GENEL VANA DIFFERENCE IN ENERGY FLOW
As Genel Vana, we offer repair services specific to the needs of the energy sector. We offer special maintenance solutions without disrupting production, taking into account facility safety. We specialize in natural gas combined cycle power plants, thermal power plants and geothermal energy facilities. We detect faulty parts, quickly measure and mark them. You can leave your valves in safe hands with our expertise in material selection in repair kit production. As Genel Vana, we are here with our reliable, high-quality and meticulous service approach.
Globe control valves used in the energy sector (Class 600, 900, 1500, 2500) operate under high pressure and temperature conditions in steam lines ranging from 300-450-550°C. Over time, the seat/plug components may undergo deformation, requiring maintenance due to issues such as flow leakage, body and bonnet plug stem, and gland leakage. These valves are equipped with Stellite coating with a hardness of 1mm/3mm at 58 HRC on the seat rings and plug surfaces. In high-pressure valves, the seat ring is welded to the valve body. These valves belong to the most challenging repair group, requiring expertise and experience. We can successfully handle this task. You can trust us.
REPAIR OF HIGH-PRESSURE VALVES
1) Worn parts of the Stellite coating are filled with Stellite welding wire using argon (TIG) welding. Subsequently, excess material is shaved off through mechanical processes, and grinding is performed to achieve the final dimensions. This is a short-term solution, and we do not prefer it unless necessary.
2) KFor a permanent solution, we connect the valve body to our four-axis CNC horizontal machining center.
With a short program, the spindle on the machining center, using a suitable milling tool, removes the welded seat ring from the body and clears the cavity.
The re-manufactured seat ring, produced on our C-axis CNC lathe machine, undergoes heat treatment and is ground to its final dimensions after reaching a hardness of 58 HRC. The same procedures are applied to the plug component.
The prepared seat ring is then mounted onto the valve body. The entire body is annealed at high temperatures and flawlessly welded to the body using a special robot arm that we produce in-house. While this method may increase costs and require a CNC machine, we prefer this solution. The valve becomes as good as new, and you can find this genuine repair service exclusively at VALGEN.
RAW REPAIR KIT MATERIALS FOR HIGH-PRESSURE VALVES
We use special Swedish steel in the production of seat/plug. This material has a unique formulation tailored to our company and is ordered in large quantities from the steel manufacturer. All chemical properties and production information of the material are kept confidential by us. This special steel transforms into a soft material that can be welded after the body is annealed following heat treatment. Additionally, it can operate continuously at 550 bar pressure and 700°C temperature. In the production of the repair kit, the fluid, pressure, and temperature conditions of the valve are of great importance. Using our metal analysis detector, we determine the structure of the material, prepare technical drawings, and achieve perfect production with the right material selection on our CNC machines.
We worked meticulously on the repair of the Crane 12" ANSI Class 900 Parallel Slide valve. The plug was re-manufactured on our CNC machine, and the valve body's seat ring was precisely corrected by grinding on our CNC machine.