Falcon Valves & Flanges Pvt Ltd

Andheri East, Mumbai, Maharashtra

Material Capabilities: Engineered for Extremes

At Falcon, we specialize in manufacturing Floating and Trunnion Mounted Ball Valves that withstand the most demanding environments. From standard industrial applications to highly corrosive and high-pressure service (up to Class 2500#), our foundry and sourcing capabilities cover the complete spectrum of metallurgy.

Below is a brief guide to the material grades we offer:

1. Carbon Steel (Standard Service)

The backbone of the valve industry, offering excellent strength and durability for general applications.

• WCB / A105: The industry standard for non-corrosive flow at moderate temperatures. Ideal for water, oil, and gas transmission.

• Low-Temperature Carbon Steel (LCC / LCB / LF2): Specifically heat-treated to maintain impact toughness in sub-zero environments, essential for cryogenic and northern climate applications.

2. Stainless Steel (Corrosion Resistance)

Designed for clean services and environments requiring resistance to oxidation and chemical attack.

• Austenitic Stainless (CF8/304, CF8M/316, CF3M/316L): Provides excellent resistance to general corrosion and pitting. Widely used in chemical processing, food & beverage, and pharmaceutical sectors.

• Stabilized Grades (321, 347): Alloyed with Titanium or Niobium to prevent intergranular corrosion at elevated temperatures.

3. Duplex & Super Duplex (High Strength & Durability)

Bridging the gap between standard stainless and high-nickel alloys, these materials offer superior strength and resistance to Stress Corrosion Cracking (SCC).

• Duplex (2205 / CD3MN): Offers twice the strength of standard stainless steel with excellent resistance to chloride environments.

• Super Duplex (2507 / CE3MN): Designed for highly aggressive conditions, such as offshore oil & gas platforms and desalination plants, where pitting and crevice corrosion are major concerns.

4. Alloy Steel (High Temperature & Pressure)

Formulated to withstand extreme heat and pressure cycles without deforming or failing.

• Chrome-Moly Steels (WC6, WC9, C5, C12): These grades maintain high creep strength at elevated temperatures, making them the preferred choice for power generation and high-temperature refinery processes.

5. Nickel Alloys (Severe Service)

When standard steels fail, Nickel alloys provide the ultimate protection against extreme heat, oxidation, and aggressive acids.

• Inconel (600, 625, 718, 825): Exceptional strength and oxidation resistance at extreme temperatures.

• Monel (400, K500): Renowned for its resistance to rapidly flowing brackish water or seawater and hydrofluoric acid.

• Hastelloy (C276, C22): The premier choice for the most severe chemical environments, offering unmatched resistance to pitting and stress corrosion cracking in sour gas and acid services.

6. Exotic & Reactive Metals (Specialty Applications)

Falcon prides itself on manufacturing valves from materials that are difficult to source and machine.

• Titanium (Grades 2, 5, 12): Incredible strength-to-weight ratio and immunity to seawater corrosion. Vital for aerospace, marine, and chlor-alkali industries.

• Zirconium: Offers unique resistance to highly corrosive acids (hydrochloric, sulfuric, acetic) where even stainless steel and nickel alloys dissolve.

7. Special & Custom Grades

We specialize in the "hard-to-get." If your project requires a specific, non-standard metallurgy not listed here, Falcon has the supply chain and engineering expertise to manufacture it to your exact specifications.

Why Choose Falcon Materials?

• Full Traceability: All materials come with complete Mill Test Certificates (MTC) ensuring compliance with ASTM, ASME, and NACE MR0175 standards.

• NACE Compliance: We offer materials specifically heat-treated and tested for Sour Service (H2S) environments.

• Rigorous Testing: Positive Material Identification (PMI) is performed to guarantee the chemical composition of every valve we ship.

Falcon Forged UNS N08825 (Alloy 825) Check Valves

Falcon Alloy 825 check valves are engineered for automatic protection against flow reversal. By utilizing the unique Nickel-Iron-Chromium chemistry of Alloy 825, these valves remain functional and corrosion-free in environments that would typically cause standard valves to seize or leak.

Available Types of Falcon Check Valves

We offer three primary configurations to suit different flow velocities and piping orientations:

1. Piston (Lift) Check Valves

• Design: Utilizes a forged piston that "lifts" off the seat via fluid pressure.

• Best For: High-pressure gas or liquid service in smaller pipelines (typically up to 2").

• Feature: Usually spring-loaded to ensure rapid closure and prevent "slamming."

2. Swing Check Valves

• Design: Features a hinged disc that swings open with forward flow and closes when flow stops.

• Best For: Full-flow applications where low pressure drop is required.

• Feature: Designed with an internal hinge pin to minimize leak paths to the atmosphere.

3. Ball Check Valves

• Design: Uses a free-moving forged Alloy 825 ball to seal against the seat.

• Best For: Highly viscous fluids or applications where "chattering" is a concern.

• Feature: Exceptionally simple design with minimal moving parts for long-term reliability.

Key Features & Design Standards

• Forged Construction: Manufactured to ASTM B564, ensuring a rugged, high-density body that eliminates the risk of "pinhole" leaks common in castings.

• Gravity & Spring Assisted: Precision-calibrated springs ensure the valve closes the moment flow velocity drops, protecting upstream pumps.

• Metal-to-Metal Seating: Precision-lapped seats provide a tight seal even in high-temperature and high-acid environments.

• Zero-Leakage Sealing: Compliant with API 598 pressure testing requirements.

Technical Specifications

Common Applications

• Chemical Injection Lines: Preventing chemicals from backing up into the supply pumps.

• Desalination High-Pressure Pumps: Protecting expensive reverse osmosis (RO) pumps from back-pressure.

• Sour Gas Processing: Preventing H2S gas migration during system shutdowns.

• Offshore Scrubber Systems: Handling corrosive seawater and acidic condensates.

Falcon Quality Assurance: Integrity You Can Trust

At Falcon, quality is the cornerstone of our manufacturing process. Our UNS N08825 (Alloy 825) check valves are designed and tested to meet the stringent demands of the global energy and chemical sectors, ensuring they act as a fail-safe barrier against backflow in the most aggressive media.

1. Material Integrity & Verification

• PMI (Positive Material Identification): Every valve body, cover, and internal component is verified using X-ray fluorescence (XRF) to ensure the Nickel (38–46%), Chromium (19.5–23.5%), and Molybdenum (2.5–3.5%) content exactly matches the UNS N08825 specification.

• ASTM B564 Forging Standards: We exclusively use forged blanks that are free from the porosity and structural defects common in cast alternatives.

• Full Traceability: Each valve is stamped with a heat number and accompanied by an EN 10204 3.1 Mill Test Certificate (MTC).

Specialized Performance Testing (Optional)

For critical or "severe service" applications, Falcon provides advanced testing options:

• Fugitive Emission Testing: To ISO 15848-1, ensuring the cover-to-body seal meets environmental safety standards.

• NACE MR0175 / ISO 15156 Compliance: Verification that the valve is resistant to Sulfide Stress Cracking (SSC) for "sour" gas service.

• Dye Penetrant Testing (DP): Non-destructive testing on all forged surfaces to ensure the absence of surface cracks or fissures.

The Falcon Quality Commitment

We understand that a check valve failure can lead to catastrophic pump damage or hazardous leaks

Falcon is a premier manufacturer specializing in high-performance valves engineered for extreme sub-zero environments. Our low-temperature service valves are designed to maintain bubble-tight shut-off and operational integrity in conditions where standard valves would fail.

We offer a comprehensive range of designs to suit various piping configurations:

• Gate Valves: For full-flow, low-pressure drop applications.

• Globe Valves: Ideal for throttling and frequent operation.

• Check Valves: To prevent backflow in cryogenic lines.

• Ball Valves: Quarter-turn valves for quick shut-off, featuring cavity pressure relief.

• Sizes: Available from 1/2" to 24" (larger sizes available upon request).

• Pressure Classes: ASME Class 150 to 2500.

Cryogenic service requires materials that remain ductile at temperatures as low as -196°C.

• Body/Bonnet: ASTM A351 Gr. CF8/CF8M (Stainless Steel) or ASTM A352 Gr. LCB/LCC  or  ASTM A350 LF2(Low Carbon Steel).

• Trim: 316 Stainless Steel with Stellite facing for wear resistance.

• Seals/Gaskets: PTFE, PCTFE (Kel-F), or Graphite (fire-safe).

• Extended Bonnet: Essential to keep the packing gland away from the cold fluid to prevent freezing.

Our valves are manufactured in state-of-the-art facilities using precision CNC machining and controlled welding processes.

• Design: API 600, API 602, API 608, or ASME B16.34.

• Face-to-Face: ASME B16.10.

• End Connections: Flanged (ASME B16.5), Butt-weld (B16.25), or Socket-weld.

Every valve undergoes rigorous testing to ensure safety in hazardous environments.

• Cryogenic Testing: Per BS EN 12567 or MSS SP-134, involving liquid nitrogen cooling to verify seat leakage at service temperatures.

• Shell & Seat Test: API 598.

• Fugitive Emissions: ISO 15848-1 to ensure environmental compliance.

Falcon valves are the trusted choice for:

• LNG (Liquefied Natural Gas): Terminals, carriers, and regasification plants.

• Industrial Gases: Liquid Oxygen (LOX), Nitrogen (LIN), and Argon (LAR).

• Aerospace: Launchpad fuel handling systems.

• Ethylene Plants: Low-temperature petrochemical processing

The most critical component for low-temperature service is the extended bonnet. Falcon’s design ensures that the stem packing remains at an ambient temperature, preventing the packing from freezing and ensuring a leak-proof seal.

• Cavity Pressure Relief: In cryogenic ball and gate valves, trapped liquid can vaporize and create massive internal pressure. Falcon valves feature automatic pressure relief (vent holes or self-relieving seats) to ensure safety.

• Live-Loaded Packing: We utilize Belleville spring washers to maintain a constant load on the gland packing, compensating for thermal expansion and contraction during temperature fluctuations.

• Stellite™ Hard Facing: All seating surfaces are hard-faced with Stellite to prevent "galling"—a common issue when metal-to-metal contact occurs at extreme sub-zero temperatures.

• Anti-Static & Fire-Safe: All designs are inherently anti-static and tested to API 607 standards to ensure performance even in the event of a fire.

We have a particularly strong presence and a deep list of approved vendors in the following regions:

• Middle East / Gulf: Saudi Arabia (Major supplier to SABIC & Farabi), United Arab Emirates (UAE), Qatar, Kuwait, Oman, and Iraq.

• Africa: Nigeria, Kenya, Sierra Leone, Tanzania, and South Africa.

• Southeast Asia & Asia-Pacific: Malaysia, Indonesia, Sri Lanka, Nepal, and Australia.

• Europe & CIS: United Kingdom, Bulgaria, Turkmenistan, and various CIS nations.

• Americas: United States, Canada, and Paraguay

As the world transitions towards a cleaner energy future, hydrogen is emerging as a pivotal fuel source. At Falcon Valves and Flanges Pvt Ltd., we are proud to be at the forefront of this revolution, offering a comprehensive range of Hydrogen Service Valves designed and manufactured to meet the stringent demands of the entire hydrogen value chain – from generation to fueling stations.

Handling hydrogen presents unique challenges due to its small molecular size, high diffusivity, and potential for hydrogen embrittlement in certain materials. Falcon 's Hydrogen Service Valves are meticulously engineered to overcome these challenges, ensuring unparalleled safety, leak-tightness, and long-term reliability.

Key Features and Benefits:

• Forged Construction for Unmatched Integrity: Unlike cast valves, our hydrogen valves are primarily manufactured through the forging process. This ensures a superior grain structure, eliminating internal defects, voids, and porosity that can compromise integrity under high pressures and the unique demands of hydrogen. Forging provides exceptional strength, ductility, and resistance to hydrogen-induced degradation.
   
• Optimized Material Selection: SS316Ti and Beyond: We utilize premium material grades, with SS316Ti (Stainless Steel 316Ti) being a cornerstone of our hydrogen valve range. SS316Ti is a titanium-stabilized austenitic stainless steel known for its enhanced resistance to intergranular corrosion, particularly at elevated temperatures, and its improved mechanical properties. This makes it an ideal choice for challenging hydrogen environments where material stability is paramount. For specific applications requiring even greater resistance to hydrogen embrittlement or extreme conditions, we offer valves in other specialized material grades on request.
   
• Leakage Prevention: A Critical Imperative: Hydrogen 's small molecular size makes leak prevention crucial for both safety and efficiency. Our valves incorporate advanced sealing technologies, precision machining, and rigorous testing protocols to ensure zero fugitive emissions. This includes specialized packing designs and tight tolerances, critical for preventing hydrogen escape throughout the system.
• Comprehensive Application Coverage: Falcon Hydrogen Service Valves are designed to perform across the entire hydrogen ecosystem, including:
  • Hydrogen Production: Valves for electrolysis, steam methane reforming, and other generation processes, handling various pressures and temperatures.
  • Hydrogen Compression and Storage: Robust valves built to withstand high pressures for efficient compression and safe storage in tanks and cylinders.
  • Hydrogen Transportation: Reliable solutions for pipeline and mobile transport applications.
  • Hydrogen Fueling Stations: Precision control valves for safe and efficient dispensing of hydrogen to vehicles.
• Rigorous Quality Assurance: Every Falcon Hydrogen Service Valve undergoes stringent quality control procedures and comprehensive testing, including helium leak testing, to verify absolute integrity and performance under the most demanding conditions.

Choose Falcon Hydrogen Service Valves for a secure, efficient, and sustainable future, where the power of hydrogen flows reliably and safely.

Alloy 825 Valves

Alloy 825 Valves are made to work in highly aggressive industrial environments. These products are assured to give outstanding resistance to corrosion and heat. To serve your demands, we at Falcon Valves specialise in manufacturing high-quality Alloy 825 Valves. We promise to give a trustworthy, reliable flow control in applications where conventional valve materials fail.

Alloy 825 Valves an outstanding choice for use in

• chemical processing,
• offshore oil & gas,
• pollution control,
• nuclear fuel reprocessing,
• Marine applications.

Falcons Alloy 825 Valves are offered in different kinds, like gate, globe, check, and ball valves. All kinds are rightly engineered to withstand corrosive fluids and work under high pressure and temperature.

Why Choose Falcon Valves for Alloy 825 Valves?

• Years of industry experience - Decades of proficiency in designing field metal valves for harsh environments.
• Top material choice Just certified Alloy 825 materials are utilised, ensuring reliability and fulfilment.
• Customisation Capability personalised solutions for pressure size, rating, end connection, and valve design.
• Advanced Manufacturing CNC precision-machining and in-house excellence testing for leak-proof and true results.
• On-Time Delivery Streamlined manufacturing and logistics to meet your project deadlines proficiently.
• Compliant with worldwide Standards Valves are properly tested to meet ASME, API, and ASTM standards.
• Technical assistance and paperwork Get assistance from design to post-installation, like the material test certificates and examination reports.

Prime features of Alloy 825 Valves

Superior Corrosion Resistance

• It is quite resistant to phosphoric, sulfuric, and nitric acids and seawater. It turns perfect for chemical and marine setups.

Excellent Mechanical Strength

• It is about to keep the high tensile strength and dimensional stability under pressure and temperature distinctions.

Chloride Stress-Corrosion Resistant

• It is effective in chloride-rich environments where other materials are prone to cracking or ruin.

High-Temperature Capability

• Appropriate for the elevated temperature services without compromising performance.

Highly durable and long-lasting

• Low wear and tear, even in callous operating conditions, leads to reduced protection and extended service life.

Flexible Application

• Ideal for industries like petrochemical, fertiliser, water treatment, oil & gas, and pollution control systems.

Invest in reliability and performance with Falcons Alloy 825 Valves the favored choice for severe-service flow control.

If you are interested in our products and wish to place order, just contact our team. We also accept the customized orders from the side of the customer. Contact us now for more information.

Falcon Valves and Flanges Pvt Ltd. offers a specialized range of Ammonia Service Valves, meticulously engineered to ensure safe and reliable operation in challenging ammonia applications. Recognizing the highly corrosive, toxic, and flammable nature of ammonia, our valves are designed with critical considerations for material selection, sealing integrity, and rigorous cleaning procedures.

Manufactured from carefully chosen material grades such as carbon steel for anhydrous ammonia and stainless steel for applications where moisture may be present, our ammonia valves minimize the risk of corrosion and stress cracking. Each valve undergoes stringent cleaning and testing protocols to eliminate any traces of oil, grease, or hydrocarbons, crucial for preventing hazardous reactions with ammonia. With various pressure ratings and valve types available, Falcon Ammonia Service Valves provide a robust and secure solution for critical flow control in industries like fertilizers, refrigeration, and chemical processing.

Introducing Falcon Valves and Flanges Pvt Ltd. 's Triple Offset Butterfly Valves (TOBV) – meticulously designed and manufactured in-house to meet the most demanding industrial applications. Our TOBVs feature a unique triple offset geometry, providing a bubble-tight shut-off and bidirectional sealing, ensuring superior performance and extended service life.

Crafted from a wide range of high-quality material grades and available in various pressure ratings, Falcon TOBVs deliver exceptional reliability and efficiency for critical flow control in diverse industries.

Falcon Valves and Flanges Pvt Ltd. possesses extensive, in-hand experience in designing and manufacturing specialized Vinyl Chloride Monomer (VCM) Service Valves for critical applications within the petrochemical industry. Recognizing VCM as a colorless, highly flammable, and toxic gas that is typically handled as a liquefied gas under pressure, our valves are engineered to manage its unique and challenging properties.

Our VCM valves are precisely manufactured in high-grade materials such as Stainless Steel and Monel, chosen specifically for their excellent corrosion resistance and mechanical integrity in the presence of VCM, which can exhibit corrosive tendencies, especially when moisture is present. Stainless Steel (e.g., 316L) offers robust performance, while Monel (e.g., Monel 400, K500) provides superior resistance to stress corrosion cracking and general corrosion, crucial for applications where extreme purity and long-term reliability are paramount.

Having successfully supplied VCM valves to numerous petrochemical plants, Falcon Valves leverages its deep understanding of VCM 's characteristics – including its low boiling point, high vapor pressure, and potential for polymerization – to deliver solutions that ensure optimal safety, leak-tightness, and operational efficiency. Each valve is designed to withstand the pressures and temperatures inherent in VCM service and undergoes stringent quality control and testing to prevent leaks and ensure reliable flow control in this demanding environment.

Falcon Valves and Flanges Pvt Ltd. proudly presents its highly specialized Chlorine Service Valves, expertly engineered for the extreme demands of chlorine applications. Given the highly corrosive nature of both wet and dry chlorine, our valves are meticulously crafted from premium Hastelloy and Titanium grades, offering unparalleled resistance to pitting, crevice corrosion, and stress corrosion cracking.

With a proven track record, Falcon Chlorine Service Valves have been successfully deployed in numerous critical projects for industry leaders such as SABIC Saudi Arabia and Transco Abu Dhabi, demonstrating our commitment to delivering reliable, long-lasting solutions for the safe handling of chlorine in chemical processing, water treatment, and other vital sectors.

Falcon Sulphuric Acid Valves: Uncompromising Performance for Corrosive Environments Sulphuric acid (HSO) is one of the most widely used industrial chemicals, integral to processes across the Mining, Petrochemical, Steel, and Fertilizer industries. However, its highly corrosive nature presents significant challenges for valve integrity and operational safety. At Falcon Valves and Flanges Pvt Ltd., we specialize in designing and manufacturing a comprehensive range of Sulphuric Acid Valves engineered to excel in these demanding applications, ensuring long-term reliability and minimizing downtime.

Our extensive portfolio includes all types of valves – from ball and gate to globe, check, and butterfly valves – meticulously crafted to handle various concentrations and temperatures of sulphuric acid. The cornerstone of our offering lies in our precise material selection, leveraging advanced alloys to provide unparalleled corrosion resistance.

The Falcon Advantage: Superior Material Selection for Sulphuric Acid Service Choosing the right material is paramount for safe and efficient sulphuric acid handling. Falcon Valves offers valves manufactured from a range of high-performance alloys, each selected for its specific benefits in resisting sulphuric acid 's corrosive effects:

1. SS316 (Stainless Steel 316):

Benefits: Stainless Steel 316 is a cost-effective and widely used austenitic stainless steel, offering good general corrosion resistance. It performs well in dilute sulphuric acid solutions and at lower temperatures. Its molybdenum content enhances its resistance to pitting and crevice corrosion.

Applications: Ideal for less aggressive sulphuric acid concentrations (up to 20% at ambient temperatures) and where moderate corrosion resistance is acceptable. 

2. SS904L (Stainless Steel 904L):

Benefits: SS904L is a super austenitic stainless steel known for its exceptional corrosion resistance, particularly in moderate to high concentrations of sulphuric acid and at elevated temperatures. Its higher content of chromium, nickel, and molybdenum, coupled with copper addition, significantly improves its resistance to uniform corrosion, pitting, and stress corrosion cracking in sulphuric acid environments. It outperforms SS316 in more aggressive conditions.

Applications: Highly recommended for concentrations up to 70% at moderate temperatures, and for various concentrations at ambient temperatures where superior resistance is required. Suitable for critical lines in fertilizer plants, pickling lines in steel mills, and various petrochemical processes.

3. Alloy 20 (Carpenter 20 / UNS N08020):

Benefits: Alloy 20 is a nickel-iron-chromium alloy with additions of molybdenum and copper, specifically designed for excellent resistance to sulphuric acid. It provides superior performance across a wide range of sulphuric acid concentrations and temperatures, including hot and moderately concentrated solutions. Its composition offers outstanding resistance to stress corrosion cracking, pitting, and crevice corrosion in sulphuric acid, as well as other aggressive acid.

Applications: A preferred choice for highly corrosive sulphuric acid applications, especially in the 20-50% range at boiling temperatures, or 85-95% concentrations at lower temperatures. Widely used in the fertilizer industry (e.g., phosphoric acid production), chemical processing, and pharmaceutical applications where robust acid resistance is critical.

4. Hastelloy C276:

Benefits: Hastelloy C276 is a nickel-molybdenum-chromium superalloy with excellent resistance to a wide range of severe corrosive environments, including very aggressive sulphuric acid concentrations, especially at high temperatures and in the presence of impurities or oxidizing agents. It offers exceptional resistance to pitting, crevice corrosion, and stress corrosion cracking. Its versatility makes it the material of choice when other alloys fail.

Applications: Reserved for the most challenging sulphuric service.

Engineered for the Elements: Falcon’s Seawater Specialization

Falcon is a global leader in the design and manufacture of high-performance valves engineered specifically for the world’s most demanding seawater environments. With decades of expertise, we provide robust flow-control solutions that eliminate the risks of marine corrosion and material fatigue. From offshore platforms to desalination plants, Falcon ensures operational longevity where others fail.

Falcon Product Portfolio: Seawater & Industrial Valves

Falcon designs and manufactures a comprehensive range of valves and strainers, strictly adhering to international standards such as API, ASME, ANSI, BS, and DIN. Below are the technical details of our core product line:

1. Isolation & Flow Control Valves

2. Specialized & Critical Service Valves

• Check Valves (Non-Return):

  • Types: Swing Check, Dual Plate, Lift Check, Nozzle Check.

  • Features: Quick-closing to prevent water hammer; essential for seawater injection and ballast systems.

• Safety & Relief Valves:

  • Function: Critical overpressure protection for pressure vessels and pipelines.

  • Materials: Engineered in SS904L and Inconel to maintain spring integrity in corrosive atmospheres.

• Control Valves:

  • Types: Pneumatic or Electric Actuated for precise pressure and flow regulation.

  • Application: Ideal for desalination plants and chemical processing where seawater is the primary media.

3. Filtration & Protection

• Industrial Strainers:

• Types: Y-Type, T-Type, Basket (Simplex/Duplex), Fabricated Strainers.

   

   

• Details: Heavy-duty mesh liners in Cupro Nickel or Stainless Steel to protect downstream equipment from marine debris.

Technical Summary & Material Standards

Falcon ensures all products meet the rigorous demands of marine and offshore environments through:

• Manufacturing Standards: Conforming to API 6D, API 600, ASME B16.34, and ISO 9001.

• Material Grades:

  • Duplex/Super Duplex: ASTM A890 Gr. 4A/5A/6A, ASTM A182 F51/F53/F55.

  • Nickel Alloys: Monel 400, Inconel 625, Hastelloy C276.

     

     

  • Exotics: Titanium Gr. 2 & Gr. 5, Nickel Aluminium Bronze (ASTM B148 C95800).

     

     

• Testing: 100% Hydrostatic and Pneumatic testing; optional NDT (Radiography, UT, Dye Penetrant) and Pitting Resistance Equivalent Number (PREN) verification.

Seawater Material Specialization & Quality Excellence

At Falcon, the foundation of our seawater specialization is the Science of Corrosion Resistance. Seawater is a living, aggressive medium that causes pitting, crevice corrosion, and biofouling. Our quality process ensures that every valve is metallurgically matched to its specific subsea or splash-zone environment.

The Falcon Advantage: Material Integrity

We utilize High-PREN (Pitting Resistance Equivalent Number) materials to ensure our valves exceed a rating of 40, providing a robust defense against chloride-induced stress corrosion cracking (CSCC).

As Falcon Valves, we are proud to be a globally recognized and leading manufacturer of high-performance Non-Slam Nozzle Check Valves. Engineered for critical applications, our valves are the ultimate solution for safeguarding pipelines and equipment by effectively preventing destructive water hammer, mitigating surge pressures, and significantly extending the operational lifespan of vital systems. This advanced design inherently minimizes maintenance requirements and substantially reduces the total cost of ownership, ensuring seamless, efficient, and reliable fluid management even in the most demanding environments.

Our meticulously designed Non-Slam Nozzle Check Valves are indispensable across a wide array of mission-critical industries. We are trusted partners in the Oil & Gas, Petrochemical, Desalination, Pipeline, Liquefied Natural Gas (LNG), and Refinery sectors, where reliability and safety are paramount. Understanding the severe challenges posed by these industries – from extreme temperatures and pressures to highly corrosive media and abrasive slurries – our valves are built not just to meet, but to consistently exceed, these stringent industry and regulatory demands.

Our unwavering commitment to quality is evident in the broad array of premium material grades available, ensuring optimal material selection for every specific application. We guarantee unparalleled durability, exceptional performance, and superior resistance to diverse service conditions. Our core offerings include:

• Carbon Steel: Robust and cost-effective for general industrial applications.
• Low Temperature Alloy Steel: Specifically engineered for cryogenic services and applications subjected to extremely low temperatures, ensuring integrity and performance where standard steels would embrittle.
• Stainless Steel: Range including SS 304, SS 316, and high-performance options such as Duplex Stainless Steel (e.g., UNS S31803, UNS S32205) and Super Duplex Stainless Steel (e.g., UNS S32750, UNS S32760), ideal for corrosive, chloride-rich, and moderately high-temperature environments, offering enhanced strength and pitting resistance.

Crucially, our expertise extends to a diverse and specialized selection of Nickel Alloy grades, meticulously chosen for their superior resistance in aggressive industrial processes. These include:

• Monel® (Monel 400 UNS N04400, Monel K-500 UNS N05500): Renowned for exceptional resistance to seawater, hydrofluoric acid, sulfuric acid, and alkaline solutions.
• Inconel® (Inconel 600 UNS N06600, Inconel 625 UNS N06625, Inconel 718 UNS N07718): Ideal for high-temperature strength and outstanding corrosion resistance in a variety of aggressive environments, including sour gas and chemical processing.
• Hastelloy® (Hastelloy C-276 UNS N10276, Hastelloy C-22 UNS N06022): Provides unrivaled resistance to a broad range of aggressive chemical process environments, including strong acids, oxidizers, and reducing agents, with superior resistance to pitting and crevice corrosion.
• Incoloy® (Incoloy 800 UNS N08800, Incoloy 825 UNS N08825): Offers excellent resistance to general corrosion, pitting, crevice corrosion, and stress-corrosion cracking in various aqueous media, including sulfuric and phosphoric acids.
• Nickel 200 (UNS N02200) / Nickel 201 (UNS N02201): Commercially pure nickel, offering superb resistance to caustic alkalis and good resistance to reducing acids.
• Carpenter 20® / Alloy 20Cb-3 (UNS N08020): Exceptional resistance to hot sulfuric acid and many other aggressive chemicals.
• Hastelloy B-2 (UNS N10665) / Hastelloy B-3 (UNS N10675): Primarily molybdenum-nickel alloys, offering outstanding resistance to non-oxidizing acids like hydrochloric and sulfuric acid.

Falcon Valves flow control solutions that enhance operational efficiency, extend equipment longevity, and bolster overall system safety. Trust Falcon Valves for unparalleled quality, meticulous engineering, and reliable performance that consistently defines industry benchmarks.

Falcon Valves and Flanges Pvt. Ltd. manufactures a specialized line of service valves designed specifically for high-consequence chemical environments, including Lithium service (often associated with Lithium Hydroxide or Lithium Brine processing).

Because lithium compoundsparticularly in liquid or slurry formcan be highly abrasive, corrosive, and prone to crystallization, these valves are engineered for extreme durability and sealing integrity.

• Specialized Material Selection: To resist the chemical degradation caused by lithium salts and alkalis, Falcon utilizes high-grade materials such asTitanium Grade 2, Alloy 20, Hastelloy, Duplex/Super Duplex Stainless Steel, and Monel.

• Leak-Proof Sealing: Designed to prevent the escape of hazardous lithium-based fluids, these valves often feature enhanced gland packing and reinforced seat designs to maintain a tight shut-off.

• Anti-Crystallization Design: Many of these valves are designed with smooth internal flow paths to prevent "dead zones" where lithium salts might settle and crystallize, which could otherwise lead to valve jamming or seat damage.

• Standard Compliance: They are typically manufactured to meet international standards such as API 600, API 6D, API 607 (Fire Safe), and ISO 15848 (Fugitive Emissions).

• Lithium Mining & Extraction: Handling aggressive brines and acidic solutions during the leaching process.

• Battery Chemical Processing: Specifically for the production of Lithium Hydroxide and Lithium Carbonate.

• Refining: Used in the chemical treatment and purification stages where moisture-sensitive or corrosive lithium compounds are present.

Falcon Valves and Flanges Pvt. Ltd. provides specialized flow-control solutions for the lithium industry, focusing on the unique challenges of brine extraction and chemical refinement. Lithium service is particularly demanding because the mediaoften high-concentration brines or chemical slurriesis both highly corrosive and highly abrasive, with a tendency to crystallize and seize moving parts.

Below are the expanded technical and design details for these valves:

Standard stainless steel often fails in lithium brine service due to chloride-induced pitting. Falcon utilizes superior alloys to ensure longevity:

• Body & Gate/Ball: High-grade alloys like Hastelloy C276, Titanium (Grade 2 or 5), Super Duplex (SS 2507), and Alloy 20.

• Linings: For acidic slurries or leaching processes, valves may feature PFA/FEP linings or full body liners that protect the metal from direct contact with aggressive media.

Lithium salts (Lithium Carbonate/Hydroxide) readily precipitate out of solution, which can "freeze" a valve.

• Self-Cleaning Seats: In ball valves, the seat design often includes a "scraping" action to clear crystals from the ball surface during every cycle.

• Knife Gate Technology: For lithium slurries, Falcon provides Knife Gate Valves that can cut through thick media and solids. These often feature a "bottomless" or "through-conduit" design so that solids are pushed out rather than trapped in the seat pocket.

• Cavity Fillers: Ball valves can be fitted with PTFE cavity fillers to eliminate dead spaces where brine could settle and crystallize.

• Evaporation Pond Management: Handling raw, concentrated brine.

• Ion Exchange & Solvent Extraction: Control of purified lithium streams.
• Precipitation Tanks: Regulating the flow of sodium carbonate/lime mixtures during the chemical conversion of lithium.

Triple Offset Butterfly Valves

To manage the critical shut-off and accurate control, a proper flow system is required. Triple Offset Butterfly Valves stand as the reliable option. We at Falcon Valves are here with the top high-performance Triple Offset Butterfly Valves that ensure tight shut-off, the least torque, and superior strength across a broad range of industrial applications.

Our advanced valves are engineered with three diverse offsets two on the shaft and one on the disc. It can remove the friction at the time of the operation, ensuring long-lasting performance and zero leakage. The special design reduces wear and tear on sealing surfaces, making the valve perfect for frequent cycling and critical shut-off conditions.

We are serving the demands of different industries like

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• Oil & gas,
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• Petrochemical,
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• Power,
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• Marine,
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• Pulp & paper industries
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Falcons Triple Offset Butterfly Valves are built to manage the toughest challenges.

Prime features of Falcon Triple Offset Butterfly Valves available with us

Zero Leakage Shut-Off

The triple-offset geometry confirms that the disc moves away from the seat without any friction. It can end in bubble-tight shut-off and extended sealing life.

High-Pressure and High-Temperature Resilience

Planned to work in the extreme conditions, our valves are appropriate for temperatures up to 1000F (538C). It is even better for high-pressure applications.

Low Operating Torque

The offset design reduces the torque requirements, permits smooth operation and easy automation with pneumatic or electric actuators.

Long Service Life

With the least contact in the middle of the sealing components, the wear is radically reduced, leading to more operational life and reduced costs of maintenance.

Get the Compact and Lightweight Design

We give space-saving benefits over usual valve types, making installation and management faster without affecting performance.

Flexible Applications

Appropriate for handling aggressive media, including hydrocarbons, acids, steam, and gas, making them suitable for important flow control systems.

Corrosion-Resistant Stuff

We give a wide range of stuff like stainless steel, duplex steel and high-alloy compositions to make sure compatibility with corrosive fluids.

Different End Connections

We offer wafer, lug, and double flanged styles to suit diverse piping systems and installation choices.

Meets Global Industry Standards

We manufacture according to the API 609, ASME B16.34, and other significant global quality standards.

Why select Falcon Triple Offset Butterfly Valves?

At Falcon Valves, we merge precision engineering, cutting-edge design, and years of manufacturing excellence to convey butterfly valves that break the competition.

Proficiency You Can Trust

With years of experience serving mission-critical sectors, Falcon Valves is known for its innovation and reliability.

Custom Solutions Offered

Do you need a special size, trim, or actuator setup? We give customised solutions to match your precise technical requirements.

In-House Quality Control

Our team follows up a strict testing for leakage, torque, and pressure ratings. We make sure to give the maximum safety and reliability.

Get faster delivery and support.

Our well-organised production and logistics ensure quick turnaround times. Get the technical support from our team.

Falcons Triple Offset Butterfly Valves give an ideal balance of performance, reliability, and budget friendliness for high-stakes industrial settings. If you\'re planning to upgrade your systems or looking for a valve solution for a new project, contact our team at Falcon. Contact us for a custom quote.

At Falcon, we provide specialized cryogenic valve solutions engineered to perform in the most demanding ultra-low temperature environments. From the massive scale of LNG (Liquefied Natural Gas) terminals to precision industrial gas applications, our valves ensure safety, zero-leakage, and operational integrity where standard equipment fails.

Our cryogenic range is designed for media that must be kept in a liquid state through extreme refrigeration, including LNG (-162°C), Liquid Nitrogen (-196°C), Liquid Oxygen, and Liquid Hydrogen.

• Extended Bonnet Design: All Falcon cryogenic valves feature an extended bonnet (per BS 6364) to keep the stem packing at ambient temperature, preventing freeze-up and ensuring smooth actuation.

• Cavity Pressure Relief: To prevent catastrophic failure from liquid expansion (boil-off) trapped in the valve cavity, our designs incorporate automatic internal pressure relief systems.

• Low-Temperature Metallurgy: We utilize high-grade austenitic stainless steels (304L, 316L) and specialized alloys that maintain high impact strength and ductility at temperatures as low as -196°C.

• Design Standards: API 6D, ASME B16.34, BS 6364, and ISO 28921.

• Testing: Every valve undergoes rigorous Helium Leak Testing and cryogenic submersion tests at -196°C to guarantee bubble-tight performance.

• Sealing Technology: Features PCTFE or TFM soft inserts for bubble-tight shut-off, or specialized metal-to-metal seating for severe service.

• Safety: Inherently Fire Safe designs certified to API 607/ISO 10497.

Note: Our valves are available in manual, pneumatic, or electric configurations, with actuators specifically lubricated for low-temperature reliability.

Every Falcon cryogenic valve features an extended bonnet design. This critical feature creates a "gas column" that keeps the stem packing away from the cryogenic fluid, preventing freeze-ups and ensuring bubble-tight sealing at the gland.

• Cryogenic Gate Valves: Ideal for full-flow, low-pressure drop isolation in LNG storage and transport.

• Cryogenic Globe Valves: Precision-engineered for throttling and regulating flow in cryogenic pipelines.

• Cryogenic Ball Valves: High-performance, quarter-turn valves for rapid shut-off, featuring pressure-relieving seats to prevent over-pressure due to liquid expansion.

• Cryogenic Check Valves: Robust designs to prevent backflow in liquid gas systems, ensuring plant safety.

• Cryogenic Butterfly Valves: Compact, lightweight solutions for large-diameter cryogenic service, often utilized in marine and processing terminals.

For cryogenic service, Austenitic Stainless Steels are the industry standard because they remain ductile and resist brittle fracture at temperatures as low as -196°C. The most common grades are SS 304/304L (CF8/CF3) for general liquid nitrogen and oxygen service, and SS 316/316L (CF8M/CF3M), which is preferred for LNG and marine environments due to its superior corrosion resistance. For high-pressure or high-cycle components, nitrogen-strengthened grades like Nitronic 50 are utilized to ensure mechanical integrity under extreme thermal stress.

Falcon Manufacturing specializes in the precision engineering and production of high-temperature valves designed for the most demanding industrial environments. By integrating advanced metallurgy with specialized machining techniques, Falcon ensures peak performance where standard components fail.

Falcon’s reputation is built on its ability to handle "unworkable" materials and achieve microscopic tolerances:

• Stellite™ Specialists: Expertise in applying and machining cobalt-based Stellite alloys. This provides exceptional resistance to wear, galling, and corrosion at extreme temperatures.

• Precision Machining: Utilizing specialized heavy-duty machinery tailored for high-nickel alloys and hardened steels.

• Lapping & Grinding: Advanced finishing processes that ensure bubble-tight seals and metal-to-metal seating, critical for high-pressure safety.

• Custom Engineering: In-house design capabilities to modify valve geometry for specific thermal expansion requirements.

Falcon produces a wide range of valve types, each optimized for high-heat cycles:

Falcon Manufacturing & Design provides high-integrity sealing solutions across all major industry standards, specifically focusing on metal-seated valves that survive extreme thermal cycling.

Falcon manufactures valves according to ANSI/FCI 70-2 and API 598 standards. Their specialized lapping and grinding processes allow them to achieve superior shut-off even in metal-to-metal configurations:

• Class IV (Standard Industrial): The benchmark for metal-seated valves, allowing a maximum of 0.01% leakage of rated capacity. Ideal for general steam and hydrocarbon service.

• Class V (Critical/High-Pressure): A rigorous standard for high-pressure applications where leakage must be minimal (measured in microliters per inch of orifice). Falcon achieves this through precision Stellite™ seat grinding.

• Class VI (Bubble-Tight): While typically reserved for soft-seated valves, Falcon’s Triple Offset Butterfly Valves and high-precision metal-seated ball valves are engineered to achieve bubble-tight, zero-leakage performance in critical gas and hazardous liquid services.

Falcon works with an extensive range of materials to ensure chemical compatibility and structural integrity at temperatures ranging from -268°C to 540°C (-450°F to 1000°F).

• Sealing Technology: Seats are available in Integral, Renewable, or Weld-deposited (Stellite) formats.

• Testing Rigor: Every valve undergoes hydrostatic and pneumatic testing per BS 5146 or API 598 to verify the specified leakage class before dispatch.

• Precision Finishing: Their in-house lapping and grinding machines are specifically designed to handle hard-faced surfaces, ensuring a mirror finish that prevents "wire-drawing" and premature seat failure in high-velocity steam.

Falcon UNS N04400 (Alloy 400) Forged Gate Valves

Falcon’s UNS N04400 forged gate valves are high-strength, solid-solution hardened valves that offer exceptional resistance to a wide range of corrosive environments. While Alloy 825 is the specialist for sulfuric acid, Alloy 400 is the industry benchmark for marine engineering and hydrofluoric (HF) acid service.

1. Advanced Design Characteristics

• Optimized Flow Path: Our forged gate valves feature a full-port design that minimizes turbulence and pressure drop, critical for high-velocity liquid flow.

• Wedge Geometry: Precision-machined solid wedges provide high structural stability, while flexible wedges are available for larger sizes to prevent "thermal binding" in high-temperature cycles.

• Outside Screw & Yoke (OS&Y): The rising stem design ensures that the stem threads are never in contact with the corrosive media, extending the service life of the valve.

   

   

• Fugitive Emission Control: Standard graphite or PTFE packing sets are engineered to meet stringent environmental leakage standards.

2. Manufacturing Excellence

• ASTM B564 Precision Forging: Falcon utilizes closed-die forging to ensure a refined grain structure. This eliminates the porosity and shrinkage defects often found in Monel castings (ASTM A494 M35-1), providing superior toughness and weldability.

• Cold-Work Strengthening: Alloy 400 gains its strength through cold working during the manufacturing process, and Falcon’s thermal management ensures the material retains its high ductily and impact strength.

• CNC Machining & Lapping: Seats and wedges are precision-lapped to a mirror finish, ensuring a metal-to-metal seal that exceeds API 598 requirements.

3. Quality & Testing Regime

Every Falcon valve is a "Safety-Critical" component. Our testing protocol includes:

• Hydrostatic Testing: High-pressure shell and seat tests at 1.5x and 1.1x the pressure rating.

• Pneumatic Testing: Low-pressure air testing to verify bubble-tight integrity.

• PMI (Positive Material Identification): 100% verification to ensure the 63% Nickel and 28-34% Copper ratio is exact.

• NACE Compliance: Available for "sour" service in accordance with NACE MR0175/ISO 15156.

• Traceability: Heat numbers are hard-stamped on the valve body, linked to EN 10204 3.1 Mill Test Reports.

4. Application Area Expertise

Falcon has decades of experience deploying UNS N04400 valves in the world’s most punishing environments:

• Marine & Shipbuilding: Handling seawater in high-velocity piping, fire-main systems, and brine heaters where standard stainless steel would pit instantly.

• HF Alkylation Units: A specialized application in oil refineries where Monel 400 is the only material capable of resisting hydrofluoric acid.

• Chemical Production: Handling chlorinated solvents and non-oxidizing chloride salts.

• Power Generation: Used in boiler feedwater heaters and other heat exchangers.

Technical Specifications

The Falcon Experience

With over 15 years of experience in exotic alloy fabrication, Falcon doesn't just supply valves; we provide material consultation to ensure your project uses the right alloy for the right environment. Our Alloy 400 valves are trusted by global leaders in the Navy, desalination, and petrochemical industries.

Falcon's "Double-Verify" Quality Policy

Regardless of the alloy, Falcon applies the same Precision Forging (ASTM B564) and API 598 Testing standards. Our engineering team is available to review your Media Data Sheets to ensure the metallurgical selection matches your pipeline's life-cycle requirements.

Pressure Reducing Control Valve is a device that controls the flow of air, liquid, or whatever other fluid in a process to minimize pressure. Falcon Valves & Flanges Pvt Ltd is a leading manufacturer and supplier of various types in a variety of applications, including the Pressure Reducing Check Valve.

Our pressure control valves at Falcon Valves & Flanges Pvt Ltd are intended to provide customizable pressure control and restricting functions. As a reputable pressure control valve manufacturer, we serve the nation's major manufacturing markets. Our extensive product line contains hydraulic pressure control valves in a range of patterns as well as process control valves, which would be applicable to a wide range of uses.

We are in the business of producing and supplying Cast Steel Globe Valve. It is highly regarded by customers due to its unrivalled quality and durable construction. The valve is in high demand in businesses and is available at a competitive price.

Falcon Valves & Flanges Pvt Ltd's Cast Steel Globe Valve is a high-quality product. All of our Cast Steel Globe Valves are produced with quality assured materials and advanced techniques, ensuring that they meet the standards in this extremely demanding field. The components used to make our valves are obtained from the most reputable and official vendors, who were chosen after conducting extensive market research. Falcon Valves & Flanges Pvt Ltd products are well-known in the market for their excellent quality.

Falcon Valves & Flanges Pvt Ltd is committed to providing our clients with a diverse selection of high-quality Stainless steel check valves. These valves come in a variety of requirements and can be customised. These are made in conjunction with the variables shown using high-quality stainless steel, iron, and other materials.

A valve is a piece of machinery that governs, directs, or assists in the determination of the rhythm of a liquid (flammable gasses, fluids, fluidized solids, or slurries) by entrance, closure, or temporarily obstructing various pathways. These valves are available in different of sizes, dimensions, element grades, and pressure capacities. Among the implementations are water supply, petroleum and gas, power companies, oil and natural gas, and other low-pressure configurations.

Falcon UNS N04400 (Monel 400) forged globe valves are specifically engineered for high-precision throttling and flow regulation in environments where seawater or hydrofluoric acid would rapidly degrade standard alloys. While ball valves are excellent for quick isolation, the Falcon globe valve is the "workhorse" for controlling the flow rate and pressure with extreme accuracy.

Falcon globe valves are designed to provide superior control under high-pressure differentials.

• Plug-Type Disc: Features a heavy-duty, tapered disc that allows for fine-tuned throttling. The disc and seat are precision-lapped to ensure a bubble-tight shutoff when closed.

• Outside Screw & Yoke (OS&Y): The rising stem design keeps the actuator threads outside the flow stream, protecting them from the corrosive "reducing" media typical of Monel applications.

• Integral Backseat: Allows the stem packing to be replaced while the valve is under full pressure, ensuring maximum safety and system uptime.

• Forged Structural Integrity: By using ASTM B564 forgings, Falcon eliminates the risk of "hot shortness" or internal casting defects, ensuring the valve body can withstand high-velocity fluid impact.

• Nickel-Copper Strength: The 63% Nickel and 30% Copper composition of Monel 400 provides a unique blend of high strength and excellent weldability.

   

   

• Erosion Resistance: Globe valves often face high-velocity flow at the seat. Falcon uses Monel K-500 for the stem and internal trim to provide extra hardness and resistance to "wire-drawing" (erosive wear).

• Titanium-Stabilized Forging: Our forging process ensures the material retains its ductility and corrosion resistance even at sub-zero or elevated temperatures.

Each Falcon globe valve is subjected to a comprehensive testing regime:

• Hydrostatic Testing (API 598): Every valve undergoes a shell test at 1.5x the pressure rating and a seat test at 1.1x.

• HF Acid Service Cleaning: For refinery applications, valves are meticulously cleaned and dried to prevent any reaction between residual oils and hydrofluoric acid.

• PMI (Positive Material Identification): 100% verification of all pressure-retaining parts to ensure the chemical signature matches UNS N04400.

• Dimensional Precision: Machined on high-precision CNC centers to ensure a perfect fit for the bolted bonnet and gasket.

• Marine Engineering: Controlling seawater flow in fire-main systems and heat exchangers.

• HF Alkylation Units: Precision throttling of hydrofluoric acid in oil refineries.

• Salt Production: Regulating the flow of boiling brine and salt slurries.

• Chemical Processing: Handling non-oxidizing chlorides and caustic solutions.

Falcon's expertise lies in understanding the metallurgical behavior of Monel. We ensure that our forging process avoids the "hot-shortness" (brittleness during forging) that often plagues lower-quality manufacturers, resulting in a valve that is as tough as the environment it serves.

While the standard globe valve is a powerhouse, Falcon leverages the unique properties of Monel 400 (UNS N04400) to manufacture specialized configurations for "Extreme Service" applications. Because Monel is both highly ductile and resistant to specific acids, it allows for designs that standard stainless steel cannot support.

Various design available are Y-Pattern (Flow-Efficient) Monel Globe Valves,  Bellows-Seal Monel Globe Valves,  Needle-Type Throttling Monel Valves,  Cryogenic Monel Globe Valves,  Stop-Check (Non-Return) Monel Globe Valves

Check valves are used in horizontal pipelines to preclude flow reversal. Check valves are not suggested for use in vertical pipelines; however, if used in a vertical implementation, the valve must be implanted for upward flow only.

Cast steel check valve is widely used in water, steam, air, gas, and corrosive liquids. Our Cast steel check valves at Falcon Valves & Flanges Pvt Ltd are manufactured using materials that have undergone all quality assurance and are processed in accordance with stringent quality specifications. The rigid, strong design ensures a longer lifetime. The use of hard-faced trim material guarantees perfect sealing and a longer lifespan.

Our Forged Hastelloy C276 Gate Valves are engineered for the most aggressive corrosive environments, where standard stainless steels fail. Hastelloy C276 is a nickel-molybdenum-chromium superalloy with an addition of tungsten, designed to have excellent corrosion resistance in a wide range of severe environments.

• Design Standard: Manufactured in accordance with API 602 (for forged steel gate valves) and ASME B16.34.

• Rising Stem (OS&Y): Outside Screw and Yoke design ensures the stem threads are not in contact with the process fluid, preventing corrosion and easing lubrication.

• Bolted Bonnet: Features a high-integrity gasketed joint for ease of maintenance and reliable sealing under high pressure (Class 800 to 2500).

• Full Bore Design: Maximizes flow capacity and minimizes pressure drop across the valve.

• Body & Bonnet: Precisely forged for superior grain structure and increased strength over cast alternatives.

The manufacturing process for Hastelloy C276 requires specialized expertise due to the material's work-hardening characteristics:

• Precision Forging: Bodies are forged at controlled temperatures to prevent "hot shortness" and ensure a uniform metallurgical structure.

• Solution Annealing: Post-forging heat treatment is performed to restore maximum corrosion resistance and ductility.

• Advanced Machining: Utilizing high-torque CNC centers to achieve the tight tolerances required for API 602 compliance.

Every valve undergoes a rigorous verification process to ensure zero-leakage performance in critical service:

• Hydrostatic Testing: Conducted per API 598 (Shell and Seat test) to ensure structural integrity and bubble-tight shutoff.

• Pneumatic Testing: Low-pressure air testing to detect minute leaks in the seating surfaces.

• Material Verification: 100% Positive Material Identification (PMI) to guarantee the alloy composition meets UNS N10276 standards.

• Non-Destructive Testing (NDT): Including Liquid Penetrant Testing (LPI) on welds and critical forged surfaces.

• Certification: Full MTC (Material Test Certificate) to EN 10204 3.1 providing chemical and mechanical properties.

These valves are ideal for:

• Chemical Processing (Hydrochloric and Sulfuric acid service).

• Flue Gas Desulfurization (FGD) plants.

• Offshore Oil & Gas (Sour gas and high-chloride environments).

• Pharmaceutical and Waste Treatment.

These properties ensure the valve can withstand both high-pressure mechanical stress and extreme thermal fluctuations.

Hastelloy C276 is often referred to as the "Universal Corrosion-Resistant Material." Here is how it outperforms standard stainless steels and other nickel alloys:

• Pitting Resistance: In chloride-rich environments (like seawater), 316L often suffers from localized pitting. C276 has a much higher PREN (Pitting Resistance Equivalent Number), typically $> 65$, compared to 316L's approx 24.

2. Superiority Over Monel® 400

3. Resistance to Stress Corrosion Cracking (SCC)

4. Stability During Welding

Engineered for Zero Leakage in Extreme Environments

Falcon Metal Seated Ball Valves are precision-engineered solutions designed specifically for severe service applications where standard soft-seated valves fail. Built to withstand extreme temperatures and aggressive media, these valves combine robust metallurgy with state-of-the-art manufacturing processes to deliver Class VI shut-off capabilities, ensuring safety and efficiency in the most demanding industrial processes.

• Severe Service Design: Optimized for high-temperature service and abrasive environments where thermal stability and mechanical strength are critical.

• Superior Metallurgy: Manufactured in a wide range of Nickel Alloy grades (such as Inconel, Monel, and Hastelloy) to provide exceptional resistance to corrosion, oxidation, and thermal shock.

• Precision Manufacturing: We utilize specialized, proprietary machinery for the grinding and lapping of both the ball and seat. This "mate-lapping" process ensures a perfect 360-degree contact patch between the sealing surfaces.

• Class VI / Zero Leakage: Through our advanced lapping techniques, Falcon achieves a sealing performance that rivals soft-seated valves (ANSI/FCI 70-2 Class VI), providing a "bubble-tight" seal even at elevated temperatures.

To achieve Class VI (Zero Leakage) performance in metal-seated valves with interchangeable seats, Falcon employs a specialized combination of precision manufacturing and mechanical design.

Unlike traditional metal-seated valves where the ball and seat are "mate-lapped" as a matched pair (meaning if one fails, you must replace both), Falcon's design utilizes advanced 360° CNC lapping technology to achieve true interchangeability.

Here is the breakdown of the special designs used:

The core innovation is the manufacturing process itself. Standard lapping often moves in a single plane, creating microscopic directional grooves. Falcon uses specialized Multi-Axis Lapping Machines that rotate the ball and seat in a random, non-repeating 360° pattern.

• Perfect Sphericity: This process grinds the ball to a roundness tolerance of < 5 microns ($< 0.005$ mm).

• Non-Directional Finish: It creates a uniform, matte surface finish with no "grain" for leak paths to form.

• Result: Because the geometry is mathematically perfect rather than "hand-matched, " you can replace just the seat or just the ball during maintenance without losing the zero-leakage seal.

To maintain Zero Leakage (Class VI) under the thermal expansion of high-temperature Nickel Alloys, Falcon uses a dynamic seat loading system.

• Spring Energization: Behind the metal seat, Inconel X-750 or 718 Belleville disc springs apply constant mechanical pressure.

• Low-Pressure Sealing: At low pressures (where metal seats usually leak), the springs force the seat against the ball to create the seal.

• Thermal Compensation: As the valve heats up to extreme temperatures (e.g., 600°C+), the springs compress to absorb the thermal growth of the ball, preventing the valve from seizing while maintaining the seal.

A metal-to-metal seal requires surfaces that will not gall (weld together) under high friction. Falcon utilizes High Velocity Oxygen Fuel (HVOF) coating.

• Micro-Hardness: The sealing surfaces are coated with Chrome Carbide or Tungsten Carbide, achieving hardness levels > 68 HRC.

• Surface Tension: The coating is polished to a mirror-like finish (Ra < 0.2), which creates high surface tension that liquid/gas cannot easily penetrate, mimicking the sealing capability of a soft elastomer.

For high-temperature service which often involves polymerization or coking (common in Nickel Alloy applications), Falcon employs a Sharp Edge Seat design.

Because Chlorine Dioxide is highly unstable and aggressive (often more corrosive than wet chlorine), Falcon utilizes specialized exotic alloys and severe-service designs to ensure safety and longevity.

For Chlorine Dioxide service, standard stainless steels (like 304/316) typically fail due to stress corrosion cracking. Falcon offers valves in high-grade exotic alloys specifically resistant to oxidizing environments:

• Primary Grades:Hastelloy C-276 (UNS N10276) and Titanium Grade 2 (Commercially Pure) or Grade 5.

   

   

• Alternative High-Performance Alloys: Hastelloy C-22, Super Duplex (UNS S32750/S32760), and PVDF-Lined or PFA-Lined carbon steel (for lower temperature/pressure applications).

• Trims: Often matched to the body material (e.g., Titanium trim in a Titanium body) to prevent galvanic corrosion.

Falcon offers a wide range of sizes to accommodate different piping scales, from dosing lines to main process headers:

• Standard Range:1/2" (DN15) to 24" (DN600).

   

   

• Specialty/Large Bore: Up to 48" (DN1200) for specific butterfly or gate valve configurations upon request.

• Pressure Ratings: Typically Class 150# to Class 900# (PN20 to PN150), with higher pressure classes available for specific injection systems.

Falcon provides several valve architectures optimized for hazardous chemical handling:

• Ball Valves: The most common choice for ClO. Available in Floating and Trunnion Mounted designs. They feature Full Bore flow to minimize pressure drop and cavity-free (or cavity-filled) seats to prevent ClO gas accumulation inside the valve body.

• Plug Valves: Sleeved plug valves (often PTFE/PFA sleeved) offer a cavity-free design that is excellent for preventing the entrapment of unstable ClO.

• Butterfly Valves: High-Performance Triple Offset valves for larger diameter lines. These provide bubble-tight shutoff using metal-to-metal or laminated seals compatible with corrosive gases.

• Check Valves: Swing or Dual Plate check valves (with Hastelloy springs/internals) to prevent backflow into generation systems.

• Globe Valves: For precise flow throttling of precursor chemicals or ClO solution.

Falcon employs rigorous standards to handle the toxicity and explosiveness of Chlorine Dioxide:

• Design Standards: Designed in accordance with ASME B16.34, API 6D, and API 600.

• Sealing Technology: Features Low Fugitive Emission packing (certified to ISO 15848-1 or API 622) to prevent toxic gas leakage into the atmosphere.

• Cleaning: Valves undergo "Oxygen Cleaning" or specialized Chlorine Cleaning processes to remove all oil, grease, and hydrocarbons which can react explosively with Chlorine Dioxide.

• Testing: Rigorous testing includes Hydrostatic Body Testing (1.5x design pressure), High-Pressure Pneumatic Seat Testing, and Helium Leak Testing to ensure zero leakage.

• Manufacturing: Investment casting (lost wax) for smaller sizes to ensure high surface finish and defect-free casting; Forged bodies for high-pressure small-bore valves to ensure structural integrity.

chrome moly/alloy steel valves f11/f22/f5/f9

falcon manufactures and stocks a large range of ‘chrome-moly’ valves. these valves are manufactured from low alloy steel containing chromium and molybdenum making them suitable for higher temperature service especially for higher pressure and temperature combinations. in addition, these valves have the added advantage of anti-corrosive properties. grades include forged astm a182 f5, f5a, f9, f11 and f22, and their cast equivalents astm a217 c5, c12, wc5, wc6 and wc9. higher grades like a112 f9/astm a217 c12a are available on an indent basis.

types

• alloy steel gate valves
• alloy steel globe valves
• alloy steel check valves

size

• gate valve: ¼” to 48”
• globe valve: ¼” to 24”
• check valve: ¼” to 36”

pressure rating

• 150# to 2500#

end connections

• flanged 
• butt weld
• socket weld

Falcon Forged Monel 400 (UNS N04400) Check Valves are the definitive "backflow prevention" solution for high-salinity and acidic environments. In these critical services, a check valve must be reliable; if it fails to close, the resulting backflow can destroy expensive pumps or cause hazardous chemical leaks.

Falcon manufactures Monel check valves in several configurations to handle different flow velocities, pipeline orientations, and media viscosities.

The most common choice for small-bore high-pressure piping.

• Mechanism: Uses a forged Monel piston that is lifted by the fluid pressure.

• Best For: High-pressure gas or liquid service.

• Falcon Specialization: Typically spring-loaded to ensure fast closure in vertical or horizontal lines and to prevent "water hammer."

Designed for systems where "Full Flow" and minimal pressure drop are the priority.

• Mechanism: A hinged Monel disc swings open with forward flow and is forced shut by gravity and back-pressure.

• Best For: High-volume liquid systems with low-to-medium pressure.

• Falcon Specialization: Features an internal hinge pin design to eliminate external leak paths, a critical safety feature for HF acid service.

The ultimate design for viscous fluids or "dirty" service.

• Mechanism: A free-rotating Monel ball acts as the sealing element.

• Best For: Applications with particulates or high viscosity where a piston might get "stuck."

• Falcon Specialization: The ball rotates during operation, ensuring even wear and a constantly refreshed sealing surface for longer life.

A specialized "hybrid" valve used in power and steam systems.

• Mechanism: Functions as a check valve automatically, but can be manually closed using a handwheel (like a globe valve) to isolate the line entirely.

• Best For: Boiler feedwater systems and high-pressure steam.

Falcon’s expertise in Monel forging allows us to offer these valves with specialized construction methods:

• Bolted Cover (BC): The standard design for easy internal maintenance and cleaning.

• Welded Cover (WC): A "leak-proof" design where the cover is seal-welded to the body—preferred for lethal gas or HF Alkylation service.

• Pressure Seal Cover: Used for Class 1500 and 2500 high-pressure applications where the internal pressure helps tighten the seal.

In industries like desalination or HF Alkylation, the check valve's internal trim is under constant attack. Falcon uses Monel K-500 for the springs and seat overlays to provide the extra hardness required to resist erosion and fatigue, ensuring that the "heart" of your piping system remains secure.

Every Falcon valve must pass a multi-stage testing sequence before it is certified for shipment.

The Falcon Series Forged Globe Valve in Hastelloy C-276 (UNS N10276) is engineered for precision throttling and high-integrity shut-off in the world’s most hostile chemical environments. Unlike standard cast valves, our forged construction provides a dense, non-porous grain structure, making it the premier choice for high-pressure, high-temperature, and "critical-leakage" applications.

Every Falcon globe valve is designed with a focus on durability and ease of maintenance:

• Outside Screw and Yoke (OS&Y): Protects the stem threads from the process media, preventing thread corrosion and ensuring smooth operation.

• Rising Stem: Provides a clear visual indication of the valve position (Open/Closed).

• Plug-Type Disc: Features a precision-contoured seating surface for linear flow control and high-velocity throttling.

• Bolted Bonnet: Secured with high-strength fasteners and a high-integrity gasket for safe, repeatable maintenance access.

Hastelloy C-276 is widely regarded as the "Universal Alloy" for corrosion resistance. By utilizing the Falcon forged process, we enhance these natural properties:

• Total Corrosion Immunity: Exceptional resistance to pitting and crevice corrosion in chloride-rich environments.

• Aggressive Acid Handling: Stable in the presence of wet chlorine gas, hypochlorite, and oxidizing salts.

• Mechanical Integrity: * Tensile Strength: 690 MPa

  • Yield Strength:  283 MPa

  • Hardness: 100 HRB (Maintains ductility in cryogenic and high-temp service).

At Falcon, quality is not an inspection; it is a manufacturing standard.

• Forging Process: Bodies are forged using controlled thermal cycles to prevent grain growth and maintain maximum alloy toughness.

• Precision Machining: CNC-machined seats and discs ensure a mirror-finish for bubble-tight sealing.

• 100% PMI Verification: Every single pressure-retaining part is verified via Positive Material Identification to ensure 0% material substitution.

• NACE Compliance: All Falcon C-276 valves are processed to meet NACE MR0175/ISO 15156 for sour service.

Before a Falcon valve is shipped, it must pass a rigorous testing battery:

1. Shell Hydro-Test: Tested at 1.5 times the rated working pressure.

2. High-Pressure Seat Test: To ensure zero-leakage closure.

3. Low-Pressure Air Test: To verify seal integrity at the molecular level.

4. Visual Inspection: Checked for surface finish and dimensional accuracy according to ASME B16.11 (for SW ends).

Falcon Forged Globe Valves are the preferred choice for:

• Chemical Processing: Metering and throttling of Sulfuric, Hydrochloric, and Phosphoric acids.

• Oil & Gas: High-pressure "Sour Gas" injection and control lines.

• Pharmaceuticals: Handling reactive catalysts and aggressive cleaning agents.

• Environmental: Flue Gas Desulfurization (FGD) and wastewater neutralization.

Falcon API 600 Gate Valves: Special Alloy Expertise

Falcon is a global leader in the engineering and manufacturing of API 600 Gate Valves, specializing in high-performance metallurgy for the most demanding environments. While standard carbon steel suffices for many, our core strength lies in providing corrosion-resistant alloy (CRA) solutions for offshore, subsea, chemical, and desalination industries.

Special Grade Material Portfolio

We provide a comprehensive range of exotic materials, ensuring superior resistance to pitting, crevice corrosion, and stress cracking:

• Nickel Alloys: Inconel (600, 625, 825), Monel (400, K500), and Hastelloy (C22, C276).

• Nickel Aluminum Bronze (NAB): Specifically ASTM B148 C95800/C95500 for superior seawater corrosion resistance.

• Titanium: Grade 2, Grade 5, and Grade 12 for extreme strength-to-weight ratios and chemical inertness.

• Stainless & Duplex: 254 SMO, Super Duplex (Gr. 4A, 5A, 6A), and 904L.

Technical Specifications & Capabilities

Quality Assurance & Rigorous Testing

Every Falcon valve undergoes a stringent quality protocol to guarantee zero-leakage performance in critical service.

1. Design Integrity: Full compliance with API 600 wall thickness requirements, which are heavier than standard valves to ensure a longer erosion/corrosion life.

2. Inspection (NDT): * Positive Material Identification (PMI): To verify chemical composition of exotic alloys.

   • Radiography (RT) & Dye Penetrant (DP): For casting integrity.

   • Magnetic Particle (MP): For surface crack detection.

3. Testing Standards: * API 598: Standard hydrostatic shell and seat testing.

   • Fugitive Emission Testing: Per API 624 / ISO 15848-1.

   • Cryogenic Testing: Down to -196°C (optional for LNG/Oxygen service).

Why Choose Falcon for Special Grades?

• Deep Metallurgy Experience: Over 20 years of experience handling volatile and corrosive media where material selection is the difference between safety and catastrophe.

• Custom Trim Configurations: We offer API Trims 1 through 18, including Stellite 6 hard-facing for erosion resistance in titanium and nickel bodies.

• Global Compliance: Fully certified to ISO 9001:2015, CE/PED, and Fire Safe standards (API 607).

• Third-Party Inspection: We regularly host inspectors from TUV, DNV, BV, and Lloyd’s for project-specific witness testing.

Specialized Trim Materials (API 600)

Material selection for the "Trim" (Stem, Wedge Face, and Seat Rings) is vital. We match the trim to your specific process media:

• Trim 5 (Full Stellite): For high-pressure steam and abrasive slurries.

• Trim 11 (Monel): Specifically for Hydrofluoric Acid (HF) alkylation units.

• Trim 16 (Stainless Steel/Stellite): Ideal for general corrosive service in chemical plants.

• Titanium Trim: Used in Bleach plants (Pulp & Paper) and high-concentration Chlorides

Manufacturing & Quality Nuances The Casting & Forging Process

For special grades like Titanium and Nickel Aluminum Bronze, the casting process is notoriously difficult due to gas porosity and shrinkage.

• Falcon Advantage: We utilize Vacuum Induction Melting (VIM) or argon-oxygen decarburization (AOD) refined ingots to ensure the purity of our special alloys.

• Heat Treatment: All valves undergo solution annealing or age-hardening in calibrated furnaces to ensure the crystalline structure meets ASTM requirements for ductility and hardness.

Testing & Traceability

• EN 10204 3.1 & 3.2: We provide full 3.1 material traceability as standard; 3.2 (Independent Witness) is available upon request.

Falcon UNS N08825 (Alloy 825) forged ball valves represent the pinnacle of high-pressure, quarter-turn isolation technology. Designed specifically for severe service where standard stainless steel or duplex alloys fail, these valves combine the rapid operation of a ball valve with the extreme chemical resistance of a nickel-iron-chromium-molybdenum-copper alloy.

Falcon Forged Alloy 825 Ball Valves Specialized Design Features

• Precision Forged Body: Manufactured to ASTM B564, our forged bodies provide a high-strength, non-porous structure that is significantly more reliable than cast valves in high-pressure gas applications.

• Quarter-Turn Efficiency: Designed for fast, 90-degree actuation with low torque requirements, even at maximum differential pressure.

• Floating & Trunnion Designs: Available in Floating Ball (for standard high-pressure service) and Trunnion Mounted (for larger sizes or extremely high pressures) to ensure seat integrity.

• Blow-out Proof Stem: Engineered for maximum safety, the stem is designed to remain secure within the valve body even under extreme pressure surges.

• Fire-Safe Design: Standard construction includes secondary metal-to-metal seating to maintain seal integrity in the event of a fire.

Precision Manufacturing

• Mirror-Finished Ball: Each Alloy 825 ball is diamond-lapped to a mirror finish. This reduces friction, extends the life of the seats, and ensures a bubble-tight seal.

• Titanium Stabilization: Our manufacturing process preserves the titanium-stabilized matrix of Alloy 825, preventing intergranular corrosion after machining or welding.

   

   

• Seat Material Versatility: While the body is forged Alloy 825, we offer specialized seat inserts (PTFE, RPTFE, Devlon, or PEEK) to match the specific temperature and chemical needs of your process.

Testing to Top Industry Standards

Every Falcon ball valve is subjected to a rigorous "Zero-Leakage" testing regime before dispatch:

• API 598 Pressure Testing: Includes high-pressure hydrostatic shell and seat tests, and low-pressure air seat tests.

• API 607 Fire Testing: Certified designs that ensure performance during and after high-temperature exposure.

• Fugitive Emission Testing (ISO 15848-1): Verifies that the stem seal prevents hazardous gas leakage into the atmosphere.

• PMI Verification: 100% Positive Material Identification of all pressure-retaining components to confirm the Alloy 825 chemical signature.

Technical Specifications

Primary Industry Use

• Offshore Oil & Gas: High-pressure chemical injection and manifold isolation.

• Petrochemical Plants: Managing highly corrosive acids and volatile organic compounds.

• Water Treatment: Handling concentrated chlorine and brine solutions in desalination.

Falcon Alloy 825: Chemical Compatibility Guide

The unique chemistry of Alloy 825 (Ni-Fe-Cr-Mo-Cu) allows it to bridge the gap between standard stainless steels and expensive high-nickel alloys. Below is a breakdown of how Falcon valves perform against the most aggressive industrial chemicals.

1. Performance in Acidic Media

• Sulfuric Acid (H2SO4): Exceptional resistance to all concentrations up to 80% at boiling temperatures. The addition of Copper in the Falcon alloy matrix specifically enhances resistance to this "reducing" acid.

• Phosphoric Acid (H3PO4): Outperforms 316L and Duplex in fertilizer production lines, resisting pitting even in the presence of fluoride impurities.

• Nitric Acid (HNO3): The high Chromium content ensures the valve remains passivated (protected) in oxidizing environments.

• Hydrochloric Acid (HCl): Resistant to dilute concentrations at moderate temperatures.

We manufacture, export and supply the most comprehensive range of Butterfly Valve to suit a wide range of industrial applications. The Butterfly Valve can seamlessly be integrated with a consistent range of manual, electrical, pneumatic, hydraulic actuators to create complete flow control packages. The Butterfly Valve temperature range of from -50^oC to +500^oC. Butterfly Valve is produced by employing the best raw materials, carefully selected, correctly identified and analyzed. The machining is carried out with the aid of the latest type equipment according to the most up-to-date methods.

Falcon UNS N04400 (Monel 400) forged ball valves are the ultimate solution for high-pressure isolation in marine and hydrofluoric acid environments. By combining the rapid, quarter-turn operation of a ball valve with the superior mechanical properties of a Nickel-Copper forge, Falcon provides a valve that is practically immune to the corrosive effects of brackish water and high-velocity brine.

Falcon ball valves are engineered for "Zero-Leakage" performance in hazardous conditions.

• Forged Body Integrity: Manufactured per ASTM B564, our forged bodies offer a high-density molecular structure, ensuring zero porosity and superior resistance to thermal shock compared to cast alternatives.

• Blow-out Proof Stem: The stem is designed to be bottom-entry, ensuring it remains securely inside the valve even under extreme pressure surges.

• Self-Cleaning Seats: The wiping action of the ball against the seat during operation clears away scale and debris—essential for marine applications where bio-fouling can occur.

• Anti-Static Protection: Features an internal grounding mechanism to prevent static electricity discharge, a critical safety requirement for refinery and gas services.

• Precision Lapping: The Monel 400 ball is diamond-lapped to a mirror finish. This reduces operating torque and prevents premature seat wear, ensuring the valve remains easy to operate over thousands of cycles.

• High-Strength Stem: We use high-tensile Monel 400 or Monel K-500 for the stem to provide the extra torque capacity needed for high-pressure sealing.

• Advanced Seating Options:

  • PTFE/RPTFE: For general chemical and marine service (up to 200°C).

  • PEEK/Devlon: For high-pressure "Sour Gas" or abrasive media.

  • Metal-to-Metal: For high-temperature or slurry applications.

Every Falcon Monel 400 valve is a product of rigorous quality control:

• PMI Verification: 100% Positive Material Identification confirms the 63% Ni / 30% Cu ratio, ensuring no "dilution" of the alloy's properties.

• Hydrostatic & Pneumatic Testing: All valves are tested to API 598 standards for both high-pressure shell integrity and low-pressure bubble-tight seating.

• HF Acid Service Preparation: For refinery orders, valves are specially cleaned and degreased to meet stringent UOP or Phillips HF Alkylation specifications.

• Traceability: Full EN 10204 3.1 certification is provided for all pressure-retaining parts.

Falcon holds deep domain expertise in deploying Monel 400 valves across several niche sectors:

• HF Alkylation Units: Decades of experience supplying valves that resist the highly aggressive "Reducing" nature of hydrofluoric acid.

• Subsea & Offshore: Expertise in designing valves for seawater cooling systems and fire-water loops where bio-fouling and chloride-ion cracking are the primary threats.

• Salt Processing: Proven reliability in brine heaters and evaporation plants where standard stainless steel fails within months.

The "Falcon" brand is a mark of durability. Our forged Monel 400 ball valves are specifically chosen by engineers who prioritize long-term Life Cycle Cost (LCC) over cheap initial price, as our valves significantly reduce maintenance intervals and unplanned shutdowns in corrosive environments.

At Falcon, we specialize in the engineering and supply of high-performance valve solutions specifically designed for the grueling demands of phosphoric acid production. Handling phosphoric acid is a delicate balance of managing extreme corrosion, abrasive slurries, and scaling—challenges that standard valves simply can’t survive.

We don't just provide valves; we provide reliability for the fertilizer and chemical processing industries. Our expertise covers the entire phosphoric acid lifecycle:

• Corrosion Resistance: Utilizing advanced alloys (such as Alloy 20, Hastelloy, and Duplex steels) and specialized linings to prevent chemical degradation.

• Slurry Management: Our valves are engineered to handle "green" and "amber" acid streams containing gypsum and other abrasive solids without clogging or eroding.

• Scale Mitigation: Innovative designs that minimize "dead spaces" where scale buildup typically occurs, ensuring long-term operational efficiency.

With decades of field experience, Falcon understands that a valve failure in a phosphoric acid plant doesn't just mean downtime—it’s a safety and environmental risk. We deliver engineered endurance that keeps your plant running smoother, longer.

Building on our general overview, Falcon’s phosphoric acid service valves are manufactured to rigorous technical standards to ensure they withstand the specific chemical and physical stressors of HPO production.

Phosphoric acid often contains impurities like fluorides and chlorides that can strip away standard protective layers. We utilize high-alloy materials specifically suited for these environments:

• Super Austenitic Steel: SS 904L and 254 SMO for superior resistance to pitting and crevice corrosion.

• Specialty Nickel Alloys:Alloy 20 (Carpenter 20), Hastelloy C276, and Incoloy 825 for high-temperature concentrated acid streams.

   

   

• Duplex Alloys: Duplex (UNS S31803) and Super Duplex (UNS S32750) for a high-strength, erosion-resistant solution in slurry lines.

Our valves are designed to meet or exceed international safety and performance benchmarks:

• Design Standards: API 6D, ASME B16.34, and BS EN ISO 17292.

• Face-to-Face: ASME B16.10 or DIN EN 558.

• Flange Dimensions: ASME B16.5 (1/2" to 24") or ASME B16.47 (26" and above).

• Testing & Inspection: Every valve undergoes hydrostatic and pneumatic testing per API 598 or EN 12266-1 before shipment.

To combat the scaling and abrasive nature of phosphoric acid:

• Soft Seats: Virgin PTFE, Glass/Carbon-filled PTFE, or Devlon V for bubble-tight shut-off.

• Metal Seats: Hard-faced with Stellite 6 or Tungsten Carbide for slurry-heavy "green acid" applications.

• Stem Packing: Multi-V-ring live-loaded packing to ensure zero leakage to the atmosphere.

• Filter Feed Isolation: Designed to handle the high gypsum content without seat "locking."

• Evaporator Loop: Materials chosen to resist the aggressive corrosion seen in the concentration stages where temperatures rise significantly.

• Acid Storage & Loading: High-cycle reliability for railcar and tank truck loading stations

Falcon UNS N08825 Forged Gate Valves Precision-Engineered for Severe Corrosive Isolation

Falcon’s UNS N08825 (Alloy 825) forged gate valves are the industry standard for reliable, full-bore flow control in environments where standard stainless steel fails. By utilizing a high-nickel, molybdenum, and copper alloy forged to ASTM B564 standards, these valves offer unparalleled resistance to sulfuric and phosphoric acids, as well as chloride-induced stress corrosion.

Design & Construction

• Forged Body Integrity: Unlike cast valves, our forged bodies eliminate porosity and offer a refined grain structure capable of withstanding extreme pressure cycles.

• Outside Screw & Yoke (OS&Y): Designed with a rising stem and non-rising handwheel to keep stem threads out of the process media, ensuring longevity and ease of lubrication.

• Wedge Options: Available in Solid Wedge (for high-pressure stability) or Split Wedge (for better sealing in fluctuating temperatures).

• Sealing Excellence: Precision-ground seating surfaces minimize friction and ensure a bubble-tight shutoff.

Key Features

• Superior Corrosion Resistance: Specifically stabilized with titanium to resist intergranular corrosion after welding or thermal processing.

• Robust Bonnet Design: Choice of Bolted Bonnet (BB) for ease of maintenance or Welded Bonnet (WB) for high-pressure, leak-proof security.

• Integral Backseat: Allows for the repacking of the stem under pressure (safety precautions apply).

• Full Port Design: Minimizes pressure drop and turbulence across the valve.

Technical Specifications

Quality & Compliance

Every Falcon Gate Valve is subjected to rigorous API 598 pressure testing. We provide full documentation, including:

• MTR (Mill Test Reports) to EN 10204 3.1.

• NACE MR0175/ISO 15156 compliance for Sour Gas service.

• PMI (Positive Material Identification) to verify alloy composition.

Falcon UNS N08825 (Alloy 825) valves are high-performance solutions designed for the world’s most demanding industrial environments. Because this alloy provides exceptional resistance to both oxidizing and reducing acids (like sulfuric and phosphoric acids) and is immune to chloride-ion stress corrosion, it is a staple in critical infrastructure.

Below are the primary industries and specific applications where Falcon Alloy 825 valves are deployed:

1. Oil & Gas (Onshore & Offshore)

Incoloy 825 is a "frontline" material for the energy sector, particularly in "sour" environments containing hydrogen sulfide (H2S).

• Sour Gas Service: Used in valves for wellheads and gathering systems where $H_2S$ and $CO_2$ levels are high.

• Subsea Systems: Ideal for subsea manifolds, flowlines, and risers due to its resistance to seawater pitting and high pressure.

• Refining: Applied in hydrotreater units and crude distillation where sulfuric acid corrosion is a constant threat.

2. Chemical & Petrochemical Processing

This is the most common application for Alloy 825, thanks to its unique Nickel-Iron-Chromium-Copper-Molybdenum balance.

• Acid Production: Handling and storage of sulfuric, phosphoric, and nitric acids.

   

   

• Fertilizer Manufacturing: Used in the production of ammonium sulfate and phosphoric acid evaporators.

• Pickling Operations: Forged valves in steel pickling lines that use hot sulfuric acid solutions.

• Specialty Chemicals: Reactive vessels and piping systems involving organic and inorganic chlorides.

3. Marine & Desalination

The high copper and nickel content makes these valves virtually immune to the corrosive effects of stagnant and flowing seawater.

• Desalination Plants: Used in brine heaters and heat exchangers where high-salinity water is processed.

Falcon Forged UNS N08825 (Alloy 825) Globe Valves

Falcon Globe Valves are purpose-built for high-precision flow regulation and frequent operation in highly corrosive environments. Manufactured from premium Nickel-Iron-Chromium-Molybdenum-Copper alloy, these valves provide the "Gold Standard" in durability for acid-handling and sour-gas applications.

1. Advanced Design Features

• Throttling Excellence: Designed with a spherical body and a contoured plug-type disc, allowing for fine-tuned flow control and minimal seat erosion during partial opening.

• Outside Screw & Yoke (OS&Y): The stem threads are isolated from the process media, preventing thread corrosion and ensuring smooth operation even in harsh chemical environments.

   

   

• High-Integrity Sealing: Features a tapered, metal-to-metal seat, precision-lapped to achieve a bubble-tight shutoff and prevent "wire-drawing" of the seal.

• Integral Backseat: Allows for stem packing replacement while the valve is in service, enhancing safety and reducing downtime.

2. Manufacturing Process

• Precision Forging (ASTM B564): Unlike casting, which can leave internal voids (porosity) and brittle structures, Falcon’s forging process compresses the alloy. This creates a continuous, directional grain flow that follows the contours of the valve body, resulting in maximum impact strength and fatigue resistance.

   

   

• Stabilized Metallurgy: Our Alloy 825 is titanium-stabilized during the forging process to prevent intergranular corrosion in the heat-affected zones (HAZ) after welding.

• CNC Machining: All critical tolerances, including the seat and stem threads, are finished on high-precision CNC centers to ensure 100% interchangeability of parts.

3. Rigorous Testing & Quality

At Falcon, quality is verified, not just promised. Each Globe Valve undergoes a multi-stage testing protocol:

• Hydrostatic Shell & Seat Test: Performed at 1.5x and 1.1x the rated pressure respectively, according to API 598 standards.

• Fugitive Emission Testing: Available for critical service to ensure zero leakage from the stem packing (ISO 15848-1 compliance).

• Positive Material Identification (PMI): Every single valve body and bonnet is verified via X-ray fluorescence to ensure the exact chemical composition of Alloy 825.

• Dye Penetrant Inspection: All forged surfaces are inspected for surface irregularities to guarantee a defect-free finish.

Technical Summary

Key Industrial Applications for Falcon Alloy 825 Globe Valves 1. Chemical Processing & Acid Handling

The most critical application for Alloy 825 globe valves is in the regulation of highly corrosive acids.

• Sulfuric Acid Plants: Used in the concentration and piping of sulfuric acid, where the alloy's resistance to "reducing" environments is vital.

   

   

• Phosphoric Acid Production: Essential for throttling flow in fertilizer production lines where phosphoric acid causes severe pitting in standard stainless steels.

• Pickling Lines: Regulating the flow of heated acid baths in steel mills and metal finishing plants.

2. Oil & Gas (Sour Service & Midstream)

In the energy sector, these valves manage fluids that are both high-pressure and chemically "sour."

• Gas Dehydration Units: Regulating the flow of glycols and other chemicals used to remove water from natural gas.

• Sour Gas Throttling: Managing the flow of gas containing high concentrations of $H_2S$ and $CO_2$, where resistance to Sulfide Stress Cracking (SSC) is required.

• Acid Gas Injection: Used in carbon capture and storage (CCS) and enhanced oil recovery.

4. Marine & Offshore Engineering

• Desalination Plants: Precise control of high-salinity brine flow. The globe valve’s ability to throttle is critical for maintaining pressure across desalination plant