Increasing the Opening Degree to Extend Service Life
When first using a ceramic control valve, operate it at its maximum opening, such as 80%. This ensures that initial erosion and wear from impurities in the pipeline occur outside the damaged parts of the valve core. After removing impurities from the pipeline, adjust the valve opening to a slightly larger than normal range. As the fluid continues to damage the valve core and the flow rate increases, correspondingly reduce the opening. This process of continuous damage and gradual closure ensures the entire valve core is fully utilized until the valve core root and sealing surface are damaged and unusable.
Cleaning the Pipeline to Extend Service Life
Weld slag, rust, solidified lime slurry, wire, rags, etc., in the pipeline can cause blockages or jamming at the throttling orifice and guide parts, leading to valve core breakage. This frequently occurs in newly commissioned systems and during the initial commissioning period after major overhauls. This is the most common failure. In such cases, disassembly and cleaning are necessary to remove debris. If the sealing surface is damaged, it should be ground. Simultaneously, open the bottom plug to flush away debris and flush the pipeline. Before commissioning, fully open the control valve and allow the medium to flow for a period of time before putting it into normal operation.
Increasing the Valve Diameter Improves Lifespan
We calculate the correct CV (capacity ratio) using the CV value formula to select the appropriate valve diameter. Under the same flow rate, the smaller the valve diameter, the faster the fluid velocity, and the more severe the erosion of the valve core and seals. It is recommended that users appropriately increase the valve diameter within the range of freely adjustable opening to reduce wear.
Ceramic Control Valves Initially Used a Two-piece Structure
For a more rational valve structure, it was changed to the commonly used three-piece structure. This structure, due to its double seat, also has double sealing characteristics. At the same time, when selecting ceramic ball valves, pay attention to valves with a beveled transition design; such control valves can reduce fluid impact.
Relocating the Point of Failure Improves Lifespan
Relocate the most severely damaged areas to less critical locations to protect the sealing surfaces and throttling surfaces of the valve core and seat. Typically, the most severe erosion and the fastest fluid velocity in a ceramic ball valve occurs at the lower part of the fluid inlet. For the current three-piece structure of ceramic ball valves, the ball core can be reversed, allowing one ball core to be used four times at the inlet, thus extending the valve's lifespan by four times.