how to properly store and maintain backup gate valves

Properly storing and maintaining backup gate valves is crucial to ensure that they remain functional and reliable when needed, especially since gate valves are often used for emergency shutoff or isolation in critical systems. Here’s a step-by-step guide on how to properly store and maintain backup gate valves:

1. Storage Conditions

• Dry and Clean Environment: Store the gate valves in a clean, dry location to prevent corrosion or contamination. Moisture and dust can damage the internal components of the valve, particularly the seals and moving parts.

  • Avoid Direct Exposure to Water: Place the valves on pallets or racks in a dry area, away from water or areas where humidity could be high.
  • Temperature: Ensure the storage area is within a temperature range suitable for the material of the valve. Extreme temperatures (too high or too low) can affect materials like seals and gaskets.
  • Cover the Valves: If possible, cover the valves with protective plastic sheeting or bags to keep out dirt and moisture.

• Vertical Storage: Store the gate valves in the upright position (valve bonnet facing up) to maintain the integrity of the valve and prevent any deformation or damage to the valve body. Valves should be stored with the stem pointing upward if they have a rising stem design.

• Protection from Physical Damage: Store the valves in a way that prevents them from being dropped or knocked. Use racks or shelving to keep them organized and avoid any contact that could damage the valve body or sealing surfaces.

2. Preparation for Long-Term Storage

• Lubrication: Before storage, apply a light coat of lubricant to the valve’s moving parts (e.g., stem, threads, and bonnet). Lubricating the valve ensures that the internal components do not seize or corrode over time.

  • Use the appropriate lubricant based on the valve material and the fluid type that will pass through the valve. Ensure that the lubricant is compatible with the valve seals and other materials.

• Close the Valve: If the valve is a non-rising stem type, ensure that the valve is closed before storage. This will help maintain the integrity of the seat and prevent dirt or contaminants from entering the valve body.

• Sealing Openings: For extra protection, seal the valve openings (inlet and outlet) with plastic caps or plugs. This will prevent dust, debris, or moisture from entering the valve and contaminating the internal components.

3. Inspection and Maintenance During Storage

• Periodic Inspections: Regularly inspect the stored gate valves to ensure they have not been exposed to damaging conditions. Look for:

  • Corrosion or rust on the exterior or in any exposed areas (particularly on the stem and flange).
  • Any visible signs of moisture or condensation inside the valve body or around the stem area.
  • Damage to protective coverings, seals, or gaskets.

• Cleaning: If dust or dirt accumulates on the valves, clean them with a soft cloth or a brush. For stubborn dirt, you can use a mild soap and water solution, but ensure that the valve is thoroughly dried afterward to prevent moisture from causing rust or corrosion.

• Lubrication Check: Periodically check the lubrication on moving parts. If the lubricant has dried up or degraded, reapply the appropriate lubricant.

• Rotate the Valve Stem (if applicable): For valves with a rising stem, it’s a good idea to rotate the stem periodically to prevent it from seizing. A few turns every few months can help keep the valve in good working order.

4. Testing Before Use

• Functionality Check: Before using the backup gate valve in the field, perform a functional test to ensure it opens and closes correctly. This should be done after it’s removed from storage and before it is installed in a system.

  • Verify the seal integrity by checking for any signs of leaks or failure when the valve is in the closed position.
  • If the valve has an actuator, make sure the actuator is functioning correctly and the valve stem moves smoothly.

• Inspection of Seals and Gaskets: Check the gaskets and seals for any signs of degradation, cracking, or drying out. Replace any worn or damaged seals before installation.

5. Proper Documentation

• Record Keeping: Keep a detailed log of each valve stored, including the valve type, serial number, storage conditions, and lubrication dates. This will help track the maintenance history and provide useful information for future inspections or repairs.

• Manufacturer's Recommendations: Always refer to the manufacturer's storage and maintenance guidelines. Specific instructions may exist for the type of gate valve you have, including particular temperature ranges or types of lubricants to use.

6. Storage Duration

• Short-Term Storage (less than 6 months): If the valve will only be stored for a short time, minimal maintenance may be required. However, regular inspections and ensuring the valve remains clean and dry are still important.

• Long-Term Storage (more than 6 months): If the valve will be in storage for extended periods, the storage conditions, lubrication, and sealing of openings become more critical. In this case, more frequent inspections and possible re-lubrication every 6 months are recommended.

Conclusion

To ensure backup gate valves remain operational when needed, store them in a clean, dry, and temperature-controlled environment. Regularly inspect them, maintain lubrication, and check for signs of damage or corrosion. By taking these precautions, you will increase the longevity and reliability of the valves, ensuring they function properly when required for system operation or emergency isolation.