Specification

TIANYU 12″ Class 150 Full Bore Two-Piece Trunnion Mounted Ball Valve: Precision Control for Industrial Fluid Systems

I. Product Overview

The TIANYU 12-inch (DN300) Full Bore Two-Piece Trunnion Mounted Ball Valve features a two-piece forged body design with trunnion-mounted ball technology, integrating electric actuation with manual override. Constructed with WCB carbon steel body, A105+ENP coated ball, and RPTFE seats, it is engineered for medium-pressure applications in oil & gas, petrochemical, power generation, and municipal industries. With a full bore (FB) flow path, spring-loaded seats, and bidirectional sealing capabilities, the valve delivers reliable performance across temperatures from -29°C to 180°C, balancing automation efficiency with maintenance flexibility.

II. Core Advantages

(A) Two-Piece Design: Compact & Serviceable

Symmetrical Forged Construction:
The two-piece body, joined by high-strength bolts, ensures coaxiality within 0.05mm. This design reduces weight by 15% compared to three-piece valves, saving installation space while enabling 40% faster maintenance via unilateral flange disassembly.
Dual-Seal Redundancy:
Metal-to-metal body joints with flexible gaskets provide secondary sealing, meeting ASME B16.34 requirements for high-pressure applications.

(B) Trunnion-Mounted Ball with Spring-Loaded Seats

Bidirectional Block & Bleed (DBB):
Spring-loaded RPTFE seats achieve zero leakage (ANSI/FCI 70-2 Class V) in both flow directions. A vent/drain port prevents cavity overpressure, enhancing safety in critical applications.
Wear Compensation:
Spring-loaded seats maintain sealing integrity even with up to 0.2mm of wear, extending service life by 30% and reducing maintenance costs.

(C) Full Bore Flow Path: Efficiency Unleashed

Equal Diameter Flow:
The unobstructed bore (≥300mm) matches pipeline diameter, minimizing pressure drop (Cv ≥1,200) and turbulence. Ideal for high-flow applications like gas transmission and refinery feed lines.
Smooth Internal Surface:
Precision-machined internals (Ra ≤1.6μm) prevent media accumulation, reducing clogging risks and ensuring long-term reliability.

(D) Intelligent Electric Actuation System

High-Performance Actuator:
IP66-rated intelligent actuator with 4-20mA/Modbus communication, ±1° positioning accuracy, and ≤15-second full-stroke time. Built-in overload protection and temperature compensation ensure stable operation in harsh environments.
Manual Override:
Worm gear handwheel with 1:30 ratio and ≤80N·m torque (API 609 compliant) enables emergency operation during power outages.
Real-Time Monitoring:
Integrated position sensors and fault diagnostics provide remote status updates, enabling predictive maintenance and reducing downtime.

(E) Material Excellence

Component	Material	Key Properties
Body	WCB Carbon Steel	Tensile strength ≥485MPa, Charpy V-notch impact energy ≥27J at -29°C
Ball	A105+ENP Coating	Surface hardness HV500-600, 3x improved wear resistance, salt spray tested
Seats	RPTFE	Compression set ≤10% (150°C ×72h), resistant to hydrocarbons and aqueous media
Stem	17-4PH Stainless Steel	Nitrided surface (0.3mm depth), torsional strength ≥900MPa, blowout-proof design

III. Technical Specifications

Parameter	Standard Rating	Customization Options
Size	12″ (DN300)	8″-24″ (DN200-DN600, custom sizes available)
Pressure Class	Class 150 (PN2.0MPa)	Class 300/600 (PN5.0/10.0MPa, upgraded design)
End Connection	Flange (ANSI B16.5 RF)	Butt-weld (ANSI B16.25), socket-weld
Design Standards	API 608, ASME B16.34	CE, ATEX (explosion-proof options)
Testing	API 598 (1.5x hydrostatic)	Fire-safe testing (API 607)
Actuation	Electric + Manual Override	Pneumatic/hydraulic actuators available

Product Overview

IV. Manufacturing & Quality Assurance

(A) Precision Manufacturing Process

Two-Piece Body Fabrication:
- Forged and CNC-machined components joined via dowel pins and high-strength bolts, ensuring ≤0.05mm coaxiality.
- WCB bodies undergo normalizing + tempering for uniform mechanical properties. NDT includes 100% RT (ASME SE-164 Level B) and MT (ASME SE-709) with defects ≤ASTM E446 Level 2.
Ball & Stem Machining:
- A105 forged balls machined to ≤0.02mm roundness with Ra ≤0.8μm sealing surfaces.
- ENP coating (≥0.05mm thickness) provides corrosion resistance exceeding 500-hour salt spray testing.
- Stems feature cold-rolled threads (6g accuracy) and nitrided surfaces (0.3-0.5mm depth).
Seat Assembly & Testing:
- Hydraulically preloaded RPTFE seats with ≤0.05mm sealing clearance. Each valve undergoes 1.5x hydrostatic testing (30-minute hold) and helium leak testing (≤1×10⁻⁴ mbar·L/s).
- Sampled valves complete 100,000 cycle life testing with ≤15% torque decay and Class V sealing retention.

(B) Quality Traceability & Certification

Material Certification: Furnaces records, CMA-certified chemical analysis, and third-party PMI testing available.
System Compliance: ISO 9001, API 608, ATEX II 2G Ex db IIC T4 (for explosion-proof actuators).
Warranty: 24-month comprehensive warranty with unconditional replacement for manufacturing defects.

Valve Details

VI. TIANYU Customization Capabilities

With 15+ years of industrial valve expertise, TIANYU offers tailored solutions for the 12″ Class 150 two-piece ball valve:

Material Upgrades: CF8M stainless steel, duplex steel for corrosive media.
Sealing Solutions: Stellite hard seats for high-temperature/abrasive applications.
Actuation Expansion: Pneumatic/hydraulic actuators, enhanced explosion-proof ratings.
CFD Optimization: Flow simulation for custom bore designs and reduced turbulence.
Rapid Delivery: 22-day standard lead time, 15-day expedited service for small batches.
Global Support: Six technical centers providing lifecycle management, 48-hour spare parts delivery, and AR-assisted maintenance.

Application

V. Product Application Scenarios

(A) Petrochemical Industry

In refinery atmospheric/vacuum unit oil pipelines (350℃, Class 150), TIANYU’s WCB body resists medium-temperature oil corrosion, while the full-bore flow path ensures smooth transfer of residues and gasoline. The intelligent actuator integrates with DCS systems for precise fractionator feed regulation, reducing annual energy losses by ~8% in one petrochemical project.

(B) Natural Gas Transmission

At gas distribution stations in long-distance pipelines, the Class 150 WCB ball valve handles natural gas (-20℃, 1.6MPa) with pressure regulation. The DBB function prevents upstream/downstream leakage, and the handwheel ensures supply continuity during power outages. In a West-East Gas Pipeline branch project, the valve achieved 2,000 start-stop cycles without leakage, extending maintenance intervals to 3 years.

(C) Power Generation

In thermal power plant demineralized water pipelines (120℃, 1.0MPa), the PTFE seal meets zero-leakage requirements for clean media. The actuator’s Modbus communication integrates with the plant’s DCS, enabling automatic makeup water control for demineralized water tanks. In a 300MW unit application, the valve’s ≤8-second response time matches load changes.

(D) Municipal Energy

For gas pressure regulation stations (natural gas, 1.2MPa) and district heating networks (hot water, 95℃, 1.6MPa), flange connections enable quick installation, and WCB resists environmental corrosion. The manual override suits municipal maintenance needs, with continuous winter operation in a provincial capital’s heating project.