compressor safety valve leaking factory

Valve leakage is a common but troublesome occurrence in industrial facilities. While some valves are expected to have a certain level of leakage, especially as they begin to reach nameplate set pressure, other valve leakage is problematic and can even be dangerous for your facility. If you suspect valve leakage, here are a few reasons why your safety or pressure relief valve may be leaking, how to test the valve, and how to troubleshoot a valve you’ve confirmed is leaking. Four common reasons a pressure relief valve might be leaking include:

Pressure relief and safety relief valves will leak if the valve isn’t fully closed. This is a common problem in industrial settings where environments are often dusty or dirty. If there is any debris in the valve, it can obstruct the valve from fully closing, causing it to leak.

Pressure relief valves age and can begin to deteriorate, especially in factories and facilities where they encounter extreme temperatures and a great deal of wear. Over time, valves can become damaged, which affects their ability to close properly. If there is any damage or excessive wear to the valve seat or seal, leakage is likely.

Another common cause of safety relief valve leakage is when the valve is the wrong size for the project. Whether it’s a loose fit or the wrong fit entirely, a poorly fitting valve won’t be able to function properly, and will often leak.

If you suspect a leaking safety relief valve, or if you would like to complete regular maintenance to prevent valve leakage in the first place, it’s good to know that it is possible to test for a leaking valve. Known as a seat tightness or leakage test, these tests maintain the pressure relief valve’s inlet pressure at a certain percentage of the valve’s set pressure, so the valve technician can assess the valve’s condition.

The AccuTEST inline valve testing system offers a unique feature —  the Lift and Hold test — specifically designed to test for leakage. The system performs an automated leakage test according to the operator’s requirements. The operator sets the percent of set pressure and the duration of the test. When the operator starts the test, the AccuTEST system takes over, holding the valve at the appointed percentage of set pressure for the specified duration. While the system holds the valve at pressure, the operator is able to count any bubbles in the valve to assess its condition and determine whether the valve is leaking or not.

When you have confirmed the source of the leak, you can assess whether the valve could be repaired, or if it should be completely replaced. For example, if the valve is the wrong size or if the valve is damaged, it’s best to replace it. If the valve can be cleaned and adjusted to function properly, then repair may be an option.

Once your leaking safety relief valve has been repaired or replaced and is functioning as it should, it’s important to consider implementing regular maintenance and testing. Leaking pressure relief valves can present serious complications for the functionality of your facility. Implementing a regular maintenance and pressure relief valve testing schedule can help you stay in front of concerns like this, ensuring your facility is running efficiently, and at pressure, at all times.

If you are concerned about a leaking safety or pressure relief valve, or are seeking inline valve testing equipment that is capable of performing seat tightness or leakage tests, you might be interested in AccuTEST’s equipment. With exclusive Lift and Hold testing capabilities, AccuTEST inline pressure relief valve testing equipment offers the functionality you need. See how our equipment works in real-time — schedule a live webinar demo today.

Most air compressors have a number of precautions built in to avoid the risk of a tank rupture. The compressor itself will probably have an automatic shut-off control that turns off the motor once the maximum tank pressure is reached.

In case the auto-shutoff switch fails, there will typically also be a safety valve built into the tank. Such safety valves, such as the Conrader hard seat valve shown above, are rated to specific pressures. A 100 PSI valve will open up at ~100 PSI in order to vent excess air to keep the pressure at or below 100 PSI.

Essentially, safety valves have spring-loaded pistons. Below their factory-set pressures, internal springs hold the pistons downward, creating a seal. But once the pressure inside a tank or device overcomes the built-in pressure limit of a safety valve, the piston is pushed upwards, opening the valve seal to lower and equalized the air pressure.

Safety valves typically also have loops attached to the pistons so that you can manually rapidly depressurize a device or air tank. You should check safety valves every now and then to ensure they can open freely.

There are two main types of safety valves – hard seat and soft seat valves. Hard seat valves are rugged and inexpensive, but typically leak a little bit. Soft seat valves are a little less rugged and more expensive, but they are built with better seals that aren’t as prone to leaking.

I went with Conrader hard seat valve for a recent project, but there are other good brands as well. Safety valves are available in a wide range of pressures and in different styles.

Amazon carries a couple of valves directly and through 3rd party vendors, but your best bet is to check with Grainger, Zoro, McMaster Carr, or another industrial suppliers that have wider selections.

At factories, industrial air compressor issues are among the costliest problems that can affect a given production. Trouble is, an industrial air compressor leak can be difficult to pinpoint unless you know which parts to inspect on the unit and peripheral devices. In order to run a profitable facility, you must be able to identify and rectify problems like air leaks when they emerge within your compressed air system.

If you are wondering why your air compressor is leaking air, read on to learn the reasons why this happens and the steps you can take to rectify the problem.

Air leaks are a major cause of energy waste and lost pressure in compressed air systems. Leaks can occur in many different areas, making it difficult to pinpoint and diagnose such a problem. The keys are identifying the signs of an air compressor leak and knowing how to rectify the issue. If you know where to look, you could learn how to fix an air leak in an industrial air compressor.

The various parts of a compressor are all susceptible to wear and tear, meaning that your leaking air compressor may be suffering from a variety of different issues. If your compressor is leaking air or oil, it could be due to problems with the tank itself or with faulty or leaky components.

Holes from heavy-duty use or old age can lead to a leaking air compressor. Air leaks can also result from corrosion and rust. When compressed air sits in the tank, water will accumulate. Moisture not properly drained will slowly wear away at the tank, forming pinholes that allow air and water to escape.

Badly rusted or damaged air compressor tanks need to be replaced, as any patching or welding will increase the risk of explosion. Small pinholes can sometimes be repaired, but you must do so quickly — delaying repair will only let them get bigger and prevent your tank from holding air.

The pressure switch measures the pressure inside your tank so it can turn off the compressor once the tank reaches capacity. Over time, the diaphragm inside the pressure switch will crack and form holes, letting air leak out of the tank.

If you notice leaks coming from odd places like mounting elements, you will want to check the pressure switch. Air leaks around an exterior unloader valve may also signal a pressure switch issue.

If your pressure switch is fine, the air leak may be caused by the unloader valve itself. The unloader valve is attached to the pressure switch and serves to close the valve and seal the air in once the pressure reaches its required setting. The rings on this valve can loosen over time, letting air leak out.

You can tell if air is leaking from the unloader valve if you can feel a steady stream of air at the bottom. You may also hear a hissing noise that lasts for more than a few seconds after you turn off your air compressor.

Tubes and hoses are among an air compressor’s more delicate components, so they are prone to wear and tear. If you notice an air leak while your air compressor is running, it may be due to a crack or hole in one of your lines. You can often identify problem areas by feeling the tubes for leaks.

If you have an air compressor oil leak, it might be due to holes within the piston chamber. Oil leaks may also be due to excessive oil in the compressor chamber or the oil filter leaking through the head or the air filter.

When compressor leaks occur, the consequences could either be immediate and obvious or slow and subtle, depending on the source of the problem and the extent of its development. The two most obvious signs of air leaks and oil leaks are, respectively, as follows:

Reduced Air Pressure: If your compressor has an air leak, you will gradually lose air pressure at your end-point applications. If your compressor has gradually become less efficient, the problem could easily be down to a leak in one of the hoses or connecting points.

Lost Compressor Power: If the compressor seems to burn oil more rapidly, yet the usage cycles have not changed, chances are good the unit is no longer holding oil properly. If you recently gave the machine an oil refill and already the compressor is showing symptoms of insufficient oil supply, you probably have an oil leak in the unit.

Learning how to know if an air compressor is leaking is one of the most important aspects of operating an industrial facility. The easiest way to determine the presence of an air leak is to shut off the unit with the compressor on full charge. If this causes the gauge to plummet, that would indicate an air leak. If the compressor self-reactivates as a counter-mechanism, that too would indicate an air leak in the system.

Air hoses: Some of the easiest spots for air leaks to develop are along the hoses that connect an air compressor to various pneumatic tools. One way to search for leaks is to power-off the compressor and unplug its cables, then lather the hoses with hand soap and reactivate the machine. If bubbles form at any spot along one of the hoses, you have found your air leak.

O-rings: The rubber ring that serves as a buffer and barrier along the internal circumference of a connecting tool could be the source of an air leak. The problem could be located at either end and possibly in several places if your compressor attaches to multiple tools.

Condensate traps: In an air compressor, loose components adjacent to the pressurization chamber could all be sources of air leaks. The parts where moisture is trapped and separated could easily be sources of leaks, especially if the parts are poorly maintained and failing within the system.

Shut-off valves: The first places to check on an air compressor are the valves, which could easily leak air if they are not fastened tightly with seals and connectors in all the necessary places.

Drains: Any parts from which water is drained should be inspected on a periodic basis. If gunk or corrosion forms around these areas, this would indicate that the health of your compressor is declining, possibly due to poor upkeep.

If you have an oil leak, the likeliest sources are the pistons and the oil gasket. Check these parts on a periodic basis, including each time you refill the oil in your air compressor.

Provided the leak has not extended too far or covered too many points in the system, tightening connections and replacing parts are the most straightforward ways to fix an air compressor leak. Tightening connections and internal fasteners can provide short-term solutions, while replacing and repairing parts can be a wise investment to ensure you benefit from the full service life of your equipment.

Replace hoses and tubes: If you isolate a leak along one of your tubes or hoses, remove the affected part and trade it for a newer, stronger, properly fitted replacement. To improve your system’s performance from here, try to shorten the distance between the compressor and any pneumatic tools attached to the unit.

Tighten the connectors: All connecting points across your compressed air system should be inspected for leaks on a regular basis and tightened if necessary. If a connection is ill-fitted or improperly fastened, refasten the parts or replace the connectors if needed. If possible, reduce the number of connecting points between the compressor and your end-point tools.

Replace the valve seals: Valves are vulnerable spots for air leaks on an air compressor. Inspect the outlet valves on your machine to ensure all outgoing pressurized air is contained along streams that lead to pneumatic tools and machines. Replace any seals that appear worn or defective.

Replace the condensate drain: In an air compressor, the water tray is there to hold the very thing you do not want passing through the system. However, the draining component can only do its job as long as it remains in good shape, free of mold or wear. Replace this part if it no longer performs as intended.

Tighten lose internal fasteners: The parts inside the motor of your air compressor could destabilize your system if the screws become loose and unhinged. Inspect the fasteners inside your air compressor and tighten any parts that appear shaky, loose, unstable or rusted.

Replace the oil gasket: If the gasket gets worn or damaged, replace it with a new gasket that matches the measurements required for your air compressor.

The preceding steps should be relatively easy to perform, especially if you have done maintenance on your compressor in the past and know the various internal and external parts. If none of these measures do the trick, it probably means you have a more serious matter on your hands that can only be fixed by a service professional.

When you reduce air compressor downtime, you gain a whole host of benefits that can extend the service life of your air system and make your factory more profitable on multiple fronts.

Reduced downtime: By eliminating air compressor leaks, you could prevent larger problems that could lead to system downtime. This can be a boon for your productivity and profits, as downtime is one of the most time-consuming and costly problems that can occur in a factory. Otherwise, downtime incidents could result in thousands of dollars in losses, even if the problem only lasts for a few hours.

Consistent operations: If your air compressor behaves reliably with no air leaks, you can generally count on consistent performance from the machines. In an industrial setup, one of the most important things to have is a system that performs consistently, without fail, on a nonstop basis, allowing you to focus on other facility operations.

Maximized efficiency: One you eliminate leaks from your air compressor, your pneumatic applications will benefit from maximized efficiency. Applications that once took minutes could now take seconds, thanks to the improved air pressure and power. You could end up producing more in the span of a day with less consumption of energy.

Money saved: The boosted productivity and efficiency of a leak-free air system will translate to money savings at your facility. Without leaks, your equipment will be less prone to the kind of problems that could lead to costly repairs. As you produce more products, your factory will make more money. Overall, a leak-free compressor is more profitable on both ends.

Energy efficiency: After you eliminate leaks in your air compressor and tools, your factory will need less energy to operate because your air system will not strain itself while performing basic functions. As such, your factory could save significant sums of money on electricity costs.

In order to run a productive and profitable industrial facility, you must keep your air compressors working efficiently at all times. To that end, any air leaks that occur must be identified and fixed before such problems spiral out of hand. In certain cases, a leak can be patched with some DIY work. In other cases, you must get professional help to save your equipment from developing even costlier issues down the line.

At The Titus Company, our team specializes in air compressor repairs for industrial companies. Contact us today to learn more about our air compressors or to request information about our air compressor repair services.

Pressure relief valves ensure efficiency and safety in many chemical, oil, and gas plants, but they’re susceptible to leaks. If a pressure relief valve is leaking, systems can become overpressurized and even fail, especially if the valve isn’t addressed or repaired quickly.

When you shut down the system, carefully examine the pipelines and the valve itself to determine the cause of the leak. This will help you figure out exactly what you need to do to repair it.

Pressure relief valve leaks usually occur when the valve isn’t properly seated or when the seal is broken or damaged. Leaks can also happen when the pressure relief valve is operating too closely to the set point.

If the valve isn’t completely repaired after your first attempt, you have up to 15 days to perform any additional repairs according to the EPA. If the valve still isn’t fixed, then you can either replace the pressure relief valve or wait until the next shutdown cycle to do more repairs.

When the pressure relief valve has been fixed or replaced, it’s important to take the necessary steps to avoid leaks in the future. To do that, consider implementing a leak detection and repair (LDAR) program for your company.

An LDAR program will help to train workers on everything they need to know about detecting and repairing a leak before system damage can occur. It will also help you monitor valves more efficiently so you can spot leaks faster and spend less money on overall valve repair and maintenance costs.