In the beating heart of a million industrial processes lies the humble valve. This valve plays a central role in helping complex processes run smoothly, safely, and efficiently.
This article looks at one type of valve, the standardized cast steel valve.
We’ll explain the impressive benefits offered by this design and material.
We’ll also examine why you should use these valves in many modern industries. We’ll also explain why they are the best choice for some of the most difficult industrial environments.
Read on to discover the benefits of standardized cast steel valves and what they can offer your business.
They Are More Durable
Standardized cast steel valves are tough and durable. They will last a long time, and it’s one reason they are a popular choice in industrial processes.
The toughness is thanks to the cast steel material. It can handle lots of pressure. That means you won’t have to worry about wear and tear or breakages.
They last longer than valve materials like brass, aluminum, or PVC.
For example, aluminum valves could deform if subject to a heavy load. PVC won’t withstand high temperatures, making it less resilient to manufacturing processes.
Furthermore, the standardized manufacturing process means you’ll always get the same high quality. That means each valve will offer the same durability.
That is an essential quality for industries relying heavily on long-lasting valves that withstand the most intense industrial processes. It’s easy to see why standardized cast steel is a popular choice.
They Are Versatile
Standardized cast steel valves are incredibly versatile. Various industrial processes can use these parts.
The toughness and resilience of the material means the industry can use them in many conditions. That includes high-pressure environments, extreme temperatures, or corrosive environments.
For instance, the petroleum industry benefits from the versatility of gate valves made with cast steel. They are efficient and strong enough to handle crude oil and natural gas.
The valves cope well in these high-pressure temperature conditions. The cast steel comes in different alloys like stainless or carbon to create a more custom valve to better fit specific demands like pressure and temperature.
These valves can be used in boilers and steam-handling systems in power plants. They offer a safe and reliable solution for those operations.
Another real-world example is valves used in chemical plants. Cast steel can handle strong chemicals and high temperatures. Similarly, the material is useful in marine environments where corrosion is risky.
In summary, the versatility of standardized cast steel makes it a popular choice for some of the toughest and most demanding industries worldwide.
They Offer Precision
Precision and control of fluid flow are crucial in any industrial process. Standardized cast steel offers an advantage in this respect. These valves provide exceptional flow control.
The standardized design ensures the volume of fluid passes at the correct rate. That is vital in industries that need this level of accuracy. For example, it benefits petrochemicals, water treatment, food manufacturing, and beverage plants.
Let’s look at the petrochemical industry in more detail. Here, precise value control is needed for many important chemicals, and it’s a critical part of the process.
Accurate flow equates to safety and efficiency. So cast steel valves are more than an advantage; they are essential.
Likewise, water treatment plans involve a purification process. Accuracy is fundamental here. Standardized valves that offer accurate flow ensure the water treatment is successful.
Precision matters with food and drink manufacturing, too. A slight change in flow could impact the ingredients during the production process. That could affect quality and leave a company liable for legal issues.
They Are Resistant to Corrosion
Corrosion is a key factor when choosing valves. Corrosion is where metal oxidizes, leading to a weak and damaged surface.
When that happens, valves need replacing, which means higher parts and maintenance costs for industrial machinery.
Cast steel performs well in this respect as it offers high corrosion resistance, with varying alloys providing you the chance to present corrosion in the harshest conditions.
It can resist the effects of rust, which is the most common form of corrosion.
That means industries can use cast metal in environments with strong corrosive substances. Take the example of the oil and gas industry. This type of business will use corrosive fluids in their industrial processes. A gate valve using cast steel is ideal.
Using cast steel valves on a large scale can reduce the frequency of machinery inspection and maintenance. It saves money and reduces downtime.
That is also an important factor in chemical plants. Here, cast steel valves withstand the strong chemicals that could cause corrosion. That means fewer risks of a damaged machine or a chemical spill.
The robustness of standardized cast steel helps and protects critical elements.
Marine environments also come with the problem of corrosion due to the effect of saltwater on metals. So, a valve with high corrosion resistance is essential in this industry.
They Have a Standard Fit
The standardized measurements in cast steel valves play an important role. It offers an accurate and reliable fit within any industrial system.
That, in turn, means it offers consistent quality. Standardization means the valves meet international quality standards. They provide precise dimensions that guarantee compatibility and interchangeability.
If something does break on a production line, you won’t be delayed sourcing a unique valve or checking measurements. Standardized cast valves come with the reassurance that they’ll fit and work perfectly.
Similarly, in large industrial HVAC systems, valves control the flow of heating and cooling fluid. Size is critical here as an overheated environment could become a problem for many industrial processes.
Standardized valves help ensure a secure fit, reducing the risk of leaks, blockages, or breaks.
They Work in Extreme Heat Conditions
Many industrial processes involve extreme temperatures. Having parts that can withstand high or low temperatures is vital.
Cast steel valves are invaluable in environments where operations happen in hot environments.
They come with excellent thermal durability. So, the valves will function when exposed to extreme heat or cold. It helps avoid maintenance issues or halted processes.
In power plants, for example, these processes involve steam and pressure. Standardized cast steel valves in various alloys can be used in these environments to help control the steam flow.
They won’t break under the pressure of steam flowing through at extreme temperatures.
That is the same situation in other industrial processes, such as petrochemicals. These businesses use heat as part of the processing and can involve high-temperature reactions. Steel valves ensure a reliable, uninterrupted operation.
Other examples include metal smelting and glass manufacturing. A high-performance alloy called Inconel, made of nickel and chromium, is used here. Furnaces can use cast steel valves in this high heat without damage.
That keeps the manufacturing process running smoothly without issues.
They Are Strong
The strength of standardized cast steel valves is a notable advantage. That strength makes them an excellent choice when placed under pressure. That makes them the right choice in heavy-duty industrial processes.
They can withstand these processes without succumbing to deformation or failure.
For instance, oil and gas environments require high-strength materials. That ensures gate and other valve designs in this environment cope with the pressure of fluids over a long period. Performing well in these conditions makes cast steel reliable.
Strength is a vital quality in industries with hydraulic systems.
Stainless steel valves are the most common choice here as they can handle this pressure without a performance decline. That makes them valuable in industries such as construction and aviation.
These valves can even work in the most intense environments where strength is essential. Coolant systems in a nuclear power plant use robust, high-strength, cast steel valves. They can offer reliability in high-risk environments such as nuclear energy.
They Are Economical
All industrial processes need cost control, and parts need to be cost-effective. A standardized cast steel ball valve can offer an economic advantage in this sense. Steel is an affordable material.
As a metal, it doesn’t suffer volatile price changes like other materials. Plus, the standardized casting process means these valves are produced at a relatively low cost. So, they are an affordable option in industrial processes where cost is key.
Furthermore, the durability of cast steel means it needs less frequent replacement. This longevity helps spread the long-term expense of using them in an industrial process.
When looking at the total cost of ownership, the cost of steel fares well. It has an affordable initial purchase price. Plus, ongoing maintenance costs are low due to the reliability of the steel.
In other words, it’s a highly economical choice in large-scale industrial processes that can offer a significant financial advantage.
They Are Easy to Maintain
One factor that any industrial process needs to consider is ongoing maintenance.
All parts need regular inspection and maintenance to keep the system running smoothly. Yet, choosing material that offers easy repair and lower maintenance is an advantage. It can make the entire industrial process more efficient.
The sturdy and modular design of a standardized cast steel gate, globe, check, or ball valve helps with maintenance. The standard design means maintenance teams can fix issues without replacements.
If a fault happens, individual parts can often be replaced instead of replacing an entire unit. That also helps reduce waste alongside maintenance costs. So, it’s a valuable feature if a business wants to achieve environmental sustainability.
The hardy nature of cast steel reduces the need for frequent inspection and maintenance. It has a longer service life and will reduce the downtime needed for repairs in an industrial process.
That is valuable in industries where equipment reliability is paramount, and downtime is a problem. For example, keeping power or water treatment plants running is essential for businesses and end users.
When a valve does need repair, downtime isn’t as significant as it might be with other valves.
That’s because standardization makes it easier to spot and fix a problem or find a replacement. More uptime is financially beneficial to any industrial process. And in some cases, it’s critical for safety too.
They Offer Customization
A standardized cast steel valve can come with a degree of customization.
That ensures they can cater to the specific demands of various industries. Despite the standardized label, these valves offer modifications to fit an application’s needs.
For instance, a manufacturer can customize internal components to handle specific fluids. That makes them match the needs of varied industries, like slurries in mining or fluids in beverages.
A manufacturer can also customize the valve size. They can fit different parts to ensure optimal operations (like fluid control).
In industries like pharmaceuticals or biotechnology, stainless steel valves can include a specific interior. This coating can help prevent contamination.
They Offer an Excellent Safety Record
Industrial processes are often high-risk environments. Safety is paramount. That means having parts like valves that offer an excellent safety record. These cast steel valves have earned a reputation as a trustworthy material.
The rigorous manufacturing standards and strong materials mean they are reliable and safe. That makes them ideal in environments with high pressure, extreme temperatures, or corrosion risks.
In these environments, unexpected breakages could potentially lead to dangerous situations. Replacement parts with an excellent safety record can protect people, machinery, and buildings.
Industries, including chemical, oil, gas, and power, must prioritize safety.
The consistent quality of the standardized process used to create these valves makes them a safer choice.
It means they offer reliable performance. Varied designed valves can be equipped with fail-safe mechanisms to ensure safe operation in an emergency, like a power outage.
Therefore, they meet the industrial processes needed to create a safe and secure environment. They can protect against chemical leaks, overheating processes, or gas explosions.
Cast Steel Valves: The Right Choice for Your Business
As you can see, cast steel valves offer an unrivaled array of features, making them an excellent choice for modern industry.
Their blend of durability, versatility, and value for money means they offer many businesses the safe and reliable choice needed to keep their operations running.
We invite you to explore this further by contacting our team here at DHV Industries. Our engineering excellence in cast steel valves will help you find the valve solution for your business.
