The product life cycle diagram below shows the typical life cycle of a product once in production.
Key Stages in an Industrial Valves Life Cycle
Most industrial valves are designed and produced, with a durable metal body, fibre gaskets and / or O-rings and seals selected for the intended pressure, temperature, and media. By weight, most industrial valves are +98% metal which is usually fully recyclable. Valves have been known to last 20+ years when correctly selected for the application and with regular maintenance.
1. Engineering, Design, and Selection (Birth)
Selection: The most critical phase, determining if the valve matches the application's pressure, temperature, and fluid characteristics.
Design & Modeling: Modern design utilises 3D modeling and digital twins for performance simulation.
Standards Compliance: Designing to meet industry standards (e.g., API, ASTM).
2. Manufacturing and Assembly
Material Sourcing: Selection of raw materials (castings, forgings) based on corrosion resistance and pressure needs.
Machining: Precise machining of the valve body and trim for optimal fit.
Assembly & Testing: Components are assembled and subjected to rigorous testing (e.g., seat leakage, pressure testing) to certify performance.
3. Installation and Commissioning
The valve is installed in the system and begins operation, delivering full performance when new. Proper installation is essential, including correct orientation and securing to prevent future issues. It is always worth reading the products installation and operating manual first (IOM).
4. Operation and Maintenance (Life)
The metal body provides long-term structural integrity, while seals and O-rings wear gradually due to mechanical movement, heat, pressure, and chemical exposure. Worn rubber components are inspected and replaced periodically to restore sealing and extend the products usable life.
Operation: The valve operates under normal, cyclic, or, in some cases, extreme conditions.
Inspection: Periodic, proactive inspection for leaks, noise, and vibration.
Maintenance & Repair: Includes lubrication, tightening packing, or repairing/replacing worn internals to extend life.
Monitoring: possibly using smart sensors and diagnostic technology to predict remaining useful life.
5. Decommissioning and Disposal (End of Life)
When sealing issues or body wear can no longer be addressed cost-effectively, a new valve is installed and the existing valve body is recycled and the seals disposed of responsibly.
Removal: Safe removal from the system after the valve has reached its end-of-life, often indicated by excessive maintenance costs or inability to maintain a seal.
Refurbishment/Recycling: Many industrial valves are made of metal, making them ideal for recycling or refurbishment (e.g., rebuilding the valve body).
Factors Affecting an Industrial Valves Lifespan
Operating Conditions: Harsh environments (corrosive, high-pressure, abrasive) significantly reduce life.
Cycle Rate: High-frequency activation increases fatigue.
Maintenance Quality: Depending on the valve type, regular maintenance can extend a valves service life beyond 20 years, while neglected valves may fail within 5 years.