Hydraulic relief valves limit system pressure to protect components. The valves also limit the hydraulic system&#;s maximum output force. All hydraulic system relief valves work by balancing the hydraulic force with an adjustable spring force. Whenever the relief valve opens in response to a predetermined pressure, it releases heat. A properly adjusted valve will enable the system to operate correctly, while controlling the amount of heat generated.
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If valves are not set properly or monitored carefully, the hydraulic system can malfunction and suffer damage.
Below we describe the steps involved in setting hydraulic system relief valves and the signs that a valve needs replacing.Below we describe the steps involved in setting hydraulic system relief valves and the signs that a valve needs replacing.If a relief valve is set but is releasing pressure before a system reaches maximum pressure, or if it&#;s constantly leaking or chattering, something may be wrong with the system.
A properly maintained pressure relief valve can stay in service for up to 30 years. If you&#;ve been testing your valves regularly, it&#;s likely there&#;s something else in your system to blame.
That said, pressure relief valves can and do fail. It&#;s important to learn the signs of a possible failure in order to quickly solve the problem and keep your facility safe.That said, pressure relief valves can and do fail. It&#;s important to learn the signs of a possible failure in order to quickly solve the problem and keep your facility safe.
Here are 3 signs of pressure relief valve failure to watch out for.
If your system is not reaching the right pressure, it could be a sign of pressure relief valve failure. In some cases, this could be fixable. If the valve was calibrated to the wrong set pressure, it could simply be releasing early. This can happen with changes to your facility&#;s plant design. In some cases, technicians forget to recalibrate pressure relief valves for the system&#;s new normal operating pressure. Your valve technicians can go in and adjust the valve&#;s set pressure to address this issue.
If that doesn&#;t solve the problem, and the rest of your system is working properly, then your pressure relief valve likely needs to be changed. After years of service, the valve could be damaged or eroded from environmental dirt and debris, which block the valve from fully closing. This can cause chattering, where the valve isn&#;t all the way open, but is opening and closing rapidly, stopping it from properly doing its job. When your system cannot reach pressure, you will likely experience production slowdown or downtime.
Pressure relief valves and safety relief valves are what keep a facility safe. If your system builds up more than safe maximum pressure, safety relief valves open up to let off additional pressure, keeping your facility, your employees, and your equipment safe.If your system is above pressure and your pressure relief valves have not released, this could be a relief valve failure. You will need to ensure that the valves are set to the correct set pressure.Contaminants, like dirt, lint, rust, sludge, or even the misalignment of the valve can cause the pressure relief valve to stick. At this point, you might see that your system is above pressure, or you will notice other pressure relief valves in the system releasing to make up for this valve&#;s malfunction.While the other two signs appear obvious, this last sign is more noticeable when you&#;re directly inspecting your pressure relief valves. Leaking valves are a problem, and can contribute to slower, less efficient production, but they can be more difficult to notice, as their effect on the entire system can be much smaller. This is part of the reason that valve testing and maintenance is so important.
If your pressure relief valve has no pressure, it is likely that the balance hole is plugged, the spring is broken, or the valve has a loose fit. In the case of a loose fit or broken spring, replacement is a must. The valve does not function properly within your system, which means it&#;s not protecting your facility, your employees, or your equipment in the event that there is a larger problem.
Pressure valve leakage is a little more complicated to troubleshoot, as there are many possible causes. It could be the valve, it could be that misalignment is causing a failure to reseat after a correct opening, or it could be that there is more pressure in your system than the valve&#;s set pressure. A quality inline safety relief valve testing system can help you here.
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Properly setting, inspecting, and maintaining pressure relief valves in a hydraulic system is key to operating a safe facility.
A failing pressure relief valve is most often a symptom of a greater problem. In most cases, It is important to look at the &#;why&#; behind pressure relief valve failure, rather than just replacing the valve in question.
This article from the Journal of Emerging Technology and Advanced Engineering provides a helpful flowchart outlining the troubleshooting procedure to take in the event that you experience pressure relief valve failure.
Within a hydraulic system, there has to be hydraulic system pressure &#; it is the pressurised fluid that creates the fluid power that transfers the force into mechanical power.
However, there are usually set parameters of pressure that will keep a hydraulic circuit working efficiently. If the pressure setting is too low the power will be compromised, or fail. Conversely, too much pressure can not only damage the parts of the hydraulic system but can also be dangerous within some hydraulic systems.
This is why hydraulic pressure control valves and hydraulic pressure relief valves are a part of almost every hydraulic system. They help to keep system pressure under the upper limits and also maintain pressure within a hydraulic circuit.
This article will go through the different types of valves, explain how they work and look at the importance of regular calibration.
A relief valve, also sometimes called a safety valve, helps to reduce system pressure to avoid the damage that can be caused to the hydraulic system if the pressure becomes too high. They are commonly composed of a spring-loaded piston inside an orifice. The bottom of the piston will be pushed up when the pressure in the system reaches a particular point so the pressurised fluid can enter the cylinder through the orifice and provide pressure relief.
These self-operating valves help to keep pressure at a constant level. They are also known as pressure-reducing valves or pressure-reducing regulators. They allow fluid or oil to enter until a predetermined pressure is reached further along the system, once it has it stops the flow usually with a pintle and a diaphragm.
Sequence valves are similar to pressure relief valves only they are specifically used in fluid power systems where there are two circuits and two actuators both powered by a single pump and so the flow needs to be directed in a sequence that is related to the fluid pressure. From the one actuator until it reaches a certain maximum pressure or level, when the sequencing valve will then direct it to the second actuator.
As the name suggests, proportional control valves allow for a variable flow control rate rather than a simple open or closed valve. They can do this with a restrictor which enables any number range of spool positions and there for any flow rate.
As we have seen, hydraulic pressure control valves and pressure relief valves ensure that hydraulic systems work efficiently, safely and without putting undue pressure on the components of the system thus helping to ensure its longevity.
However, the valves are only effective if they are correctly calibrated. Incorrectly calibrated valves cause numerous problems and system errors such as incorrect flow rate sequence valve name, temperature and pressure.
This, in turn, can cause system inefficiency, costly repairs and hazardous working conditions.
As a general rule, your hydraulic valves, especially your pressure relief valves, should be calibrated by a qualified professional hydraulic engineer at least annually. Some systems may require more frequent calibration.
Any hydraulic system is only ever as efficient as its least efficient component and hydraulic pressure relief valves and control valves are no exception. All the different types of control and hydraulic relief valves have an important role and it is essential, not only for the performance of your hydraulic systems but for the safety of your workers and your budget that you ensure they are well maintained and calibrated.
If you have any questions, want to book your annual service and calibration or need to order replacement pressure control valves get in touch with our team at MCH Hydraulics.
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