Automatic control valves, much like everything else we purchase these days, are not all created equal. Some fall into the high quality bracket with pricing to match, while others hover closer to the lower quality and price sensitive end of the scale. Unfortunately, when evaluating control valve prices, it is not always clear what you are being offered and what standards the valve actually meets. Here are a few questions to consider and ask the supplier to ensure you get years of trouble free operation that lasts longer than it takes the sales person to drive out of your parking lot!
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Q 1 What materials are being used?
Make sure you know what the different components of the valve are made of, as this will certainly affect the life of your valve, specifically:
Body Material &#; is the valve body cast iron or ductile iron? Traditionally valves were cast iron but ductile iron has become the new standard due to its superior physical properties that are much better at weathering the elements.
Body Coating &#; Most of the world insists on fusion bonded coating of a valve, inside and out. Unfortunately here in North America, that is not always requested. This just makes common sense for valves that are constantly wet and sit in locations that are not always dry and pristine. A valve should last for many years, so insisting on a coated valve is a wise choice.
Seat Material &#; bronze is typically the common material for seats but over time, depending on water quality and velocities, bronze wears resulting in the need for replacement. This is time consuming and expensive as seat replacement requires a complete disassembly of the entire valve. Ideally go for stainless steel.
Valve Internals &#; Most valve manufacturers utilize stainless steel for their valve stems. Make sure that you ask what grade of stainless you are getting as not all stainless steel is created equal. 316 SS is always the best choice because it is harder and least likely to corrode.
External Fasteners &#; Over time valves experience condensation or flooding and this can play havoc with coated studs or bolts. There is nothing worse than trying to remove heavily rusted studs out of an old valve to perform maintenance. Request stainless steel fasteners as this will ensure that bolts will be removable at any age.
Q 2 Does the valve supplier fully understand your application?
Too frequently a specification will be requested and a valve is supplied that is simply the wrong valve for the job. It may also be the case that there is just a better solution. Ensure you give your valve supplier all the necessary pressure and flow details including details of the actual application and what you want this valve to do. Having the wrong valve for the wrong application, at best case will result in a significantly shorter life and worst case, a malfunction that can result in destruction of the valve and other parts of your water distribution system.
Q 3 Will this new valve fit into my existing piping layout?
Don&#;t be tempted to just stay with brand X because that is the valve you may be replacing and has the same lay lengths. Most manufactures can be quite innovative on providing solutions to combat varying lay lengths so explore all of you options rather than just settling because you think it may be easier.
Q 4 Do you need specialty tools for maintenance?
Nobody wants to have to carry around a specific tool that only performs one task. Ensure that your valve can be maintained with everything you would carry in regular tool kit. Some valve manufacturers require specialized seat removal tools, or vice jaws installed with copper jaws to protect valve stems. While these are great ideas, they are certainly not things that the average operator has in his toolkit.
Q 5 Will your personnel receive complimentary factory qualified training?
Control valves are not so difficult to understand and once taught, most operations personnel can easily perform maintenance. Ensure that you will not be reliant on the additional cost of having to bring out a factory person every time your valve requires maintenance. Request that a factory-trained representative is on site when the valve is commissioned. This will allow your operators to be schooled in the regular maintenance needs, know what to look for if things go awry and how to start up a valve in a new system or after service. Simple tricks like removing air out of the pilot system are valuable lessons to see in practice.
Q 6 Does your valve have a solid warranty?
These days having a product with the long term back up of the factory is important. Three years should be the standard to ensure there are no manufacturing faults.
Q 7 Can I make changes to the valve if required
Having a valve &#;expansion ready&#; for the future can save you money and make your decisions a whole lot easier. For example, can you add a limit switch or a position indicator easily? Or, if you need to move the pilot system to the other side of the valve, can you do it, or is it not possible because the valve body does not have the required connections? Things always change and a flexible valve gives you more options to keep your now perfect valve, perfect down the road.
Q 8 Does your valve meet industry standards?
There are third party accreditations that ensure your valve was built to the correct specifications. For example; NSF 61, WRAS, UL/FM, AWWA, ISO et.al. They are important because they ensure that the valve has been built to a given standard so the user can be assured they meet approval for such things as low lead content, bacterial growth tests, functional tests etc.
Q 9 Do you have local and factory support?
Make sure there is someone in the area that is factory trained and available to come out and assist when you have questions or problems. This sounds like a given but it&#;s best to ensure the local agent will in fact be there for you when you need him. When a valve fails, timing is usually of the essence so you should know whom to call prior to such an event.
Q 10 Is the valve solution offered able to handle future needs?
In the world of &#;low bid wins&#;, a supplier may be tempted to squeeze as small a valve as possible into the application in order to reduce price. Make sure that the offered solution will supply your needs for the foreseeable future without the burden and additional cost of having to change a valve in a couple of years.
Contact us to discuss your requirements of valve parts casting manufacturer. Our experienced sales team can help you identify the options that best suit your needs.
The process of choosing the right metal casting supplier should not be the same as choosing your supplier for bolts, manufacturing equipment, or office supplies. While some may treat metal castings as a commodity, they are far from it and the process of selecting the right supplier for a specific application requires careful consideration.
Supplier qualification is the most important part of the purchasing process. Traditionally, a purchaser&#;s primary responsibility was to find qualified and responsive suppliers. In some cases, purchasers assumed that any supplier willing to contractually meet the purchase requirement was qualified. However, using low cost and unqualified suppliers can cause quality issues, and wasted time and money in the long run.
To help you through the process, here are some things to consider when choosing the right metal casting supplier.
Experience in Your Market
When selecting the right foundry to work with, determine if they have experience in your market. A metal supplier that truly understands your products, applications, terminology, and pain points can anticipate needs and potential problems. This is especially important in defense, nuclear, aerospace or other high compliance markets. The good news is that most casting manufacturers will publish their key markets on their websites, making it easy to determine when considering a supplier.
Process Diversity
Companies try to sell you what they have to offer and some casting suppliers only offer one type of casting process. For example, a company that only uses the investment casting process will try to sell you on why that process is best for your application. But what if using the sand casting process is best for you and your needs? Instead, look for a supplier that offers a range of casting processes so the best option for YOU is selected.
If your components have a range of designs, applications, and sizes, it is likely that the best casting process is not the same for every part. If working with a single source for all of your casting needs is important to you, the supplier needs to be diverse in its capabilities. When combined with other integrated capabilities, this can help simplify and compress the supply base.
Product Quality, Service, and Price
When selecting the right casting supplier, careful consideration should be given to quality, service, and price. Take an internal audit on what really is important to you, noting that most companies may be acceptable in all areas but can probably only truly excel in one. If the lowest price possible is most important, for example, the supplier will likely not be world class in quality and service. Which are your &#;Must haves&#;? Lowest price? Meet the spec? Quick response? Easy to do business with?
Certifications and Testing
Does your application require that the casting supplier have proper certifications such as ASME, Nadcap, or PED? If so, confirm that your potential supplier has the proper certs. Granted, a supplier could go through the process to obtain the required certifications but more than likely, time does not allow for that. Most casting suppliers will list their certifications on their website, and companies are searchable by certification. Be diligent.
Do you require non-destructive testing (NDT), mechanical testing, or chemical testing? While all metal casting suppliers can outsource any needed testing, some have all those capabilities in-house which can potentially save time and money. If your application does not require any testing, a casting supplier specializing in high compliance work with in-house capabilities may not be the right fit either.
Machining Capabilities
Buyers increasingly select casting suppliers who have machining capabilities. This can avoid conflict if defects are discovered during machining. If a third party is machining, it may result in &#;finger-pointing&#; about who is at fault. Is it a casting issue or a machining issue? If the casting supplier discovers an issue during machining, the problem is resolved faster with no dispute over whose fault it is. The foundry &#;owns it&#; and there is less time needed for processing, shipping, and handling or replacing. Problem or no, integrated machining simplifies the supply chain and reduces handling time and shipping cost before the product makes it to the customer.
Choosing The Right Supplier
Value Added Services
What do you need from your casting supplier? Are you looking for someone to just deliver a metal component to your doorstep or do you need more? For example, if you do not have in-house metallurgy expertise, confirm that the supplier can provide guidance in selecting the proper alloy based on your specific application. Do you have a need to raise the expertise of the overall metal in your company through training or information sharing?
Do you want a supplier who can review your design and material selection and provide recommendations to make your products last longer or save money? Some suppliers may do a great job producing a product to spec but have few other capabilities. Others will exceed the letter of the PO to help you save time and money.
Do you have requirements for both ferrous and non-ferrous alloys? Some foundries are limited or specialized. Make sure the supplier can meet all your material or alloy requirements to eliminate the need for multiple suppliers.
Tour Their Facility
What better way to determine if someone is the right casting supplier than to see their operations firsthand with a plant tour? Most manufacturers are more than happy to have you as a guest in an effort to gain your business. If, by the end of the tour, you have doubts about operations, capability or culture, they are probably not the right supplier for you.
Questions to Ask Yourself
- Does the supplier have experience in your products and/or markets?
- Can the supplier fulfill several of your product requirements to limit the number of needed vendors?
- What is REALLY important to you? Is it quality? Price? Customer service? Something else? How do supplier strengths compare with your needs?
- Does the supplier currently have the certifications you require?
- Does the supplier have the proper testing capabilities?
- Do they regularly deal with the alloys required?
- What value-added services do you need? Does the supplier offer them?
- Is the company stable with a strong history and future?
- What are their values and do they align with yours?
- Do you see your company doing business with them? Can you build a relationship with them?
- What is the supplier&#;s casting products list?
Conclusion
While some may treat metal castings as a commodity, they are far from it, and therefore, the process for selecting the right supplier for your specific application requires careful consideration. Take an internal audit of your company&#;s needs and wants, and determine what is most important. Research the supplier&#;s website. Talk to a sales rep or business associate. Ask a lot of questions. Visit their facility. Get an understanding of what they can do for you and if you can see yourself building a strong, mutual relationship with them.
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