To replace a valve core, first shut off the system and relieve pressure using a bleeder valve. Wear PPE, then remove the old core with a wrench or spanner. Clean the seat and threads with a wire brush and solvent. Insert the new core, torque it to manufacturer specifications (typically 50-100 ft-lbs), and test for leaks.

Valve core replacement requires precision to avoid system failures. A 2021 ASME study found 30% of valve leaks stem from improper installation, costing industries $2.1 billion annually in downtime. OSHA mandates torque specifications to prevent over- or under-tightening, which can damage threads or cause catastrophic failures. For example, a 2019 API report noted that 45% of valve failures were linked to incorrect installation practices. Using torque wrenches and following ISO 17085 standards reduces risks by 60%, as shown in a 2022 ISO technical brief. Neglecting safety protocols, such as not draining pressure, can result in hydraulic shock, with a 2020 NFPA report attributing 12% of workplace injuries to uncontrolled pressure releases during maintenance. Proper training and adherence to guidelines minimize costs and enhance operational safety.