Specification

TIANYU DN100 PN16 Explosion-Proof 2-Way Electric Ball Valve with Stainless Steel/WCB Body – Flanged Connection for Gas, LPG, Oil and Industrial Steam Control

I. Product Overview

TIANYU DN100 PN16 explosion-proof 2-way electric ball valve is a specialized industrial valve designed for safe, reliable flow control in hazardous environments, specifically handling flammable media like gas, LPG, and volatile industrial fluids. It features a quarter-turn rotary ball structure, flanged connections, and an explosion-proof electric actuator, balancing robust performance with enhanced safety—critical for industries where ignition risks are a primary concern.

Constructed from corrosion-resistant materials (304/316 stainless steel or WCB cast carbon steel) and compliant with global pressure, temperature, and explosion-proof standards, the valve operates at PN16 (16 bar) and adapts to diverse temperatures via dual-seal options (PTFE/PPL for low-to-moderate temps, metal for high temps). It supports both on-off shutoff and basic throttling, enabling remote integration into automated systems in gas distribution networks, LPG storage facilities, petrochemical plants, and food processing lines. Rigorous testing ensures it meets explosion-proof, leakage, and structural integrity requirements, delivering consistent performance in harsh, high-risk settings.

II. Key Attributes and Specification Parameters

Basic Attributes

Structure Design: 2-way quarter-turn ball valve with a floating ball; the ball rotates 90° via electric actuation to open/close the flow path, and line pressure enhances seal contact for tight shutoff.
Body Material:
- 304/316 stainless steel: Superior corrosion resistance for coastal, food, or high-purity gas applications.
- WCB cast carbon steel: High mechanical strength (tensile strength ≥485MPa) and cost-effectiveness for non-corrosive media (light oil, dry gas).
Internal Component Materials:
- Ball: 304/316 stainless steel (matching body material), precision-machined to a mirror finish (Ra ≤0.8μm) for smooth rotation.
- Stem: 316 stainless steel (higher corrosion resistance than 304), paired with a graphite packing gland to prevent leakage and gas permeation.
- Seal Material:
  - PTFE/PPL: -40℃ to 80℃, API 598 Class VI bubble-tight shutoff for clean media (natural gas, food-grade oil).
  - Metal (304/316): -40℃ to 350℃, withstands thermal expansion and abrasion from steam or heated oil.
Pressure Rating: PN16 (16 bar) standard; optional up to PN64 (64 bar) for high-pressure systems.
Temperature Range:
- PTFE/PPL Seal: -40℃ to 80℃.
- Metal Seal: -40℃ to 350℃.
Nominal Diameter Range: DN15 to DN300; focus on DN100 (4-inch) for balanced flow in medium-scale pipelines.
Connection Type: Flanged ends (ASME B16.5 Class 150/300, DIN EN 1092-1 PN16/PN40) with raised face (RF) and precision-drilled bolt holes.
Actuation System: Explosion-proof electric actuator (EXD IIB T4 Gb / IECEx IIB T4):
- Voltage: DC 12V/24V, AC 24V/110V/220V/240V (50/60Hz).
- Control Modes: On-off (standard); optional proportional control (4-20mA signal).
- Safety Features: IP66 aluminum alloy housing, sealed terminal box, optional manual override for power failure.
- Cycle Life: 1,000,000+ actuation cycles.
Media Compatibility: Flammable media (natural gas, LPG, propane), non-corrosive fluids (light oil, lubricants), steam, compressed air, food-grade liquids.
Design & Testing Standards:
- Design: API 6D, ASME B16.34, ASME B16.5, ATEX 2014/34/EU, IECEx.
- Testing: API 598, ISO 10497, IEC 60529, 100+ open/close cycle tests.

Product Overview

III. Product Features

TIANYU DN100 PN16 explosion-proof electric ball valve offers core features tailored to hazardous and industrial environments:

Certified Explosion-Proof Performance: EXD IIB T4 Gb / IECEx IIB T4 rating contains and prevents ignition of flammable gases in Zone 1/2 areas. Sealed housing and flameproof joints block gas ingress to the motor, eliminating spark risks—essential for gas/LPG facilities.
Dual-Seal Adaptability: PTFE/PPL seals deliver API 598 Class VI shutoff for low-temperature clean media, reducing emissions and meeting environmental rules. Metal seals withstand high temps (up to 350℃) and abrasion, maintaining integrity in thermal cycling.
Precise Electric Control: ±1° position accuracy and fast response (0.5–1 second per 90° rotation) enable emergency shutoffs in gas pipelines. Optional 4-20mA proportional control allows fine flow adjustment for industrial burners or process loops.
Global Voltage & Connection Compatibility: Multi-voltage options (AC 110V/220V/240V, DC 12V/24V) fit global power systems. ASME/DIN flanges eliminate custom adapters, suiting international projects.
Durable Construction: 304/316 stainless steel resists pitting and salt air corrosion; WCB undergoes normalizing heat treatment to prevent cracking under pressure. Chrome-plated 316 stems reduce friction, extending service life by 50%.
Emergency Manual Override: Optional mechanical handle enables operation during power outages or actuator failure, ensuring continuity in critical applications (LPG tanker unloading, hospital gas supply).
Low Maintenance Design: Modular actuator components allow quick replacement without removing the valve. Stainless steel parts need no painting; PTFE seals resist gas degradation, extending maintenance intervals to 1–2 years.

IV. Manufacturing Process

TIANYU follows a strict 10-step workflow to ensure safety, precision, and reliability, aligned with international standards:

1. Raw Material Inspection: 304/316 stainless steel and WCB undergo chemical analysis (optical emission spectrometry) to verify alloy content. Mechanical testing (tensile, hardness) confirms strength compliance with ASTM standards.
2. Valve Body Casting:
- Stainless steel: Investment casting (lost wax process) for smooth surfaces (Ra ≤1.6μm) and dimensional accuracy (±0.05mm), eliminating porosity.
- WCB: Sand casting for cost-effectiveness; molten WCB (1500–1550℃) is poured into molds, slow-cooled, and shot-blasted post-casting.
3. Heat Treatment:
- Stainless steel: Solution-annealed (1050–1100℃) and quenched to restore corrosion resistance.
- WCB: Normalized (880℃, 1 hour) and air-cooled to relieve stress and enhance impact resistance.
4. CNC Machining:
- Ball: CNC-turned (±0.02mm tolerance) and ground to Ra ≤0.8μm; bore drilled to match DN100 flow path.
- Seat: CNC-milled grooves for seals; metal seats (304/316) ground to ±0.01mm tolerance for uniform contact.
- Flange: RF faces machined to ASME B16.5 Class 150; bolt holes drilled via coordinate positioning.
5. Explosion-Proof Actuator Assembly:
- Housing: Die-cast aluminum alloy with flameproof joints (gap ≤0.1mm), powder-coated for corrosion resistance.
- Motor & Wiring: Explosion-proof motors (EXD IIB T4) installed; sealed terminal boxes (IP66) and cable glands prevent gas ingress.
- Gear Train: Precision-machined gears lubricated with high-temperature grease (200℃ resistance).
6. Seal Installation:
- PTFE/PPL: Molded rings bonded with high-temperature adhesive.
- Metal: 304/316 rings press-fitted and welded; faces lapped to Ra ≤0.4μm.
7. Valve Core Assembly: 316 stem inserted with graphite packing gland; ball mounted on stem and aligned with flow path.
8. Actuator Mounting: Mounted via ISO 5211 brackets; drive shaft coupled to stem and torque-calibrated (50–100 N·m for DN100).
9. Testing:
- Shell Test: 1.5×PN16 (24 bar) water pressure for 10 minutes; no leakage/deformation (ultrasonic verification).
- Seat Test: 0.6MPa gas for API 598 Class VI (PTFE) or Class IV (metal) leakage.
- Explosion-Proof Test: Spark testing in methane-air chamber (ATEX compliance).
10. Final Inspection & Marking: Dimensional checks via CMM; laser marking (DN, PN, material, explosion-proof rating, serial number) for traceability.

Valve Details

V. Product Advantages

TIANYU DN100 PN16 explosion-proof electric ball valve outperforms standard valves in key areas:

Hazardous Zone Safety: Certified design eliminates ignition risks, complying with OSHA (US), ATEX (EU), and GB 3836 (China). Critical for gas/LPG facilities to prevent catastrophic incidents.
Temperature & Media Versatility: Dual seals handle -40℃ to 350℃, fitting mixed-process facilities (e.g., food plants using refrigerated oil and heated steam).
Remote Control Efficiency: Electric actuation enables SCADA integration, reducing on-site personnel in hazardous areas (e.g., offshore LPG terminals).
Long Service Life: 304/316/WCB resist corrosion; 1,000,000+ actuator cycles lower replacement costs. Modular design cuts maintenance time by 40%.
Global Compatibility: ASME/DIN flanges and multi-voltage actuators fit international projects, avoiding custom engineering.
Environmental Compliance: PTFE/PPL seals meet API 598 Class VI, reducing fugitive emissions and complying with EPA methane rules.

Application

VI. Product Applications

The valve excels in industries requiring safe control of flammable/high-temperature media:

Gas & LPG Distribution: Natural gas pipelines, LPG storage tanks, propane delivery lines. Explosion-proof actuator prevents sparks; PTFE seals avoid leaks. Remote control handles pressure fluctuations in urban networks.
Petrochemical & Oil: Light oil transfer, diesel blending, low-pressure gas processing. WCB handles pipeline stress; 316 resists crude oil impurities. Metal seals suit heated oil (up to 350℃) in refineries.
Food & Beverage: Edible oil transfer, syrup dosing, cleaning steam lines. 304 meets FDA standards; PTFE prevents contamination. Controls LPG flow to steam boilers for sanitization.
Water & Wastewater: Biogas flow from anaerobic digestion. Explosion-proof design safely operates in methane-rich environments; corrosion-resistant materials withstand moisture.
Marine & Offshore: Shipboard LPG tanks, offshore gas platforms. IP66 actuator resists saltwater; ISO 7005-compliant flanges integrate with ship pipelines.
Power Generation: Steam flow in auxiliary boilers, gas-fired turbines. Metal seals handle 350℃ steam; fast actuation maintains stable pressure for turbine efficiency.

TIANYU DN100 PN16 explosion-proof 2-way electric ball valve, with stainless steel/WCB body, flanged connections, and dual seals, ensures safe flow control for gas, LPG, and steam. It features EXD IIB T4 certification, wide voltage compatibility, and 1M+ cycle life, suiting hazardous/industrial sectors. Customizable in size (DN15–DN300), seal type (PTFE/metal), voltage (AC/DC), and explosion-proof rating (ATEX/IECEx) to meet specific application needs.