The correct sizing of a check valve is therefore a critical consideration that is often misunderstood. In applications where there is insufficient flow to keep the valve against its stop a lower Cv value valve is required to prevent characteristics like flutter. Sizing check valves should thus be based on the specific application, rather than the line size, to ensure the valve is fully open or closed under typical operating conditions. This characteristic of check valves is often overlooked, and it is commonly found that such problems ultimately arise from poorly specified check valves, rather than the actual valves themselves.
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With the potentially significant negative outcomes that can result in response to a failed check valve, ensuring check valves are well maintained and operate correctly is critical for plant operators. For example, check valves are used in all stormwater and wastewater systems where they prevent backflow. Failed check valves which are corroded or jammed can result in standing water or flooding and associated health impacts because of contact with contaminated water. Check valve failure modes associated with wear or poor maintenance can include problems related to noise and vibration from water hammer, reverse flow, leakage or damage. Sticking valves can occur when material like scale or debris is trapped between the valve body and the moving parts such as the disc or ball. Where the valve seat or other elements become damaged or material is lodged this can result in leaking. Along with contamination, other factors which may negatively affect check valves include high temperatures, worn elastomers and seat seals, incorrect installation or poor maintenance and assembly. Valves may also stick or leak as they age and begin to break down.
As mechanical check valves deteriorate, they typically give warning signs of their poor condition. For example, they may start to vibrate, emit noises or chatter and it is also possible that components may fail and be lost from the mechanism. As check valves fail reverse flows may also occur. Simply listening for fluid flow when the valve is in the closed position is indicative of leakage and a strong warning sign to act. It is useful to note that Rubber Duckbill Check Valves are &#;passive&#; devices and not prone to this type of deterioration. Relatively simply measures such as minimizing debris in the line through filters and correctly lubricating check valve components can help to eliminate premature failure. However, it is also worth noting that check valves do need to be replaced on a regular basis. Products that are based on high quality and experienced engineering inevitably has a significant impact on performance with cheaper products often a false economy. While typical component lifespans are application specific, manufacturers suggest metal and plastic check valves should be replace every 5-7 years whereas check valves manufactured from rubber may remain fully serviceable for up to 35-50 years.
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Check valves are typically a low-cost component and as such are frequently overlooked. This can be a high-risk approach given that the cost of check valve failure is significant. The potential for catastrophe is real where reverse flow can halt production or even extensively damage a facility. Consequently, where check valves begin to show any sign of trouble plant operators must promptly renew the component with a high-quality replacement.
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