API 6D 20“ Class1500LB A105 Zero Leakage Turbine Forged Steel Worm Gear 3PC 600 Pound Flange Trunnion Ball Valve

II. Manufacturing Technology and Core Product Features

A. Full Process Standardized Manufacturing & Multi-Stage Strict Quality Control Mechanism

• Raw Material Inbound Inspection Management: All incoming ASTM A105 forged bar stock, UNS S32205 duplex steel round billet, Stellite surfacing welding wire and composite sealing strip raw materials are delivered to factory physical and chemical laboratory for PMI positive material identification, spectral composition analysis and mechanical property sampling test. Only raw material batches passing chemical component ratio calibration, tensile strength, hardness and impact toughness verification can be released to subsequent forging processing flow; unqualified raw material batches are directly returned to upstream suppliers to block defective source inflow into production links, and all material heat numbers are recorded for full lifecycle traceability.
• Closed Die Precision Forging and Normalizing Heat Treatment: Three split body blanks adopt 2000-ton fully automatic closed die forging press molding, precisely controlling metal fiber flow to follow valve body force bearing outline and avoid fiber breakage which reduces pressure resistance performance. After forging forming, blanks enter segmented temperature control furnace for complete normalizing heat treatment to homogenize internal metal grain structure and eliminate forging residual internal stress, greatly improving anti-fatigue and anti-crack performance under ultra-high pressure circulation loads. Post heat treatment finished forged blanks implement 100% UT ultrasonic non-destructive flaw detection and MT magnetic particle inspection complying with ASME V specification, eliminating invisible internal and surface crack defects that threaten long-term high-pressure pipeline service safety.
• Five-Axis CNC Ultra-Precision Machining of Critical Sealing Components: Valve body seat matching circular surface, trunnion bearing fitting hole, stem through hole and flanged positioning surface are processed by five-axis linkage CNC machining center with micron-level strict dimensional tolerance control. The UNS S32205 ball spherical surface undergoes numerical control turning and precision mirror lapping treatment to reach Ra 0.4μm ultra-smooth surface roughness value, ensuring uniform full-surface attaching between ball and sealing ring after assembly to achieve Class VI zero leakage shut-off effect. Trunnion shaft outer circle adopts centerless precision grinding to obtain mirror smooth outer diameter, reducing friction abrasion loss between shaft and bearing sleeve during millions of full stroke switching cycles.
• Composite Sealing Ring Hot Press Forming and Fire Resistance Pre-Verification: Multi-layer soft-hard composite sealing components are hot pressed under constant temperature and tonnage hydraulic equipment, with layered structure parameters locked according to API 607 fire resistance requirements. Random sampled sealing ring pieces from each production lot carry out high-temperature fire simulation aging test inside special thermal test chamber to verify sealing retention performance after flame exposure, eliminating sealing failure risk under pipeline fire accident conditions.
• Dust-Free Closed Assembly and Complete Full-Item Finished Product Performance Test: Full valve assembly operation is finished inside independent constant temperature dust-free assembly workshop; all body connecting high-strength alloy bolts are locked by calibrated digital torque wrench following unified standardized torque value to avoid uneven clamping force causing sealing ring deformation and medium leakage. After assembly completion, all finished valves sequentially experience shell hydrostatic pressure test, helium gas tightness leakage test, full-stroke cycle endurance test, high-low temperature alternating stability inspection and API 607 fire resistance test formulated by international standards. Products failing any single testing item enter designated rework flow instead of being stored in finished product warehouse; only fully inspected qualified units go through heavy-duty anti-rust epoxy coating and fumigated export wooden box packaging before shipment to global oil & gas operators and international EPC contractors.

B. Distinctive Core Structural Product Features

• Dual Trunnion Fixed Ball Ultra-High Pressure Resistant Design: Double-end trunnion support structure balances medium thrust acting on the ball under Class 1500LB ultra-high differential pressure, preventing ball lateral deflection and localized sealing surface abrasion, extending sealing system service life more than three times compared with floating ball valve alternatives deployed under identical high-pressure working conditions.
• Three-Piece Split Forged Body Easy Maintenance Layout: Separable front body, middle body and rear body split structure allows disassembly of internal ball, trunnion and sealing components without removing the entire valve from pipeline, cutting overhaul time by over 60% and avoiding large-scale pipeline shutdown production loss during routine maintenance.
• Full Bore Straight Through Low Flow Resistance Flow Channel: Unobstructed circular full bore internal channel without any protruding support structure minimizes fluid turbulence and pressure loss during medium circulation, reducing long-term energy consumption of fluid transmission equipment such as compressors and oil transfer pumps for end-user industrial facilities.
• UNS S32205 Duplex Anti-Corrosion Trim Matching A105 Forged Body: High-strength duplex stainless steel ball and internal trim deliver exceptional chloride and sulfide corrosion resistance, compatible with offshore seawater injection and sulfur-containing crude oil high-pressure pipelines, solving rust and pitting failure problems of ordinary carbon steel and 304 stainless steel trim under corrosive high-pressure media.
• Integral API 6D Compliant Anti-Blowout Stem Safety Structure: One-piece shoulder limit design on the stem shaft completely restricts upward ejection displacement under full Class 1500LB internal medium pressure, eliminating major safety hazards of stem blowout in ultra-high pressure pipeline accidental working conditions.
• Worm Gear Labor-Saving Manual Driving Unit: Alloy carburized worm and worm wheel pair greatly reduces required manual rotation torque for full ball stroke switching under maximum rated pressure; external mechanical opening pointer provides real-time visual valve position feedback without auxiliary electronic monitoring equipment, adapting remote unmanned pipeline station operation management demands.
• API 607 Certified Full Fire-Safe Sealing System: Multi-layer composite soft-hard sealing assembly retains reliable metal hard sealing shut-off performance after polymer soft layer burns out under fire temperature, complying with mandatory fire safety codes for oil, gas and petrochemical industrial facilities globally.
• Full-Set International Authoritative Certification Endorsement: Entire product research, forging production and finished testing workflow passes ISO9001, API Q1 quality system audit and EU CE PED safety certification, all dimensional and pressure performance indicators meet North American, Middle Eastern and European oil & gas industry procurement standards to smoothly access international large-scale energy project tendering lists.