8 Ways to Extend the Service Life of Industrial Valves

Valves are manufactured to last long. However, there are circumstances that industrial valves do not last the way they are supposed to. Identifying these conditions can help lengthen the life of the valve. In addition, maintenance is an important aspect of any valve life.



Valve wear and tear is normal occurrence. But, with the right installation and maintenance, you can prolong the service life of your valve. Band-aid solutions are not permanent solutions when it comes to valve maintenance. 

There are so many ways to extend the valve service life and three factors have always come into play. These are the selection process, the installation process and the maintenance process. Choosing the right kind of valve is pivotal to valve life cycle. The other two maximize valve life expectations.

This article discusses the various ways of how to extend the service life of industrial valves.

#1 Understand Valves

The first step in maintaining valve integrity to extend its life is to understand how a particular valve works.

Check the UNIQUE label on your valve to know valve specifications, including the type of system the particular valve should be used for. Additionally, always read the manual that comes along with the valve to know what material the valve is made of, the pressure and temperature range of the valve and the likes.



For example, ball valves are only used for tight shut-off. Gate valves have throttling capacity but are more prone to friction. Butterfly valves are lightweight and good for media isolation but there is a tendency that substrates would remain in the valve. A relief valve would be a great choice for throttling.

Part of understanding each valve is knowing its proper installation. Know what type of bore should be used for the valve if pressure is a huge consideration. Whether the valve should be bolted, welded or connected in other ways are also major factors, which could mean potential leakages or a tight seal. 

One of the problems is that when you are not familiar with the valve parts, you might end up ruining the valve because of recognition errors. One such example is the turning of the travel stops on the valve and the actuator. Travel stops often look like bolts and nuts. But the former ones should not be touched as they keep the disc from rotating.

However, damage to the valve can be avoided by letting oneself know the appearance of the external valve components and their positions.

Technical considerations such as pressure, flow direction, temperature, are also part of the learning curve. Calculate the best efficiency point (BEP) and know the value of the valve working at its optimum.

#2 Select the Right Valve



Valve selection could be daunting. However, that is the make-or-break stage. If you scrimp on the selection process, you might choose the improper valve, which could mean a potential loss. 

One of the major causes of leakage is the wrong valve design or material in relation to the media. In the long run, the wrong valve would lose its optimal performance. That will cause losses.

What you should do is to know the answers to these questions:

1.What is the nature of the media?
2.What is the temperature range of the media?
3.What is the pressure range of the media?
4.Is the valve going to be in an open position or is it going to be closed all the time?

To avoid selecting the wrong valve, please always review the valve specifications and ask the right questions.

#3 Ensure Proper Installation

Proper installation begins in the upkeep of the valves after these are delivered. Valves can get damage from corrosion caused by negligence, especially when the valves are exposed to air. 



Another common issue among valve technicians is the removal of end caps that act as a protection for the internal valve parts. When these are removed, foreign bodies can get inside the valve, which can cause damage to the seats if the valve becomes operational. Once the seats get damaged, there is a high potential for leakage.

Additionally, the valve should be inspected thoroughly before it is installed to the system, which is to ensure that the body and the components are not damaged during the shipping. 

#4 Clean the Valve

For valves to last longer, it is imperative that these should be cleaned at least once a year or if needed, especially when the plant area is dirty. Use proper equipment such as cloths, lubricants or wire brushes to clean the valve body and components such as the stem threads, studs, nuts and the likes.

It is also important that the valves are properly cleaned before installing. In this way, the valves do not contain contaminants that might harm not only the valves but also the media that would flow through them.

#5 Coat the Valve

In some applications that contain corrosive media or require high pressure and temperature, coating the valves with thermal coatings can increase the service life of valves. The high-velocity oxy-fuel process should be used for thermal coatings as this has been proven to be great in coating the valves.

#6 Regular Check-ups

True enough, valves should be checked regularly. While this task could be tedious, it is a must. For ball valves and other related valves, by doing so, you are ensuring that the valves are free from damage and still maintain tight shut-off. Throttling valves need checking for damage caused by friction.



As a rule of thumb, valves that are used frequently should be replaced within six months. However, for critical applications, valves should be checked every three months. Such check-ups should include checking for leakages, corrosion and defective parts.

During regular check-ups that you'd find cracks, cuts and even leaks on the valve. Such occurrences are normal when valves are frequently used for a long time. 

#7 Preventive Maintenance

If the valves are not corrosion resistant, use products that should prevent corrosion that could potentially damage the valve. A simple monthly application of a general purpose lubricant can do wonders and potentially increase the valve life span. However, take note of the lubricant suggested by valve manufacturers.

Additionally, preventive maintenance should begin with making sure that the material used in valve manufacturing should match the specification sheet provided for the end-user. Also, make sure that the valves are regularly greased, which is part of the preventive maintenance. 

Periodic tests should be carried out in order to detect possible leaks and other situations as early as possible. While this may be viewed as a costly endeavor, one of the best ways to increase the lifespan of industrial valves is to perform the leak test.

#8 Field Machining

When valves are used over and over again, the sealing capacity of the connections wears off. To make sure that the valves do not leak at the flanges without having to remove the valve from the system, field machining is utilized.

In Summary

By learning the nature of the particular valve, cleaning the valve and doing preventive maintenance, among others, can increase the life of industrial valves. Should you wish to learn more about industrial valves, feel free to contact UNIQUE.