Overcome the multiple constraints of a complex case, such as manufacturing piston valves for polyethylene

Background

Guichon is assigned providing special valves for one of the biggest polyethylene manufacturing sites.

Valves detail:

  • 16 pneumatic piston valves: type 606 (metal to metal) – from 1×2 inches Class 600 to 3×3 inches CLASS 600 passing through 2×2 CL150
  • 24 motorized piston valves: type 606 – from 3×4 inches CL600 to 6×6 CL600
  • Connection parts
  • 84 manual piston valves: type 606 – from 1×1 inches CL600 to 4×4 CL600

Material

A352 LCB (Low temp. Carbon steel resisting to -52°C) & CF8 stainless steel.

 

Piston valve-single acting actuator 606 type class 150 Guichon Valves 3D
Piston valve-single acting actuator, 606 type, class 150, DN2”
piston valve double acting actuator guichon valves class 600 3D
Piston valve double acting actuator, 606 type, class 600, DN3”

It deals with a more than 100 valves order but above all, a multiple constraints order:

  • A large number of customized special valves
  • Some technical constraints:
    • Polar external environment (-52°C)
    • Some adaptation parts to create for assembly on large diameters’ piping (24’’ adapters on 2’’ valves)
    • A very long engineering work including 35 new valves designs, long lengths valves (until 4m long)
  • A substantial documentary management

The solutions proposed by Guichon

1/ The order consists of 124 valves

Considering an important quantity of customized valves to manufacture, Guichon needs to adapt the internal organization:

  1. Specially dedicated project team and manager
  2. Re-audited internal and subcontracting flows
  3. Batch manufacturing: the products are allocated to different manufacturing batches according to their pressure, dimensions, handling characteristics
  4. Stringent follow-up of the project team at every step of the process for traceability and to ensure valves’ quality
  5. Strict monitoring of the suppliers and sub-contractors

2/ Handle the technical constraints

– To be able to meet the very low temperature requirements, some specific stainless steel and carbon steel grades have been selected.

– To be able to match some 24’’ND on 2’’, the engineering office created some specific adapters. Guichon passes through welding procedure and welders qualifications to be able to weld such strong thickness adapters, approaching 70mm.

Adaptation piece 2'' on 24'' Guichon Valves
welder guichon valves

3/ Substantial documentary management:

documentation guichon valvesMany documents to provide for the project (from 30 to 40 different types of documents, for ex: Russian certification template, Russian technical passport, material certificate summary, certification of wooden crates treatment, pictures of internal and external packaging for each dispatched batch… in Russian)

– Need to obtain some Russian GOST system certifications, allowing to certify each valve according to the Gost russian certificationcountry legislation:

– Procurement of the CU TR 32 certification extension, authorizing the company to export to Russia (equivalent to PED in Europe)

– Procurement of the CU TR 12 certification for the ATEX standard: certifies that the product can be used in ATEX zones in Russia.

– Procurement of the CU TR 10 corresponding to the machinery and equipment safety certification.

The products design was thus approved by the certifying body, resulted in a CU TR 10/12/32 certification and allowed us to obtain the EAC certification for our 606N and 606M type valves.

piston valve electric actuator 606 type, class 600 guichon valves 3D
Piston valve electric actuator, 606 type, class 600, DN6”
Piston valve manual, 606 type, class 600 guichon valves 3D
Piston valve manual, 606 type, class 600, DN4”

Our strengths to handle complex cases

Listening and accompanying the customer through a project team and expert engineering office.

Reactivity and agility to meet the customer requirements.

 

Adaptation capacity to react to many technical uncertainties and customer requirements that evolve throughout the project while limiting as much as possible the costs-deadlines impact.

piston valve electric actuator 606 type, class 600 guichon valves
Piston valve with electric actuator 606 type, class 600, DN6”
piston valve double acting actuator guichon valves class 600 3D
Piston valve double acting actuator, 606 type, class 600, DN3”