Major Safety Valve Failures & Solutions: Prevent Leakage & MalfunctionMeta Description: Learn about the three most common safety valve faults—valve leakage, body joint leakage, and main valve failure to act—with expert solutions. Ensure your pressure vessel and pipeline system safety.The main safety valve product names of China Safety Valve Network include:,Spring Fall Lift Safety Valve,Spring Fall Lift Safety Valve, With RadiatorSpring Low Lift Air Compressor Safety Valve,(With Connecting Pipe)Safety Reflux ValveSingle Lever Safety Valve,Spring Fall Lift, Low Lift Thread Safety Valve,Sleeve Insulation Safety Valve,Safety Check ValveStatic Weight Type Safety Valve,Safety Decompression Valvesanitary Safety Valve,SFV Danfoss Refrigeration Safety Valve,Thermal Power Station Used Non-standard Safety Valve,Ultra-high Pressure Safety Valve,Vacuum Negative Pressure Safety Valve,Water Heater Safety Valve,YD Type Bursting Disc

Optimized Content:Safety valves are critical protection devices for pressure vessels and pipeline systems. Their core function is to automatically open and discharge excess medium when system pressure exceeds the set limit, and reseal when pressure normalizes. The operational reliability of safety valves is paramount, directly impacting equipment integrity and personnel safety, making their maintenance a top priority.

Here are the three most common safety valve failures and their practical troubleshooting solutions:

1. Safety Valve Leakage (Seat Leakage)

Fault Description: This occurs when seepage happens at the sealing surface between the valve disc and valve seat under normal operating pressure. It leads to medium loss and can cause erosion damage to the metal sealing faces.

Acceptance Standard: For steam safety valves, sealing performance is typically deemed acceptable if there is no visible leakage or audible leakage noise at the outlet.

Solution Focus: Inspection and possible regrinding or replacement of the disc and seat set.

2. Valve Body Joint Surface Leakage

Primary Causes:

Insufficient or uneven bolt preload

Use of non-compliant or substandard gaskets (e.g., incorrect toothed gasket specifications)

Poor flatness of the joint sealing surface

Impurity or contaminant contamination on the sealing surface

Step-by-Step Solutions:

Tighten bolts evenly using a diagonal crisscross pattern while measuring gaps for consistency.

Replace with certified, compliant gaskets.

Disassemble and regrind the joint surface to restore flatness (if applicable).

Thoroughly clean all sealing surfaces to remove any debris or old gasket material.

3. Main Valve Failure to Open After Pilot Valve Actuation (Pilot-Operated Valves)

Risk Level: EXTREMELY HAZARDOUS. This failure can leave equipment operating in an overpressure condition, risking severe equipment damage or major accidents.

Root Cause: Typically due to jamming or sticking of the valve's moving parts.

Common Inducements:

Improper assembly during maintenance.

Contamination by dirt, oil, or impurities inside the valve.

Corrosion of internal components.

Insufficient surface finish or defects (e.g., scratches, hard spots) on critical surfaces like the piston chamber wall.

Solution Focus: Complete disassembly, meticulous cleaning of all moving parts, inspection for corrosion or damage, polishing or replacement of defective components, and careful reassembly following manufacturer specifications.

Keywords Integrated: safety valve, pressure vessel safety, pipeline safety system, safety valve failure, valve leakage solution, seat leakage, body joint leakage, bolt tightening procedure, pilot operated safety valve troubleshooting, main valve failure, valve sticking, overpressure protection, safety valve maintenance, preventive maintenance safety valve.