III. Feature Description

A. Electric Actuation: Automation & Remote Control for Industrial Efficiency

B. Flanged Connection: Leak-Tight Integrity & Easy Maintenance

• Leak Resistance: The RF flange and gasket create a uniform seal even under pressure fluctuations. In a petrochemical plant’s DN300 oil line, TIANYU’s flanged valves showed zero leakage after 3 years of service, while threaded valves required quarterly gasket replacements due to vibration-induced loosening.
• Simplified Maintenance: Flanges allow the valve to be removed from the pipeline without cutting, reducing maintenance downtime by 70% compared to welded valves. For example, replacing a worn PTFE seal in a DN200 valve takes 2 hours with flanged connections, versus 8 hours for welded valves (which require cutting, re-welding, and pressure testing).
• Scalability: Standard flange dimensions (ASME B16.5) enable easy retrofitting into existing pipelines. A power plant upgrading its cooling water system, for instance, could replace old gate valves with TIANYU’s flanged ball valves without modifying pipeline flanges.

C. PTFE Sealing: Chemical Inertness & Bubble-Tight Performance

• Chemical Inertness: Resists attack from 95% of industrial chemicals, including sulfuric acid (50%), sodium hydroxide (30%), and crude oil. In a chemical plant’s DN150 acid line, PTFE-sealed valves maintained sealing integrity for 4 years, while rubber seals degraded within 6 months.
• Low-Temperature Stability: Remains flexible at -30℃, making it suitable for chilled water systems (e.g., food processing plants cooling fruit juices). Unlike rubber seals, PTFE does not harden or crack in cold conditions, ensuring consistent leakage performance.
• High-Temperature Tolerance: Withstands up to 200℃, compatible with saturated steam (180℃, PN1.0MPa) in power plant auxiliary systems. The seal’s low friction (coefficient ≤0.04) also reduces actuator torque requirements, extending motor life by 30%.

D. Floating Ball Design: Pressure Adaptability & Structural Stability

• Pressure-Enhanced Sealing: When media flows, pressure pushes the ball against the downstream PTFE seat, creating a tighter seal as pressure increases. This ensures ANSI/FCI Class VI leakage even at minimum operating pressure (PN0.6MPa), critical for low-pressure water lines where seal pressure is limited.
• Radial Stress Reduction: The floating design eliminates radial movement of the ball under high pressure (PN1.6MPa), reducing wear on seats and extending seal life by 50% compared to trunnion-mounted balls in low-to-medium pressure applications.
• Simplified Construction: Fewer components than trunnion-mounted valves reduce manufacturing complexity and cost, making the floating ball design a cost-effective choice for DN125–DN500 low-pressure systems (e.g., municipal water, HVAC).

E. Material Versatility: Adaptation to Diverse Industrial Media

• Water & Wastewater: Cast iron (HT200) or WCB bodies with PTFE seals handle potable water and sewage. The cast iron’s painted surface resists rust in buried pipelines, while PTFE resists corrosion from chlorine-based disinfectants.
• Oil & Gas: 316 stainless steel bodies with PTFE seals regulate crude oil and natural gas flow. 316’s molybdenum content resists chloride corrosion (e.g., seawater in offshore pipelines), while PTFE prevents oil leakage.
• Steam & HVAC: WCB bodies with PTFE seals control saturated steam (≤180℃) in power plants and commercial buildings. WCB’s thermal stability withstands steam temperature cycles, and PTFE’s low friction ensures smooth valve operation.
• Chemicals: 316 stainless steel bodies with PTFE seals handle acids and alkalis. PTFE’s chemical inertness prevents media contamination, making it suitable for pharmaceutical or food-grade chemical lines.

IV. Manufacturing Processes

A. Material Inspection & Preparation

• Raw Material Verification:
  • Metallic Materials: Cast iron (HT200), WCB, and 304/316 stainless steel billets undergo spectral analysis to confirm chemical composition (e.g., C: 0.25–0.35% for WCB, Cr: 18–20% for 304). Ultrasonic testing (UT) detects internal defects (porosity, cracks) in cast components, ensuring structural integrity under pressure.
  • Plastic Materials: Reinforced POM balls are tested for tensile strength (≥60MPa) and impact resistance (≥10kJ/m²) to ensure durability in low-pressure applications.
  • Seal Materials: PTFE sheets are tested for compression set (≤20% after 70 hours at 200℃) and chemical resistance (immersion in 50% sulfuric acid for 100 hours with no weight loss >1%).
• Surface Preparation:
  • Cast components are sandblasted to remove scale and surface defects, improving paint adhesion (for cast iron) or passivation (for stainless steel). Stainless steel components undergo acid passivation to enhance the chromium oxide passive layer, boosting corrosion resistance.
  • PTFE seals are precision-cut to match the ball’s curvature, with a tolerance of ±0.05mm to ensure uniform contact.

B. Valve Body & Ball Machining

• Valve Body Machining:
  • CNC turning centers shape the valve body, with flange faces machined to a flatness tolerance of ≤0.05mm/m and surface finish of Ra ≤3.2μm—critical for proper gasket seating. Internal seat pockets are honed to a diameter tolerance of H7 (0–+0.03mm) to fit PTFE seals snugly.
  • Flow channels are machined to full-port dimensions, minimizing pressure drop. For DN500 bodies, the flow channel diameter is matched to the pipeline inner diameter (508mm for 20-inch), ensuring unobstructed media flow.
• Ball Machining:
  • Balls are CNC-turned to a spherical tolerance of ±0.02mm, then lapped to a surface roughness of Ra ≤0.8μm using diamond abrasive. This precision ensures uniform contact with PTFE seals, delivering low leakage.
  • Metallic balls (carbon steel, stainless steel) undergo heat treatment: carbon steel balls are quenched and tempered (850℃ quenching, 550℃ tempering) to achieve hardness of 28–32 HRC, while stainless steel balls are solution-annealed (1050℃ for 30 minutes) to restore corrosion resistance.
  • Plastic balls (reinforced POM) are injection-molded, then CNC-trimmed to remove flash and ensure dimensional accuracy.

C. Actuator Integration & Calibration

• Actuator Assembly:
  • The actuator’s gearbox is assembled in a cleanroom to prevent dust contamination. Gears are lubricated with synthetic grease (temperature range: -40℃ to 150℃) to reduce friction and noise.
  • The motor and control board are wired to the electrical connector, with insulation resistance tested to ≥100MΩ at 500V DC to prevent electrical shorts.
• Valve-Actuator Integration:
  • The actuator is mounted to the valve via an ISO 5211 adapter flange—standard for valve-actuator compatibility. The actuator’s drive shaft is connected to the valve stem via a spline coupling, ensuring torque transmission without slippage.
  • Laser alignment tools confirm coaxiality between the actuator and valve stem (runout ≤0.05mm), preventing binding during operation.
• Calibration:
  • Torque Calibration: A torque tester adjusts the actuator’s output to match the valve’s requirements (e.g., 80N·m for DN125 PN0.6). Overload protection is set to 120% of rated torque (e.g., 96N·m for DN125) to prevent motor damage.
  • Position Calibration: The 4–20mA feedback signal is calibrated to ensure 0mA corresponds to fully closed and 20mA to fully open, with a hysteresis of ≤1% for precise control.

D. Quality Testing & Certification

• Hydrostatic Testing:
  • Shell Test: The valve body is filled with water and pressurized to 1.5×rated pressure (e.g., 2.4MPa for PN1.6) for 30 minutes. No leakage, sweating, or deformation is allowed—test results are documented in a hydrostatic test report.
  • Seat Test: The valve is closed, and water is pressurized to 1.1×rated pressure (e.g., 1.76MPa for PN1.6) on the inlet side. Leakage is measured using a flow meter, with results required to meet ANSI/FCI Class VI.
• Operational Testing:
  • The valve undergoes 100 open-close cycles with electric actuation to verify smooth operation. Torque is recorded at each cycle to ensure consistency (variation ≤5%).
  • Manual override is tested to confirm it can fully open/close the valve within 20 turns (for DN500), even if the actuator fails.
• Environmental Testing:
  • The actuator is subjected to IP67 testing (immersion in 1m of water for 30 minutes) to confirm dust and water resistance. Explosion-proof actuators undergo additional testing per ATEX/IECEx standards (e.g., flameproof enclosure testing to prevent ignition of external flammable vapors).
• Certification Documentation:
  • Each valve is accompanied by a Material Test Report (MTR) for all metallic components, a hydrostatic test report, and compliance certificates (ISO 9001, CE). API 6D-certified valves include additional documentation (e.g., pressure-temperature rating tables, fire test reports if applicable).