Without valves, the pipe structure is incomplete. Valve manufacturers must produce high-quality valves because safety and service life are the most important factors in a pipeline phase.
What is the secret to high-performance valves? What is it that helps them work better? Is it because of the material? Do the calibration devices make a difference? The reality is that all of this is important. Before delving into an industrial valve’s finer points, it’s important first to understand how valves are made.
This article will go into the entire process of producing industrial valves from start to finish. This will help readers understand the manufacturing process of industrial valves better.
1. Design and Order
First, a customer orders a valve, either a customized valve or a valve, from a list of already available valve designs. In the case of a personalized one, the company provides the customer with a template. The order is produced once the design has been accepted by the latter. A reservation deposit is also provided to the company by the customer.
The manufacturing department will look for raw materials for the stem, spool, body, and bonnet once the orders are generated and the design begins. If supplies are in short supply, the production department will order them from suppliers.
3. Checklist completion
If all of the supplies have arrived, the production team double-checks the list to ensure everything is in order. It is also at this stage that the final draft of the design is accepted. The quality assurance team carefully inspects the products to ensure that they are of the highest quality.
4. The Production Process
This covers the bulk of the industrial valve manufacturing operation. Each of the major 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 start of the process to the end date at this stage. Also, the leader develops a comprehensive organisational plan.
The two most popular methods for producing valves are listed below.
1: The Casting Process
A pre-shaped substance that has been washed. A turning operation accompanies cleaning. Turning is the process of cutting away excess material with a lathe or a turning machine. It requires mounting the pre-shaped body and connecting it to the turning motor. This system spins at a fast rate. A single-point cutter cuts the body into the desired and precise form as it rotates. Aside from that, turning will make grooves and holes.
The next step is to electroplate metal, with copper plating on various parts of the valve body. Copper plating ensures that the body is fully sealed.
The polishing of the body is the next move. Technicians then create the threads that allow such valve parts to be attached to other components or pipes. Since valves involve holes, holing occurs as well. Keep in mind that the size of the holes in each valve varies depending on the application. This is where rules and regulations play a role.
The valves are then coated with Teflon or another form of elastomer. After painting, it’s time to bake. Baking binds Teflon to the human body.
The seat goes through the same thing as the body. Since the seat is inside the body and acts as a valve, it must be perfectly fitted to its connection for proper sealing. The seat has an extra rubber wrapping to ensure tight fitness, while the body only has Teflon.
In the stem’s case, having the right proportions is key, and it doesn’t have to be manufactured to perfection.
2: The Forged Technique
This process can be used to summarise the forged method.
Cutting and Forging.
Following the material collection, the next step is to cut it into the appropriate lengths and widths. Following that, each component is partially heated and forged.
Trimming is the next move. Excess material or the burr is extracted this way. The body is then flashed to give it the correct valve shape.
The next stage is sandblasting. As a result, the valve is smooth and clean. The size of the sand used is dictated by the specifications or expectations of the customer. The valves are first sorted to remove those that are faulty.
Depending on the consumer’s specification and specifications, machining enhances the sizes and shapes of threads, holes, and other components.
Certain acids and other chemicals are used to treat the valve surface.
5. Bring it all together
The assembly process is when technicians attach all of the valve components. The assembly is frequently performed by hand. At this point, technicians assign output numbers and designations to the valves based on the regulations in effect, such as DIN or API.
6. Pressure Test
The valve must be checked for real leakage pressure during the pressure test process. In some situations, air at 6-8 bar pressure fills the closed valve for some time. Depending on the valve size, this could take anything from 2 hours to a day.
Valve repair occurs if a leak occurs during the timeline.
Water pressure is used to detect leaks in some situations. The valve passes the test if it does not leak as the number of water increases. This suggests that the valve is capable of withstanding increased strain. The valve returns to the warehouse if there is a leak. Until running another series of pressure checks on this batch of valves, the technicians would search for leaks.
7. Quality Management and Inspection
QA staff will then closely check the valves for leaks and other manufacturing errors.
The production of industrial valves is a complicated operation. It isn’t just a matter of putting the valve together. Several factors influence its performance, including raw material sourcing, machining, heat treatment, welding, and assembly. Before the valve is handed over to the customer, it should be thoroughly tested to ensure proper operation.