Sleeve Type Soft Sealing Plug Valves

I. Product Features: Flexible Sealing Meets Efficient Flow Path

(A) Flexible Sealing System

1. Fully Encapsulated Sleeve Design
   • Zero-Leakage Assurance: EPDM or FFKM sleeves bonded to the plug via vulcanization ensure bidirectional bubble-tight sealing (API 598 Class VI), reliable at 0.05MPa low pressure.
   • Wear Self-Compensation: 70±5HA Shore hardness sleeves maintain ≥90% elastic recovery after 100,000 cycles, doubling service life compared to conventional valves.
2. Optimized Flow Path
   • Full Bore Design: Identical ID to pipeline (DN15-DN300) increases Cv by 25% (Cv≥100 for DN100), reducing pumping energy by 12%.
   • Anti-Scaling Structure: 45° helical grooves in sleeve 内壁 self-clean at ≥1m/s flow, minimizing scale buildup by 80% in high-hardness water (≥300mg/L).

(B) Material & Application Matrix

II. Manufacturing Processes: Precision Molding & Quality Control

(A) Key Manufacturing Steps

1. Body Forging & Machining
   • Precision Forging: 800-ton presses produce WCB/A351 CF8M bodies (forging ratio ≥3:1), ASTM No.8 grain size, UT tested for ≥Φ2mm defects.
   • 5-Axis Machining: CNC machines achieve ≤0.02mm cylindricity for sleeve cavities, verified by laser measurement (±0.005mm accuracy).
2. Sleeve Molding Technology
   • Injection Vulcanization: Rubber compounds molded at 180℃±5℃, 15MPa, forming bubble-free structure with ≥12MPa tensile strength.
   • PTFE Encapsulation: Cold-pressed PTFE powder (0.8-1.2mm thickness) sintered at 380℃, Ra≤0.8μm surface finish.
3. Assembly & Testing
   • Torque Calibration: Smart torque wrenches (±2% accuracy) set assembly torque (e.g., 150±15N·m for DN100), ensuring consistent operation.
   • Helium Mass Spectrometry: Leakage ≤5×10⁻⁹Pa·m³/s at 1.1x pressure for critical applications.

(B) Full-Dimension Testing

• Hydrostatic Test: 1.5x pressure (water) for 30 minutes, ≤0.3% drop (e.g., 4.5MPa for Class 300);
• Gas Seal Test: 0.6MPa air with bubble detection, suitable for food-grade nitrogen;
• Life Cycle Test: 100,000 cycles with ≤0.01cc/min leakage, exceeding industry standards (50,000 cycles).

III. Product Applications: Ideal for Clean Media Across Industries

(A) Municipal & Building

• Potable Water: NSF 61-certified EPDM sleeves reduce flow resistance by 18% vs. butterfly valves in DN200 pipelines, lowering pumping costs.
• Wastewater: NBR sleeves resist H₂S (≤100ppm), lasting 7 years in aeration systems, 3.5x longer than cast iron valves.

(B) Food & Beverage

• Dairy Processing: FDA-compliant PTFE sleeves ensure ≤0.01mg/cm² CIP residue in pasteurization systems, preventing cross-contamination.
• Brewing: EPDM sleeves withstand hop acids (pH 4-5), with 60% lower operating torque than ball valves for precise automation.

(C) Chemical & Pharmaceutical

• Fine Chemicals: FFKM sleeves handle 200℃ chlorine (1.2MPa) for 5+ years with ≤0.01cc/min leakage.
• Pharmaceutical: 316L bodies with EPDM sleeves meet GMP requirements (Ra≤0.4μm) for purified water systems.

(D) Power & Energy

• Circulating Water: DN300 valves reduce maintenance costs by 40% in 300MW power plants, resisting sediment (≤100mg/L).
• LNG Terminals: Cryogenic valves (-162℃) with F316L bodies and special EPDM sleeves (API 6A PR2) for BOG recovery.

IV. Advantages: TIANYU’s Global Competitiveness

1. Zero-Leakage & Environmental Benefits
   • Bidirectional Sealing: Bubble-tight in both directions, meeting ISO 15848-1 Class B emission standards.
   • Lubricant-Free Design: Eliminates contamination risks, ideal for food/pharma applications.
2. Low Maintenance & Longevity
   • Replaceable Sleeves: 30-minute sleeve replacement reduces repair costs by 75% vs. full valve replacement.
   • Aging Resistance: EPDM sleeves maintain ≥80% tensile strength after 1000-hour UV exposure (ISO 4665), suitable for outdoor use.
3. Global Certifications & Service Network
   • Compliance: CE-PED, API 6D, ASME BPVC Section VIII certifications for global markets.
   • Rapid Response: 6 regional warehouses ensure 48-hour emergency shipments, cutting downtime by 50%.
4. Lifecycle Value Commitment
   • Energy Efficiency: Full bore design saves ~$2,500/year in electricity for DN200 valves (8,000 hours).
   • Sustainability: 100% recyclable bodies, degradable sleeves, compliant with EU RoHS Directive.