Spears® True union valves are designed and produced for trouble-free operation and use. However, certain aspects of installation and application can result in valve malfunction. This guide identifies some of the more common problems encountered and their necessary corrective actions. Such problems have been categorized as External Leaks, Internal Leaks, Frozen Movements, and structural Breakage.
External leaks
| Location | Possible Cause | Corrective Action |
| At Thread or Socket Connections | Improper solvent cementing. | Replace end connector(s) according to installation instructions. |
| Improper threads. | Check threads for proper size; replace or reinstall. |
| Insufficient or improperly applied thread sealant: incompatible sealant (paste). | Reinstall thread connection according to proper procedures; check paste compatibility |
| Over-tightened thread joint splitting connector. | Replace cracked end connector(s). |
| Insufficient valve support splitting connector. | Replace cracked end connector(s). Add supports on each side of the valve. |
| Location | Possible Cause | Corrective Action |
| At Union Nuts | End connector misaligned. | Check system alignment – end connector(s) must be parallel. Check for adequate valve support. |
| Displaced or damaged o-ring; Particles in o-ring groove. | Remove the valve and inspect the o-ring for physical or chemical damage. Check o-ring compatibility, and replace accordingly. Clean and reseat the o-ring. |
| System contraction pulling end connectors; improper end connector spacing. | Check thermal variations; anchor pipe each side of valve; install expansion loop. Correct spacing. |
| Loose Union Nut. | Re-tighten nut. |
| Displaced or pinched seal carrier o-ring. | Remove and disassemble seal carrier; re-seat or replace o-ring. |
| Location | Possible Cause | Corrective Action |
| At Stem | Damaged stem o-ring | Remove and disassemble valve stem; inspect for physical or chemical damage. Check o-ring compatibility, clean, and replace accordingly. |
Internal Leaking
| Location | Possible Cause | Corrective Action |
| In-line Leakage Past Valve | Ball obstruction | Check that the valve is in its "full closed" position. If not, remove the valve and check for solids blocking the ball port. Clean and reinstall the valve. |
| Broken stem | Remove end connectors and check for ball rotation while operating the valve. Replace as necessary. |
| Seal Carrier Loose | True Union Valves – remove valve; CAREFULLY tighten seal carrier (located on the inlet end of the body). IMPORTANT: Generally only a slight adjustment is required. A properly adjusted valve should have significant resistance to operation without binding – AVOID OVER_TIGHTENING! |
| Teflon Seat Damage or Debris Laden | Remove and disassemble valve seat o-rings; check for physical or chemical damage (nicks, cuts, scoring, etc.). Clean and replace as necessary. |
| Seat o-ring Displaced, Damaged, or Debris Laden | Remove and disassemble valve ball. Check for physical or chemical damage. Check o-ring chemical compatibility; clean and replace accordingly. Check for excessive system flow rate. |
| Ball Damage | Remove and disassemble valve ball. Check for physical damage (excessive nicks, scoring, etc.) at the seat sealing surface (perpendicular to the ball port). Clean the surface; replace the ball if necessary. Check for chemical damage and valve material (PVC, CPVC) compatibility. |
| Solvent-Cement (glue) Contamination from Installation Spillage | Remove the valve and check for glue deposits on the ball and seat areas. Clean, If possible; excessive damage may require component replacement. |
| Thermal damage (component distortion) | Check system operating temperature, external heat sources (including the direct sun), and heat generated from system design or valve placement. |
Frozen movements
| Location | Possible Cause | Corrective Action |
| Unable, or very difficult, to open/close; sometimes accompanied by stem break (shear) | Internal Obstructions; Sediment or Particle Buildup; Solvent Cement on Ball | Remove valve and check for solids, debris, or solvent cement deposits blocking the ball or valve interior. Check for sediment particles lodged around ball-to-seat contact areas. Remove the stem and check for the same. Clean and reinstall. |
| Over-tight Seal Carrier | True-Union Valves – remove valve; slightly loosen seal carrier (located on the inlet end of body). IMPORTANT: Generally, only a slight adjustment is required (either valve). |
| Chemical Attack (generally appears as distortion, peeling, etching, or bleaching of ball sealing surfaces or other internal components) | Check Valve material (PVC, CPVC) chemical compatibility with system fluids. Be sure to consider operating temperatures with this determination. |
Structural Breakage
| Breakage | Possible Cause | Corrective Action |
| Handle Broken | Frozen movement.
External impact. | See the "Frozen Movements" section. Replace.
Identify and correct source. |
| Handle stripped | Overextended open/close range.
Excessive exposure to direct sunlight has softened handle material. | Replace handle.
Shield or screen valve from direct sun exposure. |
| Stem Sheared / Broken | Frozen movements; external impact. | See the "Frozen Movements" section. |
| Broken Union Nut | Nut has been over tightened to draw-up align end-connectors; external impact.
Inadequate valve supports.
Excessive internal pressure / Hydraulic Shock | Adjust spacing between end-connectors for proper valve lay-lengths. Check system alignment – end connector(s) must be parallel.
Provide system support on each side of the valve.
Check System air pressure and surge pressures; check for entrapped air. |
| End Connector Break | System misalignment; External impact.
Over-tighten thread-joint connection.
Inadequate valve support. | Check System alignment – end connector(s) must be parallel.
Install new end connector according to installation instructions.
Provide system support on each side of valve |
| Body Break | External impact.
Excessive internal pressure.
System misalignment.
Inadequate Valve Support.
Chemical attack. | Identify and correct source.
Check system pressure and surge pressure; check for entrapped air.
Check system alignment – end connector(s) must be parallel.
Provide system support on each side of the valve.
Check the chemical compatibility of systems fluids. |
Certain corrective actions of this guide may not be feasible with the compact ball valve (sealed unit).
Improper system operating temperatures and chemical incompatibility can cause a variety of functional and structural failures. Be sure to use proper valve material types for both temperature and chemical resistance.
Most valve problems are traceable to improper system design or installation. Be sure to have all designs performed by a qualified Engineer and installation made by properly trained personnel.
Spears valve Installation Instructions and maintenance procedures should be followed in conjunction with all corrective actions.
Title: Spears® Ball Valve Trouble Shooting Guide
Description: This guide identifies some of the more common problems encountered and their necessary corrective actions
Published: 9/5/2008
Last Edited: 1/20/2023
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