Automatic control valves are critical components in water utility systems, regulating pressure, flow and level throughout the distribution network. Despite their critical role, they are frequently among the least maintained components in a water distribution system. So what happens when we neglect these vital assets?

When a pressure-reducing valve failed to open at a municipality in central Arizona, it overpressurized a zone, resulting in a line break. The valve had never caused an issue, so it was overlooked and had received no maintenance in over 15 years. 

Failure of an automatic control valve is not common, and it’s usually unexpected because they are often treated as “set it and forget it” devices, tucked away under city streets. It is therefore not surprising that the number one cause of failure is lack of preventive maintenance. 

Whether a customer has 10 control valves or 500, finding the time, staff and budget to maintain them can become overwhelming and lead to neglect. Even districts with preventive maintenance schedules often mix all assets into one master program, which becomes a job in itself to manage. It’s important to give control valves the little attention they need with a dedicated ACV preventive maintenance program. This can be done in a software asset management program, or in some cases using a manufacturer’s cloud service, which can be free.  

Planning and scheduling maintenance

Proactive maintenance planning helps prevent valve failures and system disruptions. Develop a comprehensive maintenance schedule that accounts for valve age, criticality and operating conditions. High-priority valves in critical locations should receive more frequent attention, typically quarterly inspections, while less critical valves may require semiannual checks.

Begin by creating a detailed inventory of all control valves in your system, including specifications, installation dates and maintenance history. Schedule maintenance during periods of low demand to minimize service disruptions. Always ensure backup systems are operational before beginning maintenance work.

Visual inspection protocols

Visual inspections serve as the first line of defense in valve maintenance. During inspection, examine the valve body and actuator for signs of corrosion, leakage or physical damage. Check for proper alignment and ensure all external components are secure. Pay special attention to several key areas: Look for external leakage around bonnets, stems and flanges, and listen for any unusual noise or vibration during operation. Verify the proper positioning of limit switches and indicators, carefully inspect the condition of control lines and pilot systems, and check for any signs of erosion or cavitation damage. It seems obvious, but thorough visual checks of each part can help identify potential issues before they become more serious.

Check for air-related issues

Entrapped air can severely impact valve performance and cause erratic behavior. To address air-related problems, maintenance teams should implement several essential checks. Start by verifying that air-release valves are functioning correctly, then check for proper valve venting during startup procedures. While the system is running, listen carefully for unusual sounds that might indicate air binding in the valve. It’s crucial to ensure adequate upstream pressure to prevent air entering the system, and regularly monitor downstream conditions for any signs of air accumulation. These systematic air-related checks help maintain optimal valve performance and prevent operational disruptions caused by air entrapment.

Don’t strain your strainers

Strainers protect control valves from debris and must be regularly cleaned. Begin by cleaning strainers according to manufacturer recommendations and consistently check differential pressure across strainers to detect any clogging. Inspect strainers for damage or deterioration and document the cleaning frequency to help identify potential system issues. In poor water areas consider installing pressure gauges across strainers for continuous monitoring, as this can provide valuable data about strainer performance and help predict when maintenance is needed before problems occur.

Power and control systems

For electrically actuated valves, power system reliability is crucial. Regular electrical maintenance should include a comprehensive series of checks and tests to ensure consistent operation. This maintenance begins with testing backup power systems and thoroughly checking electrical connections for any signs of corrosion. Technicians should verify proper voltage and current readings throughout the system while also inspecting the seal integrity of all electrical enclosures to prevent moisture intrusion. Finally, testing control signal accuracy and response ensures the valve operates precisely as instructed.

Recordkeeping and documentation

Many districts still have notebook files, the dreaded binder or the history stuck in one employee’s head. With increasing turnover due to an aging workforce, it’s vital to know which areas or valves are more troublesome. Using a central data management system ensures valuable “insider” knowledge is accessible long past retirement. Some manufacturers have free software that is all set up to help with tracking valves, like Cla-Val’s Link2Valve program.

Detailed records of all maintenance activities, should include:

• Date and type of maintenance performed
• Parts replaced and repairs made
• Performance test results
• Unusual observations or concerns
• Follow-up actions required

Training and inventory management

Keep up to date on operator training (often provided free by manufacturers), which should include a review of procedures and safety protocols. Training directly supports effective inventory management, where maintaining accurate spare parts tracking, identifying critical components and nurturing vendor relationships ensures emergency parts are available when needed. These elements work together to enable rapid emergency response when needed — maintenance teams must be ready to execute rapid response procedures, follow established emergency repair protocols, maintain clear communication channels and activate backup systems when required. 

Takeaways

A good valve maintenance program provides comprehensive and valuable insights into the performance and longevity of each valve. By analyzing data, municipalities can make informed decisions about upgrades and replacements, and help budget for the upcoming fiscal year. This proactive approach helps extend the life span of the valves and enhances the efficiency of the entire water system.

By implementing these maintenance practices and establishing a comprehensive valve maintenance program, water utilities can significantly improve system reliability and reduce operational costs. Remember that maintenance requirements may vary based on valve type, application and operating conditions, so adjust your program accordingly while maintaining compliance with manufacturer recommendations and industry standards.

Lance Phillips is the service sales manager with Cla-Val. He has worked in the water industry for over 14 years and is dedicated to delivering innovative solutions and driving customer satisfaction through tailored service offerings.