Adjustment valve installation and method for improving life

When installing the regulating valve, it is important to pay attention to the following key points:

1. Before installation, ensure that any dust or debris accumulated during storage is thoroughly cleaned from the valve. Keep the area clean throughout the installation process to prevent damage to the seat and trim caused by impurities. It’s recommended to cover the open flange with a protective cap if it won’t be welded on the same day.

2. Make sure the arrow on the valve body aligns with the flow direction of the medium. This ensures proper operation and prevents unnecessary stress on the internal components.

3. Regulating valves are precision instruments, so they must not be subjected to stress from pipe deformation. Ensure that the flanges and pipes are installed vertically and accurately to avoid misalignment. Proper support for the pipeline is also essential to prevent bending or deformation under the weight of the valve.

4. When welding the regulating valve to the pipe, special care must be taken. Inadequate welding or unremoved stress can cause deformation. During the welding process, make sure that welding slag does not enter the valve, as this can damage its performance. If slag lands directly on the valve plug, it may affect the valve's operation and cause serious damage to both the plug and the seat.

5. During pipeline testing and blowing, remove the regulating valve and replace it with a straight section of pipe to prevent debris such as welding slag or metal shavings from getting stuck between the plug and seat. After removal, tightly wrap the flange end of the valve with plastic sheeting for protection.

There are several methods to improve the life of the regulating valve:

1. Extended working method: Operate the valve at a higher opening initially, such as 90%, to reduce cavitation and erosion on the spool head. As the spool wears, the flow increases, and the valve closes again. This cycle gradually reduces wear and extends the valve’s life. A larger opening means less erosion, which can increase the lifespan by up to 5 times compared to operating in the middle or small openings.

2. Reduce S (pressure drop) to increase the working opening. Close the manual valve connected in series on the pipeline until the regulating valve reaches the ideal opening. This method is especially effective when the valve is initially selected for a small opening.

3. Reduce the valve diameter to increase the working opening. For example, change from DN32 to DN25 or replace the valve core with one that has a smaller seat diameter. This can significantly extend the service life of the valve.

4. Transfer the damage location: Move the most damaged areas to a secondary position to protect the sealing and throttling surfaces of the valve seat.

5. Enlarge the throttling channel: Thicken the valve seat to create a longer throttling path, reducing erosion and increasing durability.

6. Change the flow direction: Flow-open type valves direct the flow toward the opening, causing more damage to the sealing surface. Flow-closing type valves direct the flow toward the closed side, protecting the sealing surface and extending the valve’s life.

7. Use special materials: Choose materials resistant to cavitation and erosion to manufacture the throttle components. These materials can withstand the harsh conditions and extend the valve’s operational life.

8. Modify the valve structure: Consider using multi-stage valves, anti-cavitation valves, or corrosion-resistant valves to enhance longevity. Changing the valve design can significantly improve its performance and service life.