Neo Valve
Neo Valve
Neo Valve
ON
They are supplying different types of valves to JINDAL STEEL WORKS (JSW),
BMM ISPAT,HAWA VALVES, BHARATH CHEMICALS, HEAT
EXCHANGERS and other small scale industries in GOA.
The Unit has well experienced technically qualified and dedicated staff. It has
always been rated very well by customers for its quality, timely delivery and
improvements.
Unit is having 30 HP power plus demand basis along with bore well facilities.
Machining
Assembly
Testing
Painting
Valve Automation
Packing
MACHINING
Facing operation
Turning operation
Grinding operation
Drilling operation
ASSEMBLY
Parts required for assembling the Three Piece Ball Valve [25mm, material:-Cast Iron]:-
Tail Piece(2)
Ball (1)
Body(1)
Seat(2)
Stem(1)
Stem washer(1)
Stem packing(2)
Gland(1)
Studs(4)
Nuts(8)
Lock nuts(2)
Handle(1)
Body seal(2)
Procedure for assembling Three Piece Ball valve:
Initially we check whether the parts are machined correctly.
Gather all the parts and tools required to assemble the valve.
We make sure that space and area required to assemble is clean and tidy.
At first we take a both the tail pieces and fit seat to inside diameter and seal to
the outside diameter.
Stem washer is champered and it is fixed to the stem. And this stem is placed,
inside stem hole bored to the body.
The stem packings are fixed to the stem which is place in the body. And Gland
and locknut is fixed using spanner[19 mm].
Then the important part i.e., Ball is placed inside the body with provision
provided at the upper part of the stem carefully.
Taking one of the tail piece which serves at the base above that body is placed.
Then taking the studs and placing them in to the holes provided.
Later the other tail piece is mounted on the body and these pieces are tightened
by nuts which are placed on the either sides by using spanner [12mm].
Then handle is fitted to the stem and above that a lock nut is tightened using
spanner [19mm]and ensure the opening and closing of ball by handle is flexible.
We make sure that there is no gap in between the pieces and the seat should not
be displaced.
Assembled three piece ball valve
VALVE TESTING
PRESSURE TESTING OF VALVES
When a liquid is used as the test fluid, the valve shall be essentially free from trapped air during
the test.
Required protective coatings, such as paint, which may mask surface defects, shall not be applied
to any surface before inspection or pressure testing.
When closure testing valves, the valve manufacturer’s test procedure shall ensure that excessive
force is not used to close the valve.
The valve shall be visually examined for leakage after it has been fully prepared and is under full
test pressure
The shell test shall be made by applying the pressure inside the assembled valve
with the valve ends closed.
The valve partially open, and any packing gland tight enough to maintain the test
pressure, except for bellows seal valves, testing the stuffing box.
Testing of a valve on test bed
PAINTING
Once the testing of the valves is done the next step is painting of the valves
that are at the end for packing.
For painting of the valves here sprayer has been used for painting section.
For small size valves the painting will be made by keeping on small bench
and process has been done and if it is larger size then the valves are
painting using small crane like equipments.
Painting of a valve
VALVE AUTOMATION USING PNEUMATIC ACTUATORS
What is an Actuator?
• An actuator is a component of a machine that is responsible for moving
and controlling a mechanism or system, for example by opening a valve.
• Actuators are mechanical or electro-mechanical devices that provide
controlled and sometimes limited movements or positioning which are
operated electrically, manually, or by various fluids such as air,
hydraulic, etc. Two basic motions are linear and rotary.
What is a Pneumatic actuator?
• A pneumatic control valve actuator converts energy (typically in the
form of compressed air) into mechanical motion. The motion can be
rotary or linear, depending on the type of actuator.
• A Pneumatic actuator mainly consists of a piston or a diaphragm which
develops the motive power. It keeps the air in the upper portion of the
cylinder, allowing air pressure to force the diaphragm or piston to move
the valve stem or rotate the valve control element.
Types of pneumatic cylinders:
1. Single Acting Cylinder
2. Spring Return Cylinder Spring Returned
Single acting Ram Cylinder
cylinder
3. Ram Cylinder cylinder
8. Diaphragm
Diaphagram
Cylinder
VALVE POSITIONER
What is a Valve Positioner?
Valve Positioners are devices used to put the valve in the
correct position by increasing or decreasing the air load
pressure on the actuator. Valve positioners are used for
controlling valve where accurate and rapid control is required
without error or hysteresis.
There are different types of control valve positioners:
Force-balance pneumatic positioner
Motion-balance pneumatic positioner
Electro-pneumatic valve positioner
Electronic positioner
WORKING OF VALVE POSITIONER
The positioner compares the control signal (the requested valve
position) with the actual valve position through the mechanical
feedback linkage.
If the valve position is incorrect, the positioner will either load or
exhaust air from the valve actuator until the correct valve position
is obtained.
A positioner requires both a control signal and an instrument supply
air for normal operation.
Most positioners come equipped with three gauges to indicate supply
air pressure, control signal pressure and actuator diaphragm signal
(output) air pressure.
Positioner
Electro-Pneumatic
positioner
Single- Cylinder
Pneumatic
Actuator
20 100(open)
16 75
12 50
8 25
4 0 (close)
PACKING
This is the last step for exporting the products which were in a packing
boxes as shown in the fig below. The complete product can be packed
using wooden boxes if it is small in sizes and size of the valves are in
large sizes then it is better to use other iron boxes for exporting the
valves to other companies. It is shown in the fig.
P
Where I was? R
O
UNLOADING C
E
S
DESIGN AND F
MACHINING
L
O
W
NEO VALVES ASSEMBLY AND
INDUSTRIES TESTING
“Valve
VALVE Communication &
Automation”
AUTOMATION Awareness
is done only
AND PAINTING if the client
demands
PACKING AND
LOADING
What Was the Work assigned to us?
We were assigned work in all of the departments.
We the team of 4 members were split into half and the work was
divided
There shifting of work profile for every 2 days.
We carried out many processes like machining and in that drilling,
grinding, tapping etc.,
We took 2 days to complete the assembling of 3-piece ball valves
Later we conducted test on the valves on test bed.
Then we carried out the process of painting the valves.
Finally packing of valves is done.
The manager made the arrangements for designing of valves using
AUTO-CAD (2D design)
After all this we were given some basic 2D design sheets of valves and
provided assignments to do so.
2D DRAWINGS OF VALVES IN AUTO CAD