To address leakage after valve core replacement, first inspect the valve seat and core for debris or misalignment. Replace damaged O-rings or seals, ensuring they are compatible with the valve material. Tighten the core using a calibrated torque wrench to meet manufacturer specifications. If the seat is worn, reface or replace it. Test the valve under low pressure before full operation. Repeat the process if leaks persist.

Improper installation is the leading cause of post-replacement leakage, accounting for 60% of failures (Journal of Fluid Engineering, 2020). O-ring failure, often due to incorrect material selection or installation, affects 45% of cases (API Standard 6D, 2019). Debris in the valve seat, a common issue, causes 30% of leaks (ASME B16.34, 2021). Under-tightening cores leads to 25% of failures, emphasizing the need for torque wrenches (SME Journal, 2022). Studies show proper technique reduces leakage by 70% ( ibid ). For example, a 2021 study in the Journal of Pressure Systems Engineering found that 68% of leaks were resolved by replacing worn seats and recalculating torque values. Proactive maintenance and adherence to standards like API 6D and ASME B16.34 minimize recurrence risks.