How Wrong Valve Selection Slowly Destroys Plant Reliability

How Wrong Valve Selection Slowly

 Destroys Plant Reliability

 

How Wrong Valve Selection Slowly Destroys Plant Reliability

Why “Bad Valves” Often Aren’t Bad Valves

When a valve fails, the first reaction is usually: “Supplier gave us a bad valve.”

In many cases, the real issue is different. The valve was never the right one for that job. It was the wrong type, wrong rating, or wrong material. So it was “set up” to fail from day one. Valve reliability starts with selection, not with repair.

Common Shortcuts During Valve Selection

In busy projects and plant upgrades, teams often take shortcuts. A few examples:

1. Copy‑paste from an old project

Someone opens the last project file and copies the same valve line into the new spec.

No one checks if the new service has different pressure, temperature, or media.

Result: a valve sized and rated for one duty is dropped into a very different duty.

2. Only matching the pipe size

Another shortcut is: “Line is 4 inch, so valve is 4 inch, finished.”

No one checks required flow pattern, or control range.

Result: valves that are oversized or undersized.

Oversized valves hunt and cannot control well.

Undersized valves choke and cause high pressure drop.

3. Choosing only by lowest price

Sometimes procurement has one main rule: pick the lowest quote that meets the basic spec.

Extra checks on trim design, seat type, or coating are skipped to “save time and money”.

Result: small savings during purchase, big losses later in downtime and repairs.

 

What Wrong Selection Looks Like in the Field

Here are simple, real‑world patterns you may have already seen.

Wrong valve type

• Ball valve used for throttling a dirty slurry → seats cut and leaking within months.
• Gate valve used half‑open to control flow → severe vibration, damaged seats.
• Globe valve used where a simple on/off valve was enough → high pressure drop and energy use.

Wrong pressure class

• Valve with rating just equal to normal operating pressure, not including surges.
• When process has a few spikes, seats and packing see forces they were never designed for.
• The valve is blamed, but the rating choice was too tight.

Wrong trim or material

• Carbon steel trim used in slightly corrosive service → stem pitting, early leakage.
• Soft‑seated valve used in high‑temperature service → seat hardens or burns, cannot seal.
• Stainless body with wrong gasket type → crevice corrosion at flanges.

All of these look like “bad quality valves” when they fail.

In truth, the duty was wrong for that design.

 

Simple Pre‑Order Checklist for Valves

Before sending a valve enquiry or PO, run through this short checklist.

It takes a few minutes and can save many shutdown hours later.

1. Process details
• What fluid? Clean, dirty, corrosive, or with solids?
• Normal and maximum temperature?
• Normal and maximum pressure, including surges?
2. Function in the line
• Is the valve for on/off isolation or for control/throttling?
• How often will it move? Rarely, daily, or many times per hour?
3. Valve type fit
• For tight on/off with low drop → ball or gate (depending on cleanliness and speed needed).
• For control and throttling → globe or control valve design.
• Make sure the type matches the function, not just “what was always used”.
4. Sizing and rating
• Check that valve size and Cv match the flow, not only the pipe size.
• Confirm pressure class gives a safe margin above all expected conditions.
5. Materials and trim
• Body and trim materials compatible with media and temperature.
• Seat and packing types suitable for temperature, pressure, and any solids.
6. Standards and history
• Meets required standards (ASME, API, IBR, etc. as needed).
• Ask: “Have we used this exact combination before in similar service? What happened?”

If any point is unclear, pause the order.

Talk to the supplier or a valve specialist with these details in hand.

A short discussion here is far cheaper than a forced shutdown later.

 

Final Thought

Most “bad valves” are good valves placed in the wrong job.

If selection is careful, installation and maintenance become easier, and plant reliability goes up.

If selection is rushed, even the best brand will keep failing, and everyone will blame the wrong cause.

FOR INDUSTRIAL VALVES

You Can Visit Our Website: www.unimaxvalves.com

You Can Contact Us

Mr. Khursheed Ahmad Khan

+91 7977539875 / +91 9920307161

Email

sales@unimaxvalves.com

Address

I-304 Sahara Colony Phase -1, Shil Mahape Road, OPP. Pooja Punjab Hotel, Shil Phata Kalyan Thane 421204 Maharashtra India.