Inverted Pressure Balance Lubricated Plug Valves

I. Product Features: Innovative Pressure Balance and Forced Lubrication

(A) Pressure Balance and Low Torque Operation

1. Inverted Plug Structure
   • Self-Balancing Mechanism: The tapered plug (3°±1°) balances inlet/outlet pressure via a bottom piston chamber, reducing operating torque by 60% (≤100N for DN200), significantly lower than conventional valves (≥250N).
   • Dual Sealing Surfaces: Top soft seal (PTFE/PEEK) achieves zero leakage (API 598 Class VI), while bottom metal seal (Stellite®6 overlay) withstands Class 2500 (PN420) ultra-high pressure.
2. Forced Lubrication System
   • High-Pressure Grease Injection: Three evenly spaced grease ports (6mm diameter) with Class 3000 grease valves allow on-stream lubrication, forming a 0.3-0.5mm protective film that reduces wear by 80% and extends seal life 3x.
   • Self-Cleaning Design: 60-mesh stainless steel filters in grease channels prevent clogging, reducing grease injection frequency from weekly to monthly in shale gas applications.

(B) Sealing Technology and Material System

(C) Flow Path Optimization

• Full Bore Design: Identical plug and pipeline diameter (DN50-DN600) increases Cv value by 25%, saving 15% annual pumping energy for DN300 lines;
• Anti-Static Device: Conductive spring (≤10Ω resistance) eliminates electrostatic buildup, compliant with ISO 10497 for flammable media (e.g., hydrogen, LNG).

II. Manufacturing Processes: Precision Forging and Quality Assurance

(A) Key Manufacturing Steps

1. Die Forging Technology
   • Triple Upsetting-Drawing Process: 1600-ton presses refine grains to ASTM No.11+ (forging ratio ≥5:1), enhancing fatigue resistance by 50%, with UT testing for ≥Φ1.5mm defects.
   • Precision Plug Machining: 5-axis CNC machines achieve IT5-grade taper precision (Ra≤0.2μm), verified by optical inspection (±0.001mm accuracy), ensuring 98% sealing surface contact.
2. Surface Treatment and Coating
   • Hardfacing Technology: Plasma powder welding deposits 2-3mm Stellite®6 layers, X-ray verified for defect-free bonding (≥500MPa strength).
   • Corrosion Protection: Epoxy coating (100μm) for marine valves (1000-hour salt spray resistance); anti-oxidation treatment for high-temp valves (700℃ tolerance).
3. Lubrication System Integration
   • Precision Grease Port Drilling: Coordinate boring machines ensure ±0.05mm positioning for uniform grease distribution;
   • Grease Compatibility Testing: Each batch undergoes 72-hour media immersion testing to ensure no swelling or degradation.

(B) Full-Dimension Testing

• Hydrostatic Test: 1.5x pressure (water) for 45 minutes, ≤0.5% drop (e.g., 13.5MPa for Class 900);
• Gas Seal Test: 1.1x pressure (helium), leakage ≤1×10⁻⁹Pa·m³/s (better than API 6D Class VI);
• Torque Consistency: ≤8% torque variation across 0.1MPa to nominal pressure, ensuring smooth operation;
• Life Cycle Test: 100,000 cycles with ≤5% grease consumption and ≤0.03mm plug wear.

III. Product Applications: Preferred Solution for High-Pressure Industries

(A) Oil & Gas

• Shale Gas: Sulfur-resistant valves (NACE MR0175) operate 7+ years in 1500ppm H₂S, extending grease injection intervals to 3 months;
• Subsea Pipelines: Deepwater valves (F316 body) with DNV GL certification withstand 1500m depth and 20MPa pressure, maintaining ≤0.1cc/min leakage.

(B) Chemical & Petrochemical

• High-Viscosity Media: In 200℃ asphalt pipelines (500cSt), flow resistance is 40% lower than ball valves, with maintenance cycles extended from 6 months to 2 years;
• Polymer Reactors: T-type valves control 30% solids-laden polyethylene slurry, preventing particle buildup and reducing downtime by 5+ times annually.

(C) Energy & Power

• Supercritical Power Plants: High-temp valves (F91 plug) achieve ≤15s 启闭 at 540℃/25MPa, with 1/3 the torque of traditional valves (ASME BPVC Section III compliant);
• LNG Terminals: Cryogenic valves (-162℃, F316L) with API 6A PR2 certification ensure ≤0.5s emergency shut-off in loading arms.

(D) Municipal & Environmental

• Wastewater Treatment: Wear-resistant valves (tungsten carbide coating) handle 15% solids-laden sewage for 8 years (4x standard lifespan), with automatic grease compensation for wear;
• Industrial Gas Recovery: Anti-static design prevents sparks in 10MPa hydrogen pipelines (99.99% purity), with soft seals ensuring zero leakage.

IV. Advantages: TIANYU’s Global Competitiveness

1. Pressure Balance Core Benefits
   • Low Torque Operation: 60% less operating force, enabling manual operation up to DN300 and 30% smaller actuator sizes, reducing equipment costs;
   • High-Pressure Adaptability: Class 2500 capability with anti-jamming design for frequent on/off cycles in high-pressure systems.
2. Intelligent Lubrication & Longevity
   • Online Maintenance: Grease injection without shutdown, optional smart monitors for 95% accurate wear prediction;
   • Wear Resistance: 3x longer life in particle-laden media due to Stellite®6 and lubrication film, cutting unplanned shutdown costs.
3. Customization & Global Certifications
   • Special Designs: Fire-safe (API 607), cryogenic (-196℃), and anti-frost solutions for extreme environments;
   • Full Compliance: 25+ certifications including API 6D, CE-PED, GOST-R for global market access.
4. Global Service & Sustainability
   • Rapid Response: 8 regional centers with 24/7 support, 48-hour emergency parts delivery, reducing downtime by 75%;
   • Environmental Commitment: 98% recyclable components, 40% lower forging energy, 180kg CO₂e reduction per DN800 valve (EU CE PED compliant).