Diaphragm Valves - Failure Modes

- TEFLON Diaphragm (2) Failure – The diaphragm is a combination of a TEFLON(thinner) and a

RUBBER piece(thicker).
o TEFLON(PTFE)/RUBBER cracks.
o TEFLON(PTFE)/RUBBER burned out – Higher than acceptable temperature conditions.
o TEFLON(PTFE)/RUBBER diaphragm pinched by foreign matter.
o TEFLON(PTFE)/RUBBER diaphragm pinched by foreign matter stuck on the valve body
seam (red rectangle area).

Note: All these failures will eventually happen with the rubber inner diaphragm once the
TEFLON diaphragm fails. Once both diaphragm fail, the fluid find a through it, it will the BONNET (5)
chamber, generating corrosion and accelerating the failure of other valve components.
- Valve Body Failure – Metal housing where the fluid is guided through.
o Corrosion – Can be accelerated if the body material is not properly specified by the fluid
being used.

Stainless Steel Corrosion Example

o Welding cracks – Only happen on valve bodies that are welded directly to the pipe
(Example: Fermenter bottom valves, header valves). – This failure will normally generate
fluid leaks and it will get bigger and bigger with time.

o Pitting – Corrosion pitting is a type of localized corrosion that occurs on the surface of a
metal. It is characterized by the formation of small, deep cavities or pits on the metal
surface, which can weaken the material and lead to structural failure if left unchecked.
- Valve Nut Failure – Nut (6) locked to the valve bonnet (5).
o Friction Wear – It happen with time, the more you use more wear you will see it. It is
accelerated if the nut is not properly lubricated.
 Signs of Nut Failure: Valve Handwheel (8) hard to open/close. Valve handwheel
stuck or tighter in a spec position where you need to apply more force to turn it.
o Corrosion – Can be accelerated if the body material is not properly specified by the fluid
being used. The Nut is normally fabricated of a self-lubrication metal such as Bronze or
Brass, these materials are not super resistant to chemicals compared to stainless steel
for example, if in contact with corrosive fluids, the failure can be accelerated.

- Valve Leaking Product - Normally through/between body/diaphragm/bonnet.

o Heat Cycle – Heat cycles of Rubber/Teflon when the materials are heated for a certain
period and then cooled. With time, the rubber/Teflon start losing its elasticity, we start
to see a gap between the metal parts and the Rubber/Teflon diaphragm, and this is
when the leaks start.
o Improper torque – Bonnet bolts not properly tightened, gaps are not fully sealed, leaks
start to happen.