Applications of Valve Manufacturing

Sometimes it doesn't take much to determine the right valve for the job. With a glance at the process requirements and a few basic calculations, the ideal valve type and material become obvious. Perhaps it's a simple on/off control for an unimportant line or maybe a high-precision regulator for a sensitive chemical process.

But sometimes valve selection isn't so cut and dry. Choosing the optimal valve for complex industrial applications with varying pressures, temperatures, and fluid properties can be a challenge.

Valve specifications offer important information for engineers, allowing them to select the most appropriate valve for a specific application. To make informed decisions, engineers may need to understand the valve manufacturing processes and materials, as well as comprehend the unique requirements of the intended application.

Regardless, selecting the wrong valve can lead to leaks, failures, and costly downtime; even a small mismatch is too much.

In this article, we'll take a deep dive into:

• The different types of valves used in industrial applications
• Key factors to consider when choosing a valve
• How valve manufacturing processes influence valve selection
• & much more

How Valves are Made | A Brief Overview 

Valve manufacturing is an industry that goes beyond simply making the component. Rather, it includes the design, production, and distribution of valves made for controlling the flow of fluids and gases in various industrial applications. By maintaining systems to operate efficiently and safely, valves play a key role in industries such as:

• Oil and gas
• Power generation
• Water treatment
• Chemical processing 

Improper or faulty valves can lead to system failures, leaks, and other potential hazards, making their precise manufacturing and maintenance vital for industrial success.

Valves are manufactured using a variety of materials, each chosen based on the specific requirements and conditions of their intended application. Common materials include:

• Stainless steel
• Carbon steel
• Bronze, brass
• Various alloys

The choice of material is influenced by factors such as: 

• Temperature
• Pressure
• Type of fluid or gas that will flow through the valve.

Casting and forging are two of the most common methods used in manufacturing valves, each offering distinct advantages for the quality and performance of the final product. These methods involve:

• Casting: involves pouring molten metal into a mold where it solidifies into the desired shape which allows the creation of complex shaping and specific details. 
• Forging: this is the process that involves shaping the metal using compressive forces often at high temperatures. This process results in the final products being stronger and more durable than casted parts. Forged parts are ideal for any high-pressure/high-stress environments.
  
  

Resource: A more in-depth guide 

for different stages of the valve manufacturing process

What Are the Different Types of Valves?

Valves are available in a variety of varieties, each designed to satisfy specific requirements. These types vary based on several factors, including their function, design, material, size, and pressure rating. Provided is an overview of some of the most common types of valves:

Ball Valves: Feature a spherical disc, the part of the valve that controls the flow through it. These valves are known for their durability and ability to maintain and regulate high pressures, high volume, and high flow of fluids. 

• Advantages: They offer quick shut-off, low leakage risk, and are easy to operate.
• Disadvantages: Not suitable for throttling applications.
  
  

Gate Valves: Function by lifting a gate out of the path of the fluid, providing a clear and unobstructed passage. They are commonly used when a straight-line flow of fluid and minimum restriction is needed. 

• Advantages: Low-pressure drop and bi-directional. 
• Disadvantages: Slow operation and not suitable for throttling.
  
  

Butterfly Valves: Use a rotating disc to permit or block the flow. They are compact, light, and suitable for large-volume water applications. 

• Advantages: Fast operation, minimal space required, and low-pressure drop. 
• Disadvantages: Less effective at high pressure and potential for cavitation.

Check Valves: Designed to prevent backflow in a piping system. They open with forward flow and close against reverse flow. 

• Advantages: Automatic operation and protection against backflow. 
• Disadvantages: Can cause pressure drop and are not suitable for pulsating flow.
  
  

Globe Valves: Control the flow in a pipeline via a movable disk-type element and a stationary ring seat in a generally spherical body. 

• Advantages: Precise throttling control and good shut-off capability. 
• Disadvantages: Higher pressure drop and larger size.

In addition to the commonly used valves, several specialized valves are designed to specifically meet industrial requirements in challenging environments. These valves are engineered to perform functions that are not typically able to be delivered by commonly used valves. Two of these most commonly used specialized valves are:\

Needle Valves: Designed for precise control of flow rates. They have a small port and a threaded, needle-shaped plunger. 

• Advantages: Precision control and excellent shut-off. 
• Disadvantages: Not suitable for high-flow applications.
  
  

Diaphragm Valves: Use a diaphragm that presses against a seat at the top of the valve to control flow. 

• Advantages: Suitable for corrosive and abrasive media and provides an excellent seal.
• Disadvantages: Limited to low-pressure applications and slower operation.

Find out more about our supply of custom valves here
 

Designing the Right Valve for the Right Application 

When selecting a valve for a particular application, several key technical specifications must be taken into account to keep optimal performance within a system. When speaking to a valve manufacturer it is important to consider the following:

• Valve Size: The size of the valve is a core specification that affects the flow rate and pressure drop in the system. It is important to choose the correct size to provide efficient flow control and minimal pressure loss.
• Material: The material of the valve body and internal components must be chosen based on the nature of the fluid it will be handling. Common materials include stainless steel, brass, PVC, and cast iron, each offering different levels of corrosion resistance, temperature tolerance, and mechanical strength.
• Pressure Rating: The pressure rating indicates the maximum pressure the valve can withstand. It is important to select a valve with a pressure rating that exceeds the system’s maximum operating pressure to ensure safety and prevent failure.

The performance of a valve is measured by its three key needs that are key to discuss with your valve manufacturer:

• Reliability: A reliable valve should function consistently under the specified operational conditions without frequent failures or malfunctions. This is necessary for maintaining the quality of the entire system.
• Durability: The lifespan of a valve depends on factors such as material quality, manufacturing processes, and operating conditions. Durable valves reduce the need for frequent replacements and lower the overall cost of any errors.
• Maintenance Needs: Valves that require minimal maintenance are preferable, especially in systems where accessibility is limited. Regular maintenance schedules should be established to inspect and service valves to make sure they perform at their best.

Compliance with Industry-Specific Safety Standards and Regulations

Valves are no different than any other components in that they  must comply with industry-specific safety standards and regulations set by entities such as: 

• ASME (American Society of Mechanical Engineers)
• API (American Petroleum Institute)
• ISO (International Organization for Standardization) 

Compliance with these regulations and standardizations certifies that valves are manufactured to high-quality specifications and performance benchmarks.

Environmental and operational safety are also important to consider when designing and selecting valves for use in various systems. Key considerations include:

• Emergency Shut-Off: Valves equipped with emergency shut-off mechanisms are essential for preventing potential hazards such as leaks, overpressure, and catastrophic failures. These mechanisms provide immediate response to abnormal conditions, preserving system quality and safety.
• Environmental Impact: Selecting valves made from environmentally friendly materials and maintaining proper disposal of old valves can minimize environmental impact. Leakage prevention and reliable sealing help avoid contamination of the surrounding environment.
• Operational Safety: Making sure that valves are installed correctly and regularly inspected for any wear and tear is vital for maintaining safe operation. Adequate training for personnel handling valve systems is also important to prevent accidents and make certain that proper maintenance practices are followed.

By following these safety considerations, industries can optimize valve performance and maintain safe operations across various applications.

Turning the Wheel: Driving Progress Through Valve Manufacturing

As with any engineering challenge, choosing the correct valve for a specific application requires careful consideration and attention to detail. Anything left unaddressed, or a small mismatch in valve selection, can equate to a much larger and more costly issue later.

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