DN100 PN40 3-Piece Trunnion Mounted Hard Metal Seal BW Ball Valve for Flow Control

Specification

DN100 PN40 3-Piece Trunnion Mounted Hard Metal Seal BW Ball Valve

Name	Cast steel Trunnion Ball Valve
Size	2″-60″; DN50-DN1500
Normal pressure	Class 150/300/600/900/1500/2500; PN16/PN40/PN64/PN100/PN160/PN250
Design standard	API 6D, API 608,ASME B16.34, MSS SP-72; BS5351,ISO17292,EN13709
Fire safe design	API607,API 6FA
End flange	ANSI B 16.5,ASME B16.47; EN1092,DIN2543~DIN2547,AS2129
Face to Face	ANSI B 16.10,API 6D; DIN3202,EN558-1,EN12982,ISO 5752
Top flange	ISO 5211
Test standard	API598,API6D; DIN3230,EN12266,ISO 5208
Suitable temperature	-29~250°C
Medium	Fresh water, sewage, sea water, air, vapor, food, medicine, oils, alkalis, salt etc.
Operation	Hand Operated,Gear Operated, Electrical Actuated, Pneumatic Actuated

Structure

– Full Port or Reduce Port

– Split Body

– Bolted Bonnet with spiral-would gasket

– Fire Safe Design

– Anti-static Design & Blow-out proof stem

– Double seat structure

– Butt Weld Ends to ASME B16.25; DIN 3239,EN12627

– Flanged Ends to ASME B16.5; EN1092,DIN2543~DIN2547

Main Part & Materials

Part Names	Part Materials
Body	WCB/A105	LCB/LF2	CD4MCuN/F51	CF8/F304	CF8M/F316	CF3/F304L	CF3M/F316L
Bonnet	WCB/A105	LCB/LF2	CD4MCuN/F51	CF8/F304	CF8M/F316	CF3/F304L	CF3M/F316L
Ball	A105+ENP	SS304	F51	SS304	SS316	SS304L	SS316L
Stem	F6a	F304	F51	F304	F316	F304L	F316L
Trunnion	F6a	F304	F51	F304	F316	F304L	F316L
Bearing	Cu
Antistatic spring	A313-304	A313-304	A313-316	A313-304	A313-316	A313-316	A313-316
Seat Retainer	13%Cr	SS304	F51	SS304	SS316	SS304L	SS316L
Seat Spring	A313-304,A313-316,Inconel X-750
Seat Seal Ring	Ni60,STL,WC
Packing	Graphite
Gasket	SS304+Graphite/SS316+Graphite
Bolts/Nuts	B7/2H	L7/4	B8M/8M	B8/8	B8M/8M	B8/8	B8M/8M
Suitable Medium	W.O.G etc.		HNO3, CH3OOH etc.
Suitable Temperature	-29~250 °C	-29~250°C	-29~250 °C	-29~250 °C	-29~250 °C	-29~250 °C	-29~250 °C

Product Overview

I. Product Overview

TIANYU 3-piece trunnion mounted hard metal seal butt-weld (BW) ball valve is a high-performance flow control device engineered for extreme industrial conditions. Its 3-piece split structure enables easy maintenance, while the trunnion-mounted ball ensures stability under high pressure. Hard metal sealing (metal-to-metal) withstands abrasive media and high temperatures, complemented by butt-weld connections for leak-tight integration. Constructed from robust materials (carbon steel, stainless steel), it complies with API 6D and ASME standards, making it ideal for flow control in oil, gas, chemical, and power sectors where reliability and durability are critical.

II. Key Attribute Parameters

Size Range: 2″~24″ (DN50~DN600), covering small to large-diameter pipelines to meet flow requirements in process loops, transmission lines, and high-pressure systems.
Pressure Rating: PN16~PN420 (Class 150~2500), with PN40 (6.4MPa) as a common specification, suitable for medium to ultra-high pressure applications.
Temperature Range: -46℃~450℃, with material upgrades (e.g., alloy steel) enabling operation up to 550℃ for high-temperature steam or thermal fluid systems.
Material Configuration:
- Body: Carbon steel (WCB), stainless steel (316), or duplex stainless steel, selected for corrosion resistance and structural strength.
- Ball & Stem: 316 stainless steel or Stellite-coated alloys, ensuring wear resistance and compatibility with abrasive media.
- Seal: Hard metal-to-metal (316 stainless steel/Stellite), with spring-loaded seats to compensate for thermal expansion and wear.
Connection Type: Butt-weld (BW per ASME B16.25), providing a permanent, leak-tight joint that eliminates flange-related leakage risks, ideal for high-pressure or vibration-prone systems.
Operation: Manual (gear), electric, or pneumatic, with gear-operated models reducing torque by 60% for easy handling of large-diameter valves.
Standards Compliance: Design per API 6D, ASME B16.34; testing per API 598; fire-safe certification per API 607, ensuring compatibility with global industrial standards.

III. Structural Features

3-Piece Split Body: The valve body splits into three sections (two end caps and a middle section) connected by bolts, allowing easy disassembly for in-line maintenance (ball, seat, or stem replacement without removing the valve from the pipeline). This reduces downtime by 50% compared to 1-piece or 2-piece valves.
Trunnion-Mounted Ball: The ball is supported by upper and lower trunnions, distributing pressure loads to prevent deformation under high pressure. This design eliminates “ball blowdown” (displacement due to flow force), ensuring stable operation even in pressure surges—critical for Class 600+ systems.
Hard Metal Sealing: Precision-lapped metal seats and ball surfaces (Ra ≤0.8μm) form a bubble-tight seal (ANSI FCI 70-2 Class V). Spring-loaded seats automatically compensate for thermal expansion and wear, maintaining tightness across temperature cycles and long-term use.
Butt-Weld Connection: Welded joints (full penetration) create a seamless transition between valve and pipeline, minimizing pressure drop and eliminating flange gasket leakage risks. Suitable for buried pipelines or systems with strict leakage requirements (e.g., toxic or flammable media).
Safety Enhancements: Anti-blowout stem (prevents ejection under high pressure), anti-static device (dissipates static to avoid sparks), and fire-safe graphite backup seals (API 607 compliant) for hazardous environments.

IV. Manufacturing Processes

Material Forging: Body, ball, and trunnion components are forged (forging ratio ≥3) to eliminate internal defects, enhancing strength. Raw materials undergo spectral analysis (e.g., 316: 16-18% Cr, 10-14% Ni) and ultrasonic testing to verify integrity.
Precision Machining:
- Ball & Seats: CNC grinders achieve ball roundness ≤0.01mm and surface finish Ra ≤0.8μm; seats are lapped to match ball contours, ensuring uniform contact for tight sealing.
- Body & Weld Ends: CNC lathes machine butt-weld ends to dimensional accuracy (±0.5mm) for proper fit-up with pipelines; trunnion bores are precision-machined to ensure smooth ball rotation.
Heat Treatment: Forged components undergo annealing (650-700℃) to relieve stress; metal seats are Stellite-coated (hardness ≥55 HRC) for wear resistance, then tempered to enhance toughness.
Assembly & Testing:
- Seats are pre-loaded with springs and tested at 1.5×rated pressure to validate compensation capability.
- Each valve undergoes API 598 testing: hydrostatic shell test (1.5×rated pressure, 30 minutes), gas tightness test (0.6MPa nitrogen, leakage ≤0.1×10⁻⁶ mL/s), and 1000+ operation cycles to verify durability.

Valve Details

V. Product Advantages

Easy Maintenance: 3-piece design allows in-line access to internal components, reducing maintenance downtime—critical for continuous-process industries like refineries.
High-Pressure Stability: Trunnion mounting and forged body withstand Class 2500 (42MPa) pressure, outperforming floating ball valves in high-pressure systems by 30% in service life.
Durable Sealing: Hard metal seats resist abrasion, corrosion, and high temperatures, lasting 5× longer than soft seals in abrasive media (e.g., crude oil with sand, slurry).
Leak-Tight Connection: Butt-weld joints eliminate flange gasket failures, making it ideal for systems with toxic, flammable, or high-value media (e.g., natural gas, petrochemicals).
Versatile Compatibility: Materials like duplex stainless steel adapt to corrosive environments (seawater, sour gas), while alloy steel variants handle high-temperature steam, suiting diverse industrial needs.

Application

VI. Application Fields

Oil & Gas Industry: Upstream (wellhead, high-pressure gathering lines) for crude oil and natural gas; midstream (transmission pipelines) for high-pressure gas transport; downstream (refineries) for process loops with abrasive media.
Chemical & Petrochemical: Controls hydrocarbons, solvents, and corrosive fluids in reaction systems and high-pressure distillation columns, where metal sealing resists chemical erosion.
Power Generation: Regulates high-pressure steam in boiler feed lines, turbine bypass systems, and flue gas desulfurization, withstanding thermal cycling and pressure fluctuations.
Mining & Metallurgy: Handles slurry, tailings, and high-pressure water in mineral processing, where hard metal seals resist wear from solid particles.
Marine & Offshore: Suitable for offshore platform pipelines and subsea systems, with butt-weld connections and corrosion-resistant materials (duplex stainless steel) resisting saltwater damage.