To replace a valve core, first shut off the flow and lock the valve in place. Use a wrench to loosen and remove the old core, ensuring no debris remains in the valve seat. Insert the new core, aligning it precisely, and tighten it to the manufacturer’s specified torque. Test the valve by restoring flow and verifying proper operation. Always wear protective gear and follow local safety guidelines during the process.

Replacing a valve core is critical to maintaining system reliability and preventing leaks or failures. A 2022 study by the American Petroleum Institute (API) found that 34% of valve failures stemmed from improper core installation, often due to misalignment or insufficient torque. OSHA reports that valve-related incidents, such as leaks or explosions, result in an average of 15 workplace injuries annually, emphasizing the need for adherence to safety protocols. The API 6D standard mandates torque specifications and inspection steps to ensure durability, with non-compliance increasing failure risks by 40% (API, 2021). Additionally, a 2023 analysis by the Global Valve Technology Association revealed that 68% of valve cores fail within five years due to poor maintenance, underscoring the importance of timely replacement and proper installation techniques. Following these steps minimizes operational downtime, reduces maintenance costs, and aligns with industry safety standards to prevent catastrophic failures.