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Be it Quarter Turn Valves or ROSOV, the designing and manufacturing of high-performance industrial valves is a complicated and intriguing process. The raw materials which the manufacturers choose to make these valves play a very crucial role in determining the overall quality of the final product. What&#;s more, the tools and equipment used to process the raw materials are also of immense significance when it comes to the shape, size, geometry, angle, and accuracy of the industrial valves.
If we want to understand the process of industrial valve manufacturing, then we have to familiarize ourselves with the steps that are involved in this process. The process involves the following:
Finally, the end product goes for comprehensive quality testing along with tolerance, pressure, and temperature. The production of valves can be further divided into different components such as actuation devices and manufacturing components. Debarring of the valve body is all that the manufacturing process begins with. Next, the design engineers involved create the threads while aiming at attaching the parts of the valves to the components or the pipe. Finally, the valve is tested for functional parameters and offered for sale in the open market.
All begins with the order that a customer places and accordingly the design engineers start working on the project. Once the design of a valve is created, it is sent to the client for approval. After the prototype is approved, the order is placed and the work starts for the required amount of products or valves. All the required materials are sourced according to the nature of the application or the environment in which the valves are to be installed. Different industries call for different valve requirements, and therefore the manufacturer takes the call accordingly.
Choosing the right kind of materials is one of the most crucial phases in the process of industrial valve manufacturing. It is so because the valves that find applications in the power sectors cannot be used in marine applications. And therefore as per the gravity of the industry-specific requirements, the raw materials are chosen. Since a valve involves so many parts, not a single material can fit all production needs. Different materials are required because the manufacturer has to make different parts or components of the valve. Therefore, the design engineers move to the inventory and look for the required materials. In case the required material is not readily available, then they have to procure it from the best suppliers.
When all the materials are in place, all the members of the manufacturing team need to create a checklist to make sure that all the materials are ready to begin the manufacturing process. As said earlier also, an industrial valve has so many components and parts and therefore its manufacturing needs many different materials. Apart from it, a comprehensive quality check is conducted on all the raw materials in place by the quality team before the materials go to the shop floor for production. This is a standard procedure followed by all the reputed valve manufacturers in India and abroad.
When it comes to the production process involved in the manufacturing of industrial valves, it includes the making of the valve bodies, stems and seats. Casting is the most preferred method to make these components of the valve. However, over the years, some drastic changes have taken place in the production process, and some reputed manufacturers in India and the world have also started making use of the forging method to make the components of the valves. The forging method includes the following steps:
Cutting and forging
Trimming
Sandblasting
Machining, and
Surface treatment.
When it comes to producing valve components with extremely complex inner cavities, the contemporary casting processes make use of a core to carry out the task. The valve bodies are often made using a single piece or cast by making use of cores or moulds.
Assembling is the most important procedure in the process of manufacturing valves. When all the parts or components of the valve are ready, the manufacturing team must follow all the standard procedures for assembling. Almost all the major parts of the valves are deep-cleaned and assembled separately. After the production process gets completed, all parts are assembled as per the procedure to create a completely new valve as desired by the customers. The assembling process is generally accomplished by making use of the valve body as a reference part.
Now comes the turn of pressure test in which all the valves need to undergo a pressure test. The hydrostatic pressure test is considered to be the most basic pressure test for valves. The said test is all about partially opening the valve is putting it under hydrostatic pressure which is around 50% higher in comparison to its rated working pressure. During the test, it is ensured that the sealing surface of the valve is leak-proof and the applied pressure does not come down against its rated working pressure.
Inspection and quality controls are the last but not the least important steps in the value manufacturing process. All the valves are inspected and checked very minutely for all types of flaws and shortcomings including leakage or error. Industrial valve manufacturers and suppliers take inspection and quality control calls very seriously.
Advance Valves is one of India&#;s largest professionally-managed industrial valve manufacturing companies. The company holds a boastful position amongst the Top 3 'Make in India' Valve Manufacturers as per the latest. The company makes use of advanced technology and efficient processes to achieve the highest standards of quality & delivery. The company has also focused on innovation and therefore the products made by the company always shine in the national and global markets.
THINKTANK is the manufacturer of industrial valves, especially control valves, self-operated pressure regulators, safety valves, and high-performance butterfly valves. Based on over 30 years of our family group business in industrial valves, here I just simply list 10 steps to let you know the process of manufacturing, and how we control the quality before shipment.
Before that, I would like to let know, that so far China valves are still in the developing process, not like the
The USA or European market with really advanced technology. We have to admit this point, and when we clearly know our position, and how far we are from those international brands, we can do better and more solid advancements, and improve our weaknesses.
So it&#;s hard for us from the standardization part, not just to manage cost, raw material cost(need to stock much), but also for paper works. It&#;s a common weakness in Chinese factories, but over the last 10 years, we learn a lot from our customers. Appreciate them assisting us in progressing such fast.
Standardization means each part should be manufactured in accordance with customers&#; approved CAD drawing, and of course, the drawing should be in accordance with the valve design and manufacture standard, shell test standard, face-to-face dimension, leakage class, connection dimension, and so on. Reference MSS, API, ASME, BS, DIN, GB, JB standard.
Different types of industrial valves have different standards, you can find the corresponding standards in the following valves.
When our drawing, datasheet, and commercial offer get customers approved, we will send the Proforma Invoice to our customers and wait for them to sign back or release the contract for us. After the advance payment/deposit kicks into our account, we will start the procurement of raw materials for this case.
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For industrial valves of raw materials, it has to consider various grades of steel casting body, forging steel
body, special alloy steel, and duplex steel material.
All the raw materials are inspected by our quality control department before raw materials into the manufacturing process. Before the raw materials enter the warehouse, the steel casting, rods, forging materials, nuts & bolts, tubing, and piping, etc, all have checked the chemical composition, dimension inspection, and hardness test if necessary. If quality is passed, we will stamp a &#;PASSED&#; label on the parts.
Through the issued the manufacturing procedure card to apply the raw materials from the warehouse supervisor for the machining workshop. The body, bonnet, seat, plug, etc are machined on CNC machines. after being machined our QA inspects and measures the dimensions again.
After all the parts passed dimensionally and visually, the valve body, and the bonnet is transferred to the test bench for a hydrostatic test, in case there is zero leakage of the bonnet and body before assembly. If there is any leakage or drops of the test fluid from the body of the bonnet, the component must reject and send back to the foundries.
The qualified body and bonnet are transferred to the assembly area. In case of parts uniformity and interchangeability, the body and bonnet are drilled on the machine. In some projects, the valve seat and plug or other components need to be lapped before assembly. In other projects, the seat and plug should be lapping after assembly. To care transfer process, make sure components&#; surface has no scratches.
For more product assembly videos or test videos, please just feel free to click here.
After the complete assembly, we are going to transfer the valve to the hydrostatic bench for the shell
test, low-pressure test, and seat leakage test. Witness by QA colleague, in accordance with drawing to see if the result meets relevant standards. If qualified then transfer to the painting area.
Use a grinder or sander to make better surfaces and smooth finishing based on customers&#; requirements.
For carbon steel body is sprayed with one coat of corrosive resistant primer. Observe the surface and if any is uneven, use a high-temperature putty to make a better surface. The painting color number should be the same as the customer requested. If for corrosion environments, the coating thickness must according to the relevant standard.
After the test & inspection, painting, and functional test, the customers informed the third party to arrange the witness and inspection. And our quality assurance department records project name, tag number, model, process quality checks, furnace number, and all the details into our system.
Commonly we use ply-wooden cases to packaging industrial valves. The catalog, manual book, and maintenance guidelines will be along with the goods if the customer needed.
Shipping mark, Packing list, Invoice, and other details the customer mentioned, we double-check with the
customer before shipment. After approval, the goods were finally dispatched and handled over to the forwarder.
We all know that a reliable industrial valve must go through a standardized manufacturing process to guarantee that each spare component is standard, hence maintaining the stability of the valve&#;s quality throughout assembly and operation. THINKTANK has over 30 years of expertise in the manufacturing of industrial valves, particularly control valves, and is headquartered in Taipei, Taiwan. We have adopted Japanese technology, constantly innovating, and have been developing more widely used control valve abilities.
In , so far we have replaced FLOWSERVE, FISHER, and SAMSON with our own brand THINKTANK brand in three projects in Middle-East Market. And provided OEM service for 7 new brands, hope you will be the next friend we meet.
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