Knowing these tips to extend the life of your control valve by two years

Control valves are critical components in industrial processes, ensuring precise control of fluid flow and pressure. Their reliability and longevity directly impact production efficiency and quality. To maximize their service life, it’s essential to understand the factors that contribute to their wear and implement effective maintenance strategies. Here are several practical tips and techniques to extend the lifespan of control valves:

1.Operate at High Opening Degrees:

Initially operating the control valve at a high opening degree, such as 90%, allows destructive forces like cavitation and erosion to primarily affect the valve core head.

As the valve core deteriorates, the flow rate increases, prompting a slight closure of the valve. This gradual process ensures the entire valve core is utilized until the root and sealing surfaces are compromised.

Operating at a large opening degree creates a larger throttling gap, reducing erosion. This method can extend the valve’s service life by 1-5 times compared to operating at mid or low opening degrees from the start.

Control valve

2.Reduce the Valve Resistance Ratio (Pressure Drop Ratio) S:

Decreasing S, by increasing system losses outside the control valve, reduces the pressure drop across the valve.

To maintain flow, the control valve opening must increase. Simultaneously, the reduced pressure drop mitigates cavitation and erosion.

Practical measures include installing orifice plates downstream to consume pressure drop or partially closing upstream manual valves to achieve the desired control valve opening.

3.Reduce Caliber and Increase Operating Opening Degree:

Increasing the operating opening degree can be achieved by reducing the valve’s caliber. Methods include:

Replacing the valve with a smaller caliber valve (e.g., DN32 to DN25).

Replacing the valve core and seat with smaller diameter components.

4.Transfer Damage Location:

Shifting severe damage from critical areas to less critical ones protects the sealing and throttling surfaces of the valve core and seat.

This strategy effectively prolongs the valve’s service life.

5.Change Flow Direction:

In flow-open type valves, the flow direction can cause cavitation and erosion to primarily affect the sealing surface.

Changing to a flow-close type valve directs these forces downstream of the throttling point, protecting the sealing surface and valve core root.

Caution: This change may induce valve jump (when opening) and instability due to vortex effects during regulation.

6.Utilize Special Materials:

To combat cavitation (pitting) and erosion (grooving), consider using special materials for throttling components.

Examples include 6YC-1, A4 steel, Stellite, and hard alloys.

For corrosion resistance, opt for materials like rubber, Teflon, ceramics, Monel, or Hastelloy.

7.Select Appropriate Valve Structure:

Improve valve longevity by choosing alternative valve structures or valves designed for extended service life.

Options include labyrinth valves, multi-stage valves, anti-cavitation valves, and corrosion-resistant valves.

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Related Article:

Common Faults and Influencing Factors of Control Valves

Troubleshooting Common Control Valve Issues

How to maintain a control valve?