Have you ever wondered how industrial valves are manufactured? Without valves, the pipe system is incomplete. Valve manufacturers must supply high-quality valves since safety and service life are critical considerations in a pipeline procedure.
What is the secret behind high-performance valves? What is it that makes them perform better? Is it because of the materials? Do the calibrating machines really make a difference? All of this, in fact, matters. Before delving into the finer points of an industrial valve, it’s necessary first to understand how valves are created.
These are various types of valves that are generally used to regulate the flow of various liquids or gases. This can be done by opening, closing, and partially obstructing the pipeline or other passages.
So we have gathered seven basic things that a valve manufacturer should know:
1. Order And Design
Firstly, a customer must place an order, whether for a custom valve or the one already available in your valve designs. In the event of a customized one, the provider presents the consumer with a design. The sales representative places an order after the latter has given his approval. In addition, the customer makes a predetermined deposit with the company.
The manufacturing department will begin looking for raw materials for the stem, spool, body, and bonnet after the orders have been placed and the design has already started.
For example, a butterfly valve generally requires various types of raw materials such as iron, stainless steel, aluminium, PVC, etc. If materials are in short supply, the manufacturing department should order them from vendors.
3. Valve Materials
The materials with which your valves are built may be a crucial factor in maintaining safe operation and lowering maintenance and replacement costs during the life of your operation, depending on your intended application.
Stainless steel valves are ideal for corrosive media (chemicals, seawater, and acids), environments with tight sanitary standards (such as food and beverage production and pharmaceuticals). These types of valves are the high pressure and high temp check valve.
Suppose you’re working with solvents, fuels, or volatile organic compounds (VOCs). In that case, a valve made of a non-sparking material like brass, bronze, copper, or even plastic is usually a preferred choice. Internal (wetted) trim pieces should be tested for chemical compatibility in addition to choosing the suitable body material. The valves should be tested for chemical compatibility, as well as pressure and temperature limits if it contains any elastomers.
4. Completing the Checklist
Once all the materials have arrived, the manufacturing team double-checks the list to ensure everything is in order. It is also at this point that the final draft of the design is approved. In addition, the materials are rigorously inspected by the quality assurance team. This is to assure the highest possible quality of raw resources.
5. Production Procedure
This includes the majority of the activities involved in the production of industrial valves. Each of the critical components is handcrafted. Frequently, there is a checklist that lists all of the spare parts’ names and the materials that should be used for each.
The team leader offers a timeline for the actual manufacturing, from the commencement of the operation to the completion date, at this phase. In addition, the leader frequently creates a thorough operational strategy.
The two most prevalent ways of making valves are discussed here.
A pre-shaped material is initially cleaned thoroughly. Cleaning is followed by a turning process, which is cutting away extra material with a lathe or a turning machine. It entails mounting the pre-shaped body and connecting it to the turning device. This machine spins at a very fast rate. A single-point cutter slices the body into the desired and exact shape as it spins. Turning can also make grooves and holes, among other things.
The next stage is to apply a plating metal to various parts of the body. The most commonly used metal for this process is Copper. Copper plating guarantees that the body is completely sealed.
The valves are then painted with Teflon or another type of elastomer. After painting, it’s time to bake. Baking links Teflon to the human body.
Following the selection of the material, it must be cut into the desired lengths and widths. The next step is to forge each component by partially heating it to a specific temperature.
Trimming is the next stage. This is when the burr or extra material is removed. The body is then flashed to give it the proper valve shape.
The next phase is sandblasting. This process is used to make the valves smooth and clean. The size of the sand used is determined by the requirements or specifications of the customer. The valves are first sorted to remove any that are faulty.
Depending on the design and requirements of the customer, machining improves the sizes and shapes of threads, holes, and other components.
6. Assembly Procedure
The assembly phase is when the specialists connect all of the valve components together. The assembly is usually done by hand. At this point, specialists assign production numbers as well as designates the valves based on the regulations they follow, such as DIN or API.
7. Pressure Test
The valves must be pressure tested for leaks during the pressure test phase. In some circumstances, air at 6-8 bar pressure is used to fill the closed valve for a period of time. Depending on the valve size, it could take anywhere from 2 hours to a day.
Repairs are done to the valve in case a leak occurs after the timeframe. If this is not the case, the valve will advance to the next phase.
However, sometimes water pressure is also used to detect leaks. The valve passes the test if it does not leak as the volume of water increases. This indicates that the valve is capable of withstanding increased pressure. In case there are any leaks, the valves get returned to the warehouse. Before doing another series of pressure testing on this batch of valves, the specialists will look for leaks.
The production of industrial valves is a difficult task. It isn’t only a matter of putting the valve together. Its efficiency is influenced by several parameters, including raw material acquisition, machining, heat treatment, welding, and assembly. Before being handed over to the customer, valves should go through a series of testing to guarantee that they are in good working order.