Industrial Valve Operating Conditions & Reliability Analysis

Industrial valves are crucial components in fluid control systems, and their operating conditions directly influence the stability, reliability, and service life of equipment. The valve's working environment is affected by various factors, including the working pressure and temperature of the medium, the characteristics of the medium, pressure and temperature fluctuations, drive methods, installation position, maintenance cycles, and the need for special protection measures. Therefore, understanding the operating conditions of an industrial valve and the requirements they impose on materials and structures is essential to ensure safe valve operation.

Impact of Operating Environment on Valve Performance

The working pressure and temperature of a valve are critical factors that affect its performance. Generally, the higher the working pressure and temperature, the more severe the operating environment. This is especially true for valves installed offshore, where the environment is more complex and harsh. These conditions demand that valves possess high strength and reliability. Specifically, pressure-bearing and pressure-controlling components must have sufficient strength and durability, with materials' thermal strength, oxidation resistance, thermal stability, and low-temperature impact toughness being particularly important in extreme high and low-temperature conditions.
In high-pressure environments, sealing surface materials must exhibit excellent scratch resistance, wear resistance, corrosion resistance, and erosion resistance. Since high-pressure media tend to have higher flow velocities, sealing surfaces are susceptible to erosion. Thus, it is essential to select appropriate sealing materials based on the medium's characteristics, working temperature, and pressure. Furthermore, valves working in low and ultra-low temperature environments must ensure that the materials have good low-temperature impact toughness to prevent material embrittlement.

Requirements for Valves Operating in Corrosive Media

The presence of corrosive media places higher demands on valve materials. Valves working with corrosive media must have pressure-bearing and pressure-controlling components, including gaskets and packing, that exhibit excellent chemical corrosion resistance. If materials lack sufficient corrosion resistance, the valve's service life will be significantly shortened, and it may even lose its functionality in a short period. Therefore, valve materials must be precisely selected for different corrosive media to ensure long-term stable operation in such environments.

Impact of Pressure and Temperature Fluctuations on Valves

In practical operations, the working pressure and temperature of valves often fluctuate. These changes can lead to poor sealing at the connection flanges. Under high pressure and temperature, connection bolts and gaskets are prone to deformation, and when pressure and temperature decrease, the gasket may lose its sealing ability due to insufficient compression. Such periodic fluctuations in pressure and temperature not only adversely affect the sealing performance but can also lead to material fatigue, accelerating wear and aging of valve components, ultimately impacting the valve's normal operation.

Impact of Drive Methods on Valve Performance

The drive method of a valve determines the force characteristics it experiences during operation. Electric actuators can cause large impact loads when closing a valve, especially in globe valves, which may generate significant impact on the sealing surface. Hydraulic actuators typically provide smooth loading and are less likely to impact the valve. Pneumatic actuators have less impact on ball and butterfly valves, but they may still produce some impact loads in globe valves. In particular, in safety valves, when the valve disc returns to its seat, the spring and weight mechanism may also impact the sealing surface, affecting the sealing performance and reducing the valve's service life.

Impact of External Environment on Valves

Valves used in outdoor environments are often exposed to harsh weather conditions. For example, wind and rain can lead to rusting and even damage the lubrication system; if dust and sand accumulate at the valve's connection points, component wear will be accelerated. Offshore valves, in particular, are constantly exposed to salt spray environments, where chloride ions can rapidly accelerate corrosion, leading to valve failure. Therefore, materials used in offshore valves must be chosen for their resistance to chloride corrosion, and suitable anti-corrosion coatings should be applied.
For underground valves, a fully welded structure with extended sections should be chosen to prevent damage from erosion by groundwater and sediment. Moisture, chemicals, and mechanical wear in underground environments can accelerate the aging of valve components, making protective treatment essential.

Measures to Extend Valve Service Life

To ensure valves operate stably over long periods under harsh working conditions, it is critical to select the appropriate materials and structure. The main components and materials of the valve should be carefully selected according to the working environment to meet the requirements for different pressures, temperatures, and media. Additionally, regular maintenance and servicing are crucial to extending valve life. Periodically cleaning valve interiors, injecting lubricants, and performing necessary repairs or replacements can effectively improve valve performance and extend its service life.

Conclusion

In conclusion, the operating conditions of a valve are influenced by various factors, including working pressure, temperature, medium characteristics, installation position, and maintenance cycles. Proper material selection, appropriate design, and regular maintenance are all key to ensuring long-term, reliable valve operation. Only by considering these factors comprehensively can valves maintain stability and efficiency in complex environments, providing reliable fluid control solutions for industrial production.