Ever wonder how the top standard and butterfly valve manufacturers make high-performance industrial valves? Valves are an important part of all piping frameworks and a large number of other applications. No pipe systems can be considered complete without valves since safety and durability are always the primary concerns when it comes to their applicability. This is the reason valve manufacturers always confront the challenge of meeting the highest quality parameters during the design and development of valves.
This blog discusses the following in detail:
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Top secrets behind the functioning of high-quality valves
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What makes them better in terms of overall performance?
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The materials they are made with
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What matters most when manufacturing a valve
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Different aspects associated with the manufacturing and processing, and
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Which is the top butterfly valve manufacturer in India?
Order and Design
It begins when a customer places an order, regardless of the nature of the valves. The ordered valves might be custom-made or even the ones which are already available in the stock of the manufacturer. If it is a case of the customized one, the manufacturer exhibits the design to the concerned customer and asks for approval. Once approved, the sales department of the concerned manufacturing company takes the order to the next level. With all this happening in the backdrop, the customer also makes a pre-defined payment to the standard and butterfly valves manufacturer in India .
Inventory
Once all the primary things are over and the designing process begins, the personnel in the manufacturing department start the process of raw material selection keeping in view the following:
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Stem
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Spool
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Body, and
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Bonnet.
When the search for the best materials comes to an end, the manufacturer produces those material(s) from the supplier without any second thought.
Completing the Checklist
Once the raw material is in place, the manufacturing team gives relooks to the list again to make sure that everything is in place to move ahead. Here at this juncture, all the necessary approvals for the final design draft take place ensuring everything is in the right order and in sync with what the customer wants. Additionally, the personnel responsible for the quality check of the raw material once again conduct a comprehensive check on the materials procured. This exercise by the quality people is carried out to make sure that the materials are really of uncompromising quality.
Production Process
The production process involves a large number of activities in the making process of high-performance industrial valves. One of the most amazing aspects associated with valve manufacturing is that each part or component to be used is made individually. Generally, there is a master checklist containing all the names of the parts or components along with the material description to be used to make each part.
Here at this juncture, the team leader determines the timeline for everything involved in the production process right from the beginning to the date of completion. The entire team needs to act upon the same to meet the deadlines given. Additionally, the concerned team leaders also draw up a comprehensive operational plan to make things smoother.
Two of the most common methods for the manufacturing of high-performance industrial valves are discussed below:
#1: Cast Method
In the casting method, the initial pre-shaped material is cleaned to perform the turning process. Turning is nothing but the most well-known methodology or technique adopted to remove the extra material by making use of a lathe or turning machine. To carry out this process, the pre-shaped body is mounted to the turning machine, and when this machine rotates, the removal of the extra material begins leaving the body in the desired shape. The next step in this process involves the polishing of the body. After that, the technicians create the threads which permit the attachment of certain valve parts to different other components or the pipes. It also needs to be noted here that each valve is different and calls for different hole sizes as per the requirements. This is where different standards and norms come into play.
#2: Forged Method
The forged method can be summarized in the following processes:
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Cutting and Forging
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Trimming
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Sandblasting
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Machining
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Surface Treatment.
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Assembly
Assembly as the name suggests is the procedure or phase in which the responsible technicians or engineers attach all the components or parts together to create the desired end product. Oftentimes, the assembling job is performed manually. It is where the technicians assign the valves the following:
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Production numbers
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Batch number
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Designation according to DIN or API and the likes.
Pressure Test
In the pressure test stage, the valves need to go through genuine tension testing for spillage. At times, air with 6-8 bar pressure fills the shut valve for a specific number of hours. It could go from 2 hours to a day, contingent upon the valve size. If there is a break after the period, a valve fix occurs. If not, the valve will continue toward the next stage. In different cases, spillage is recognized through water pressure. In case the valve doesn't spill as the volume of water increases, it finishes the assessment. This implies that the valve can endure the rising strain. Assuming there is some spillage, the valve gets back to the distribution centre. The specialists will check for spillages before playing out one more arrangement of strain tests to this cluster of valves.
Inspection and Quality Control
In this phase, the QA personnel conduct a comprehensive quality inspection of the batch of valves for leaks and other production errors.
Concluding Remarks
Advance Valves Group is among the leaders who provide world-class technology solutions to global customers for the past three & half decades. The company has a strong network of offices and dealers across India, the Middle East, the US & Europe. The company boasts of having a rich product portfolio that includes Valves like Dual Plate Check Valves, Balancing Valves, Triple Eccentric Butterfly Valves & Valves with Pre-Insulation manufactured at its four fully equipped ultra-modern facilities in India.