Classifications and Benefits of China Valves in Industries ...

The demand for industrial valves is rising exponentially and has driven significant changes in the valve automation industry. Industries now aim to leverage all the benefits provided by the valve industry.

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Technological advancements have segmented valve automation into various categories, each offering unique services. These include fluid power actuators, limit switches, positioners, electric actuators, and network capabilities. Depending on the industry and usage, one can select the appropriate application and valve type.

With new features and advancements, operators can quickly and efficiently adjust certain parameters such as open time, close time, and flow characteristics. Its simple structural design and device portability prove extremely useful in meeting diverse application needs.

Mechanical valves are extensively used in the plumbing and piping industries in key sectors such as oil, gas, mining, and water/sewage. Household and commercial industries commonly employ hot and cold taps as valve types. Some simple valves are hand-operated, controlled manually by turning a handle or wheel. In contrast, complex valves require external force to function. These automated types rely on an actuator to operate the valve based on the set-up and input. This precise control leads to excellent management of specific requirements.

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For isolation to regulating flow in certain industrial applications, numerous valve types perform similar functions but are fundamentally different.

To understand the functionality of valve types, let’s take an in-depth look at the most commonly used kinds of valves: Butterfly, Ball, Gate, Globe, and Check valves.

Forged Steel Valve Components

Forged steel valve components are produced by closed die forging. This process involves shaping billets while they are in solid form after heating. Forging dies press the heated billets to create required shapes or dimensions. Forging is performed at various temperatures depending on the metals used.

These components demonstrate high strength, making them ideal for systems with high-pressure and high-temperature requirements. The grain structure of forged components gets refined, thereby increasing impact and overall strength. Additionally, forging eliminates defects commonly associated with casting, such as cracks, shrinkage, and porosity.

Furthermore, forging can produce valves with thinner walls, reducing the risk of thermal fatigue during operation. These forged valves can be heated and cooled more swiftly, allowing them to handle the stress of systems that continuously cycle through start-up and phase-down processes.

Cast Steel Valve Components

In contrast to forging, cast valve components start as liquid metal. This molten liquid is poured into required shapes. Once solidified, the metal is removed from the mold and excess material is eliminated through grinding and shot blasting.

One significant advantage of casting is the ability to create valves with intricate shapes and sizes. The casting process allows for more complex shapes and is a cost-effective solution for small quantities due to its affordable tooling costs. Casting also permits the use of a wider variety of metals and alloys.

Advantages of Forged Steel Over Cast Steel Valve Components

Both forging and casting methods offer unique advantages. Forgings ensure uniform wall thickness and dimensional tolerances due to high impact closed die press forces and segregation-free billets, which guarantee superior strength, uniformity, integrity, and density. Casting issues include intergranular corrosion, stress weakness, fatigue, cracks, porosity, sand pockets, weld repairs, and scars.

Another benefit of forgings is the directional flow line structure. Given the quality concerns associated with low-cost valve manufacturing, customers often specify a forging over a casting. They might even require European forgings from approved brands and mandate 100% Magnetic Particle Inspection (MPI) and Ultrasonic Testing (UT) for common A105 valves, driving up costs. High-quality forgings can reduce the need for Non-Destructive Testing (NDT), although UT and MPI are good for quality assurance, especially for larger castings and higher classes.

Valves sold as steel forgings in low-cost countries may sometimes be machined from bar rather than hot-forged, due to cheaper labor and the lack of dies for every size and class. While using bar is acceptable for smaller sizes, caution is necessary to ensure high forging quality despite certifications stating standards like A105 or 316. Ensure cold forging when required.

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