Plug Valve

I. Product Features: Full-Type Coverage and Sealing Innovation

(A) Structural Design and Functional Classification

1. Straight Through Plug Valves
   • Reduced/Full Bore: Reduced bore (Cv≤0.6 for DN50) saves 30% space for clean media; full bore (DN80+) prevents particle buildup, ideal for slurries (≤200μm) and asphalt, reducing blockages by 80% in copper mine applications.
2. Tee/Cross Plug Valves
   • L-Type/T-Type Diverters: L-type (90°) switches two paths with ≤0.1cc/min leakage (API 598 Class IV); T-type (120°) enables three-way flow with ±0.5° positioning accuracy for petrochemical material switching.
3. Pressure Balance Plug Valves
   • Dual Packing Design: Upper PTFE packing for dust prevention, lower graphite packing for pressure resistance, reducing operating torque by 50% (≤80N for DN100), suitable for high-pressure natural gas quick shut-off.

(B) Sealing Technology and Material System

(C) Material Compatibility

• Body Materials: Forged steel (A105/F316), cast steel (WCB), duplex steel (2205), Hastelloy (C-276), suitable for Class 150~2500 (PN16~420);
• Temperature Range: Cryogenic (-196℃), high-temperature (650℃), and standard (-29℃~427℃).

II. Manufacturing Processes: Precision Machining and Quality Control

(A) Key Manufacturing Steps

1. Die Forging and Forming
   • Hot Forging: 1600-ton presses refine grains to ASTM No.10+ (forging ratio ≥4:1), enhancing impact resistance by 40% for seismic zones.
   • Powder Metallurgy: MIM technology for stainless steel plugs (±0.01mm accuracy, Ra≤0.8μm), ideal for DN15~DN50 micro valves.
2. Precision Machining and Treatment
   • 5-Axis CNC: IT6-grade precision for plug sealing surfaces, polished to Ra≤0.2μm, ensuring torque variation ≤5% (DN200 test).
   • Surface Hardening: Ion nitriding for carbide plugs (0.3mm depth, HV1000+), tripling wear resistance for sand-laden crude (≤5% solids).
3. Sealing System Integration
   • Grease Injection System: Class 3000 grease valves 对接 plug cavities, tested to 1.5x pressure for emergency sealing reliability.

(B) Full-Dimension Testing

• Hydrostatic Test: 1.5x pressure (water) for 30 minutes, ≤0.3% 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);
• Life Test: 100,000 cycles with 95% sealing retention, exceeding industry standards (50,000 cycles).

III. Product Applications: Solutions for Global Industries

(A) Oil & Gas

• Shale Gas: Sulfur-resistant valves (NACE MR0175) operate 8+ years in 1000ppm H₂S, used in wellhead chokes;
• LNG Terminals: Cryogenic valves (F316L plug) with ≤15N·m torque at -162℃, API 6A PR2-certified for loading arm shut-off.

(B) Chemical & Petrochemical

• Polymer Reactors: Tee plug valves (PTFE seal) control 99.9% pure ethylene with ≤5×10⁻¹⁰Pa·m³/s leakage;
• Chlor-Alkali Plants: Hastelloy C-276 plugs last 10 years in wet chlorine, 5x longer than standard SS.

(C) Power & Energy

• Supercritical Power: High-temp valves (F91 body) achieve 30s emergency shut-off at 540℃/25MPa (ASME BPVC Section III);
• PV Silicon Production: Micro valves (DN15) control trichlorosilane with ≤1×10⁻¹²Pa·m³/s leakage for semiconductor purity.

(D) Municipal & Environmental

• Wastewater Treatment: Wear-resistant valves (tungsten carbide coating) extend maintenance cycles from 3 months to 1 year in sand-laden 污水，cutting costs by 40%;
• District Heating: Thermostatic plug valves (shape memory alloy spring) maintain ±2℃ accuracy, saving 15% energy.

IV. Advantages: TIANYU’s Global Competitiveness

1. Rapid Operation and Low Torque
   • 90° quick switch in seconds, 30% lower operating force (≤120N for DN150), ideal for emergency scenarios;
   • Pressure balance design reduces actuator size by 25% for DN300, saving equipment costs.
2. Customization for Special Conditions
   • Special Designs: Fire-safe (API 607), anti-static (ISO 10497), and anti-frost solutions for arctic/desert environments;
   • Industry-Specific: FDA-compliant mirror-polished plugs (Ra≤0.2μm) for food/pharma; seismic-resistant valves (IEEE 344) for nuclear applications.
3. Global Certifications and Support
   • Compliance: 20+ certifications including API 6D, CE-PED, GOST-R for global markets;
   • Service Network: 7 regional centers with 24/7 support, 48-hour emergency parts delivery, reducing downtime by 70%.
4. Lifecycle Value and Sustainability
   • Easy Maintenance: Modular design allows 30-minute plug/packing replacement, 60% cost savings vs. full replacement;
   • Environmental Commitment: 95% recyclable components, 35% lower forging energy, 200kg CO₂e reduction per DN1000 valve (EU CE PED compliant).