Choosing the proper industrial valves for the severe service is one of the most crucial decisions that can affect the productivity, safety, and durability of your business. Valves that are to be used in severe service conditions like high pressure, high temperature, or highly corrosive environments have to be selected very carefully so that they can meet these conditions and at the same time provide the required performance. In this article, the author will discuss the factors that should be considered when selecting industrial valves for severe service conditions with reference to ball valve suppliers. We will also compare these valves with the ones offered by a manufacturer of butterfly valves.
Severe Service Conditions
Severe service conditions are those conditions under which the valves are subjected to high pressure, high or low temperature, corrosive atmosphere or material, or any other condition that is likely to have a detrimental effect on the valve. These conditions can cause rapid deterioration of standard valves, resulting in leakage, failure and expensive time off. Thus, valves used in severe service conditions must be manufactured from materials that can withstand these conditions and at the same time offer a secure sealing system.
Valves are required to withstand the pressure in high pressure systems without bending or developing cracks. Likewise, in high-temperature applications, materials that can handle thermal expansion and do not degrade are required. Valves that are used in environments that expose the valve to fluids that are either acidic or alkaline need to be made from corrosion resistant alloys or coated with special materials. Valves are subjected to abrasive materials that can cause rapid wear of the valve parts; therefore, valves with hardened surfaces or special coatings should be used. Knowledge of these conditions is the first step in the selection of the appropriate valve for the given application.
Selection of Material
The most important criterion that has to be considered when selecting industrial valves for severe service is the material of construction. The material should be able to interact with the process fluid and should be able to withstand the conditions under which it is to be used. Materials used in severe service valves are stainless steel, Inconel, Hastelloy, and titanium. These materials provide good protection against corrosion, erosion and high temperature.
In cases where the fluid is corrosive, the valves are usually made from exotic alloys such as Hastelloy or Inconel. Stainless steel is also widely used, especially for its relatively low cost and reasonable corrosion resistance in relatively corrosive working conditions. If abrasion is an issue, the ball valve suppliers may provide valves with hardened or coated body and ball to increase the service life of the valve. However, it is advisable to discuss with your valve supplier to determine whether the selected material meets the requirements of your application.
Pressure and Temperature Ratings
Another important factor that needs to be taken into account when choosing valves for the severe service conditions is their pressure and temperature capabilities. Valves must be capable of withstanding the maximum pressure and temperature of the system in which they are used. The pressure rating of a valve is normally defined by the material of the valve body and the design of the valve.
In high pressure, the ball valve suppliers provide valves that can be used in pressure that is above 3000 psi or even more. These high-pressure valves usually have a robust body and seat to avoid deformation and to give a good sealing even at high pressure. Temperature ratings are equally crucial, especially in steam, hot gas, or cryogenic fluid applications. Valves employed in these conditions have to be able to perform and remain functional at these varying temperatures. By comparing these ratings with those of options from a manufacturer of butterfly valves, the best option for your application can be ascertained.
Sealing Technology and Leak Prevention
Severe service conditions require leak prevention as even a minor leak can pose serious risks to safety, environment, or product. The sealing technology employed in the valve is very important in determining the leak-tight characteristic of the valve. For instance, metal-to-metal seals are used in high temperature applications since they do not expand and therefore, the seal remains tight.
Soft-seated valves, which have elastomeric or polymer-based seats, are suitable for use where a bubble-tight shutoff is required, for example in gas or chemical processing. However, these materials may not be as effective in high temperature or high abrasion applications. Sealing options for ball valves are usually provided by the supplier as a range, so you can select the most suitable one for your application. Also, some of the butterfly valve manufacturers provide double or triple offset designs that improve the sealing capability by minimizing the contact between the valve disc and seat, which is ideal for severe service applications.
Maintenance and Operational Considerations
Maintenance is another important consideration when choosing a valve especially when the valve will be used in a severe service environment where the valve is likely to wear out. The ease of maintenance and availability of spare parts for the valves can also help in cutting down on the time that the valves are off for maintenance and the cost of the spare parts. Determine if the valve design permits easy maintenance without the need to remove the valve from the system or if it has to be done.
Automation and control are also the significant factors that should be taken into account in the operation of the organization. In severe service conditions, the feature of remote operation of the valves can be beneficial in terms of safety and convenience in areas that are dangerous or difficult to access. Most ball valve manufacturers provide automation packages that can be interfaced with control systems, thus minimizing the use of valves. Comparing these features with those of a manufacturer of butterfly valves will enable you to make the right decision depending on your operations.
In conclusion, the choice of the industrial valves for the severe service conditions depends on the material, pressure and temperature class, sealing system, and maintenance requirements. The suppliers and manufacturers of ball valves and butterfly valves have many years of experience, which means that you will be provided with professional advice and quality products that will be suitable for your application. Thus, by considering these factors, you can guarantee the durability of your valve systems, and reduce the chances of failure, while at the same time increasing the productivity of your processes.
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