Industrial control valves are an essential part of many industrial processes. They control the flow of gases, liquids, and slurries in pipelines and other process systems. These valves are designed to handle high pressures, temperatures, and corrosive materials. However, even the best control valves can fail over time due to various reasons. In this article, we will discuss why industrial control valves fail and the steps you can take to avoid them.
Common Causes of Control Valve Failure
Corrosion
Corrosion is the most common cause of control valve failure. Industrial processes often involve the use of corrosive materials, which can cause the valve to corrode over time. Corrosion can lead to leaks and other problems that can affect the performance of the valve. Regular maintenance and inspections can help detect and prevent corrosion.
Erosion
Erosion is another common cause of control valve failure. It occurs when high-velocity fluids or gases flow through the valve, causing the valve’s internal components to erode over time. This can lead to reduced valve performance, leaks, and other issues. Using high-quality materials and regular maintenance can help prevent erosion.
Wear and Tear
Valves are subjected to frequent use, and over time, the components can wear out. This can lead to valve failure, leaks, and other problems. Regular maintenance and inspections can help detect and prevent wear and tear.
Improper Installation
Improper installation of control valves can also cause failure. If the valve is not installed correctly, it can affect the performance of the valve and cause leaks and other problems. It is essential to have a professional install the valve to ensure it is done correctly.
Steps to Prevent Control Valve Failure
Regular Maintenance
Regular maintenance is crucial in preventing control valve failure. A regular maintenance schedule can help detect and prevent corrosion, erosion, wear and tear, and other issues that can affect the valve’s performance. Maintenance should include inspecting the valve, cleaning it, lubricating it, and replacing any worn-out components.
Selecting the Right Valve
Selecting the right valve for the job is also crucial in preventing failure. It is essential to consider factors such as the type of fluid or gas being transported, the pressure and temperature of the system, and the valve’s material. Choosing the wrong valve can lead to valve failure and other problems.
Proper Installation
Proper installation is critical in preventing valve failure. It is essential to have a professional install the valve to ensure it is done correctly. The valve should be installed according to the manufacturer’s specifications and guidelines.
Monitoring the Valve
Monitoring the valve’s performance is also crucial in preventing failure. Regular monitoring can help detect any issues before they become significant problems. Monitoring can include checking for leaks, inspecting the valve’s components, and measuring its performance.
Engineers can use control valve diagnostic tools to avoid unplanned downtime by monitoring the performance of control valves in their industrial processes. These tools provide real-time data on valve health and allow engineers to identify potential issues before they lead to system failure. By detecting problems early, engineers can schedule maintenance and repair work in advance, minimizing downtime and reducing the risk of costly equipment failures. UReason has developed the Control Valve App, a diagnostic tool that provides insights into the condition of control valves. The app helps engineers to optimize valve performance, reduce maintenance costs, and prevent unplanned downtime. With the Control Valve App, engineers can gain a better understanding of their control valves, make data-driven decisions, and ensure that their processes are running smoothly.
Conclusion
Control valve failure can lead to significant problems in industrial processes. It is essential to understand the common causes of valve failure and take the necessary steps to prevent it. Regular maintenance, selecting the right valve, proper installation, and monitoring the valve’s performance are all crucial in preventing failure. By following these steps, you can ensure the reliable performance of your control valves and prevent costly downtime.