We recently found a persistent discrepancy in flow measurements between two otherwise identical processing lines. What we assumed were interchangeable solenoid valves, despite being the same model number from the same vendor, had slightly different internal orifice designs due to a minor manufacturing revision. This subtle change significantly altered their pressure drop characteristics, affecting calibration and downstream sensor readings across the systems. The specifications sheet didn’t highlight this revision.Has anyone encountered similar issues where component ‘interchangeability’ was an overlooked assumption leading to operational headaches?