Forging vs Casting Valves

All valves are indispensable parts of any industrial system, but not all valves are created in the same way. For example, some valves are forged and other valves are cast. So what are the differences between forging vs casting valves and which type of valve is best for your specific application?

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Forging vs Casting Valve Methods

forging vs casting valves Forging and casting are two of the most common ways to create high-quality valves. The biggest difference between forging vs casting valve methods is how they’re carried out.

Forging Valves

Forged valves are created using a forging method that involves shaping metals and alloys while they’re in their solid form. Heat and industrial-size tools deliver compressive forces to bend the metals and alloys, and dies are used to cut and shape the materials to create specific valves. Forging can be performed in most temperatures depending on the metals used.

Forging valves presents many benefits for industrial companies. For example, companies don’t have to worry about wasted materials. Since forged valves are shaped into one solid piece, little effort is needed to rework the material to achieve the proper shape and size.

Forged valves have a reputation for being strong, which make them ideal for handling high-pressure and high-temperature systems. During the forging process, the metal’s grain structure becomes more refined. This leads to an increase in impact and overall strength. Also, forging boosts its resistance to common issues such as cracks, shrinkage, and porosity.

On top of that, forging can create valves with less wall thickness. This helps to reduce the likelihood of thermal fatigue during valve operation. This also means that forged valves can be heated and cooled more quickly, which allows them to adequately handle the stresses of systems that continuously cycle through start-up and phase-down processes.

Casting Valves

forging vs casting valves Unlike forging, casting uses the liquid form of metal to create valves. These metals are melted into a molten liquid and poured into various molds. Once the liquid cools and solidifies, it’s broken out of or ejected from the mold.

One of the biggest benefits of casting is that it can create valves with complex shapes, patterns, and sizes. Using a mold to manufacture these devices gives you more freedom to make different types valves with more intricate parts.

Casting valves are also a great cost-effective solution for many companies. It allows you to make valves using more types of metals and alloys. Plus, since it doesn’t require as much labor as forging valves, casting helps to reduce machining costs, especially when creating valves of complex shapes.

Most importantly, casting valves provides an easier and less time-consuming way to make replacement parts when a system’s current valves break down and deteriorate.

For more information about forging vs casting valves, contact CPV Manufacturing.

Global Pressure Relief Valve Market to Exceed $4 Billion by 2020

The global pressure relief valve market continues to grow, and there are no signs of it slowing down in the near future. Research analysts at Technavio stated in a recent report that they expect the market to grow at a compound annual gross rate (CAGR) of about 1.7% and reach values exceeding $4 billion by the end of 2020. They reported that an increased demand for pressure relief valves will stem from the power generation, chemical, and oil and gas industries over the next four years.

Increasing Nuclear Power Generation

Pressure Relief Valve Market Technavio’s market research report states that the nuclear power industry in China is one of the most prominent driving forces behind the market’s growth. Pressure relief valves play a vital role in nuclear power plants. They protect super heaters, turbines, and boilers to help the stations run at the optimal high temperatures and pressure.

In the coming years, the country is expected to expand its nuclear power industry, thus creating a higher demand for pressure relief valves. As of now, the country has 30 operating nuclear reactors, 24 under construction, and 30 being planned. By the end of 2020, the country’s nuclear power industry is predicted to reach at least 58 GWe of nuclear capacity.

Plus, with more countries expanding their power generation sectors and creating more nuclear plants, the global pressure relief valve market in this industry will be valued at $978 million and grow at a CAGR of 1.6%, according to Business Wire.

Rising Petrochemical and Chemical Sectors

Pressure Relief Valve Market Business Wire also mentioned that the global pressure relief market in the petrochemical and chemical sectors is predicted to grow at a CAGR of 2% and exceed $1 billion in value. One reason for this is that more developing countries are increasing their own chemical production and relying less on European imports. In fact, by the end of this year, India will become an exporter of polyethylene.

In addition, economic improvements in North America and APAC as well as growing top-end users of chemical products are creating more demand for chemicals and more opportunities for pressure relief valves to be used in these sectors.

In these plants, pressure relief valves are used for high pressure and back pressure, thermal expansion protection, and more.

Upwards Trend in Oil and Gas Industries

With low oil prices, the oil and gas industry has faced a number of setbacks. The New York Times reports that with prices declining throughout recent years, earnings have dropped for many global companies that were once making record profits. As a result, over two-thirds of their rigs were decommissioned.

But regardless, Business Wire reports that the constant demand of oil in global markets will cause the pressure relief valve market value to exceed 1.6 billion by 2020, growing at a 1.5% CAGR over the next four years.

However, while market values are predicted to rise in this industry, the increasing trend of using alternative energy sources could result in a slower growth pattern compared to other sectors.

CPV Manufacturing is a leading manufacturer of valves and fittings. Learn more online or contact us directly.

Mechanics of High Pressure Relief Valves

Any system or vessel produces high levels of pressure, at times too much for the system to handle. However, there’s something that can ensure protection and consistent stable operation in overpressure events: high pressure relief valves.

Read on for more information about the mechanics of high pressure relief valves.

High Pressure Relief Valves: An Overview

High pressure relief valves are vital to many piping systems and vessels. From electronic to pneumatic to hydraulic systems, they all need a high pressure valve to ensure protection and safety.

In the event of an overpressure situation where the pressure of the system is above the regulator’s setpoint, these valves will vent gas or liquid away from the vessel or system to a safe location. This ensures consistently safe pressure levels and prevents damage and complete system failure. Once the vessel or system has normalized, the relief valves will close until they’re needed again.

High pressure relief valves are known to be one of the most reliable types of overpressure protection and present numerous benefits as well. For example, they don’t block normal flow through a line, and they don’t negatively affect regulators. On top of that, high pressure relief valves act as alarms during an overpressure event.

High Pressure Relief Valves vs. Safety Valves

High pressure relief valves are commonly referred to as safety valves. However, these are two different devices. A high pressure relief valve opens gradually depending on the system’s overall pressure levels. As pressure increases, the valve’s opening gets bigger to maintain stability.

Safety valves tend to be used for more emergency situations. They operate similarly to high pressure valves, but they open instantly to their full capacity as soon as the system hits the set pressure of the valve.

Types of High Pressure Relief Valves

There are numerous types of high pressure relief valves. The most common are a spring-loaded pressure relief valve, a balanced bellows valve, and a balanced piston valve.

According to Wermac.org, the spring-loaded pressure relief valve is designed with a valve inlet or nozzle mounted on the pressurized system, a disc against the nozzle to prevent flow under normal system operating conditions, and a spring to hold the disc closed. This type of valve can also be adjusted to specific pressures.

Wermac.org also mentions that a balanced bellows valve and a balanced piston valve should be used when superimposed back pressure is variable. These valves include a pressure area equal to the seat area of the disc as well as a Bonnet that’s vented to keep the pressure area exposed to atmospheric pressure. This will also provide an easier way to detect leaks in the bellows or pistons.

Other types of pressure relief valves are:

Pilot-operated pressure relief valve
Vacuum relief valve
Power-actuated relief valve
Temperature-actuated relief valve

CPV Manufacturing offers an array of high pressure relief valves. To learn more about these and other available products, contact us today!

Symptoms of a Failing Valve and How to Prevent It

A failing valve can cause catastrophic damage to any vessel or system. However, spotting the first symptoms and preventing a failing valve can help to avoid these types of situations.

To help you understand the symptoms of a failing valve and what you can do to prevent it, read the guide below.

Why Valves Fail

Symptoms Failing Valve Valves are delicate devices designed to ensure safety and proper operation. With that said, valve failure is quite common.

According to Flow Control, many factors cause failing valves, including:

Worn elastomers and seat seals
Debris in the pipeline
Operating in excessive high-temperature situations
Improper valve installation, maintenance, and assembly

Symptoms of a Failing Check Valve

Failing valves will emit warning signs at the first hint of trouble. For example, failing check valves will start to vibrate and even lose some internal parts when problems begin to arise. Other symptoms of check valve failure include reverse flow and excessive component wear and damage.

Check valves will also emit noises as they start to break down. This situation is referred to as “water hammer” and is caused by the disc slamming into the seat of the valve. Water hammer can lead to ruptured pipelines and severe damage. To alleviate this issue, installing a faster-closing check valve is recommended to prevent pressure surges.

Valves will also start to stick and leak as they begin to break down. Sticking happens when the valve is stuck in a certain position, and it occurs when debris gets into the disc and body bore. Leaks stem from a damaged seat or disc or contaminants in the pipeline.

Preventative Maintenance

Symptoms Failing Valve As stated previously, faulty valves can cause severe damage to systems and vessels. However, the following preventative maintenance tasks can help to prevent failure and extend the life of each valve.

Keep Valves Clean

Contaminants and debris in any system can lead to valve issues and failure. Keeping the pipelines clean is one of the easiest and most effective ways to prevent this.

To prevent debris from entering the system, install filters and covers where appropriate. For liquid systems, flushing the pumps also helps to keep the system clean. A flush should be performed before shutdown to minimize the buildup of contaminants.

Lubricate Valves

Use the appropriate lubricant for valves to enhance performance and ensure proper operation. Plus be sure to reapply lubricant regularly to extend the life of each valve as well as the system they’re working with.

Use Valves as Directed

The most important preventative measure is making sure that the valves are used properly. For example, it’s critical ensure that each valve is installed and maintained correctly. On top of that, selecting the right valve for each application will help to prevent damage and valve failure.

Replace Valves as Needed

Finally, valves need to be replaced regularly to ensure optimum operation and safety. So once the valves in your system start to emit signs of trouble, it’s best to replace them with a new part immediately. Failure to do so will result in ultimate system failure.

To learn more about the valves at CPV Manufacturing, contact us now.

How to Choose the Right Pressure Relief Valve

Pressure relief valves are designed to keep plants running smoothly and safely. They protect vessels’ piping systems and various types of equipment from dangerous overpressure situations. However, not all pressure relief valves are made for every plant.

Certain applications require a specific type, and when an improper part is installed, the plant can experience serious issues and risk everyone’s safety. That is why it is important to choose the right pressure relief valve for your specific system.

To help you choose the right pressure relief valve for your plant, here is a list of factors you must consider.

Valve Materials

Pressure relief valves come in different metals. Each metal is meant to cater to specific applications. Depending on the system, a valve made with a certain material may be needed to ensure safety and proper operation. For example, stainless steel pressure relief valves have properties that allow them to work best in plants with corrosive materials.

Valve Design: Connection Size and Type

Just as each pressure relief valve is made with a variety of metals, each valve also features a specific design with a distinct connection size and type. According to the National Board of Boiler and Pressure Vessel Inspectors, the size of the valve must be at least as big as the inlet and discharge piping. In addition, certain valves are designed for specific connector types.

Set Pressure

Pressure relief valve are designed to withstand great amounts of pressure and high temperatures, but each device has its own specific limits. The set pressure is the pressure that causes the valve to open, and it’s measured in pounds per square inch (PSIG).

Pressure Relief Valve The National Board of Boiler and Pressure Vessel Inspectors state that the set pressure of the valve cannot exceed the maximum allowable working pressure. However, a valve with a set pressure less than the maximum allowable working pressure is acceptable.

Back Pressure

Back pressure, or the pressure on the outlet side of the valve from the discharge system, will also contribute to the maximum allowable working pressure of the valve. This factor can be constant or variable to the plant’s operation. Constant back pressure will require a pilot-operated valve. Variable valve pressure cannot exceed 10% of the valve set pressure.

Temperature

Pressure relief valves can also withstand high temperatures. However, specific metals can only handle certain temperatures. So the temperature of the system needs to be taken into account to ensure proper valve selection.

Required Capacity

While pressure relief valves can alleviate a great amount of pressure, they do have their limits. The maximum capacity of pressure they can relieve depends on multiple aspects, including the design of the valve and the temperature of the liquid or gas flowing through them.

Having the right pressure relief valve will not only ensure smooth operations but also the necessary protection and safety a plant needs.

Contact CPV Manufacturing for more information about choosing the right pressure relief valve and to learn more about our selection of valves, fittings, and other products.

The Difference Between Normally Closed Valves and Normally Open Valves

Normally closed and normally open are often used to describe various types of valves, specifically two-port valves. Based on each term, it’s easy to understand that the biggest difference between normally closed valves and normally open valves is how they operate. However, what are the applications for each type of valve and what benefits do they present?

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Normally Closed Valves

Normally Closed Valves and Normally Open Valves Normally closed valves are designed to block flow through the valve and are commonly used for emergency safety. During usual operation, these devices use a spring to remain closed. The valve will open when the system begins to experience overpressure to ensure safety. Once pressure begins to normalize, it will automatically close.

Solenoid valves can also be normally closed. A solenoid valve is an electromechanical device that controls the flow of liquid or gas through a system. Normally closed solenoid valves include a plunger that remains in a closed position when the system is running smoothly, like pressure relief valves.

Normally closed solenoid valves also include a coil that, when powered, will cause the plunger to open and allow liquid or gas to pass through the valve.

Normally Open Valves

Normally open valves are also used as safety devices. However, unlike normally closed valves, these parts work to maintain low pressure in a system. Normally open valves are designed to allow liquid or gas to flow through in usual circumstances. As the system builds pressure, they will begin to shut in order reduce and regulate pressure levels. In some extreme overpressure situations, they will close almost entirely.

Normally Closed Valves and Normally Open Valves There are normally open solenoid valves as well. These devices will remain open until power is sent to the coil and signals the plunger to close.

3-Port Valves

Normally closed and normally open valves are available in 3-port configurations as well. These contain a pressure port, an exhaust port, and a cylinder port and work differently than the two-port valves listed above.

For example, when the coil in a normally closed 3-port solenoid valve is not energized, the pressure port remains closed, preventing flow through the valve, and the exhaust port stays connected to the cylinder port. However, when it is powered, the pressure port opens and connects to the cylinder port while the exhaust port closes.

Normally open solenoid valves are the opposite. In usual operation, the pressure port connects to the cylinder port and the exhaust port is closed. When energized, the exhaust port connects to the cylinder port and the pressure port closes.

The difference between normally closed valves and normally open valves is not just in how they operate. Each type also has different applications and benefits that you must consider to ensure that you choose the right valve.

Employing the Right Safety Valves in Critical Applications

Materials that flow through valves during important operating conditions can be affected by hazards, meaning that the valves could be failing. Noise emission, valve and pipe component erosion, and mechanical vibration in the valves and the connected pipelines are all signs that the valves are failing.

When valves do fail, it can result in negative outcomes such as the costs of ownership, fugitive emissions and safety hazards. Safety valves are put in place to reduces these emergency safety hazards.

Safety Valves

According to an article by Empowering Valves, “Safety valves were first put in use approximately 100 years ago on steam boilers during the industrial era. They were created with the sole purpose of keeping heating and other related pieces of equipment from exploding. Today, the sole purpose of these valves is to safeguard an operation from a number of hazards by opening or closing during certain conditions.”

Pressure Relief Valves

safety valves One example of a safety valve is a pressure relief valve. This type of valve opens when a pressure level is reached in order to release the pressure, thus preventing damage to the system or other areas. Pressure relief valves are typically used in boilers, pressure vessels and other related systems.

CPV offers both high pressure relief valves and low pressure relief valves.

Valves in Gas/Vapor

Safety valves are also used in gas or vapor operations. They’re typically created specifically to deal with the chemical that is being used, such as ammonia, butane, and natural gas. It’s important that this safety relief valve can relieve the capacity of the connected compressor at operating pressure.

Vacuum Valves

Empowering Valves describes vacuum valves as being used “to prevent tank collapse when it is being emptied, in addition to clean in place or sterilization in place procedures. They are also installed on top of storage tanks to control fugitive emission losses that can result from handling flammable and hazardous petroleum products that produce vapor.”

Other types of vacuum valves that are known as breather valves, conservation vents, and safety vents are designed to protect process systems, tanks and equipment.

If you’re in need of quality valves, CPV Manufacturing has just what you’re looking for. Today, CPV is known around the world for the O-SEAL System of high pressure valves and fittings, the Mark VIII system or tube size valves and fittings, FloMaster air operated shutoff valves, and the new G-Series stainless steel shutoff, needle & check valves.The valves available at CPV Manufacturing are high-quality and reliable so you can count on them to last. Contact us directly to learn more.

Types of Pressure Relief Valves and Their Recommended Applications

A pressure relief valve is a safety device that protects a pressurized vessel or system when the pressure isn’t at the right level. This type of valve opens when a pressure level is reached in order to release the pressure, thus preventing damage to the system or other areas. Types of pressure relief valves are typically used in boilers, pressure vessels and other related systems.

It’s crucial that pressure relief valves are designed with materials that are compatible with many different types of process fluids, ranging from air and water, all the way to corrosive media.

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Find out more about the many different types of pressure relief valves so you know which kind to use for a specific application.

Spring Loaded Pressure Relief Valve

Types of Pressure Relief Valves The purpose of a spring loaded pressure relief valve is for a simple, reliable system actuated device that will provide overpressure protection. According to wermac.org, “When a pressure Relief Valve begins to lift, the spring force increases. Thus system pressure must increase if lift is to continue. For this reason pressure Relief Valves are allowed an overpressure allowance to reach full lift. This allowable overpressure is generally 10% for Valves on unfired systems. This margin is relatively small and some means must be provided to assist in the lift effort. Most pressure relief valves, therefore, have a secondary control chamber or huddling chamber to enhance lift. As the disc begins to lift, fluid enters the control chamber exposing a larger area of the disc to system pressure.”

Balanced Bellows Valves and Balanced Piston Valves

A balanced bellows valves or balanced piston design is used when superimposed back pressure is variable. Wermac.org describes the bellows or piston as being “designed with an effective pressure area equal to the seat area of the disc. The Bonnet is vented to ensure that the pressure area of the bellows or piston will always be exposed to atmospheric pressure and to provide a telltale sign should the bellows or piston begin to leak. Variations in back pressure, therefore, will have no effect on set pressure. Back pressure may, however, affect flow.”

Today, CPV is known around the world for the O-SEAL System of high pressure valves and fittings, the Mark VIII system or tube size valves and fittings, FloMaster air operated shutoff valves, and the new G-Series stainless steel shutoff, needle & check valves.

Types of Pressure Relief Valves

If you’re in need of any types of high pressure valves or fittings, CPV Manufacturing will provide you with high quality, reliable products that you can count on for years to come. Contact us directly for more information or browse CPV valves online.

Pressure Relief Devices (PRDs): Gas Cylinder Equipment Safety

Pressure relief devices (PRDs) are installed on gas valves for high- and low-pressure cylinders to minimize the risk of cylinder rupture. It’s crucial that the person who’s filling the cylinder verifies that the PRD is correct for the product. If each filler makes sure to take care of this responsibility on his or her own, everyone can be sure that this process runs smoothly and that safety is ensured.

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Different Types of Pressure Relief Devices (PRDs)

There are four PRD types. Learn more about what each one is comprised of and its purpose.

• Rupture Disk Devices: This device is a flat disk that’s typically made of metal and designed to burst at a predetermined pressure in order to permit the release of gas. The rating is usually stamped on the face of the device. It should be used for compressed air, argon, helium, nitrogen, and oxygen.

• Fusible Plug Devices: This device is a plug made of fusible metal that’s designed to yield or melt at low temperatures. The rating of the metal’s temperature is stamped onto the device. The gas that uses this type of device is acetylene.

• Combination Rupture Disks: A rupture disk is backed by the previous fusible plug. If there’s a fire, the fusible metal will melt, and the cylinder overpressure will be relieved when the disk bursts. The burst pressure of the disk and the melting point of the plug are marked with the rating. This type of device is most commonly found with medical-grade gas cylinders.

• Pressure Relief Valves: A spring-loaded valve opens when the cylinder pressure exceeds the pressure setting of the spring to discharge contents. Once the cylinder pressure decreases to the valve’s pressure setting, the valve will normally reseat without leakage.

Pressure Relief Device (PRD) Maintenance

Pressure Relief Devices Just like with any product, a pressure relief device must be maintained properly in order to perform its functions and maintain a good long-term performance.

Care should be taken when handling and storing compressed gas cylinders and to avoid plugging the PRD channels and parts in any way that could affect the functioning of the device.

All pressure relief devices must be examined internally for corrosion, damage, rust, plugging of relief device channels, or mechanical defects such as leakage or the extrusion of fusible metal. If there’s any question about whether the PRD is suitable, the cylinder shouldn’t be filled until the device is appropriate.

In addition, unauthorized personnel shouldn’t attempt to repair PRDs. If PRDs are repaired or reconditioned, the manufacturer may repair them provided they’re retested to confirm that they satisfy requirements.

Pressure relief devices ensure safety and reduce the risk of a disastrous event. Safety is the top priority at CPV Manufacturing, and that’s why customers rely on our products. CPV designs and manufactures products that exceed the requirement of industry and customer specifications.

Valve Maintenance and Tools

Valve maintenance is necessary to keep your valves running smoothly at all times. Valves are important to your process, and the results could be disastrous if they stop functioning the way they were designed to. Your valves require maintenance to work their best.

CPV Manufacturing has been the leader of valves and fittings since 1915. Safety is our first priority, so we’re dedicated to providing products that will help you avoid disaster.

Learn more about how to maintain your valves to ensure that they’re functioning properly and the tools that allow them to keep working.

O-Seal Valve Installation, Operation, and Disassembly Instructions: These will explain how to install fittings or valve end connections, from installation to operation to inspection and disassembly. There are also specific instructions on correcting leakage for tight seating and for assembly.

Valve Lubrication: This section explains the benefits of regularly lubricating valves in a system, even if the valve only performs an opening and closing action. It’s important to lubricate two surfaces that continuously slide over one another. It makes the parts last longer and work better.

While hydraulic piping systems can function without additional valve lubrication, gas piping systems function under high pressures and benefit from lubrication.

After you order your valves, CPV will detail the regular lubrication schedule and help you set it up.

Valve Flush Plugs: This section explains the function of valve flush plugs, why they’re beneficial, and how to use them.

Valve flush plugs protect the rest of the system from contamination if one section of a piping system needs to be altered, cleaned, or flushed. The three types of flush plugs are Under-Seat, Over-Seat, and Flow-Thru.

Under-Seat and Over-Seat allow for a trouble-free connection to the flushing pump. Flow-Thru plugs are meant to be inserted in valves that are in the middle of the section and being flushed or cleaned.

Valve Spacers: O-SEAL valves are exposed to the heat of welding or brazing during installation that can compromise their cleanliness and integrity. Valve spacers will help to reduce this risk.

You can also use the spacer over and over again to continue to flush the system if you encounter future problems or contamination.