To extend the service life of a control valve, one effective method is to start with a large opening, such as 90%, during initial operation. This approach helps prevent cavitation and erosion on the spool head, which can cause damage over time. As the valve deteriorates, the flow increases, leading to further wear and gradual closure until the valve core and sealing surfaces are damaged beyond use. By starting at a larger opening, the valve can be fully utilized until it reaches the end of its lifespan. Additionally, this method reduces erosion compared to operating at a medium or small opening, potentially extending the valve’s life by 1 to 5 times. For example, a chemical plant reported a two-fold increase in valve life after implementing this strategy. Another way to improve the valve's longevity is by reducing the pressure drop (S) across the valve. This involves redistributing the system’s pressure loss so that the control valve experiences less pressure drop. As a result, the valve can operate at a higher opening without excessive stress, which also minimizes cavitation and erosion. Practical steps include installing an orifice plate after the valve or closing a manual valve in series to achieve a more favorable operating position. This method is simple, efficient, and particularly useful when the valve starts with a large opening. Reducing the valve's diameter can also enhance its performance and lifespan. For instance, replacing a DN32 valve with a DN25 model or using a smaller seat diameter while keeping the body unchanged can increase the effective opening. A chemical plant that replaced DGL parts with DGL0 valves saw a one-time improvement in their valve life. Shifting the point of damage from the critical sealing surface to a less vulnerable area can help protect the valve’s integrity. This technique involves redirecting the most severe wear to a secondary location, thus preserving the sealing surface and throttle face. Increasing the throttling channel length is another effective strategy. This can be achieved by thickening the valve seat or enlarging the seat hole to create a longer path for the fluid. This not only delays the sudden expansion of the flow after throttling but also keeps the damaging effects away from the sealing surface. Some valves feature stepped or wave-like seat holes designed to increase resistance and reduce cavitation. This method is commonly used when upgrading older valves or introducing high-pressure systems. Changing the flow direction can significantly impact the valve’s lifespan. When the flow moves toward the open direction, cavitation and erosion tend to occur on the sealing surface, causing rapid damage. However, directing the flow toward the closed position shifts the erosion to the downstream side of the valve seat, protecting the sealing surface and root. This adjustment can extend the valve’s life by 1 to 2 times, especially in applications where longevity is critical. Using specialized materials is another key approach. Anti-cavitation and anti-erosion components can be made from materials like 6YC-1, A4 steel, Hastelloy, or cemented carbide. These materials are designed to resist the harsh conditions inside the valve. For corrosion resistance, non-metallic options such as rubber, PTFE, or ceramics, as well as corrosion-resistant metals like Monel or Hastelloy, are often used. Finally, modifying the valve structure can greatly improve its durability. Options include using multi-stage valves, anti-cavitation valves, or corrosion-resistant valves. Choosing the right design for specific applications ensures better performance and longer service life.

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