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 scratching, which damage the sealing surface of the valve and result in unreliable sealing and a shortened service life. For decades, regulators have faced these challenges. After the full-featured ultra-light control valve overcame the limitations of traditional valves, we focused on solving the difficult issue of 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, significantly reducing the lifespan of the seal.
2. High temperature and large temperature differences – thermal expansion and contraction can alter the compatibility of components at room temperature, leading to leakage, jamming, and even making the valve inoperable.
3. Contaminated media – this leads to severe erosion, blockage, and damage to the seat and plug, affecting both movement and sealing performance.
4. Corrosive media – these can corrode the materials in contact with them, further compromising the integrity of the valve.
5. VI-class hard-seal shut-off – especially during high-pressure closing, the plug and seat must be tightly sealed. At the moment of opening, the sealing surfaces experience friction and pulling, increasing wear.
In summary: Under severe environments caused by cavitation, erosion, corrosion, thermal expansion, jamming, and scratching, achieving a VI-class hard seal becomes even more challenging, becoming a long-standing problem that has plagued the industry for decades.
2. Reliability Analysis of Traditional Sealing Structures
1. Soft seal to soft seal material – easy to seal due to the softness of the material, but not always reliable.
2. Soft seal to stainless steel – slightly better than (1), but still not very reliable.
3. Stainless steel to stainless steel – slightly improved, but the hardness of stainless steel is still low (HRC 20–25), making the seal unreliable.
4. Multi-layer sealing seat – combining stainless steel sheets with soft materials improves temperature resistance, but the sealing reliability remains similar to (2) and (3).
5. Surfacing welding with wear-resistant alloys – such as STELLITE alloy, currently the best sealing material. However, its hardness is still limited (HRC 40–45), making it unsuitable for extremely harsh conditions.
6. Ceramic seals – offer extremely high hardness, but lack toughness, making them prone to cracking or breaking under stress.
These traditional sealing methods have been used for years, but they often fail under the most demanding industrial applications. That’s why innovation in sealing technology is crucial for improving performance and longevity in complex environments.
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