Five disciplined stages. No shortcuts. No deviations. Every VALVAX valve follows the same unbroken chain of accountability — from incoming material to certified dispatch.
Every valve begins with the selection and verification of its material. We specify only mill-certified alloys with full traceability to the originating heat. Incoming MTCs are cross-referenced against the applicable ASTM, EN, or IS standard before any material is released for production.
Our incoming inspection protocol includes hardness testing, dimensional verification of raw castings or forgings, and visual examination for surface defects. Any discrepancy against the MTC triggers a non-conformance and material is quarantined pending disposition.
Standard Material Grades
| Grade | Standard | Service |
|---|---|---|
| WCB | ASTM A216 | General service to 425°C |
| WC6 | ASTM A217 | Alloy steel to 595°C |
| WC9 | ASTM A217 | Mo-alloy to 650°C |
| CF8M | ASTM A351 | SS 316, corrosive service |
| CF3M | ASTM A351 | SS 316L, low carbon |
| LCC | ASTM A352 | Cryogenic to −46°C |
| Duplex | ASTM A890 | Chloride environments |
The method of forming a valve body is a performance decision, not a cost decision. VALVAX selects the forming method based on the pressure class, wall thickness, service temperature, and NDE requirements of the final application.
All castings undergo full NDE per the applicable standard before machining. Radiography (RT) is performed on Class 900 and above, or wherever specified by the customer. Magnetic particle (MT) or liquid penetrant (PT) examination is applied to machined surfaces on pressure-critical components.
Forming Methods
Used for large-bore bodies (2″–48″) in Class 150–900. Post-cast heat treatment per material specification. 100% RT for Class 900+.
Used for complex trim geometries and small-bore bodies requiring superior surface finish. Tighter tolerances than sand casting.
Used for all Class 800–2500 small-bore valves (½″–2″). Eliminates porosity, aligns grain flow, superior mechanical properties.
Machining is where the casting or forging becomes a valve. All bore dimensions, seat profiles, thread forms, and flange faces are produced on 5-axis CNC turning and machining centres. CNC programmes are revision-controlled; no operator improvisation is permitted on critical dimensions.
CMM inspection is integrated into the machining sequence — not only at final inspection. Each critical machined feature is verified before the valve proceeds to the next operation. Seat lapping is performed to optical flatness using traceable equipment.
Machining Capability
| Parameter | Capability |
|---|---|
| Max Bore Diameter | 1200 mm |
| Min Bore Diameter | 8 mm |
| Bore Tolerance | ±0.05 mm |
| Thread Accuracy | Class 2A/2B (ASME B1.1) |
| Surface Finish | Ra 0.4–6.3 μm |
| Flatness (flange) | 0.05 mm / 100 mm |
| CMM Measurement | Integrated per operation |
Assembly is performed in a controlled environment by trained technicians following valve-specific assembly instructions. Torque values for all fasteners are specified on the assembly drawing; torque wrenches are calibrated to national standards.
The API 598 test sequence is non-negotiable. Every valve undergoes shell hydrostatic, seat hydrostatic, and low-pressure pneumatic seat tests. Test pressure, hold time, and leakage criteria are recorded for every valve against its serial number.
Test Parameters — API 598
| Test | Medium | Duration |
|---|---|---|
| Shell Hydrostatic | Water / NaCl | Per API 598 Table 2 |
| Seat HP Hydrostatic | Water | Per API 598 Table 2 |
| Seat LP Pneumatic | Air / N₂ | Per API 598 Table 2 |
| Backseat | Water | Per API 598 Table 2 |
| FE Type Test | Methane / He | ISO 15848-1 Annex A |
Visual Inspection Checklist
No valve leaves VALVAX without a complete documentation package. The Material Data Record (MDR) consolidates material test certificates, NDE reports, dimensional inspection records, hydrostatic and pneumatic test certificates, painting certificates, and final inspection release.
Packing is specified based on valve type, size, pressure class, and shipping conditions. Flange faces are protected with plywood blanks. Threaded connections are capped. Crates are stamped with handling instructions and tagged with purchase order and item numbers.
Documentation Package
| Document | Standard |
|---|---|
| Material Test Certificate | EN 10204 3.1 / 3.2 |
| Radiographic Test Report | ASTM E94 / ASME Sect. V |
| Dimensional Inspection Report | Drawing / ASME B16.34 |
| Hydrostatic Test Certificate | API 598 |
| Pneumatic Test Certificate | API 598 |
| Painting / Coating Certificate | Customer spec / SSPC |
| Final Inspection Release | Internal QMS |
| Fugitive Emission Cert. | ISO 15848 (where required) |
We do not inspect quality into a valve — we engineer it in. Process controls, poka-yoke fixtures, and revision-controlled procedures prevent defects from occurring. Inspection confirms what the process has already achieved.
Every valve carries a unique serial number traceable to its material heat, machining programme, test records, and inspection data. A valve that cannot be fully traced is not a VALVAX valve. Full material traceability is non-negotiable.
Every non-conformance is a learning opportunity. Our corrective action process requires root cause analysis, not just containment. We track failure modes and corrective action effectiveness to drive systematic improvement.
Ready to Specify?
Our engineering team responds within 24 hours with a tailored recommendation and quote for your application.
Standard lead time for stock-range valves is 4–6 weeks from purchase order. Custom configurations, special alloys, or large bore valves (above 16″) typically require 8–12 weeks. We maintain buffer stocks of WCB bodies in common sizes to support emergency shutdowns and unplanned replacements.
All VALVAX valves are tested to API 598 as standard — covering hydrostatic shell tests at 1.5× MAWP and seat closure tests at 1.1× design pressure. We also offer pneumatic low-pressure closure testing, fugitive emissions testing to ISO 15848-1, and full witnessed inspection by third-party agencies including Bureau Veritas, Lloyd's Register, and SGS.
Yes. VALVAX is an IBR-approved manufacturer. We supply gate, globe, and check valves with IBR Form III-A certification for power plant boiler feedwater and steam applications. IBR documentation is compiled into the Material Data Record (MDR) pack delivered with every valve and is available for third-party review prior to dispatch.
Every VALVAX valve ships with a complete MDR package including: Mill Test Certificates (MTC) for all pressure-retaining components, dimensional inspection reports, NDE reports (RT / UT / PT / MT as applicable), hydrostatic test certificates, and a heat number traceability chart linking each component to its originating heat. Digital MDR packs in PDF format are available on request.
Yes. Client engineers and third-party inspectors are welcome at our facility for witnessed FAT at any stage. We accommodate hold points defined in client-approved Inspection and Test Plans (ITP). Our quality team coordinates inspection scheduling with minimum 72-hour advance notice for routine hold points.
VALVAX manufactures in Duplex 2205, Super Duplex 2507, Hastelloy C-276, Alloy 20, Inconel 625, titanium, and naval bronze. Special configurations include cryogenic valves with extended bonnets to -196°C, fire-safe designs to API 607 / 6FA, NACE MR0175 sour service preparation, and bellows-sealed stems for zero fugitive emission applications to ISO 15848 Class AH.