Prevent Downtime: Know the Warning Signs of Valve Failure

Safety relief valve failure is a silent threat that can quickly escalate into costly downtime, environmental incidents, or even catastrophic events. At MCE, we understand the vital role these valves play in keeping operations safe and compliant—especially in industries like oil and gas, power generation, food and beverage, and biofuels.  

That’s why we emphasize early detection and proactive service. This article outlines practical ways to spot valve issues before they escalate—and why MCE should be your trusted partner in keeping pressure protection equipment operating flawlessly.

6 Smart Habits That Protect Your Plant from Valve Failure

It’s critical that operators and other affected personnel understand the warning signs of a valve heading toward failure. Early detection helps you address problems before resulting in complete valve failure. Here are some tips:  

• Leaks: Check for any visible leaks around the valve body, bonnet, or outlet. 
• Corrosion or Rust: Inspect the body and spring housing for signs of corrosion, especially in humid or corrosive environments. 
• Obstructions: Ensure the outlet and discharge piping are clear of debris, dirt, or insect nests. 
• Cap and Seals: Verify caps are secure and seals are intact — no signs of tampering or damage. 

• Chattering or Popping Sounds: May indicate improper valve sizing, back pressure, or a failing spring. 
• Hissing Noise: Could suggest a valve that isn’t seating properly and is leaking gas or steam. 

• Sticking: If the valve sticks open or closed during testing, it could be due to contamination or wear. 
• Delayed Opening or Closing: Indicates calibration drift or worn internal components. 
• Frequent Lifting: A valve that opens too often may be undersized, poorly set, or facing system instability. 

• Set Pressure Verification: Confirm the valve set pressure matches system requirements and certification plate. 
• Test Records Up-to-Date: Ensure valve was tested within the required inspection interval (per ASME/API standards). 
• Maintenance Tags/History: Review service records for past repairs or noted issues.

• Spare Parts Availability: Confirm you have backup valves or kits in stock for high-risk or long-lead-time items. 
• Critical Valve Identification: Know which valves are tied to major production units or safety-critical systems. 

• Monthly: Visual & auditory walk-by inspection. 
• Quarterly: Pressure test & leak check (if applicable). 
• Annually: Full teardown, calibration, and service by certified technician (or per manufacturer/API guidelines). 

Put Downtime on Hold—Trust MCE for Valve Support

Even the smallest sign of valve failure can lead to significant consequences. MCE’s flow control division provides certified inspection, calibration, and repair services designed to catch issues early and keep your safety systems reliable. Our team works alongside operators to ensure valves are correctly sized, calibrated, and certified to meet ASME and API standards.  

With on-call crews, rapid inventory access, and deep multi-division expertise, MCE helps you maintain pressure control systems that are always ready when you need them most. Don’t wait for failure—schedule a valve health consultation with MCE today.