valve manufacturing process

The Ultimate Guide to the Raymon Valves Manufacturing Process

Der Herstellungsprozess von Industrieventilen ist sehr komplex und beinhaltet viele Variablen. Die Rohmaterialien, die bei der Herstellung verwendet werden, sind entscheidend für das Endprodukt. Die Werkzeuge, die für die Bearbeitung verwendet werden, sind Geometrie, Winkel und Form des Ventils.

Um den Herstellungsprozess von Ventilen zu verstehen, sollten wir die verschiedenen beteiligten Schritte kennen. Dieser Prozess umfasst das Auflösen von Metallen, das Formen von Materialien, die Reinigung und das Gießen. Das Endprodukt wird bearbeitet und auf Qualität sowie Druck und Temperatur geprüft.

Valve production and manufacturing process

Valve production can be further divided into many components such as the manufacturing components and the actuation device. The process of valve manufacturing is started with the debarring of the valve bodies. On the other hand the technicians create the threads so that the valve parts are attached to the component or to the pipe. Finally and lastly valves are tested for the functionality before they are being offered for sale.

1. Valves manufacturing materials

The materials of the valve construction do not need to be totally corrosion resistant, and the fluid that is provided can be contaminated. There are many materials that are used for making valves are cast iron, cast steel, forged steel, stainless steel, bronze, brass and aluminum. The material selection for making valves are done on operating parameters of the services for which valves are being used, temperature it has to control, maximum pressure and weldable material. Silicon bronze has much better resistance to stress cracking than other brasses and the increase in strength has made it an excellent choice for stem material in pressure rated valves. Bronze is the used material that is used mostly in Absperrklappen. The processing properties of these materials are very poor and it brings great difficulty to the manufacturing process.

2. The structure of the casting blank

The valves are used to change the section of the passage and direction of the medium. Valves castings are controlled components in pipeline fluid delivery systems. They come in a variety of sizes. Most of the blanks have thin shells with many complex structures and they only demand good appearance quality. They have good structure and they don’t have defects such as holes, cracks or pores. The casting process of valves is complex and so is the heat technology. These valve casting are mostly used in petrochemical, chemical, mining, petroleum paper, food pharmaceutical, drainage, water supply and in many other fields.

3. Machining technology

Valves are used to control the vacuum as well as the air. There are two vales right and left. The right valves increase both the reliability process and cost effectiveness of the vacuum system. The machines of valves sealing surfaces have very much requirements on machining accuracy, smoothness. Matching angle and sealing pair that brings great difficulty to valve machines. It is very hard to achieve the mentioned accuracy and dimension that brings the difficulties to the machine tools and it processes the equipment’s. The working principle of the valve is the closing and opening of the internal passages in order to see the flow of the gas or liquid.

4. Process arrangement of valve parts

The valve body is sometimes called the shell and it is one of the primary bodies of the pressure valve. He serves as the basic element of the valve assembly as it is the framework that holds and checks all the parts together. Body of the valve is the first pressure body of the valve that resists loads of fluid pressure by connecting the pipes. The parts of valves are casted in many forms and each form has a very specific function and it is constructed in the materials comfort ability for that function. The main parts of the valves are small and the usage of all the parts are very simple. All the parts involve the smoothness, harness and flatness of the surface that is very high. There are many kinds of parts such as sleeve valve, rotary valve, reed valve and poppet valve. The parts of the valves include seat, spacers, discs, guides, internal spring and the bushings. All the parts of the valves contain the basic valves parts that are body, actuator, bonnet, trim also called as internal elements and packing’s.

5. Valve test and inspections

To test the valve the first thing is establishing the testing procedure that is combined with the acceptance criteria and other standards that the valve exceeds or meets. All the valves want to get inspected to make sure there is no error and leakage. Industrial valve manufacturers have to take quality assurance and inspection seriously. The inspector conducts the surface treatment inspection after sandblasting. Quality controls carry out the various size inspections of the blanks at the modeling. All the records will be stored and classified in the computer for inquiry at any time. The valve shell leakage test is a test that helps to identify the presence of water and other remaining fluids in the valves casing. The valve test is conducted by giving the valve the pressure for a specific amount of time for more than one minute and for looking for the leaks. They are all performed on all kinds of valves like stop, check and isolation types. It is actually conducted to maintain the process and to evaluate the health condition of the operational valve. The valve testing machine functions on high pressure includes the testing for valve leakage, seal and seat test and seat leakage inspections. Valve testing techniques will change over the years and at the same time all the procedures will become more concise. To improve the performance of the valve plant it is very important for those working in this field to make sure that they are using the right techniques with enough knowledge.

The Manufacturing Process of industrial valves

Order, design, inventory and checklist are four stages that are basically included in the process. After the order is placed by the customer the Manufacturing department goes to find and obtain the raw materials. Completing all the steps takes time. You can get a better idea regarding the Manufacturing of the industrial valves as the process is not much complicated.

1. Order and Design

To produce the industrial valves of high quality the industrial valve production is the process. The handcrafted components are involved in it. The time of the placing of order comes once a valve has been designed and approved by the customer. The order is placed by providence and the predetermined deposit is made after the customer’s improvement on the design. The sourcing of materials and raw materials is started by the Manufacturing department once the order is placed.

2. Inventory

Der nächste Schritt nach der Auftragserteilung ist die Suche nach Rohmaterialien. Verschiedene Materialien werden benötigt, da verschiedene Teile von Ventilen hergestellt werden müssen. Für die Rohmaterialien können Sie im Lagerbestand nachsehen, und wenn Sie das Material nicht finden, müssen Sie es von Lieferanten beziehen.

3. Completing the checklist

Die Abteilung muss nach dem Sammeln der Rohmaterialien die Checkliste erstellen, um zu prüfen, ob alle wesentlichen Dinge für den Produktionsstart vorhanden sind. Auch die Qualität der Materialien, die bei der Herstellung der Produkte verwendet werden sollen, wird vom Qualitätssicherungsteam geprüft.

4. Production process

The Manufacturing of the stem, valve bodies and seat are involved in the production process of industrial valves. To produce these parts of valves the casting method is used. The forged method is used by some manufacturers. It involves sandblasting, machining, trimming, forging and surface treatment. A single piece can be used to make the valve bodies. It can also be cast by using mold or cores. A core is used by modern casting processes which helps in producing the parts that have complex inner cavities.

5. Assembly

Following proper procedures is essential in the manufacturing process for valve assembly. The industrial valves major components should be cleaned and they should be assembled separately. After the production is completed all the parts need to be assembled to create a complete valve. The valve assembly process is now carried out with the valve body by serving as a reference part.

6. Pressure test

Nach dem Montageprozess müssen die Ventile nun den Drucktest durchlaufen. Der wichtigste Drucktest für Ventile ist der hydrostatische Drucktest. Die Durchführung des Tests besteht darin, das Ventil zu öffnen und einen Druck anzuwenden, der 50% höher ist als sein Arbeitsdruck. Die Dichtfläche des Ventils bleibt leckfrei und der angelegte Druck darf nicht unter den Nenndruck fallen. Er wird als Arbeitsdruck bewertet.

7. Quality and inspection control

The final and last step in industrial manufacturing is quality and inspection control. All the valves want to get inspected to make sure there is no error and leakage. Industrial valve manufacturers have to take quality assurance and inspection seriously. The inspector conducts the surface treatment inspection after sandblasting. Quality controls carry out the various size inspections of the blanks at the modeling. All the records will be stored and classified in the computer for inquiry at any time.