During seasonal temperature drops, one of the easiest risks to overlook in industrial environments is valve freezing. Whether the medium is water, oil, or moisture in compressed air, once it freezes inside the valve body or pipeline, the valve may fail to operate, its sealing may harden, or the metal housing may even crack.

Most industrial valves can operate between –10°C and 20°C, but proper protection is essential to avoid performance loss and unexpected downtime.

Why Valves Freeze in Winter

Valve failure in winter is not caused by the metal itself becoming cold, but by the medium inside the valve solidifying or thickening. Water freezes at 0°C, certain oils become highly viscous in low temperatures, and moisture in compressed air can condense and freeze.

This often leads to sticking valve cores, hardened seals, or sluggish actuators.

In pneumatic or automated systems, even a small freeze point can disrupt an entire production line.

How Different Types of Valves Behave in Low Temperatures

Many valve types—ball valves, angle seat valves, solenoid valves, diaphragm valves, butterfly valves—can operate in low temperatures, but their sensitivity differs:

Understanding structural characteristics helps determine the right protection method.

Effective Methods to Prevent Valve Freezing

Winter protection revolves around three principles: keep it warm, keep it dry, keep it moving.

1. Insulation: shielding the valve from harsh cold environments

When a valve is exposed outdoors or in areas with strong wind, insulation becomes the most effective strategy.

Common methods include:

Wrapping the valve and pipeline with rubber insulation or rock wool

Installing electric heating tapes with thermostat control

Adding insulation boxes or shelters over key valve areas

Insulation dramatically reduces freezing risk and is suitable for nearly all valve types.

2. Draining and air-blowing: eliminating moisture inside the valve

What truly freezes inside a valve is residual moisture. Before temperatures drop, draining and blowout procedures should be completed.

Recommended actions:

Open drain ports when equipment is idle

Blow out pipes and valve cavities with compressed air

Add automatic drainers to air treatment units in pneumatic systems

If moisture remains in a pneumatic actuator, it may freeze and cause complete motion failure.

3. Keeping the medium flowing: reducing chances of freezing

For systems that run continuously, maintaining a slow and steady flow prevents medium stagnation.

Examples:

Low-speed circulation for cooling or process water

Slow oil pumping or preheating in lubrication systems

Flowing liquid is much less likely to freeze, making this a simple and cost-effective method.

Choosing low-temperature compatible materials and fluids

In extremely cold environments, the valve’s sealing and lubrication materials must withstand low temperatures.

Best practices include:

Using low-pour-point oils

Selecting seals suitable for low temperatures (PTFE, special FKM formulations)

Supplying dry, moisture-free air to pneumatic systems

For environments nearing –20°C or colder, low-temperature designed valves or metal-seated valves are recommended.

Maintenance Tips for Winter Operation

Preventive measures work best when combined with regular winter maintenance:

◆ Inspect insulation for moisture, cracks, or damage

◆ Confirm electric heating systems are operating normally

◆ Monitor for slower valve response or slight sticking

◆ Check air line filters and auto-drainers for moisture buildup

◆ Look for frost, leaks, or abnormal noises

If a valve is already frozen, avoid pouring hot water. Rapid thermal shock can crack the housing; instead, apply slow, controlled warming.

Reliable Valve Operation Begins With Proper Winter Preparation

While most industrial valves can withstand –10°C to 20°C, freezing risk comes from the medium—not the valve itself.

Through insulation, draining, moisture removal, proper material selection, and consistent maintenance, winter-related failures can be significantly reduced, ensuring stable and safe plant operation throughout the cold season.

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