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Q: Can forged valves Forged valves are integral for regulating fluid flow in several industries, including petrochemical, oil and gas, and power generation. Forged valves are renowned for their strength, resilience, and resistance to high-pressure and high-temperature conditions in various applications across several industries. However, regular maintenance is essential for ensuring optimal performance and longevity.
Forged valves are made using a forging process, which includes shaping solid metal under high pressure. Forged valves are known for their superior strength, heat and mechanical stress resilience, and good flow control properties. Forged valves offer greater dependability, enhanced mechanical qualities, and stronger resistance to corrosion compared to cast valves.
The following types of forged valves are usually available:
&#; Gate valves: These valves are ideal for on/off control applications since they provide a tight shut-off.
&#; Globe Valves: They Provide precise fluid flow control and excellent throttling capabilities.
&#;Check valves: These valves limit the direction of fluid flow only in one direction and prevent backflow.
&#; Ball valves: They provide quick shut-off and minimal pressure drop by using a revolving ball with a bore to control the flow.
&#; Butterfly valves: Suitable for large-diameter applications, these valves control the flow using a disc.
Forged valves offer several advantages or benefits as compared to other types of valves, including:
&#; Exceptional strength and endurance.
&#; Excellent resilience to pressure and temperature changes or variations.
&#; Superior sealing properties that lower the possibility of leaks.
&#; Precise flow control and minimal pressure drop.
&#; Resistance to wear, erosion, and corrosion.
&#; Low maintenance requirements and long service life.
Q: Why is upkeep crucial for forged valves?
A: Forged valves need regular maintenance to ensure their maximal function and lifespan. Periodic maintenance helps in the early detection of problems and resolution, preventing valve failures, leaks, and other operational glitches.
Q: What general maintenance advice do you have for forged valves?
A few of the best maintenance advice for forged valves are as follows:
Regular Inspection: Undertake routine visual inspections to detect any signs of wear, corrosion, or damage. Keep an eye out for leaks, cracks, or unusual vibrations.
Lubrication: Regularly apply the appropriate lubricant to the valve&#;s parts, paying specific attention to the moving stems, threads, and sealing surfaces. Doing so decreases friction and avoids seizing.
Cleaning and Flushing: Regularly clean the valve and its parts to eliminate pollutants, dirt, and debris. To remove any accumulated sediments or foreign particles that could impair performance, flush the valve and any attached pipelines periodically.
Sealing Integrity: Check valve gaskets and seals for wear or damage and replace them as necessary. Properly tighten forge valves to ensure a strong seal, bolts, and other fasteners.
Actuator Maintenance: If your forged valve has an actuator, ensure to maintain it frequently in compliance with the instructions by the manufacturer. Check the actuator&#;s power supply, electrical connections, and control system to ensure dependable functioning.
Valve Operation:
Valve Testing: Test the valves regularly to ensure they are operating appropriately. Valve testing could involve putting them through pressure, leak, or functional testing to see how well they perform under various circumstances.
Sealing integrity: Regularly inspect for wear or deterioration in the valve seals, such as gaskets or O-rings. If you want to keep the seal intact and avoid leaks, replace them periodically.
Preventive maintenance: Create a timetable for your valves&#; preventative maintenance. Prolonging their longevity and reducing the risk of unplanned breakdowns may entail routine maintenance, part replacements, or reconditioning.
Training and Documentation: Training and access to necessary documentation, such as valve specifications, maintenance procedures, and troubleshooting guidelines, should be made sure of by whoever is in charge of valve maintenance.
Q: Are there any particular maintenance considerations based on the kind of fluid or application?
A: Yes, the type of fluid or application can influence how often forged valves need to be maintained. For example:
Corrosive Fluids: If the valve operates in an environment with corrosive fluids, it is vital to opt for corrosion-resistant materials. Regular corrosion examination and suitable cleaning become even more crucial in such instances.
Applications involving high temperatures: Valves used in high-temperature applications may need specialized maintenance procedures and materials to resist high temperatures.
Abrasive medium: Valves handling medium that is abrasive may undergo faster wear. Maintaining peak performance requires regular maintenance and replacement of valve parts like seats or discs.
It is crucial to consider the particular needs of your application and, for any additional maintenance considerations, consult the manufacturer&#;s recommendations or industry standards.
Q: Should I employ professionals to maintain my forged valves, or can I do it myself?
A: It depends on how complicated or complex the maintenance procedure is and how skilled you are. Maintenance staff with the right skills and experience can frequently do simple maintenance jobs, including visual inspections, cleaning, and lubrication. However, it is better to leave more strenuous activities, such as valve disassembly, reconditioning, or significant repairs, to experts or knowledgeable valve specialists with the expertise and tools required to handle such tasks safely and effectively.
Q: Can damaged valves be repaired?
A: Depending on the type and severity of the damage, it may be possible to repair forged valves in some circumstances. Determine whether repairs are practical by consulting the valve manufacturer or a qualified valve repair service provider. They can advise whether a valve needs reparation or a replacement.
Q: Do forged valves in high-pressure or high-temperature applications require special maintenance?
A: The maintenance needs may be more stringent in applications involving high pressure or high temperature. It is vital to abide by industry standards and the manufacturer&#;s recommendations. Regular inspections, parameter monitoring, appropriate lubrication, and ensuring the valve is rated for particular conditions are all very important. Reduce the risk of overheating or damage by keeping the area around the valve clean and well-ventilated.
Forged valves are essential for industrial applications; dependable and efficient performance depends on regular and appropriate maintenance. You can ensure that your forged valves last for a very long time and work to their optimum capacity by strictly adhering to the advice and guidelines provided by the manufacturer. Regular inspections, lubrication, cleaning, and attention to sealing integrity regularly are the key to extending the lifespan of your forged valves and avoiding costly repairs or replacements.
Since , STEELSTRONG has become a well-known valve manufacturing company with two production facilities in Navi Mumbai, Maharashtra, and Sanand, Gujarat. Design, material sourcing, manufacture, assembly, and testing of valves are all STEELSTRONG tasks. We offer gate, globe, check, ball, and cryogenic valves in various sizes, pressure ratings, materials (carbon steel, alloy steel, stainless steel, duplex, Monel, etc.), and standards (ASME-ANSI, API, BS). Our success & reputation in the Indian market are largely due to our more than three decades of experience in the valve sector.
STEELSTRONG is the most preferred choice for valves across industries and varied applications.
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Cast Steel or Iron Gate Valves?
thread378- Forum Search FAQs Links MVPsForum
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MVPs
(Mechanical)
(OP)
19 Sep 06 11:35Which gate valve is better for 125 psig steam, cast steel or iron? Why?
(Electrical)
19 Sep 06 11:45Most piping specifications avoid cast iron for pressure applications. Steel is better because cast iron cracks with lower stress. A crack in a 125 psig steam could cause injury or kill people. The lost downtime is expensive. The installation labor is not much different.
(Mechanical)
23 Sep 06 23:26What is the safety valve setting? There are lots of steam systems running at 125#, but the safety valves lift at 150#. Very often, these systems are filled with 125# cast iron valves & strainers - because they're cheaper than cast steel. However, they don't meet code. Even if the safety valves lift at 125, unless the raised faces are removed from the flanges on the piping, they STILL don't meet code.Check out www.kirsner.org for some shots of failed 125 cast iron components - usually involving fatalities.I've worked with steam for 30 years, and I absolutely LOATHE 125 cast iron valves & fittings - even where permitted by code.
(Mechanical)
(OP)
25 Sep 06 12:19So is it just a matter of pressure rating, or is there any other reason for choosing one over the other? In my case you're right, the PRV lifts at 130 psig. I was going to use a 250# or 300# valve anyway, which is why I asked which is better. Both are well above my relief valve setting.
(Nuclear)
25 Sep 06 13:06BronYrAur:Here's a link to a web site that has several articles on cast iron versus steel:
Patricia Lougheed
Please see FAQ731-376 for tips on how to make the best use of the Eng-Tips Forums.
(Mechanical)
26 Sep 06 19:51Don't ignore ductile or malleable irons. They are ductile like steel but are cheaper.
Paul Ostand
www.ostand.com
(Chemical)
27 Sep 06 09:29You are correct, for 125# steam it is a good idea to use either 250# cast iron or 300# steel. The main difference is that cast iron is much more brittle than steel.
So, if you drop a cast iron valve it may crack but not a steel.
My customers prefer also steel in steam service because of the chance of water hammer. Large banging in the pipes could crack the flange of cast iron and not steel.
In refineries and chemical plants they often do not allow cast iron, but for another reason. If there is a fire, the cast iron tensile strength breaks down at a lower temperature than that of steel.
Ductile Iron is more malleable than cast iron, has many of the same properties of steel at a reduced cost. It is a great material!
(Mechanical)
27 Sep 06 23:33A gate valve for steam is the last thing I look into. I used globe, piston, diaphragm and even ball valves successfully but never a gate. Do you guys have any exploded views or pictures of the gate valves you are speaking?
(Electrical)
28 Sep 06 00:15Not sure what's wrong with gate valves for low pressure steam? I have seen many OS&Y RF #150 cast steel valves used in low pressure steam systems.
(Mechanical)
28 Sep 06 00:41Are they for control or shut off? Not that it's anything wrong but my experience has been pretty bad. Particularly, the ones that were to bypass a pressure regulating stations.
(Electrical)
28 Sep 06 01:13I assumed they are for shut off. A gate valve is a poor choice for a throttling valve.
(Mechanical)
28 Sep 06 16:52I would agree that in general a gate valve is not the best for steam as it likely will erode on the bottom of the gate.Gate valves do not throttle well like globes. However, gates do offer large Cv's for the size and if used for shut-off only and maintained full open for flowing they may be appropriate. However, do look at the design to assure the gate is out of the flow stream and talk to the manufacturer.Further, regardless what you select the valve should be for steam service in addition to having the T & P capabilities.
Paul Ostand
www.ostand.com
(Civil/Environmental)
29 Sep 06 14:56The materials gray cast iron and later developed ductile cast iron have of course been mentioned on this thread (along with some references with regard to same). Gray cast iron is of course generally a quite venerable construction material that has been around for hundreds of years in piping, valves, and other applications.However, while I don&#;t think the particular all ductile iron valves pictured should be used for steam applications you may nevertheless be interested in the general material-related features and special testing of some gate valves contained in the four minutes or so video "Ductile versus Gray Presentation" near the bottom of the page http://www.acipco.com/afc/videos.cfm under the heading &#;Product Presentation Files&#;. This video provides some more information/clues as to how/why gray cast iron valves might be more easily overloaded or broken in handling, installation, and or service events than the much stronger/tougher ductile material, and probably also why some manufacturers and users have opted instead for ductile iron constructions.
(Mechanical)
30 Sep 06 13:20rconner:That is a nice video.BronYrAur:One more bit of information. Jordan Valve makes a sliding gate valve specifically for steam service. It is available in DI, Steel and other materials. You might look at it for your application.(I don't work there but I did at one time.)
Paul Ostand
www.ostand.com
(Mechanical)
3 Oct 06 07:21steam has its own requirements. There are valves specifically manufactured for steam service. Always use a steam valve in steam service. Also, I am a great believer in calling the manufacturer and getting their expertise. You would be surprised how helpful the sales engineer can be when trying to learn about different products.
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