III. Product Features

• V Port Shear Capability: The V-shaped segment on the ball creates a strong shearing force when rotating, cutting through fibers, sludge, or small particles in the medium. This eliminates clogging— a common issue with standard full-port ball valves—making it ideal for sewage treatment, pulp processing, and mining slurry applications.
• Dual-Seal Reliability: Metal hard seals (SS304/SS316) provide excellent wear resistance and high-temperature tolerance, maintaining sealing integrity even after repeated cycles. For clean, low-temperature media, PTFE soft seals offer API 598 Class VI bubble-tight shutoff (near-zero leakage), reducing media waste and environmental risks.
• Fast Pneumatic Actuation: The pneumatic actuator delivers rapid 90° rotation (0.5-2 seconds), enabling quick response to process changes—critical for emergency shutdowns in chemical plants or flow adjustments in power generation steam lines.
• Corrosion Resistance: CF8M/SS304 materials resist pitting, crevice corrosion, and chemical attack from chlorinated water, mild acids, or coastal salt air. WCB options provide cost-effective durability for non-corrosive media, ensuring long service life across diverse environments.
• Flexible Control Modes: Supports both on-off control (for simple shutoff) and throttling regulation (with 4-20mA positioner). The positioner enables precise flow adjustment (±1% accuracy), making it suitable for processes requiring stable flow rates (e.g., chemical dosing, food beverage filling).
• Safety and Durability Enhancements: Spring return actuators ensure fail-safe operation during air supply failure, preventing process overflow or equipment damage. Explosion-proof accessories (EXD solenoid valve, EX limit switch) meet ATEX or IECEx standards, enabling use in hazardous areas (e.g., oil refineries, gas processing plants).
• Easy Installation and Alignment: Flanged connections comply with global standards (ASME/DIN), allowing seamless integration into existing pipelines without custom modifications. The actuator’s ISO 5211 mounting interface ensures quick, accurate alignment with the valve, reducing installation time.

IV. Manufacturing Process

• 1. Raw Material Selection and Testing: All materials (CF8M, SS304, WCB, SS316 stem) undergo strict incoming inspection. Chemical composition analysis (via 光谱仪) verifies material purity (e.g., molybdenum content in CF8M), while mechanical testing (tensile strength, hardness) ensures compliance with ASTM standards. SS316 stems additionally undergo salt spray testing (48 hours) to confirm corrosion resistance.
• 2. Precision Casting: Valve bodies and balls are produced via investment casting (lost wax process) for CF8M/SS304, or sand casting for WCB. This process achieves a smooth internal surface (Ra ≤1.6μm) and dimensional accuracy (±0.05mm), eliminating internal defects like porosity that could cause pressure leakage.
• 3. Heat Treatment: Cast components undergo solution annealing (for stainless steel) or normalizing (for WCB) to relieve internal stress, enhance material toughness, and improve corrosion resistance. CF8M parts are heated to 1050-1100℃ and quenched in water, while WCB is heated to 850-900℃ and cooled in air.
• 4. CNC Machining: Critical components are processed using 5-axis CNC machines for precision:
  • Ball: The V port is machined to a precise angle (15°/30°/60°, based on flow requirements) and polished to Ra ≤0.8μm to ensure smooth rotation and proper sealing.
  • Valve Seat: Metal seats are ground to match the ball’s contour (tolerance ±0.02mm), while PTFE seats are molded and bonded to the seat ring for secure attachment.
  • Flange Faces: Raised faces are machined to ASME B16.5/DIN EN 1092-1 standards, with bolt holes drilled using CNC positioning to ensure alignment.
• 5. Surface Treatment: Stainless steel components undergo passivation (using nitric acid) to form a protective oxide layer, enhancing corrosion resistance. WCB components are painted with epoxy resin (2-3 coats) to prevent rust in outdoor or damp environments.
• 6. Component Assembly:
  • Stem Installation: The SS316 stem is inserted into the valve body, with a graphite packing gland compressed to prevent stem leakage.
  • Ball and Seat Assembly: The V port ball is placed between two seats, with guided alignment to ensure the V segment aligns with the flow path.
  • Actuator Mounting: The pneumatic actuator is mounted via ISO 5211 brackets, with torque calibration to match the valve’s operating requirements (ensuring smooth rotation without overloading).
• 7. Accessory Integration: Solenoid valves, limit switches, and FRL units are connected to the actuator, with wiring checked for continuity and proper signal transmission. Explosion-proof accessories undergo additional testing to verify seal integrity.
• 8. Pressure and Leakage Testing:
  • Shell Test: The valve body is filled with water and pressurized to 1.5×nominal pressure (e.g., 2.4MPa for PN16) for 10 minutes, with no visible leakage or deformation.
  • Seat Test: Air or water is applied at 1.1×nominal pressure, with leakage rates measured to meet API 598 Class IV (metal seal) or Class VI (PTFE seal).
  • Actuation Test: The valve undergoes 500+ open/close cycles to verify actuator performance, with position feedback checked for accuracy.
• 9. Dimensional Inspection: Critical dimensions (flange thickness, ball diameter, V port angle) are measured using coordinate measuring machines (CMM) to ensure compliance with design standards.
• 10. Cleaning and Passivation: Final cleaning removes machining debris, with stainless steel parts re-passivated to restore the protective layer damaged during assembly.
• 11. Marking: Laser marking is applied to the valve body, indicating nominal diameter, pressure rating, material, and serial number for traceability.
• 12. Packaging: Valves are wrapped in bubble wrap, placed in EPS foam, and packed in export wooden cases (IPPC-certified) to prevent damage during transportation.