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Back to Case category: CNC testing (full automatic – series testing)

90,000 kg heavy ball
valve tester for kazakhstan

A well-established German ball valve manufacturer approached us with the question to prepare a plan for equipping their new production facility in Astana, Kazakhstan with the right test equipment.

The production program covered a complete range of fully welded ball valves from 2.5 up to 64” / DN65 – 1,600 mm. for both gas and liquid applications. All new valve production, and this implicates 100% body and bi-directional seat testing, in this case according to the GOST standards.

The assigned Engineered Solutions team quickly studied the valve types, range, logistics, production quantities, but also looked into the local test standards and quality requirements. The study was concluded with a proposal for the following (3) test units;

  • A fully automatic 3-station test unit, model: VCB120-MT3-CNC for simultaneously testing up to 3 ball valves in the range: 2.5 – 8″ / DN65 – 200 mm.
  • A semi-automatic test unit, model: HC120-SA for submerged gas testing ball valves in the range: 2.5 – 16” / DN65 – 400 mm.
  • A semi-automatic test unit, model: HC3000-SA for testing the large sizes, range: 16 – 64″ / DN400 – 1,600 mm.

 

The smaller machines came from the standard Ventil Engineered Solutions delivery program. These machines only required some software modfications to meet the local test standards. The real engineering challenge was found in the large machine, daily workload (range) and application, range; 16 – 64” / DN400 – 1,600 mm., with both flange and but welded ends and pressure classes 150 – 1500. All fully welded bodies which required a non-conventional clamping fixture. The largest valve required a force of 3,000 metric tons, but this could easily ‘squeeze’ and damage the smaller sizes. To prevent this effect to happen, the Ventil Engineered Solutions team designed a special clamping system and implemented radial sealing technology. These sealing adapters combine a very high level of tightness with easy (un)loading, while subjecting the valve body to zero clamping force..!

The Ventil Engineered Solutions team worked in close cooperation with the customer to adapt the specification and ‘fit’ the machines into the brand new production chain. The machine lay-out, operating system and registration software was adapted to meet all requirements and local test standards. When the order was awarded to Ventil Engineered Solutions, time directly became of the essence. Winter was approaching and and harsh climate conditions in Khazakstan could make transport by road impossible. The production and FAT testing took place, just in time and the equipment was quickly loaded for the 10 day – 5,000 km road trip, crossing 8 countries from North to Eastern Europe.

The team respondsible for building the 3 non-standard machines, also travelled to site to succesfully install, commssion and assist the new operators with the start-up of the valve production.

Quite a challenge, and job well done!

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