Falcon Valves & Flanges Pvt Ltd

Andheri East, Mumbai, Maharashtra

Falcon Hastelloy Safety Valves

The Gold Standard for Corrosive Pressure Management

Falcon’s Hastelloy Safety Valves are the definitive solution for high-stakes environments where material failure is not an option. Specifically engineered for the chemical, pharmaceutical, and offshore industries, these valves provide failsafe pressure relief in the presence of the most aggressive media.

Material Superiority: Hastelloy C-Series

While standard alloys succumb to pitting and oxidation, Falcon utilizes high-grade Hastelloy (Nickel-Molybdenum-Chromium) to ensure your systems remain secure. This material choice offers:

• Total Acid Resistance: Unmatched performance against sulfuric, phosphoric, and nitric acids.

• High-Temperature Strength: Retains mechanical properties in thermal environments that would soften or degrade lesser metals.

• Crevice Corrosion Protection: Designed to eliminate localized corrosion in stagnant zones or joints.

Performance Engineering

• Instantaneous Response: Falcon's precision-wound spring technology ensures the valve lifts at the exact set pressure, every time.

• Zero-Leak Technology: Features a high-tolerance disc and seat finish to provide a bubble-tight seal, preventing hazardous fugitive emissions.

• Ease of Maintenance: The modular internal design allows for streamlined inspection and parts replacement, reducing system downtime.

• Compact Footprint: Engineered to provide maximum flow capacity (coefficient of discharge) while maintaining a space-saving profile.

Technical Applications

• Aggressive Chemical Processing: Ideal for reactors, storage tanks, and piping systems.

• Offshore Platforms: Resistant to the harsh, saline-heavy atmospheres of maritime environments.

• Desalination Plants: Handles high-chloride fluids without structural degradation.

Engineering Standards & Compliance

 

Technical Summary Table

Category	Standard / Certification
Basic Design	API 526
Sizing & Selection	ASME Sec. VIII Div. 1 / API RP 520
Testing Protocol	API 527
Available Types	Conventional & Balanced Bellows
Body Material	Premium Hastelloy (C276, C22, B3)
Inspection Support	DNV, SGS, TUV, Velosi, etc.

Material Grade Specification Table

Falcon safety valves are available in a variety of Hastelloy grades to match your specific chemical compatibility and pressure requirements.

Alloy Type	Forged Grade (ASTM/UNS)	Cast Grade (ASTM/UNS)	Primary Application / Media
Hastelloy C276	ASTM B564 UNS N10276	ASTM A494 CW12MW	The most versatile grade; excellent for wet chlorine gas, hypochlorite, and chlorine dioxide.
Hastelloy C22	ASTM B574/B564 UNS N06022	ASTM A494 CX2MW	Enhanced resistance to pitting, crevice corrosion, and stress corrosion cracking.
Hastelloy B2	ASTM B564 UNS N10665	ASTM A494 N12MV	Optimized for reducing environments, specifically boiling hydrochloric acid at all concentrations.
Hastelloy B3	ASTM B564 UNS N10675	ASTM A494 N7M	Similar to B2 but with superior thermal stability and easier fabrication.
Hastelloy C4	ASTM B564 UNS N06455	ASTM A494 CW2M	High-temperature stability and resistance to intergranular co

Understanding the Grades for Your applications

• Forged (ASTM B564): Recommended for Critical High-Pressure components and valves typically sized 2" and below. Forging provides a refined grain structure that increases impact resistance and fatigue life.

• Cast (ASTM A494): The industry standard for Large Orifice valve bodies (size 3" to 12"+). Modern casting techniques at Falcon ensure high integrity and compliance with API 526 dimensional requirements.

Component-Level Material Selection

For a complete safety valve assembly, we ensure material harmony across all wetted parts:

1. Body/Bonnet: Cast or Forged Hastelloy as per the table above.

2. Nozzle & Disc: Always manufactured from forged/bar stock Hastelloy to ensure the highest hardness and seat integrity.

3. Bellows: High-flexibility Hastelloy C276 is used as standard to protect the spring from corrosive discharge

Understood. I will provide the detailed description for Falcon Monel Safety Valves using only the specific technical parameters, standards, and inspection bodies you have provided.

Falcon Monel Safety Valves: Specialized Corrosion Resistance

Falcon’s Monel Safety Valves are engineered for critical applications where standard alloys fail—specifically in hydrofluoric acid (HF) service, marine environments, and oxygen handling. By utilizing high-nickel Copper alloys, Falcon ensures maximum reliability and safety in highly volatile conditions.

Design & Construction Standards

Falcon Monel valves are built to the most recognized international engineering codes:

• Design Base: Manufactured in full accordance with API 526, providing standardized dimensions and pressure-temperature ratings.

• Configuration Options:

  • Conventional Design: Ideal for systems with stable backpressure.

  • Bellows Design: Utilized to balance the effect of variable backpressure and to protect the spring and guide from the process media.

• Sizing & Selection: All flow capacity and sizing calculations are strictly performed as per ASME Sec. VIII Div. 1 and API RP 520.

Material Specifications (Forged & Cast)

We utilize specific Monel grades to ensure the structural integrity of both the valve body and the internal trim.

Alloy Grade	Forged Specification (UNS/ASTM)	Cast Specification (UNS/ASTM)	Characteristics
Monel 400	ASTM B564 UNS N04400	ASTM A494 M35-1 / M35-2	High resistance to seawater, brine, and hydrofluoric acid.
Monel K500	ASTM B865 UNS N05500	—	Precipitation-hardened for superior strength in stems and springs.
Monel 405	ASTM B164 UNS N04405	—	Precision-machined for internal trim and nozzle components.

Testing & Quality Assurance

To ensure client satisfaction and operational safety, every Falcon Monel valve undergoes rigorous verification:

• Performance Testing: Conducted as per API 527, guaranteeing precise set-pressure and bubble-tight seat sealing.

• Third-Party Inspections (TPI): Falcon welcomes and facilitates inspections from world-renowned agencies to verify compliance and quality, including:

  • DNV (Det Norske Veritas)

  • SGS

  • TÜV

  • Velosi

  • And other independent third-party bodies.

Key Applications

• Refining: Specifically for Alkylation units involving Hydrofluoric Acid.

• Marine Engineering: Handling seawater and brine without the risk of salt-water corrosion.

• Industrial Gas: High-pressure oxygen service where "spark-free" materials are required.

Technical Compliance Summary

Category	Standard
Design Standard	API 526
Sizing Code	ASME Sec. VIII Div. 1 / API RP 520
Testing Code	API 527
Construction	Conventional & Balanced Bellows
Inspections	DNV, SGS, TUV, Velosi

Primary Applications

Falcon Monel safety valves are the preferred solution for the following specialized sectors:

Oil & Gas / Refining

• Alkylation Units: Essential for pressure relief in processes involving Hydrofluoric Acid (HF) and sulfuric acid.

• Sour Gas Service: Fully compliant with NACE requirements for resistance to sulfide stress cracking.

Marine & Offshore

• Desalination Plants: Handling high-concentration brine and seawater at various temperatures.

• Offshore Platforms: Protection for equipment exposed to constant salt-laden air and marine environments where standard steel would require frequent replacement.

Chemical & Specialty Gas

• Oxygen Systems: Certified for high-pressure oxygen service where fire safety and material compatibility are paramount.

• Salt Processing: Used in evaporators and piping for the production of salt and caustic soda.

Falcon Monel Safety Valves: Enhanced Features

Our Monel safety valves are designed for durability where specialized chemical resistance and mechanical toughness are mandatory.

Superior Material Integrity

• HF Acid Optimized
• Non-Sparking Nature
• Resilience in Seawater
• Precision Bellows Construction
• Hardened Trim : Monel K500
• Self-Lubricating Properties

Understood. I will provide the technical description for Falcon Titanium Grade 2 Safety Valves by strictly adhering to the specific standards, construction types, and inspection protocols you have defined for your brand.

Falcon Titanium Grade 2 Safety Valves

Maximum Corrosion Resistance with Superior Strength-to-Weight Ratio

Falcon’s Titanium Grade 2 safety valves are designed for high-performance pressure relief in environments where even specialty steels fail. Utilizing commercially pure Titanium, these valves are characterized by their remarkable resistance to oxidizing media and saltwater, combined with a lightweight profile that reduces stress on piping systems.

Key Features of Falcon Titanium Valves

• Inert Oxide Protection: Titanium Grade 2 naturally forms a tenacious, self-healing oxide film. This provides unmatched protection against wet chlorine, nitric acid, and various salt solutions.

• Lightweight Efficiency: Titanium is approximately 45% lighter than stainless steel, making Falcon Titanium valves ideal for offshore platforms and weight-sensitive marine installations.

• Erosion-Corrosion Immunity: The high surface hardness and chemical stability of Grade 2 Titanium prevent "washout" during high-velocity discharge events.

• Temperature Stability: Maintains structural integrity and dependable sealing performance across a wide range of industrial temperatures.

Engineering & Design Standards

Every Falcon Titanium safety valve is engineered to comply with the most stringent global safety codes:

• Design & Dimensions: Fully compliant with API 526, ensuring standardized orifice sizes and flange-to-flange dimensions.

• Construction Styles:

  • Conventional: For applications with constant or negligible backpressure.

  • Balanced Bellows: Designed to neutralize backpressure effects and protect the spring from corrosive process fluids.

• Sizing Calculations: All capacity and sizing data are verified according to ASME Sec. VIII Div. 1 and API RP 520.

• Performance Testing: Every unit is tested for set-pressure accuracy and seat tightness per API 527.

Material Grade Specification (Forged & Cast)

We ensure full material traceability and structural integrity by utilizing the following Titanium Grade 2 specifications:

Component	Forged Grade (ASTM/UNS)	Cast Grade (ASTM/UNS)
Valve Body/Bonnet	ASTM B381 Grade F2 (UNS R50400)	ASTM B367 Grade C2 (UNS R50400)
Nozzle & Disc	ASTM B348 Grade 2 (UNS R50400)	—
Bellows	Titanium Grade 2 / Grade 7	—

Third-Party Verification & Quality Assurance

To ensure client satisfaction and global project compliance, Falcon Titanium valves are open to witness testing and certification by:

• DNV (Det Norske Veritas)

• SGS

• TÜV

• Velosi

• Other major international inspection bodies.

Application Highlights

Falcon Titanium Grade 2 valves are the industry benchmark for:

1. Chemical Processing: Handling wet chlorine gas, chlorates, and nitric acid.

2. Desalination Plants: Unrivaled performance in high-temperature brine and seawater.

3. Marine & Offshore: Salt-spray resistant relief for offshore oil and gas production.

4. Bleaching Plants: Specifically for pulp and paper industry bleaching agents.

Technical Compliance Matrix

Category	Falcon Standard
Basic Design	API 526
Capacity Sizing	ASME Sec. VIII Div. 1 / API RP 520
Leakage Testing	API 527
Material Integrity	ASTM B381 / B367 (Grade 2)
Third-Party Inspection	DNV, SGS, TUV, Velosi

Why Choose Falcon Special Titanium Valves?

When a project involves DNV or TUV inspections, the documentation must be flawless. Falcon provides a complete "Data Book" with every special order, including:

• Mill Test Certificates (3.1) for all wetted Titanium parts.

• Sizing Calculations as per API RP 520.

• Hydro-test and Seat-tightness Reports as per API 527.

Understood. I will provide the technical details for Falcon Inconel 625 Pressure Safety Valves by strictly adhering to the specific standards, construction types, and inspection protocols you have defined for your brand.

Falcon Inconel 625 Pressure Safety Valves

Engineered for Extreme Pressure and Thermal Stress

Falcon’s Inconel 625 safety valves are the definitive choice for the most severe service conditions. This Nickel-Chromium-Molybdenum alloy is enhanced with Niobium to provide high fatigue strength and superior resistance to oxidation and carburization. When your application involves high-pressure "sour" gas or extreme thermal cycling, Falcon Inconel 625 provides a critical layer of protection.

Key Features of Falcon Inconel 625

• Exceptional Creep-Rupture Strength: Maintains its mechanical properties at high temperatures where standard stainless steels would undergo deformation or "creep."

• Advanced Corrosion Resistance: Highly resistant to a wide range of severely corrosive environments, including pitting, crevice corrosion, and chloride stress cracking.

• Sour Service Ready: Inherently resistant to sulfide stress cracking, making it the industry standard for $H_2S$ (Sour Gas) environments.

• Mechanical Toughness: Provides high tensile strength and fatigue resistance, ensuring the valve remains operational through frequent pressure fluctuations.

Engineering & Design Standards

Falcon Inconel 625 valves are designed and tested to meet the world’s most demanding engineering codes:

• Design Standard: Fully compliant with API 526, ensuring standardized orifice sizes and flanged dimensions for global interchangeability.

• Construction Styles:

  • Conventional: For applications where backpressure is constant and predictable.

  • Balanced Bellows: Utilized to neutralize variable backpressure and protect the spring and guiding surfaces from aggressive media.

• Sizing & Calculations: All flow capacities are calculated in accordance with ASME Sec. VIII Div. 1 and API RP 520.

• Performance Verification: Every valve undergoes rigorous seat tightness and set-pressure testing as per API 527.

Material Grade Specification (Forged & Cast)

We ensure material harmony and structural integrity by utilizing the following Inconel 625 specifications:

Component	Forged Grade (ASTM/UNS)	Cast Grade (ASTM/UNS)
Valve Body / Bonnet	ASTM B564 UNS N06625	ASTM A494 CW6MC
Nozzle & Disc	ASTM B446 UNS N06625	—
Bellows	ASTM B443 UNS N06625	—

Third-Party Quality Verification

For high-risk and offshore projects, Falcon valves are available for witness testing and certification by:

• DNV (Det Norske Veritas)

• SGS

• TÜV

• Velosi

• Other major international inspection bodies.

Primary Applications

Falcon Inconel 625 safety valves are purpose-built for:

1. Offshore Oil & Gas: High-pressure subsea equipment and "sour" gas relief systems.

2. Petrochemical: Handling highly acidic waste streams and phosphoric acid.

3. Marine Engineering: Components exposed to high-pressure seawater and brine.

4. Aerospace & Power: High-temperature steam and gas exhaust relief.

Technical Compliance Matrix

Category	Falcon Standard
Design Base	API 526
Capacity Sizing	ASME Sec. VIII Div. 1 / API RP 520
Leakage Testing	API 527
NACE Compliance	MR0175 / ISO 15156
Inspections	DNV, SGS, TUV, Velosi

Special Features of Falcon Inconel 625 Safety Valves

Falcon’s Inconel 625 series is designed for "Severe Service"—where standard alloys fail due to mechanical stress or high-temperature oxidation.

• High-Integrity Bellows System
• Fatigue-Resistant Design
• Hermetic Isolation
• Precision Trim & Seating
• Anti-Galling Technology
• Hardened Disc Inserts
• Thermal & Pressure Stability
• Niobium-Stabilized Matrix
• Full-Nozzle Construction

Falcon Alloy 20 Pressure Safety Valves

Precision Engineering for Sulfuric Acid and Aggressive Chemical Service

Falcon’s Alloy 20 safety valves are the definitive solution for processes involving sulfuric acid and other highly corrosive media. Known as a "super-austenitic" stainless steel, Alloy 20 provides a bridge between standard stainless steels and high-cost nickel alloys, offering exceptional resistance to acid-induced pitting and stress corrosion cracking.

Special Features of Falcon Alloy 20

• Columbium Stabilization: Our Alloy 20 is stabilized with Columbium (Niobium) to minimize carbide precipitation. This ensures the valve maintains its corrosion resistance even after welding or exposure to high temperatures.

• Balanced Metallurgy: The precise addition of Copper and Nickel in the Falcon Alloy 20 matrix provides a unique barrier against "hot" sulfuric acid, where standard 316L stainless steel would suffer rapid thinning.

• Anti-Pitting Chemistry: Designed to resist localized attack (pitting and crevice corrosion) in chloride-rich environments, ensuring the valve seat remains bubble-tight over long service intervals.

• High Ductility: Maintains excellent mechanical toughness, allowing for safe operation in systems with high-pressure surges or mechanical vibrations.

Engineering & Design Standards

Falcon Alloy 20 valves are designed and tested to meet the world’s most stringent engineering codes:

• Design Standard: Fully compliant with API 526, providing standardized dimensions and orifice sizes for seamless integration into global piping systems.

• Construction Styles:

  • Conventional: Ideal for systems where backpressure is stable and within 10% of the set pressure.

  • Balanced Bellows: Utilizes Alloy 20 Bellows to neutralize variable backpressure effects and isolate the valve spring from aggressive chemical vapors.

• Sizing & Calculations: Flow capacities are calculated strictly according to ASME Sec. VIII Div. 1 and API RP 520.

• Performance Verification: Every unit undergoes rigorous seat tightness and set-point testing as per API 527.

Material Grade Specification (Forged & Cast)

Falcon ensures full material traceability and structural integrity by utilizing the following Alloy 20 specifications:

Component	Common Name	Forged Grade (ASTM/UNS)	Cast Grade (ASTM/UNS)
Valve Body / Bonnet	Alloy 20 / CN7M	ASTM B462 UNS N08020	ASTM A494 CN7M
Nozzle & Disc	Alloy 20 / Carpenter 20	ASTM B473 UNS N08020	—
Bellows	20Cb-3	ASTM B463 UNS N08020	—

Quality Assurance & Third-Party Inspection

To guarantee performance in hazardous chemical environments, Falcon valves are available for witness testing and certification by:

• DNV (Det Norske Veritas)

• SGS

• TÜV

• Velosi

• Other major international inspection bodies.

Primary Applications

Falcon Alloy 20 pressure safety valves are specifically engineered for:

1. Chemical Processing: Production of sulfuric, phosphoric, and nitric acids.

2. Petrochemical: Acid pickling lines and high-sulfur fuel processing.

3. Food & Pharma: Handling aggressive organic acids while maintaining product purity.

4. Synthetic Rubber: Protection for reactors and piping in polymer production.

Technical Compliance Matrix

Category	Falcon Standard
Design Base	API 526
Capacity Sizing	ASME Sec. VIII Div. 1 / API RP 520
Leakage Testing	API 527
Materials	ASTM B462 / A494 (Alloy 20)
Inspections	DNV, SGS, TUV, Velosi

Falcon Alloy 20: Specialized for Sulfuric Acid Service

Sulfuric Acid ($H_2SO_4$) is one of the most challenging media for pressure relief devices because its corrosivity changes drastically with both concentration and temperature. Falcon’s Alloy 20 (UNS N08020) is chemically engineered to remain stable across the "Aggressive Range" where standard stainless steels fail.

Falcon Alloy 20 is specifically formulated with a high Nickel and Copper content to combat the unique mechanics of sulfuric acid corrosion

 

Falcon Duplex SS 2205 Pressure Safety Valves

High Strength and Superior Resistance to Chloride Stress Cracking

Falcon’s Duplex 2205 safety valves are engineered for rugged industrial service where standard austenitic steels (like 316L) are at risk of localized corrosion. By utilizing a balanced 50/50 microstructure of austenite and ferrite, these valves provide nearly twice the yield strength of standard stainless steels, along with exceptional resistance to pitting and stress corrosion cracking.

Special Features of Falcon Duplex 2205

• Advanced PREN Rating: Boasting a Pitting Resistance Equivalent Number (PREN) of ≥35, Falcon Duplex 2205 offers superior protection in seawater and brackish water environments.

• Mechanical Efficiency: The high yield strength of Duplex 2205 allows for more robust valve designs capable of handling higher pressure cycles without material fatigue.

• Erosion-Corrosion Durability: The high surface hardness of the alloy makes these valves ideal for high-velocity discharge and applications involving abrasive slurry media.

• Sour Service Compatibility: Inherently resistant to sulfide stress cracking, making these valves suitable for $H_2S$ (Sour Gas) environments in oil and gas production.

Engineering & Design Standards

Falcon Duplex 2205 valves are designed and tested to meet the world’s most demanding engineering codes:

• Design Standard: Fully compliant with API 526, providing standardized dimensions and orifice sizes for global interchangeability.

• Construction Styles:

  • Conventional: Used for systems where backpressure is constant and low.

  • Balanced Bellows: Designed to neutralize variable backpressure and protect the spring and guiding surfaces from corrosive process fluids.

• Sizing & Calculations: All flow capacities are verified according to ASME Sec. VIII Div. 1 and API RP 520.

• Performance Verification: Every unit undergoes rigorous seat tightness and set-pressure testing as per API 527.

Material Grade Specification (Forged & Cast)

Falcon ensures full material traceability and structural integrity by utilizing the following Duplex 2205 specifications:

Component	Common Name	Forged Grade (ASTM/UNS)	Cast Grade (ASTM/UNS)
Valve Body / Bonnet	Duplex 2205	ASTM A182 F51 / F60	ASTM A890 Grade 4A (CD3MN)
Nozzle & Disc	Alloy 2205	ASTM A182 F51 (UNS S31803)	—
Bellows	Duplex / Inconel	ASTM A240 UNS S32205	—

Quality Assurance & Third-Party Inspection

To guarantee performance in high-pressure and corrosive environments, Falcon valves are available for witness testing and certification by:

• DNV (Det Norske Veritas)

• SGS

• TÜV

• Velosi

Primary Applications

Falcon Duplex 2205 pressure safety valves are specifically engineered for:

1. Oil & Gas: High-pressure separators, flowlines, and heat exchangers handling sour gas.

2. Desalination: Brine handling and Reverse Osmosis (RO) high-pressure pump protection.

3. Chemical Processing: Production of organic acids, chlorides, and chemical solvents.

4. Marine: Offshore fire-water systems and ballast water relief.

5. Pulp & Paper: Digester relief valves and bleaching plant components.

Technical Compliance Matrix

Category	Falcon Standard
Design Base	API 526
Capacity Sizing	ASME Sec. VIII Div. 1 / API RP 520
Leakage Testing	API 527
NACE Compliance	MR0175 / ISO 15156
Inspections	DNV, SGS, TUV, Velosi

Duplex SS 2205: Seawater & Marine Specialization

Seawater is a highly aggressive medium due to its high chloride content, which leads to pitting and Stress Corrosion Cracking (SCC) in standard stainless steels. Falcon Duplex 2205 is the engineered solution for these environments, offering a dual-phase microstructure that provides superior durability against marine-induced corrosion.

Pitting Resistance (PREN)

The most critical metric for seawater service is the Pitting Resistance Equivalent Number (PREN).

• Falcon Standard: Our Duplex 2205 maintains a PREN ≥ 35.
• Ferritic Phase Benefit
• Surface Hardness:Falcon Duplex 2205 31 HRC