Specification

DN200 Class2500 Stainless Steel Flanged End Electric Top-Entry Trunnion Mounted Ball Valves by TIANYU

I. Product Overview

TIANYU’s DN200 Class2500 Stainless Steel Flanged End Electric Top-Entry Trunnion Mounted Ball Valve is a high-performance industrial valve engineered for extreme-pressure fluid control. Integrating trunnion-mounted ball design, top-entry structure, and electric actuation, it delivers stable operation in harsh environments involving high pressure, corrosive media, or particulate-laden fluids. Suitable for industries requiring precise automation and reliable sealing, this valve balances durability, efficiency, and ease of maintenance to meet rigorous industrial demands.

II. Important Attribute and Specification Parameters

A. Structural Type

The valve features a trunnion-mounted ball design, where the ball is supported by upper and lower trunnions (shafts) to reduce friction and ensure stable operation under high pressure. Its top-entry structure allows internal components to be accessed from the top without removing the valve from the pipeline. As a straight-through type valve, it minimizes flow resistance, while the flanged end connection ensures secure integration with pipelines.

B. Size and Pressure Rating

With a nominal diameter (DN) ranging from DN15 to DN300, it accommodates both small and medium-scale pipeline systems. The pressure rating covers Class150 to Class2500 (equivalent to PN20 to PN420), enabling stable operation in low-pressure (water supply) to ultra-high-pressure (oil and gas transmission) scenarios. It handles media temperatures from -29°C to 540°C, adapting to diverse thermal conditions—from cryogenic fluids to high-temperature steam.

C. Material Composition

Valve Body: Constructed from stainless steel (e.g., 304, 316) for superior corrosion resistance, with optional carbon steel (WCB, A105) for general industrial environments.
Ball and Stem: The ball is made of nitriding steel or wear-resistant steel, hardened to enhance abrasion resistance; the stem uses 420 or 410 stainless steel, ensuring strength and anti-blowout performance.
Seat and Bearing: Seats are crafted from nitriding steel or wear-resistant steel for metal-to-metal sealing, suitable for high pressure and particulate media; bearings are aluminum bronze, reducing friction between moving parts.
Packing: Uses PTFE or flexible graphite to prevent stem leakage, with low-emission properties for environmental compliance.

D. Connection and Operation

Flanged end connections conform to ANSI B16.5, JIS B2202, ensuring compatibility with standard pipelines. Operation is primarily electric, with actuators meeting ISO 5211 standards for easy integration into automated control systems. Optional operation modes include manual (handwheel), pneumatic, gear, or hydraulic, catering to diverse application needs.

Product Overview

III. Features Description

A. Trunnion-Mounted Ball Advantage

The trunnion support reduces contact stress between the ball and seat by distributing pressure evenly across the trunnions, making it suitable for ultra-high-pressure (Class2500) applications. Unlike floating ball valves, the trunnion design prevents excessive ball displacement under high pressure, minimizing wear and extending service life—critical for continuous operation in oil and gas pipelines.

B. Top-Entry Design for Maintenance

The top-entry structure allows technicians to access internal components (ball, seat, stem) by removing the top cover, eliminating the need to disconnect the valve from the pipeline. This reduces downtime by up to 60% compared to side-entry valves, a key benefit for industries like chemical processing and power generation where shutdowns are costly. The design also simplifies online replacement of wear parts, such as seats and packing.

C. Electric Actuation Efficiency

Electric actuators provide precise control over valve position (0°-90°), with adjustable torque and speed settings to match process requirements. They enable remote operation and integration with SCADA systems, ideal for hazardous or hard-to-reach locations (e.g., offshore platforms). The actuation system includes overload protection to prevent damage from excessive torque, enhancing operational safety.

D. Eccentric and Sealing Performance

The valve incorporates an eccentric design, where the ball’s rotation axis is offset from the valve body center. This ensures the ball and seat disengage quickly during opening, reducing friction and wear—especially valuable for media containing particles (e.g., slurry, ash). The metal-to-metal seat (nitriding steel) achieves tight sealing via preload and pressure-assisted seating, withstanding high temperatures and preventing leakage even with frequent cycling.

IV. Manufacturing Process

A. Material Inspection and Preparation

Raw materials undergo strict testing: stainless steel bodies are checked for chemical composition (via spectrometry) to verify chromium and nickel content, ensuring corrosion resistance. Wear-resistant components (ball, seat) undergo hardness testing (e.g., Rockwell hardness) to confirm durability. Trunnions and stems are inspected for straightness to prevent operational jamming.

B. Precision Machining

CNC machining centers shape the valve body, ball, and flanges to tight tolerances (±0.02mm), ensuring the trunnion alignment and eccentric geometry are accurate. The ball’s sealing surface is ground and polished to a roughness of Ra 0.8μm, while the seat is lapped to match, ensuring uniform contact. Flange faces are machined to meet ANSI B16.5 standards for leak-free connection.

C. Assembly and Testing

Assembly occurs in a clean workshop to avoid contamination. Trunnions are fitted with aluminum bronze bearings to reduce friction, and packing (PTFE or graphite) is installed with precise preload to balance sealing and stem movement. Post-assembly, each valve undergoes:

Shell pressure testing (1.5× rated pressure) to verify structural integrity;
Seat leakage testing (1.1× rated pressure) to ensure tight sealing;
Electric actuator calibration to confirm response accuracy and torque output.
Fire-safe and anti-static features are validated to meet API 607 and API 6D standards.

Valve Details

V. Product Advantages

A. High-Pressure Reliability

The trunnion-mounted design and robust materials enable stable operation at Class2500 pressure, outperforming floating ball valves in ultra-high-pressure scenarios—vital for oil and gas wellhead control or high-pressure chemical reactors.

B. Low Maintenance Requirements

Top-entry access and wear-resistant components (nitriding steel ball/seat) reduce maintenance frequency and costs. The aluminum bronze bearings minimize friction, extending service life to 10+ years under normal operation.

C. Versatility in Media Handling

Stainless steel construction and metal seats resist corrosion from seawater, acids, and alkalis, while the eccentric design prevents clogging by particulate media (slurry, ash). This makes it suitable for diverse fluids, from clean gases to abrasive slurries.

D. Automated Precision

Electric actuation enables precise flow control and remote operation, improving process efficiency and safety. Integration with control systems supports real-time monitoring, reducing manual intervention in hazardous environments.

Application

VI. Product Applications

A. Oil and Gas Industry

Used in upstream (wellhead, Christmas tree) and midstream (high-pressure transmission pipelines) operations to control crude oil, natural gas, and fracturing fluids. Its high-pressure rating and corrosion resistance make it ideal for offshore and onshore harsh environments.

B. Chemical Processing

Handles corrosive media like acids, alkalis, and chemical slurries in high-pressure reactors and transfer lines. The metal-to-metal seal prevents contamination, ensuring product purity in pharmaceutical and specialty chemical production.

C. Power Generation

Regulates high-temperature steam and cooling water in thermal and nuclear power plants. The valve’s ability to withstand 540°C temperatures and high pressure ensures reliable operation in boiler feedwater and turbine systems.

D. Wastewater and Mining

Controls abrasive media such as sewage sludge, mining slurry, and ash slurry. The eccentric design and wear-resistant materials prevent clogging and leakage, maintaining efficiency in wastewater treatment plants and mineral processing facilities.

DN200 Class2500 Stainless Steel Flanged End Electric Top-Entry Trunnion Mounted Ball Valves