blog about Six Signs of Check Valve Failure and Repair Tips

Imagine your precision hydraulic system as the human circulatory system, requiring one-way fluid flow to function properly. Check valves serve as the critical guardians of this unidirectional flow. When they fail, reverse flow can occur—reducing efficiency at best and causing complete system failure at worst, with repair costs spiraling out of control. Fortunately, check valves send clear distress signals. This article examines six common symptoms of check valve failure and provides solutions to help prevent costly damage.

When a check valve begins emitting faint clicking sounds accompanied by subtle vibrations, it's signaling potential trouble. These seemingly minor symptoms shouldn't be ignored.

Root Causes:

• Mechanical failure: Loose internal components causing vibration under fluid pressure
• Flow issues: Insufficient pressure or sudden drops preventing full valve opening
• Improper installation: Incorrect directional installation causing abnormal movement
• Selection error: Valve specifications mismatched with system requirements

Potential Consequences:

• Energy waste through reduced efficiency
• Component damage from loose parts affecting seals
• Potential equipment failure from prolonged neglect

Solutions:

• Conduct comprehensive valve inspection
• Replace or repair damaged components
• Select properly matched valve specifications
• Investigate system-wide pressure abnormalities

Distinct from subtle vibrations, loud hammering noises—known as water hammer—occur when valves close abruptly against fluid flow. While familiar from household plumbing, these shocks pose serious risks in industrial systems.

Root Causes:

• Sudden pressure changes causing rapid valve closure
• Swing check valves being particularly prone to water hammer
• Hydraulic systems experiencing more severe effects than pneumatic ones

Potential Consequences:

• Pipe and fitting damage from repeated shock waves
• Leak risks from compromised connections

Solutions:

• Select appropriate valve types for system requirements
• Install water hammer arrestors to absorb shocks
• Check for air pockets in the system
• Replace aging pipe connections
• Install pressure-limiting valves

When pressure gauges show unstable readings or reverse flow occurs, the check valve has failed its primary function of maintaining consistent unidirectional flow.

Root Causes:

• Contaminant obstruction preventing proper operation
• Loose internal components compromising seals
• Insufficient pressure to activate the valve

Potential Consequences:

• Equipment damage from reverse flow
• Energy waste from unstable flow rates
• Potential safety hazards

Solutions:

• Clean pipes and valve interiors
• Maintain proper filtration systems
• Adjust system pressure above valve activation thresholds
• Replace severely damaged valves
• Consider spring-loaded check valves for sensitive applications

Like stiffened joints, check valves can become stuck partially open or closed, compromising system stability.

Root Causes:

• Contaminant accumulation obstructing movement
• Wear or corrosion of moving components
• Degraded elastomeric seals losing flexibility

Potential Consequences:

• Pressure fluctuations from unstable flow
• System damage from excessive component stress

Solutions:

• Thoroughly clean valve interiors
• Replace worn or corroded parts
• Install upstream filtration
• Renew aged elastomeric components

From faint hissing to obvious drips, leakage represents the most visible failure mode, causing pressure loss and performance degradation.

Root Causes:

• Damaged sealing surfaces
• Insufficient closing pressure
• Cracked valve bodies
• Contaminant interference with sealing

Potential Consequences:

• Energy waste from fluid loss
• Environmental contamination risks
• Potential safety incidents

Solutions:

• Inspect and replace damaged seals
• Adjust system pressure parameters
• Replace compromised valve bodies
• Remove sealing surface contaminants
• Select appropriate replacement components based on valve type

Like all mechanical components, check valves degrade over time. Regular inspections can identify corrosion, rust, or elastomer deterioration before failure occurs.

Root Causes:

• High-temperature operation accelerating aging
• Material incompatibility with system fluids
• Inadequate maintenance practices

Potential Consequences:

• Increased failure probability
• Progressive performance decline

Solutions:

• Implement regular cleaning and lubrication
• Select fluid-compatible materials
• Control operational temperatures
• Establish replacement schedules (typically 5 years for elastomeric valves, 20+ for metal valves in optimal conditions)

Many check valve failures stem from avoidable causes—improper selection, incorrect installation, or neglected maintenance. Simply replacing failed valves addresses symptoms rather than root causes. Effective system management requires understanding operational requirements, selecting appropriate valves, and implementing proper installation and maintenance protocols.