Analysis of problems existing in the operation of regulating valve in complex working conditions
When a control valve is subjected to complex operating conditions, it can lead to severe corrosion, cavitation, erosion, jamming, and surface scratching. These issues cause significant damage to the sealing surfaces of the valve, resulting in unreliable sealing performance and a shortened service life. For decades, regulators have faced unavoidable challenges. After the full-featured ultra-light control valve overcame the limitations of traditional valves, we focused on solving the long-standing issue of difficult sealing under harsh conditions.
1. What are complex working conditions, and what problems do they cause?
1. High pressure and large pressure differential – this can cause serious erosion or cavitation, which significantly reduces the lifespan of the seal.
2. High temperature and large temperature fluctuations – thermal expansion and contraction can alter the compatibility of components originally designed for room temperature, leading to leakage, jamming, and even complete failure of the valve operation.
3. Contaminated media – this can result in severe erosion, blockage, and damage to the valve core and seat, affecting both movement and sealing performance.
4. Corrosive media – these can cause chemical damage to materials in contact with them, further degrading the integrity of the valve.
5. VI-class hard-seal shut-off – especially when dealing with high differential pressure, the valve must close tightly. At the moment of opening, the sealing surfaces experience friction and pulling, increasing wear and reducing reliability.
In summary: under severe environments caused by cavitation, erosion, corrosion, thermal stress, jamming, and scratching, achieving a VI-class hard-seal cut-off becomes even more challenging. This has remained a persistent problem in the industry for decades.
Second, the reliability analysis of traditional sealing structures:
1. Soft seal to soft seal material – easy to seal due to the soft nature of the material, but not always reliable under extreme conditions.
2. Soft seal to stainless steel – slightly better than the first, but still not fully reliable in harsh environments.
3. Stainless steel to stainless steel – slightly improved, but the hardness of stainless steel (HRC 20–25) is still low, making the seal less reliable.
4. Multi-layer sealing seats – combining stainless steel sheets with soft materials improves temperature resistance, but the sealing reliability remains similar to the previous options.
5. Surface welding with wear-resistant alloys – typically using STellite alloy, this is currently the best sealing material available. However, its hardness (HRC 40–45) is still insufficient for extremely harsh conditions.
6. Ceramic seals – while offering extremely high hardness, they lack toughness and are prone to brittle fracture, making them unsuitable for dynamic sealing applications.
By understanding these challenges, we continue to innovate and develop advanced sealing solutions that can withstand the toughest industrial environments.
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