Custom Industrial and Commercial Valve Design

At Williams Valve, we specialize in custom design for industrial and commercial valves. We’re one of the few valve companies in the US capable of creating or altering a valve design specifically to your needs.

Standard valve designs may not be able to meet the precise demands of your operational requirements. We engineer valves that are not just functional, but integrate perfectly into your system. Every industrial valve we design, manufacture, and test is built to meet and exceed applicable regulations and any OEM specifications.

When your operation demands an industrial valve solution beyond a one-size-fits-all option, our team can work with you to develop the perfect custom solution.

We Custom-Design Valves for Your Requirements

Our industrial valve design process is built on collaboration with you and our expertise in fluid dynamics and material science.

1. Understanding Your Application & Requirements
   We gather critical information about your operational parameters, including:

• Type of fluid, temperature, pressure, viscosity, corrosiveness, abrasiveness, and any unique properties
• Flow rates, required control characteristics (on/off, throttling), cycling frequency, actuation method (manual, pneumatic, electric), and desired response time
• Ambient temperature, humidity, potential for vibration, and any hazardous area classifications.
• Any specific industry codes, certifications (e.g., API, ASME, NACE), or regulatory compliance your valve must meet
• Physical dimensions, connection types, and how the valve will integrate into your existing system
• Desired lifespan, maintenance intervals, and any specific performance metrics

2. Conceptualization & Initial Design

Based on the gathered data, we start developing the concept for your valve. First, we recommend the most suitable base valve type to achieve the desired flow control and performance. We then identify optimal materials for the valve body, trim, seals, and packing. Our team then develops initial sketches and basic schematics to visualize the proposed design.

3. Detailed Engineering & CAD Modeling

Once the conceptual design is approved, we move into detailed engineering. Our team uses advanced CAD software to create precise 3D models of the valve, perform Finite Element Analysis (FEA) simulations to analyze structural integrity, and use Computational Fluid Dynamics to optimize flow efficiency and minimize pressure drop.

When everything is optimized appropriately, we create full manufacturing drawings with precise dimensions, tolerances, and material specifications for each component.

4. Prototyping & Testing (as required)

For highly complex or critical applications, we may develop prototypes for rigorous testing as needed. This allows us to verify the valve’s operational performance, measure the actual flow characteristics, and simulate prolonged operational cycles to assess the valve’s lifespan to identify any potential wear points.

5. Manufacturing & Quality Assurance

In the last stage, our manufacturing facility begins work on your new valve. Once built, it will be put through a series of tests to confirm it meets or exceeds all requirements. We deliver your new valve with complete documentation, including material certifications, test reports, and any operating manuals.

Industrial Valve Materials by Application

The choice of materials for your industrial valve is determined by the type of fluid being handled, operating temperature and pressure, environmental conditions, and any industry-specific regulations that may apply.

For many common industrial uses, where the fluid has failure low reactivity and the operating conditions are moderate, we may use:

• Carbon Steel: A versatile and strong material suitable for a wide range of industrial applications involving water, steam, air, and petroleum products at moderate to high pressures and temperatures. Its primary limitation is its susceptibility to corrosion in wet or corrosive environments.
• Bronze: Known for good machinability and corrosion resistance, bronze is often preferred in marine environments and for certain fire protection systems.

When dealing with aggressive chemicals, high temperatures, or corrosive environments, more specialized materials are necessary. These may include:

• Stainless Steel (304, 316): The workhorse of corrosion-resistant valve materials. 304 offers excellent corrosion resistance and is widely used in food and beverage, pharmaceutical, and general chemical industries. 316 contains molybdenum, and resists pitting and crevice corrosion in chloride-rich environments.
• Alloy Steels: These alloys offer enhanced strength and creep resistance at elevated temperatures, making them suitable for high-pressure steam, power generation, and refinery service.
• Nickel Alloys (Monel, Hastelloy, Inconel): They provide superior resistance to severe corrosive media, including strong acids and oxidizing agents, even at high temperatures. Often used in marine, chemical processing, pulp and paper, and waste treatment.

Available Valve Seat Designs

We offer three standard seat designs for our industrial valves. Other designs are available upon request.

WEWSeal-1
This standard seat design is suitable for a wide array of demanding applications. RPTFE seat inserts are standard for CL150 & CL300. Devlon seat inserts are standard for CL600 & above. PEEK seats are available on request for high pressure applications.

WEWSeal-2
WEWSeal-2 seat designs are for applications that require redundant sealing when access to a valve is limited or start up conditions are known to have debris in the line. Lower torque and low pressure shut-off are often achieved while providing zero leakage reliability.

Metal-To-Metal Seats
There are several services that require metal to-metal seats, such as high temperature emulsion, steam, and corrosive and/or erosive environments. Our metal-to-metal seats use various hard face material on the ball and seat face such as Tungsten Carbide Coating and Chrome Carbide Coating.

Double Block And Bleed (DBB)
Our standard trunnion mounted ball valves are manufactured to facilitate block and bleed applications in the closed position. This allows both the upstream pressure (Pu) and the downstream pressure (Pd) to be held independently from the body pressure (Pb). The double block and bleed function makes it possible to flush the valve under pressure and verify that the seats are sealing properly.

Double Isolation And Bleed (DIB)
We manufacture a single valve with two seating surfaces, each of which, in the closed position, provides a seal against pressure from a single source with a means of venting/bleeding the cavity between the seating surfaces. This is available in both DIB-1 (two bidirectional seats) and DIB-2 (one bidirectional and one unidirectional seat) configurations.

Single Piston Effect Seat (SPE)
With SPE, a self-relieving ball seating allows for fluid shutoff by the upstream seat rings. Each seat ring is of single-directional type, so it is only pushed towards the ball if the pressure in the body cavity is lower than the line pressure. Any overpressure of the fluid trapped in the body cavity pushes the seat ring away from the ball and excess pressure is automatically relieved back into the line.

Double Piston Effect Seat (DPE)
Double isolation ball sealing is a standard seat design. As each seat ring is of bidirectional type, the displacement of the body-side O-ring pushes each seat ring towards the ball, regardless of the fluid pressure distribution through the valve. This redundant sealing system forms a double barrier against the fluid, ensuring valve shutoff by the downstream seat ring if the one upstream fails. A pressure relief valve is fitted to the vent connection of the body cavity to prevent dangerous overpressure from thermal expansion of fluid trapped between the seat rings.

Innovative Contained Bonnet Gasket Design

At Williams Valve, our engineering team is constantly working to improve our products so that they not only meet but exceed the latest environmental standards. A significant recent advancement is our totally contained bonnet gasket design. In this design, the gasket that seals the joint between the valve body and the bonnet (the top cover of the valve) is fully enclosed and confined within a machined cavity. When combined with our standard stem packing, this allows your valves to surpass most fugitive emission requirements, dramatically reducing the likelihood of unwanted leaks and contributing to cleaner and safer operations.

Spring Energized Seat Design for Pipeline Valves

Pipeline valves with a spring-energized seat design automatically relieve excess body pressure inside the valve to prevent over-pressurization and potential damage to the valve or pipe.

During operation, the valve’s initial seal forms as the raised plastic ring on the seat faces contacts the gate. The seat inserts actively clean both sides of the gate with each opening and closing cycle. For low-pressure scenarios, the upstream seal is created by line pressure pushing the upstream seat against the gate, forming a tight plastic-to-metal seal. Simultaneously, the O-ring seals tightly within its recess.

If body pressure surpasses line pressure due to thermal expansion, the upstream seat is pushed back into its recess, allowing excess pressure in the body to bleed into the line between the seat and the gate. When line pressure is applied, it acts on the gate, forcing it against the plastic ring on the downstream seat. This compresses the ring until the gate rests against the steel seat, forming a double seal: first, a plastic-to-metal seal, then a metal-to-metal seal. The seal is also firmly held in its recess, with the O-ring preventing any downstream flow around the seat.

Precision Engineered Industrial Valves for Your Operation

Go beyond standard designs for unmatched reliability and efficiency. Contact Williams Valve today for industrial valves designed, manufactured, and tested to exceed all your specifications.