Triple the output
to 1000 ball valves per day
A Middle East based ball valve manufacturer asked us to help him to triple the output of his ball valve production, to 1000 pcs / day. It concerned a wide variety of split-body ball valves with just as much different pressure classes and pipe connections in the range ½ – 4”. The valves are exported to different continents and are intended for the use in many different industries. This means, different standards, different test procedures and different leakage criteria.
Range: Large variety of split-body ball valves ½ – 4” / Pressure Class 150 – 2500
Testing: Several different test fluids 0 – 700 bar / 10,150 psi
The 24/7 use and batch oriented production brought some challenging, technical requirements;
To meet the quantities of the small and large batches, the Ventil Engineered Solutions team designed a ‘5 station test unit’, Model VCBT25-MT5. Each of the 5 test stations was completed with a dedicated test and measuring system which can be switched on/off, to test 1 single valve up to a series of 5 valves simultaneously.
An important step in the design is easy and safe handling of the test objects. Small valves can be quickly (un)loaded by hand, but larger, high pressure class valves easily reach a weight of 50+ kg and have to be handled by crane. Therefore each station is completed with the rail mounted loading system.
Time is of the essence and a smart change-over system is installed to adapt to the large variety in valve ends. This includes ‘SET’ adapters for proportionally controlled clamping on the Raised Faces of flanged valves and adapters for but welded and socket welded ends. All adapters are designed to prevent ‘squeezing’ of the split-body valves.
Common air and liquid testing doesn’t require any special measures, but the intensive 24/7 use and combination with high pressure gas testing does. To ensure a long and reliable working effect, the test bay is completed with a high quality Stainless Steel finish. To enable consistent gas testing up to 700 bar / 10,150 psi, the gas test system is completed with gas boosters. These booster allow to use of air, Nitrogen or Helium.
Safety is paramount! And therefore a ‘foam spraying system’ and fully integrated camera system are installed to quickly and accurately detect leaks with high pressure gas testing.
This VCBT25-MT5 combines it all’, accuracy, safety and the efficiency to boost the high volume output to 1000 valves per day.
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Do you have questions about a certain project or you have a similar challenge in hands..?
Get in touch with the Ventil Engineered Solutions team.