ANSI DN100 Class 300 Carbon Steel Wcb with Top Flange 2PC Trunnion Mounted Ball Valve

I. Product Overview

II. Key Attribute Parameters

• Size Range: 2″~16″ (DN50~DN400), covering small to medium-diameter pipelines to meet flow requirements in process loops, transmission lines, and equipment interfaces.
• Pressure Rating: ANSI Class 150~900 (PN16~PN150), with Class 300 (5.0MPa) as a common specification, suitable for medium to high-pressure applications.
• Temperature Range:
  • Soft seal (RPTFE/PPL): -20℃~280℃, ideal for moderate temperature media.
  • Metal seal: -196℃~600℃, adapting to cryogenic or high-temperature environments (e.g., steam, LNG).
• Material Configuration:
  • Body & Closure: Carbon steel (WCB, ASTM A216), offering high tensile strength (≥485MPa) for structural integrity; optional stainless steel (CF8/CF8M) for corrosive media.
  • Ball & Stem: Carbon steel (A105N+ENP) or stainless steel (F316), with precision-machined surfaces for tight sealing.
  • Seal: Soft seal (RPTFE/PPL) for low leakage; metal seal (stainless steel) for high temps and abrasion resistance.
• Connection Type: Flanged (RF/RTJ per ASME B16.5) or butt-weld (BW), ensuring leak-tight integration with pipeline systems.
• Operation: Manual (handwheel), gearbox, pneumatic, or electric actuator, with gear operation reducing torque for large-diameter valves.
• Standards Compliance: Design per API 6D, API 608; pressure-temperature ratings per ASME B16.34; testing per API 598; fire-safe per API 607.

III. Structural Features

• 2-Piece Split Body: Valve body splits into two sections joined by bolts, balancing structural rigidity and ease of maintenance. This design simplifies internal component access (ball, seat, stem) without full disassembly from the pipeline, reducing downtime.
• Trunnion-Mounted Ball: The ball is supported by upper and lower trunnions, distributing pressure loads to prevent deformation under high pressure. This eliminates “ball blowdown” risk, ensuring stable operation in Class 600+ systems with flow surges.
• Top Flange Design: Integral top flange (ISO 5211 standard) facilitates quick actuator mounting, enabling easy upgrades to automated control (pneumatic/electric) without modifying the valve body—ideal for retrofitting manual systems.
• Dual Seal Options: Soft seals (RPTFE) provide bubble-tight shut-off (ANSI FCI 70-2 Class VI) for clean media; metal seals (stainless steel) resist wear from solid particles and high temps, suitable for harsh environments.
• Safety Enhancements: Anti-static device (stainless steel spring) dissipates static (resistance ≤10⁶Ω) to prevent sparks; fire-safe graphite backup seals (API 607) ensure basic shut-off during fire, reducing leakage risks in hazardous areas.

IV. Manufacturing Processes

• Material Preparation: Carbon steel castings (WCB) undergo spectral analysis to verify chemical composition (C≤0.30%, Mn≤1.00%) and ultrasonic testing to eliminate internal defects (cracks, shrinkage). Forged components (stem/ball) are stress-relieved to avoid deformation.
• Precision Machining:
  • Ball & Seat: CNC grinders achieve ball roundness ≤0.01mm and surface finish Ra ≤0.8μm; seats are lapped to match ball contours, ensuring uniform contact for tight sealing.
  • Body & Flange: CNC lathes machine flange sealing faces to flatness ≤0.05mm, with bolt holes drilled to ±0.1mm tolerance for alignment with pipelines. Top flange is machined to ISO 5211 dimensions for actuator compatibility.
• Assembly & Testing:
  • Seats are pre-loaded with Inconel X-750 springs to compensate for thermal expansion, ensuring consistent contact across temperature cycles.
  • Each valve undergoes API 598 testing: hydrostatic shell test (1.5×Class pressure for 30 minutes), seat leakage test (1.1×Class pressure with air/water), and 1000+ operation cycles to verify durability.
• Surface Treatment: Carbon steel bodies are sandblasted (Sa 2.5) and coated with high-temperature epoxy paint (dry film thickness ≥80μm) for corrosion resistance; stainless steel components are passivated to enhance rust resistance.