API 608 ASME B16.34 CE PED 2014/68/EU Certified DN150-DN1400 PN10-PN64 Class 150-400 WCB/CF8 Fixed Trunnion Mounted Metal Hard Seal Ball Valve
  • API 608 ASME B16.34 CE PED 2014/68/EU Certified DN150-DN1400 PN10-PN64 Class 150-400 WCB/CF8 Fixed Trunnion Mounted Metal Hard Seal Ball Valve
  • API 608 ASME B16.34 CE PED 2014/68/EU Certified DN150-DN1400 PN10-PN64 Class 150-400 WCB/CF8 Fixed Trunnion Mounted Metal Hard Seal Ball Valve
  • API 608 ASME B16.34 CE PED 2014/68/EU Certified DN150-DN1400 PN10-PN64 Class 150-400 WCB/CF8 Fixed Trunnion Mounted Metal Hard Seal Ball Valve
  • API 608 ASME B16.34 CE PED 2014/68/EU Certified DN150-DN1400 PN10-PN64 Class 150-400 WCB/CF8 Fixed Trunnion Mounted Metal Hard Seal Ball Valve

TIANYU API 608 ASME B16.34 CE PED 2014/68/EU Certified DN150-DN1400 PN10-PN64 Class 150-400 WCB/CF8 Fixed Trunnion Mounted Metal Hard Seal Ball Valve – Flange Connection Turbine Manual/Pneumatic/Electric Operation for Oil Gas Petrochemical Power Water Treatment

I. Product Overview

In the realm of critical industrial fluid control, fixed trunnion mounted metal hard seal ball valves stand as the gold standard for high-pressure, high-temperature, and abrasive media applications—delivering unmatched stability, sealing reliability, and long-term durability. TIANYU’s Fixed Metal Hard Seal Ball Valve, engineered to comply with API 608 (Steel Ball Valves for Petroleum, Petrochemical and Allied Industries), ASME B16.34 (Valves for Pressure Piping), and CE PED 2014/68/EU standards, is tailored for the most demanding sectors including oil & gas, petrochemical, power generation, water treatment, and metallurgy.
Crafted from premium materials such as WCB carbon steel, CF8 stainless steel, and other corrosion-resistant alloys, this valve features a trunnion-mounted (fixed) ball design, metal-to-metal hard sealing system, and flange connection to accommodate media ranging from crude oil and natural gas to steam, water, and abrasive slurries. The trunnion support—upper and lower shafts securing the ball—eliminates lateral movement under extreme pressure, reducing seat wear and operational torque, while the metal hard seal ensures leak-tight performance even at elevated temperatures and pressures.
Rated for nominal diameters from DN150 to DN1400 and pressure classes from PN10 (1.6MPa) to PN64 (6.4MPa) (Class 150 to 400), the valve operates reliably across a temperature range of -20℃ to 425℃—covering cryogenic service, ambient fluid transfer, and high-temperature steam applications. Available in turbine manual, pneumatic, or electric actuation, it caters to diverse operational needs, from remote pipeline branches to large-scale industrial plants requiring automated control. As a flagship product of TIANYU, it balances structural integrity, operational efficiency, and regulatory compliance to minimize downtime and lifecycle costs for critical flow control systems.

II. Important Attribute Specifications

A. Material Composition

Every component is selected to withstand harsh industrial conditions, with material versatility to match specific media, pressure, and temperature requirements:
  • Valve Body, Bonnet & Flange: WCB Carbon Steel (ASTM A216 Grade WCB) as standard—an industry-proven cast carbon steel with chemical composition (C: 0.25–0.35%, Mn: 0.60–1.05%, Si: 0.10–0.35%, P/S ≤0.035%) delivering tensile strength ≥485MPa, yield strength ≥240MPa, and impact toughness ≥27J at -20℃. Optional CF8 (ASTM A351 Grade CF8) stainless steel for enhanced corrosion resistance in chloride-rich or chemical environments, and duplex stainless steel (2205) for high strength and aggressive media compatibility. All castings undergo ultrasonic testing (UT) to eliminate internal porosity or cracks.
  • Ball: Forged A105 carbon steel (WCB valve variant) or CF8 stainless steel (CF8 valve variant), with a precision-lapped spherical surface (Ra ≤0.4μm) for uniform sealing contact. The ball features a full-port design to minimize pressure drop, and is overlayed with Stellite (cobalt-chromium alloy) on the sealing surfaces—Rockwell hardness ≥58 HRC—to resist wear, corrosion, and galling in abrasive or high-temperature media.
  • Trunnions & Stem: 13Cr stainless steel (ASTM A276 Grade 410) or CF8 stainless steel for trunnions and stem, ensuring structural stability and corrosion resistance. The stem features an anti-blowout design—an enlarged shoulder engaging the bonnet—to prevent ejection under excessive pressure. Trunnions are fitted with self-lubricating PTFE-impregnated bronze bearings, reducing rotational friction and extending service life.
  • Seat: Metal-to-metal hard seal design with Stellite overlay on both the ball and seat ring (ASTM A182 Grade F304/F316). The seat ring is preloaded with stainless steel springs to compensate for thermal expansion and minor wear, maintaining consistent sealing pressure across the valve’s temperature range. For ultra-low leakage requirements, an optional secondary soft seal (PTFE/graphite) is available, combining the durability of metal seals with the tightness of soft seals.
  • Packing & Gaskets: Multi-layer flexible graphite packing with PTFE inner ring (complying with ISO 15848-1 Class AH for low fugitive emissions) for stem sealing. Bonnet gaskets are spiral-wound graphite with 304 stainless steel reinforcement (ASME B16.20), ensuring tight sealing under thermal cycling and pressure fluctuations. Flange gaskets are non-asbestos fiber-reinforced rubber or spiral-wound graphite, compatible with ASME B16.5/GB/T 9113 flanges.
  • Fasteners: A193 B7 carbon steel bolts (ASTM A193) and A194 2H carbon steel nuts (ASTM A194) for WCB body flanges; A193 B8M stainless steel bolts and A194 8M nuts for CF8/duplex steel bodies—providing uniform clamping force and corrosion resistance.

B. Dimensional & Pressure-Temperature Parameters

  • Port Size (DN/NPS): DN150 (6”) to DN1400 (56”), full-port design (bore diameter equal to nominal pipe size) to optimize flow efficiency. Flow coefficient (Cv) ranges from 350 (DN150) to 28,000 (DN1400), minimizing pressure drop and energy consumption in high-flow applications (e.g., oil pipelines, water transmission systems).
  • Pressure Rating: PN10 (1.6MPa), PN16 (2.5MPa), PN25 (4.0MPa), PN40 (6.4MPa), PN64 (10.0MPa) / Class 150, 300, 400—aligned with ASME B16.34 pressure-temperature ratings for carbon steel and stainless steel valves. At 20℃, PN64 models withstand 10.0MPa, making them suitable for high-pressure wellhead equipment, hydraulic systems, and petrochemical process lines.
  • Temperature Range: -20℃ to 425℃ for metal hard seal; -40℃ to 230℃ for optional secondary soft seal. The Stellite overlay on the ball and seat ensures thermal stability at elevated temperatures, preventing seal degradation in steam or hot oil service.
  • End Connections: Flange (ASME B16.5, GB/T 9113, JB/T 79)—Raised Face (RF) as standard, Ring Type Joint (RTJ) optional for high-pressure PN40-PN64 service. Flange dimensions comply with global standards, ensuring compatibility with existing pipeline systems.
  • Face-to-Face Dimensions: Compliant with API 608 and GB/T 12221, ranging from 394mm (DN150) to 2300mm (DN1400)—ensuring interchangeability with valves from other manufacturers for easy retrofitting.

C. Operational Performance Parameters

  • Sealing Performance: ANSI/FCI 70-2 Class V (metal hard seal) for low leakage—leakage rate ≤0.01% of nominal flow for liquid media; Class VI for optional secondary soft seal (bubble-tight). This ensures minimal product loss and environmental contamination, critical for handling toxic, flammable, or high-value fluids.
  • Actuation Options:
    • Turbine Manual: Cast iron turbine operator with anti-slip handwheel, gear ratio 30:1 to 100:1—reducing operational torque for large-diameter valves (DN500+). Clear position indicators (open/closed) provide visual confirmation of valve status.
    • Pneumatic: Double-acting or spring-return pneumatic actuators (ISO 5211 mounting), explosion-proof (Ex d IIC T4) for hazardous environments, air supply pressure 0.4–0.6MPa. Stroke time 10–30 seconds, with fail-safe functionality (open/closed on air failure).
    • Electric: AC/DC electric actuators (IEC 60534), with remote control, position feedback, and torque limiting functions—compatible with SCADA systems. Stroke time 20–60 seconds, suitable for precision control in remote or automated systems.
  • Operating Torque: 300N·m (DN150, PN10) to 8000N·m (DN1400, PN64) for manual turbine operation; reduced by 40–60% with pneumatic/electric actuation.
  • Cycle Life: ≥100,000 open/close cycles under normal operating conditions, with maintenance interval of 24–36 months—extending service life and reducing downtime.

D. Certifications & Compliance

  • Design & Manufacturing Standards: API 608, ASME B16.34, ASME B16.5, GB/T 12237 (Ball Valves for Industrial Use), CE PED 2014/68/EU (Pressure Equipment Directive).
  • Quality & Environmental Certifications: ISO 9001 (Quality Management System), ISO 14001 (Environmental Management), ISO 45001 (Occupational Health and Safety).
  • Material & Safety Certifications: EN10204 3.1/3.2 Material Test Certificates (MTC), NACE MR0175 (for sour service containing H₂S), FDA 21 CFR 177.2600 (for food-grade applications with soft seal option).
API 608 ASME B16.34 CE PED 2014/68/EU Certified DN150-DN1400 PN10-PN64 Class 150-400 WCB/CF8 Fixed Trunnion Mounted Metal Hard Seal Ball Valve
API 608 ASME B16.34 CE PED 2014/68/EU Certified DN150-DN1400 PN10-PN64 Class 150-400 WCB/CF8 Fixed Trunnion Mounted Metal Hard Seal Ball Valve

III. Feature Description

A. Trunnion-Mounted Ball Design: Stability Under Extreme Pressure

The trunnion-mounted configuration is the defining structural advantage of this valve, setting it apart from floating ball valves:
  • Pressure Load Distribution: The ball is secured by upper and lower trunnions, which absorb the thrust generated by media pressure—transferring loads to the valve body rather than the seats. This eliminates seat deformation and uneven wear, even under PN64 high pressure, ensuring consistent sealing performance over 100,000+ cycles.
  • Low Operational Torque: Trunnion supports and self-lubricating bearings reduce friction between the ball and seats, lowering operational torque by 30–50% compared to floating ball valves of the same size. For DN1000 PN40 valves, this enables manual operation with a turbine operator, eliminating the need for expensive electric actuators in some scenarios.
  • Bidirectional Sealing: The fixed ball alignment ensures uniform contact between the ball and dual seats, enabling reliable sealing in both flow directions—simplifying pipeline design and eliminating the need for check valves.

B. Metal-to-Metal Hard Seal: Durability & High-Temperature Adaptability

The metal hard seal system is engineered for harsh conditions where soft seals would degrade:
  • Wear & Corrosion Resistance: Stellite overlay on the ball and seat surfaces (hardness ≥58 HRC) resists abrasion from slurries, sand-laden oil, and other aggressive media. Stellite’s cobalt-chromium composition also provides excellent corrosion resistance, extending seal life by 50% compared to uncoated metal seals.
  • High-Temperature Performance: Metal seals operate reliably up to 425℃, making the valve suitable for steam lines, high-temperature oil processing, and power generation systems. Unlike soft seals (PTFE/EPDM) that degrade at elevated temperatures, metal seals maintain structural integrity and sealing force.
  • Low Leakage: Class V sealing ensures minimal leakage (≤0.01% of nominal flow), critical for handling toxic, flammable, or high-value media (e.g., natural gas, crude oil). For applications requiring zero leakage, the optional secondary soft seal upgrades performance to Class VI.

C. Premium Material Construction: Strength & Corrosion Resistance

The valve’s material selection balances structural strength and environmental adaptability:
  • WCB Carbon Steel: Cost-effective and durable for non-corrosive or mildly corrosive media (water, steam, crude oil), with excellent tensile strength and impact toughness. Ideal for general industrial applications and oil & gas pipelines.
  • CF8 Stainless Steel: Enhanced corrosion resistance for chloride-rich environments (coastal areas, chemical plants) and media containing mild acids or alkalis. Prevents rust and pitting, extending valve life in harsh chemical conditions.
  • Stellite Overlay: Provides a hard, wear-resistant surface on the ball and seat, critical for abrasive media (slurries, coal dust) that would quickly damage soft seals or uncoated metal.

D. Turbine Manual Actuation: Precision & Ease of Use

The turbine manual operator is optimized for large-diameter, high-torque valves:
  • Torque Reduction: Gear ratio 30:1 to 100:1 reduces the force required to operate large valves, enabling single-person control even for DN1400 PN64 models. The worm gear design ensures smooth, consistent torque transmission.
  • Position Indication: Clear open/closed markings on the handwheel and valve body provide instant visual confirmation of valve status, reducing the risk of human error (e.g., leaving the valve partially open).
  • Durability: Cast iron housing with anti-corrosion coating protects internal gears from environmental damage, ensuring reliable operation in outdoor or harsh industrial environments.

E. Flange Connection: Compatibility & Secure Sealing

The flange connection ensures seamless integration into existing pipeline systems:
  • Global Standard Compliance: ASME B16.5/GB/T 9113 flanges ensure compatibility with pipelines worldwide, eliminating the need for custom adapters. Raised Face (RF) or Ring Type Joint (RTJ) sealing surfaces accommodate different gasket types and pressure requirements.
  • Secure Clamping: Uniform bolt torque (per ASME B18.2.1) ensures tight sealing between the valve and pipeline flanges, preventing leakage under pressure surges and thermal cycling.

IV. Manufacturing Process & Quality Control

A. Raw Material Procurement & Inspection

TIANYU maintains strict control over raw material sourcing to ensure consistent quality and traceability:
  • Material Sourcing: WCB/CF8 castings, Stellite alloy, and stainless steel components are sourced exclusively from ISO 9001-certified suppliers, with each batch accompanied by a Material Test Certificate (MTC) detailing chemical composition, mechanical properties, and heat treatment history.
  • Material Verification: Incoming castings undergo spectral analysis (XRF) to confirm chemical compliance with ASTM standards. Tensile, yield, and impact tests are performed on sample specimens—e.g., WCB must meet tensile strength ≥485MPa and impact toughness ≥27J at -20℃.
  • Non-Destructive Testing (NDT): Cast bodies, bonnets, and balls undergo ultrasonic testing (UT) to detect internal defects (cracks, inclusions) and magnetic particle testing (MPI) to inspect surface flaws. Only defect-free materials proceed to machining.

B. Casting & Heat Treatment

Casting and heat treatment are critical to the valve’s structural integrity:
  • Precision Casting: WCB/CF8 billets are melted in an electric arc furnace and poured into resin-bonded sand molds using the lost foam casting process. This ensures dimensional accuracy (tolerance ±0.05mm) and surface smoothness, reducing the need for subsequent machining.
  • Heat Treatment:
    • WCB components: Normalizing (890–920℃, air-cooled) to relieve casting stress and refine grain structure. Post-heat treatment hardness is 140–180 HB.
    • CF8 components: Solution annealing (1040–1150℃, water-cooled) to restore corrosion resistance and relieve stress.
    • Stellite Overlay: Applied to ball and seat surfaces via plasma welding, then ground to a spherical accuracy of ≤0.005mm and lapped to Ra ≤0.4μm.
  • Descaling & Cleaning: Cast parts are shot-blasted to remove surface oxide scale, then cleaned with ultrasonic baths to eliminate residual contaminants.

C. Precision Machining

Machining is performed using high-precision CNC equipment to meet tight tolerances:
  • Body & Bonnet Machining: CNC lathes and 5-axis mills process flange faces, seat pockets, and trunnion bores. Flange faces are machined to flatness ≤0.02mm/m and surface roughness Ra 1.6μm. Seat pockets are honed to coaxiality ≤0.01mm relative to the bore, ensuring uniform ball-seat contact.
  • Ball Machining: Forged balls are ground to spherical accuracy ≤0.005mm, then lapped to Ra ≤0.4μm. Stellite overlay is applied to the sealing surfaces and precision-ground to ensure consistent hardness and contact pressure.
  • Stem & Trunnion Machining: Stems are turned and ground to diameter tolerance ±0.01mm and polished to Ra ≤0.4μm. Trunnions are machined with precision threads for bearing installation, ensuring smooth rotation.

D. Assembly & Comprehensive Testing

Assembly and testing adhere to API 598 and ISO 5208 standards:
  1. Component Cleaning: All parts (body, ball, seats, stem, packing) are degreased and ultrasonic-cleaned to remove oil, debris, and metal particles—preventing contamination of sealing surfaces.
  2. Assembly Sequence: Trunnion bearings are installed first, followed by the ball, stem, seats (with preloaded springs), packing, and bonnet. Fasteners are tightened in a crisscross pattern to uniform torque (per ASME B18.2.1) to ensure even clamping force. Actuators (pneumatic/electric) are mounted in accordance with ISO 5211 standards.
  3. Pressure Testing:
    • Hydrostatic Shell Test: 1.5× rated pressure applied to the body cavity for 30 minutes—no leakage, deformation, or pressure drop permitted.
    • Hydrostatic Seat Test: 1.1× rated pressure applied to each seat (bidirectional) for 15 minutes—leakage measured via bubble counting, complying with ANSI/FCI Class V.
    • Pneumatic Test (Optional): 0.6MPa air pressure applied to the body and seats for 10 minutes—no audible leakage permitted.
  4. Operational Testing: The valve is cycled 50 times (open-close) to verify smooth operation, consistent torque, and correct actuator performance (for pneumatic/electric models).
  5. Specialized Testing:
    • Fugitive Emissions Test: ISO 15848-1 Class AH compliance verified with methane and flame ionization detector (FID).
    • High-Temperature Test: For high-temperature service valves, testing at 425℃ to confirm seal performance and structural integrity.

E. Final Inspection & Packaging

Before shipment:
  • Visual Inspection: Each valve is inspected for surface defects (scratches, dents), proper machining, and correct marking (DN, PN, TIANYU logo, certifications). Valves with surface scratches deeper than 0.05mm are rejected.
  • Documentation: Each valve is shipped with a Documentation Package including MTC, Hydrostatic Test Certificate, EN10204 3.1/3.2 Certificate, and CE PED Declaration of Conformity.
  • Packaging: Valves are packaged in plywood crates with foam insulation to prevent damage during transportation. Flange ends are capped with plastic protectors, and actuators are wrapped in waterproof film. Crates are labeled with handling instructions and product information for safe delivery.

V. Product Advantages

A. Exceptional Durability & Long Service Life

The trunnion-mounted design, metal hard seal, and premium materials (WCB/CF8/Stellite) ensure a service life of 10–15 years in typical industrial applications—vs. 3–5 years for floating ball valves or soft-seal valves. In oil & gas pipelines, these valves maintained reliable performance for 12 years without major maintenance, cutting replacement costs by 60%. The Stellite overlay resists wear from abrasive media, extending seal life by 50% compared to uncoated metal seals.

B. Reliable Sealing & Operational Safety

  • Low Leakage: Class V metal seal (optional Class VI soft seal) prevents media leakage—critical for handling toxic, flammable, or high-value fluids (e.g., natural gas, crude oil). This eliminates product loss and environmental contamination risks, ensuring compliance with global safety regulations.
  • Safety Features: Anti-blowout stem, fire-safe design (API 607 compliant), and low fugitive emissions comply with EU Industrial Emissions Directive and US EPA regulations. The trunnion design’s stability prevents valve failure under pressure surges, reducing accident risks in critical systems.
  • Bidirectional Service: Eliminates the need for check valves, simplifying pipeline design and reducing potential failure points.

C. Low Lifecycle Costs

  • Maintenance Savings: The trunnion design reduces seat wear, extending maintenance intervals to 24–36 months—minimizing operational disruptions. The metal seal is replaceable on-site without removing the valve from the pipeline, reducing downtime by 70% compared to non-replaceable seal valves.
  • Energy Efficiency: Full-port design minimizes pressure drop, cutting pumping energy costs by 15–20% annually in continuous-flow systems (e.g., oil pipelines). For a DN800 PN40 valve handling 10,000m³/h of oil, this saves ~$50k/year in energy costs.
  • Versatility: Wide material, pressure, and temperature ranges eliminate the need for multiple valve types across different process lines—reducing inventory costs and simplifying procurement.

D. Global Compatibility & Regulatory Compliance

Compliance with API 608, ASME B16.34, and CE PED ensures market access worldwide—from North American oil fields to European petrochemical facilities. The valve’s compatibility with global flange standards (ASME/GB) simplifies integration into existing systems, while certifications like ISO 9001 and NACE MR0175 ensure quality and compliance for diverse applications.

E. Flexible Actuation & Adaptability

Turbine manual, pneumatic, and electric actuation options enable customization to system requirements—from small manual valves for remote pipelines to electric valves for SCADA-controlled industrial plants. The valve’s ability to operate across -20℃ to 425℃ and PN10-PN64 makes it suitable for ambient, high-temperature, and high-pressure applications—eliminating the need for specialized valves for niche scenarios.

VI. Product Applications

A. Oil & Gas Industry

  • Upstream: Wellhead manifolds, production gathering lines, and drilling mud systems. The valve’s high-pressure rating (PN64) and metal hard seal handle crude oil, natural gas, and saltwater. Offshore platforms benefit from the valve’s durability and low maintenance needs.
  • Midstream: Pipeline transmission systems for crude oil and natural gas. Full-port design minimizes pressure drop, while bidirectional sealing simplifies pipeline layout. The metal seal resists corrosion from moisture and hydrocarbons.
  • Downstream: Refinery process lines (distillation, cracking), high-temperature steam systems, and product loading lines. The valve withstands 425℃ temperatures and corrosive process media (e.g., acids, solvents).

B. Petrochemical Industry

Process lines for ethylene, propylene, benzene, and other petrochemical feedstocks. CF8 stainless steel and Stellite seals provide chemical compatibility with aggressive media, while the trunnion design ensures reliable performance under fluctuating pressure and temperature conditions. Pneumatic or electric actuation with explosion-proof features is suitable for hazardous environments in refineries and chemical plants.

C. Power Generation Industry

  • Thermal Power Plants: Boiler feedwater systems, steam lines, and flue gas desulfurization (FGD) systems. The valve’s high-temperature (up to 425℃) and high-pressure (PN64) capabilities handle steam and corrosive FGD media. Metal seals maintain integrity in high-temperature steam service, ensuring efficient heat transfer.
  • Nuclear Power Plants: Auxiliary systems (cooling water, chemical injection) with CF8 stainless steel for corrosion resistance. The valve’s low leakage and safety features comply with nuclear industry regulations.

D. Water Treatment & Municipal Services

  • Municipal Water Supply: Large-diameter pipelines (DN500-DN1400) for potable water transmission. WCB carbon steel and metal seals resist corrosion from chlorinated water, while full-port design ensures efficient flow.
  • Wastewater Treatment: Sewage lift stations, sludge handling lines, and chemical dosing systems. The metal hard seal resists abrasion from sludge and solid particles, extending valve life in harsh wastewater environments.

E. Metallurgical & Mining Industry

  • Metallurgical Plants: Blast furnace cooling water systems, steam lines, and slag handling lines. The valve’s metal seal resists abrasion from slag and high-temperature steam, ensuring reliable performance in steelmaking processes.
  • Mining Industry: Slurry transport lines and mineral processing systems. Stellite overlay on the ball and seat resists wear from abrasive slurries (coal, iron ore), reducing maintenance frequency and replacement costs.

F. Chemical Industry

Handling of acids, alkalis, solvents, and chemical intermediates. CF8 stainless steel and Stellite seals provide chemical compatibility, while the trunnion design ensures leak-tight performance. The valve’s ability to operate at high pressures (up to PN64) makes it suitable for chemical reaction vessels and transfer lines.

VII. Customization Advantages

TIANYU’s API 608-certified fixed trunnion metal hard seal ball valve delivers robust flow control for oil & gas, petrochemical, and power sectors. WCB/CF8 construction, Stellite overlay, and trunnion design ensure durability, low leakage, and adaptability to -20℃–425℃. Customize it: opt for duplex steel (corrosion resistance), RTJ flanges (high pressure), secondary soft seal (Class VI), or electric actuation (remote control). Tailored to your media and system needs, it balances safety, compliance, and cost-effectiveness—your trusted critical-service valve solution.

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