<p>Control valves operating under harsh service conditions such as corrosive media, high-pressure differentials, and fluctuating flow regimes are subject to a variety of complex failure mechanisms that can impair process performance, safety, and system reliability. This paper presents a comprehensive analysis of the failure modes commonly observed in industrial control valves, with a particular focus on corrosion, erosion, stress corrosion cracking (SCC), thermal fatigue, deadband, and hysteresis. Through real-world case studies, the paper illustrates how these failures emerge in challenging applications such as carbon capture systems, sour gas processing, hydrogen injection, and high-velocity natural gas pipelines. The second part of the study focuses on mitigation strategies and engineering best practices to prevent premature valve degradation. These include proper material selection for corrosion and erosion resistance, optimized valve sizing based on flow dynamics, and the use of advanced actuation systems and positioners with real-time feedback and auto-calibration capabilities. Additionally, the integration of embedded sensors and diagnostic tools allows for predictive maintenance, enabling operators to detect early signs of mechanical wear or control deviation. A lifecycle-based approach is proposed to align valve design, procurement, and maintenance within a unified framework. The findings emphasize the importance of viewing control valves not as isolated components, but as integrated elements within a process control system. Applying these preventive strategies can significantly reduce unplanned downtime, improve control loop stability, and extend equipment lifespan in aggressive operating environments.</p>