Heavy-Duty Forged Pressure Shells for Hydropower Valves
Forged valve bodies serve as the primary pressure-containing shells in hydropower and large industrial valve systems. They form the structural enclosure that houses internal components such as valve discs, stems, and sealing elements, while safely withstanding internal fluid pressure throughout the valve’s service life.
Compared with cast alternatives, forged valve bodies offer superior internal integrity, enhanced resistance to pressure-induced deformation, and improved reliability for critical clean energy infrastructure.
Engineering Function & Design Role
The valve body is a static structural component, not a moving or sealing element. Its engineering role focuses on:
- Containing internal pressure
- Supporting internal valve components
- Maintaining dimensional stability under long-term load
- Providing reliable interfaces for flanges, covers, and mounting surfaces
All geometric features—such as flow cavities, flange faces, and wall thickness distribution—are designed to balance pressure resistance with manufacturability.
Manufacturing Approach
Forged valve bodies are produced through open-die forging combined with controlled pre-forming, allowing sufficient material distribution for complex wall sections and internal cavities.
This forging route enables:
- Dense internal structure across thick pressure walls
- Reduced risk of shrinkage defects common in cast bodies
- Flexible adaptation to custom valve designs and pressure classes
Subsequent machining operations define flow paths, flange faces, bolt holes, and reference surfaces, ensuring proper assembly with downstream piping and valve internals in accordance with customer-approved drawings and interface requirements..
Typical Dimensions & Weight Range
| Parameter | Typical Range |
| Nominal Valve Size (DN) | DN400 – DN3000 |
| Maximum Wall Thickness | ≤ 800 mm |
| Overall Body Envelope | Project-specific |
| Forged Weight | 100 kg – 10,000 kg |
These dimensions align with medium- to large-scale hydropower valve bodies, while remaining clearly differentiated from shaft-type or disc-type forged components.
Material Scope
Forged valve bodies are manufactured primarily from
carbon steel and Alloy Steel, selected according to system pressure, operating temperature, and applicable standards. Material selection is defined by design pressure, operating temperature, and applicable project standards.
Typical material categories include:
- Carbon steel for standard hydropower pressure ratings
- Alloy steel for higher-pressure or thicker-wall valve bodies
Valve bodies can undergo annealing heat treatment after forging and rough machining to:
- Relieve residual forging stress
- Improve internal structural uniformity
- Enhance dimensional stability during final machining
This is particularly important for thick-walled bodies with complex internal geometry.
Typical Applications
Forged valve bodies are widely used in:
- Hydropower gate valves
- Butterfly valve housings
- Large shut-off and isolation valves
- High-pressure water conveyance systems
They are especially suitable for clean energy projects where long service life and structural reliability are mandatory.
Advantages of Forged Valve Bodies
- Superior pressure resistance versus cast bodies
- Uniform internal structure in thick sections
- Lower risk of internal defects
- Suitable for custom geometries and large sizes
- Proven reliability in hydropower applications
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