TP-12D-1

Worcester Control Valves

Failure Analysis of Ball Valves

Failure Analysis Of New Valves
Features to Evaluate if the Valve has
Leakage or High Torque:

1. Look for misalignment of actuator, linkage, or handle. Need 0° to

Carbon Steel Bolts Stainless Steel and Alloy 20 Bolts
90° rotation. Stem must be perpendicular to body—no side loads.
Bolt Dia. in/lb ft/lb Bolt Dia. in/lb ft/lb
SOLUTION: Check for centrality of the actuator, coupling, stem and
alignment of all brackets. Replace parts as necessary. !?4" 96 – 120 8 – 10 !?4" 72 – 94 6–8
Use dial indicator to measure stem perpendicularity. %?16" 156 – 204 13 – 17 %?16" 120 – 144 10 – 12
#?8" 216 – 264 18 – 22 #?8" 192 – 216 16 – 18
\?16" 480 – 540 40 – 45 \?16" 336 – 384 28 – 32
!?2" 720 – 780 60 – 65 !?2" 504 – 522 42 – 46

2. Check body bolting torque; refer to IOM for correct torques. Torque
is for nonlubricated bolts.

SOLUTION: Using a calibrated torque wrench, check the torque of

bolts. Refer to attached chart or IOM.
3. Check flange bolting for proper insert compression. Body seal must
be compressed for seat sealing. Slip-on flanges and thick rubber
gaskets can affect performance of seal.

SOLUTION: Record location of piping supports, obtain photographs

4. Normal torque when rotation 0° to 90° and back to 0°. Measure
TABLE OF CONTENTS
Analysis of New Valves . . . . . . . . . . . . . . . . 1
Analysis of Valves in Service . . . . . . . . . . . . . .
and make a sketch. Retorque flange bolts, record style
and type of gasket and flange. Discuss data with
Flowserve personnel.
stem torque to open and close. Listen for scraping noises when
cycling; there must be no metal-to-metal galling. Compare data to
catalog ratings.
SOLUTION: Measure torque according to ratings, listen for noises
and replace metal parts as needed. Check air pressure
at pneumatic actuator; make sure proper torque output
is available. Record air pressure at the actuator.

Photos of Valve Failures . . . . . . . . . . . . . . . . 8

Glossary of Valve Terms . . . . . . . . . . . . . . . 10

 Flow Control Division

Worcester Control Valves

Failure Analysis of New Valves

5. Do a leak test on the valve. Pressure test from the other end of the
valve to evaluate second seat (not V-3 ball). If disassembling the
valve, mark the upstream and downstream seats and the twelve
o’clock position on each seat.

SOLUTION: Record leakage data using flow meter or count

bubbles; determine if leakage is because of bad seats
or damaged ball. Return damaged seat to Flowserve for
evaluation; replace soft seats as necessary.
6. Examine surfaces of the seat and ball for nicks and scratches.

SOLUTION: Using a “fingernail test”, determine if scratches are

acceptable, or replace seats and metal parts if
necessary. Note, if scratches can be felt on ball, this
will cause leakage during normal use.
7. If the valve was cycled or tested at high pressure, there will be a
burnishing or contact band from the ball to seat and back of the
seat from the valve body.

SOLUTION: Determine if the contact is even. Full contact on seat

may mean over-pressuring of the valve. Check for
proper assembly of the valve.
Clean and repair parts as
necessary. Do not reuse body
seal gaskets. Assure that the S
gasket is properly installed.
This gasket is not reusable.
8. Evaluate the surface finishes on the seat
and the ball. Look for porosity, cracks and
imperfections. Contamination during
installation or improper handling can
cause leakage.

SOLUTION: Look at the orientation of the

seat and sealing wearpath. Any
deformation of soft parts will
require complete rebuilding of
the valve. If there is any
bending or metal deformation,
a new valve is required.
9. Check if valve seat was properly assembled. Look for gaps between
the seat and valve body from oversized or undersized seats.

SOLUTION: Some small seats can be put in backwards preventing

proper bolting of end caps and causing leakage.
10. Evaluate the metal surface finish: radial scratches, chatter,
smearing, tearing or improper machining.

SOLUTION: Inspect machined surfaces for drag lines that could

cause scratches to stem seals, and for improper
surface finish on the pipe ends which could cause
leaking behind the seats. Replace parts as necessary.
11. Look for evidence of porosity or void in the metal parts.

SOLUTION: Any porosity or voids that could cause seal or seat

leakage means metal parts have to be replaced.

2 Failure Analysis of Ball Valves TP-12D-1

 Flow Control Division

Worcester Control Valves

12. Stem nut and locking nut should be properly adjusted for zero-
Color Chart for Various Stem Component Materials
leak stem seal. Look for rough marks inside stem bore or
possible galling. Evaluate thrust washer and stem seal for Material Color
tearing or deformation.
Polyfill Black
SOLUTION: Check that the stem seal nuts have been properly
Peek Tan
adjusted by flattening out the Belleville washers and
back off 1/6 turn. Automated valves require a double Graphite Silver Gray
locknut, MP44 valves and V51 use heavy, single Carbon-Filled PTFE Black
locknut. Check that washers are not cracked or
missing. UHMWPE Opaque White
Delrin Brown
Filled TFE Off-White

13. Missing parts or bent mounting kits can side load the stem or
reduce actuator torque.

SOLUTION: Check centrality and alignment of the actuator and

stem. Replace parts as necessary. Look for use of
proper coupling and slop between stem and coupling
and ball and stem for proper closing of the valve.

1A?f" – 2" Size Top-Mount

Valves Shown

TP-12D-1 Failure Analysis of Ball Valves 3

 Flow Control Division

Worcester Control Valves

Failure Analysis of Used Valves

NOTE: Assure all system pressure is zero and fluids are drained from
valve before loosening any bolts. If fluids are dangerous, perform
proper cleaning before valve is removed.
1. Review same causes as new valve.
SOLUTION: Record all process conditions and try to determine the
date and where the valve was bought.
2. Look for start-up problems such as weld splatter, dirt, scratches,
impingement of fluids and contamination forced into the seats or ball.
SOLUTION: Clean the valve, inspect all parts, polish ball, if
possible, rebuild and replace soft parts. No piping
compound should be in the valve.
3. Verify seats were made by Worcester Controls and properly installed.
SOLUTION: Return damaged seat and soft parts to Flowserve for
evaluation. Rebuild with authorized Worcester parts.
Use proper lubricants per IOMs.
4. Evaluate if the valve is new or has been reworked and remachined
by customer.
7. Verify if hydrotesting of the valve was done in the closed position.
Pressure over 110% of maximum ratings will damage seat.
Determine if start-up testing was performed on valves. Find out if
the valve was hydrotested and then exposed to freezing
temperatures—cavity pressure due to ice can bend metal parts.
SOLUTION: Verify temperature, possible system hydrotest and
misapplication of the valve. Use V3 vented ball, if
necessary, to prevent deformation of the seats.
Evaluate flatness of pipe ends with straight edge. No
deformation is allowed. Replace valve if necessary.
8. Thermal Effects: If valve is closed and full of liquid (1° temperature
rise equals 100 psi in trapped cavity) look for evidence of
deformation of seats, body seals, or pressure vessel.
SOLUTION: Check for thread damage or deformation of the body
bolts, seats or seals at pipe ends. Replace components
as needed.
1A?f" – 2" Top Mount Valves Shown

SOLUTION: Determine if there has been welding or painting which

would indicate rework of the valve. Look for counterfeit
valves with improper components. Determine if
alterations have damaged valve.
5. Evidence of metal corrosion or improper seat/seal selection for
application. Record pressure, temperature, media and relevant
information for analyzing failure. Record pressure at shutoff and
throttling pressure drop.

SOLUTION: Evaluate the extent of corrosion, re-evaluate material

selections, replace complete valve if necessary. Review
date of installation and discuss application with
Flowserve personnel.
6. Look for possible leak paths through stem seals, between
ball and seat, behind seat and possible “wire drawing”
of sealing surfaces. Document location of leakage.

SOLUTION: Determine where there is a leak path.

Replace soft parts. If there is wire
drawing or damage to the pipe ends or
ball, replace valve as needed.

Valve Shown in
Closed Position,
No Pressure

4 Failure Analysis of Ball Valves TP-12D-1

 Flow Control Division

Worcester Control Valves

9. Crushed ball downstream seat due to water hammer, over-

Corrosion Allowance
pressurization or piping stress can bend metal parts or deform
seats and/or balls. Average Penetration Rate Per Year

SOLUTION: Measure roundness of the ball, flatness of the pipe Code Mils Inches µm
ends, replace valve if damage has occurred.
• < 2 0.002 50
10. Ball off-center, during assembly or improper stem adjustment can
force stem down into ball. Proper assembly of valve, to sales • < 20 0.020 508
drawing or IOM. Wrong stem-to-ball engagement can yield the { 20 – 50 0.020 – 0.050 508 – 1,270
metal parts or ball won’t cycle. Improper or missing stem seals X > 50 0.050 1,270
can affect stem engagement.
Footnotes for Data Squares
1. Pitting
SOLUTION: Check the ball-stem engagement. Look for bent stems 2. Stress Corrosion Cracking
and deformation of the ball or damage to the metal 3. Intergranular Attack
parts. Assure correct assembly of parts. 4. Crevice Attack

11. Cold flow of the seat due to excessive temperature pressure or

exceeding allowable throttling pressure drop.

SOLUTION: Check the proper closed position of the valve. Evaluate

the torque of the valve, the operator output torque and
replace valve if necessary, or use large actuators.
12. “Popcorning”, polymerization or deformation of the seat due to
media absorbed into the material and mechanically expanded.

SOLUTION: Return seats to Flowserve for evaluation. Clean valve,

replace seats and seals, and consult with factory, if
possible, to upgrade to alternate material such as FEP,
High-per Fill, etc.

Cavity Filler End

Seats Plug

S.S. Ring S.S. Ring

(split) Body (solid)
Valve Body Seal
(special profile)

TP-12D-1 Failure Analysis of Ball Valves 5

 Flow Control Division

Worcester Control Valves

13. Look for rust or dirt and location of sealing band. Evaluate if the 17. Partial support. If valve is assembled with the valve not fully
relief slots are plugged and not functioning properly. May need closed, damage occurs to the seat. Look for twisted stem or
V-3 ball relief. improper top works.

SOLUTION: Look for the sealing path of the body seal, seats and
stem seals. Replace soft parts if needed. If
deformation or damage to metal occurs, replace valve.
14. 360° ridge in the downstream seat could indicate
overpressurization or hydraulic water hammer.
SOLUTION: Check that the valve was properly assembled, the
rotation of the valve to its closed position and proper
actuator sizing.
18. Distortion of the seat due to thermal expansion. V-3 porting
maybe required. Upgrade to stronger seat.

SOLUTION: Refer to examples of seat failures in attached
document. Replace parts as needed. If metal parts are
damaged, replace valve.
15. Fold over where the seat has been extruded due to improper
support during cryogenic cool down or high temperature with
improper ball position. Exceeding allowable pressure drops.
SOLUTION: Replace seats as needed. If metal damage has
occurred, replace valve. See photos of seat damage
on pages 8 and 9.
19. Wire drawing, backside or between the ball and seat. High-pressure
steam or throttling pressure drop. Do not throttle below 15° on
clean service. Consult factory for steam or slurry applications.

NOTE: Ball must be fully open or fully closed while being cooled SOLUTION: Refer to throttling pressure drop, pressure temperature
to cryogenic temperatures. ratings, and discuss application with factory.

SOLUTION: Check for ball stem alignment, replace the seats.
Check actuator mounting; review torque of the valve
using attached ratings.
16. Impingement or erosion damage to the seat.
20. Seats that are cracked or broken due to thermal shock or
misapplication.
SOLUTION: Record process conditions, upgrade to a stronger
seat, and replace valve if misapplied.

SOLUTION: Replace seats. If damage occurs to metal parts, 21. Body seals can be pinched between body and pipe end during
replace valve. assembly or repair. Use lubrication to help body seal when bolted.

SOLUTION: Check the proper assembly of the body seals, but

High differential across
most body seals are not reusable.
seat sucks seat out of cavity Ball Impingement Flattened
Area

Upstream Downstream 1
Seat Seat 2
Ball will contact seat Pressure 3
during closure, causing
further damage 4

Distance Along Pipe

Typical Velocities
Fluid Condition ft/s m/s
Liquid Normal 5 – 10 1.5 – 3
Maximum 40 – 50 12 – 15
Gas Typical 250 – 400 (<Mach 0.3) 75 – 120
Flow through a partially open ball valve. Possible flow
Steam or Low Pressure 70 – 100 20 – 30 conditions are:
Vapor Medium Pressure 100 – 170 (<Mach 0.1) 30 – 50 pv at 1: Flashing downstream of ball
pv at 2: Cavitation in ball, flashing downstream of ball
Superheated High pv at 3: Cavitation downstream of ball
Pressure 115 – 330 (Mach 0.15) 35 – 100 pv at 4: No vapor formations

6 Failure Analysis of Ball Valves TP-12D-1

 Flow Control Division

Worcester Control Valves

22. S-gaskets in backwards, or scraped at installation of center sec. 1A?s" – 2" Top-Mount Valves
Shown
SOLUTION: Properly orient the S gaskets. On the welded pipe
ends, do not reuse on butt weld and socket weld
seals. The initial body seals are rubber. These should
be replaced with metal S gaskets.
23. Graphite seat seals cracked or sheared from use of improper
lubrication to assemble.

SOLUTION: Replace seats and body seals. Use proper lubrication.

Do not reuse seat seal or body seals.
24. Pipe stress can bend valve, causing seat or body seal failure. Look
for misalignment when valve is removed and record distance from
piping support.

SOLUTION: Get photo or measure piping support to determine if

pipe ends are being damaged or body bolts are being
deformed.
25. Do not use schedule 80 or 160 pipe without special pipe ends or
consulting factory.
26. Evaluate seat for arc-shaped deformation which indicates
improper ball closing.

NOTE: Full port valves 2" to 8" and reduced port valves 3" to 8"
now use a new seat design with cavity relieving seats (CPP).

Annular Groove

Feeder Groove

Cavity Pressure Relieving Seat

Contact Area
Contact Area
Contact Area

Contact Area

Assembled Condition Cavity Pressure Condition

(zero differential) (zero differential)

TP-12D-1 Failure Analysis of Ball Valves 7


A. Abrasive particles imbedded in the soft seats scratching both the
seat and ball. Results in high torque, leakage and damage to the
metal parts of the valves.
SOLUTION: Use harder seats and polyond the ball. Alternate is to
use a more abrasive-resistant seat such as rubber or
ultra-high molecular weight polyethylene. Improve
cleaning of system at start-up.
B. High temperature softening of the seat. Failure occurred on
upstream seat, foldover due to the pressure distribution across the
seat and partial support of an open ball.
SOLUTION: Use seat materials with higher temperature capabilities
such as the X, Alpha or Gamma. Review the service conditions and
the allowable throttling drop according to the catalog ratings.
8 Failure Analysis of Ball Valves
Flow Control Division
Worcester Control Valves
C. This is a combination of erosion and corrosion due to excessive
throttling pressure drops. Solid particles in the flow may also cause
this erosion.
SOLUTION: Review the sizing of the valve to make sure you are
using larger ball openings and staying above 15%
open. Review the flow conditions for cavitation or
flashing and try to locate the valve where it is taking
less throttling pressure drop. If the media is
contaminated, try to use lower line velocities across
the valve to reduce the demonstrated wear.
D. This seat has been exposed to high temperatures and extremely
high cavity pressures. Usually this occurs when condensate or
liquids are trapped in the valve and then heated up, and over-
pressure then deforms the seat.
SOLUTION: Use the V3 cavity pressure relief and stronger seat
materials.
TP-12D-1
 Flow Control Division

Worcester Control Valves

E. An example of where the ball has not fully closed. The high-velocity
fluid flow across the valve wire draws the seat and distorts the
material. In closer examination you can see that the seat has
F. This seat has been exposed to extremely high temperatures and
rotated in the valve cavity and foldover and damage has begun to
extruded due to cavity pressure or fluid flow.
occur in more than one spot. Generally this could be attributed to:
improper actuator mounting, slop between the ball and stem,
SOLUTION: Install seats of high-pressure/temperature capability,
wrong coupling or using the wrong parts. Another cause could be
resize the valve to make sure it is within the
twisting of the stem due to extremely high torque or improper
pressure/temperature curve and is not exceeding
actuator/valve sizing.
catalog throttling drops.

TP-12D-1 Failure Analysis of Ball Valves 9

 Flow Control Division

Worcester Control Valves

Glossary
Trouble Analysis for Valves
Cavitation: “S” Gaskets:
The formation and collapse of bubbles when high velocity fluid flows 316 Stainless Steel metal gaskets used for body seals. These are
through a valve and the liquid goes below the vapor pressure. covered with Teflon or graphite.
Cavity Pressure: Surface Finish:
Cavity pressure can occur in the open or closed valve where liquid is This is the machined surface of a part which gives you a static or
trapped around the OD of the ball or inside the valve cavity. This is dynamic seal. Centrality, flatness, smoothness and type of finish are
very critical in cryogenic valves, but can also occur with temperature very important to the cycle life and zero-leak capability of the valve.
rise of liquids or steam condensate.
Throttling Pressure Drop:
Centrality: The difference between the upstream and downstream pressure. As
This is the alignment of two concentric circles, such as the ball and the valve closes and the orifice between the ball and the seat gets
stem or the seats and body. If improperly aligned, there can be smaller, pressure drop increases. Ratings are established both for
uneven forces for sealing or rotation of the valve. throttling services and steam.
Contact Band: V3 Option:
When a valve is sealing there is an area of impression between the In valves where the possibility of cavity pressure can occur, a small
seat and ball and the back side of the seat. This should be hole is drilled on the upstream side of the ball to give venting of the
approximately one third of the seat width. Full contact band is an ball. In addition, there is a second hole below the stem of the valve to
indication that the valve has been over-pressurized and the seat relieve cavity pressure around the backside of an open valve. To get
damaged. bidirectional sealing, the one-piece seat is necessary, but cannot be
used on steam or cryogenic fluids.
Cold Flow:
When the ball is pushed into the downstream seat, it may go beyond Wire Drawing:
the elastic limit of the Teflon. Excessive exposures at high pressure When a valve has been damaged due to scratching or excessive
can yield the seat and cause catastrophic failure. throttling drops, the high-velocity fluid cuts through the soft seat,
causing a wear pattern which quickly destroys the seats.
Drag Lines:
This can occur in the area of the stem seal or in the back of the body
during the machining. A broken toll or machine burr can cause a
spiral cut, which affects sealing of the valve.
Fingernail Test:
Rub the edge of your fingernail across a scratch. If the scratch can be
felt this is sufficient damage to affect sealing and wearing of the
seats. Metal parts should be buffed or replaced.
Flashing:
When fluid flow goes through an orifice, a pressure drop occurs. If
the fluids go below the vapor pressure, bubbles will form and cause
flashing.
Galling:
When dissimilar metals or metals of unequal hardness are rubbed
together, the softer metal starts to wear, and parts of the metal score
and tear, damaging the sealing surface.

Popcorning:
In the manufacturing of Teflon there are slight microscopic voids
within the material. Monomer or plastics in the liquid state will
migrate into these pores, and when they change into a solid, there is
mechanical deformation of the seat.
Porosity:
Small holes in the seats or metal parts where media can leak very
slowly, causing external leakage or contamination back into the
process.

10 Failure Analysis of Ball Valves TP-12D-1

 Flow Control Division

Worcester Control Valves

TP-12D-1 Failure Analysis of Ball Valves 11

 Flow Control Division

Worcester Control Valves

Flowserve Corporation has established industry leadership in the design and manufacture of its products. When properly selected, this Flowserve product is designed to perform its intended function
safely during its useful life. However, the purchaser or user of Flowserve products should be aware that Flowserve products might be used in numerous applications under a wide variety of industrial
service conditions. Although Flowserve can (and often does) provide general guidelines, it cannot provide specific data and warnings for all possible applications. The purchaser/user must therefore
assume the ultimate responsibility for the proper sizing and selection, installation, operation, and maintenance of Flowserve products. The purchaser/user should read and understand the Installation
Operation Maintenance (IOM) instructions included with the product, and train its employees and contractors in the safe use of Flowserve products in connection with the specific application.

While the information and specifications contained in this literature are believed to be accurate, they are supplied for informative purposes only and should not be considered certified or as a guarantee of
satisfactory results by reliance thereon. Nothing contained herein is to be construed as a warranty or guarantee, express or implied, regarding any matter with respect to this product. Because Flowserve
is continually improving and upgrading its product design, the specifications, dimensions and information contained herein are subject to change without notice. Should any question arise concerning
these provisions, the purchaser/user should contact Flowserve Corporation at any one of its worldwide operations or offices.

For more information about Flowserve Corporation, contact www.flowserve.com or call USA 1-800-225-6989.

FLOWSERVE CORPORATION
FLOW CONTROL DIVISION
1978 Foreman Drive
Cookeville, Tennessee 38501 USA
Phone: 931 432 4021
Facsimile: 931 432 3105
www.flowserve.com

© 2003 Flowserve Corporation, Irving, Texas, USA. Flowserve and Worcester Controls are registered trademarks of Flowserve Corporation. TP-12D-1 6/03 Printed in USA