parts, the valve body, and O-rings. Test each one to ensure the valves open and seal as they should.

6. Tighten Loose Connections

Tighten fittings, mounting hardware, and loose connections on each valve system to help avoid a seat leak or a shell leak.

7. Verify the Functionality of Valves

Whether it’s a gate valve, a ball valve, or any other kind of valve, slowly open and close each one to ensure proper valve operation.

8. Replace Malfunctioning Valves

When cleaning or tightening doesn’t do the trick, you may need to replace valves or valve parts, like a valve stem or valve casing, to ensure reliable operation. Ensure proper installation protocols are followed.

9. Invest in Cleaning Tools

Cleaning is the first step in maintaining an optimally functional fluid system. A wire brush, swabs, and descaling agents work wonders in cleaning a valve’s exterior and interior components. 

10. Regular Plumbing Maintenance

Valves are an integral part of a larger network of pipes and fixtures. Perform proper maintenance on all plumbing components. Check the piping system and fixtures for leaks and verify that all valves operate as expected.

11. Monitor Water Pressure Levels

Use dedicated instruments to monitor water pressure and confirm that pressure levels in the piping system are within recommended ranges. Test faucets and other outlets when possible to ensure acceptable fluid flow.

Valve Maintenance Safety Considerations

Prioritize safety in your preventative maintenance plan. Valve maintenance in industrial settings often involves working with pressurized systems and hazardous substances. Proper precautions are crucial for both personnel safety and effective valve upkeep.

Proper Handling and Transportation

When moving tanks and equipment that employ valves, follow industry standards for handling and transporting to prevent damage that could lead to leaks and safety hazards.

Regular Valve Maintenance

Inspect valves and perform preventative maintenance regularly to ensure optimal performance. Diligent upkeep helps prevent valve failures due to fatigue, corrosion, and thermal stress.

Establishing SOPs

Develop a maintenance program that includes standard operating procedures (SOPs) for maintaining and replacing valves. Thorough SOPs ensure consistency among technicians and help prevent safety concerns.

Conduct Risk Assessments

Before troubleshooting valves or performing valve maintenance tasks, conduct a thorough risk assessment and determine whether you need to take any additional precautions.

Lockout/Tagout Procedures

Make sure tanks and equipment are empty before engaging in any repair or maintenance tasks. Perform a lockout/tagout (LOTO) to isolate energy sources from the equipment and prevent accidental startup during maintenance.

The Future of Valve Maintenance

Organizations can implement a more proactive approach to valve maintenance by combining technological advancements with best practices. By proactively addressing issues before they become problems, businesses can better ensure operational reliability and enhanced safety while reducing costly repairs.

Predictive Maintenance Advancements

Advancements in digital valve controllers, the Internet of Things (IoT), and diagnostic software can combine to construct predictive models that enable personnel to anticipate issues. These technological advances significantly reduce maintenance costs and unplanned downtime.

Data-Driven Predictive Maintenance

Data is crucial to predictive maintenance. Sensors, digital controllers, and software monitor processes and gather system information. Real-time data analysis can improve the timing and implementation of every maintenance task, from valve maintenance to air compressor maintenance and beyond.

Remote Monitoring and Expert Services

Companies can leverage third-party professionals to monitor valve data and detect developing issues. When a situation arises, remote experts can alert plant personnel to take immediate action to address issues.

Proactive Repair vs. Reactive Repair

To proactively attend to preventive maintenance, brief outages can save money in the long run by reducing the likelihood of an unplanned shutdown. Waiting until there’s a problem to address issues often results in higher repair costs and can have the added expense of extensive cleanup. 

Minimize Downtime and Maintain Valves

Regular valve maintenance provides numerous benefits. Keeping a clean and well-kept fluid system helps avoid leaks, breakage, and stuck valves. With the free flow of fluids through equipment and valves, corrosion is a key issue to watch. Delaying or foregoing maintenance can result in unexpected problems down the road, which can be costly in terms of time and money. 

Consider a powerful software solution to offload much of the minutia of monitoring, scheduling, and tracking. ServiceChannel includes various tools designed to streamline numerous maintenance tasks. Contact us today to learn all the ServiceChannel facility management platform has to offer.