Specification

DN50 CLASS150 Forged Three – Piece Flange Aluminum Bronze Pneumatic/Electric Ball Valve

I. Product Overview

TIANYU’s DN50 CLASS150 forged three – piece flange aluminum bronze ball valve is a high – performance flow control solution tailored for industries with strict hygiene and corrosion – resistance requirements. Constructed from aluminum bronze, a material known for its excellent corrosion resistance, strength, and non – magnetic properties, this ball valve features a three – piece structure, flange connection, and options for pneumatic or electric actuation. Operating within a temperature range of – 29℃~150℃, it is designed to ensure reliable shut – off and regulation of various media, including chemicals, as well as applications in the food and pharmaceutical industries. Compliant with relevant international standards, it combines durability, precision control, and hygiene, making it an ideal choice for demanding industrial environments.

II. Key Attribute Parameters

Size: DN50 (2″), suitable for medium – sized pipelines in various industrial applications.
Pressure Rating: CLASS150 (2.0MPa), applicable to low to medium – pressure systems such as food processing lines and pharmaceutical fluid transfer pipelines.
Temperature Range: – 29℃~150℃, capable of handling both cold and moderately heated media, ensuring adaptability to different process requirements.
Material Configuration:
- Body: Forged aluminum bronze, providing high strength, corrosion resistance, and non – magnetic properties. Aluminum bronze typically contains 9 – 12% aluminum, which forms a protective oxide layer on the surface, enhancing its resistance to corrosion from water, chemicals, and saltwater.
- Ball: Aluminum bronze, precision – machined to ensure smooth rotation and accurate flow control.
- Seat: PTFE (polytetrafluoroethylene) or EPDM (ethylene – propylene – diene – monomer). PTFE offers excellent chemical resistance and low friction, while EPDM is suitable for applications involving water and steam within the specified temperature range.
- Stem: Stainless steel, providing strength, corrosion resistance, and preventing blow – out under pressure.
- Fasteners: High – strength stainless steel bolts and nuts, ensuring a secure connection between the three – piece components and resistance to corrosion.
Connection Type: Flange connection, compliant with ASME B16.5 standards, enabling secure and leak – tight integration with pipeline flanges.
Actuation: Pneumatic or electric. Pneumatic actuators offer fast operation, suitable for applications requiring quick shut – off, while electric actuators provide precise control and are ideal for processes that need accurate flow regulation.
Applicable Media: Chemicals, food – grade substances, pharmaceutical fluids, water, and steam.
Design Standards: Meets relevant international standards such as API 6D and ASME B16.34, ensuring product quality and compatibility with global industrial systems.

Product Overview

III. Features Description

Three – Piece Structure: The three – piece design of the valve body allows for easy in – line maintenance. The ability to disassemble the valve without removing it from the pipeline significantly reduces downtime. This is particularly important in industries like food and pharmaceuticals, where minimizing production interruptions is crucial. For example, if the seat needs replacement due to wear or damage, the middle section of the valve can be opened, and the seat can be quickly replaced.
Forged Aluminum Bronze Body: The forging process enhances the density and strength of the aluminum bronze material. This results in a valve body that can withstand high pressures and mechanical stresses. The corrosion – resistant properties of aluminum bronze make it suitable for handling chemicals, as well as food and pharmaceutical media, ensuring product purity and valve longevity. In a food processing plant, the valve can safely handle ingredients and cleaning agents without the risk of corrosion – induced contamination.
Precision – Machined Ball: The ball is precision – machined to a high degree of accuracy, ensuring smooth rotation and tight sealing. The spherical shape and surface finish of the ball allow for minimal friction during operation, reducing the torque required for actuation. This not only improves the efficiency of the valve but also extends the lifespan of the actuator and other components.
PTFE or EPDM Seat: The PTFE seat provides excellent chemical resistance, making it suitable for handling a wide range of chemicals. It also has a low coefficient of friction, which contributes to smooth valve operation. EPDM seats, on the other hand, are highly resistant to water and steam, making them ideal for applications involving these media. Both seat materials ensure tight sealing, achieving ANSI/FCI Class VI leakage standards, which means near – zero leakage.
Pneumatic and Electric Actuation Options: Pneumatic actuators can operate the valve within seconds, making them suitable for emergency shut – off scenarios. They are also relatively simple in design, requiring less maintenance. Electric actuators, on the other hand, offer precise control over the valve’s opening and closing, allowing for accurate flow regulation. They can be integrated with automated control systems, enabling remote operation and monitoring.
Flange Connection: The flange connection provides a secure and leak – tight interface with the pipeline. The ASME B16.5 compliant flanges ensure compatibility with a wide range of pipeline systems, making installation and integration straightforward. The flanges are also designed to distribute pressure evenly, reducing the risk of leakage at the connection point.

IV. Manufacturing Processes

Material Selection and Inspection: High – quality aluminum bronze ingots are selected for forging. These ingots undergo strict chemical analysis to verify the alloy composition, ensuring that the aluminum, copper, and other alloying elements are within the specified ranges. Ultrasonic testing is also carried out to detect any internal defects such as cracks or inclusions.
Forging Process: The aluminum bronze ingots are heated to an appropriate temperature and then forged into the shape of the valve body, ball, and other components. The forging process improves the mechanical properties of the material, such as strength and toughness, by aligning the grain structure.
Machining: The forged components are then precision – machined using CNC (Computer Numerical Control) machines. The valve body’s internal and external surfaces, as well as the ball, are machined to the required dimensions and surface finishes. The ball is ground and polished to achieve a smooth surface, with a surface roughness of Ra ≤ 0.8μm, ensuring tight sealing with the seat.
Seat Installation: The PTFE or EPDM seats are carefully installed into the valve body. For PTFE seats, they are often molded to fit the valve’s internal geometry precisely. EPDM seats may be vulcanized in place to ensure a secure and leak – tight fit.
Assembly: The three – piece components, including the body, ball, seat, and stem, are assembled. High – strength stainless steel bolts and nuts are used to connect the components, with a specific torque applied to ensure a secure connection. The actuator (pneumatic or electric) is then mounted on the valve, and the stem is connected to the actuator.
Testing:
- Hydrostatic Test: The valve is subjected to a hydrostatic test at 1.5 times the rated pressure (3.0MPa for CLASS150). This test is carried out for 30 minutes to check for any leakage in the valve body and seat.
- Seat Leakage Test: The seat is tested at 1.1 times the rated pressure (2.2MPa) to verify its sealing performance. The valve should meet ANSI/FCI Class VI leakage standards, which means minimal leakage.
- Actuator Performance Test: For pneumatic actuators, the response time and operating pressure are tested. Electric actuators are tested for their control accuracy, speed of operation, and power consumption.

Valve Details

Sealing Performance

Optimized seat materials provide tight contact with the copper ball, maintaining reliable sealing under pressure for unidirectional flow control.
Operational Adaptability

Ergonomic handle design ensures effortless manual operation with precise control. Optional pneumatic or electric actuation available for automation.
Material & Craftsmanship

Forged from premium copper alloy, the body undergoes precision machining for smooth surfaces, high strength, and corrosion resistance, ideal for diverse media.

V. Product Advantages

Excellent Corrosion Resistance: The aluminum bronze material offers superior corrosion resistance compared to many other metals. It can withstand exposure to chemicals, water, and humid environments, reducing the risk of valve failure due to corrosion. In pharmaceutical manufacturing, where the media must be kept pure, the corrosion – resistant properties of the valve ensure product integrity.
Low Maintenance: The three – piece design and modular components make maintenance straightforward. The ability to replace the seat or other components in – line reduces the time and cost associated with maintenance. Additionally, the use of high – quality materials and precision – machining reduces wear and tear, further extending the maintenance intervals.
Precise Flow Control: Electric actuators provide accurate control over the valve’s opening, allowing for precise regulation of the flow rate. This is essential in processes such as chemical dosing in pharmaceutical production or ingredient addition in food processing, where the amount of media needs to be controlled accurately.
Fast Operation (Pneumatic Actuation): Pneumatic actuators enable quick opening and closing of the valve, which is crucial in emergency shut – off situations or processes that require rapid flow control. In a chemical plant, for example, a pneumatic – actuated valve can quickly isolate a section of the pipeline in case of a leak or other emergency.
Hygienic Design: The materials used, such as aluminum bronze and PTFE/EPDM, are suitable for food and pharmaceutical applications. The smooth internal surfaces of the valve prevent the accumulation of media, making it easy to clean and maintain hygiene standards. This meets the strict requirements of the food and pharmaceutical industries, where product safety and purity are of utmost importance.
Wide Media Compatibility: The valve can handle a variety of media, including chemicals, food – grade substances, water, and steam. This versatility makes it a cost – effective solution, as one valve can be used in multiple applications within a plant.

Application

VI. Application Fields

Food Industry: In food processing plants, this valve can be used to control the flow of ingredients, such as oils, syrups, and water. Its corrosion – resistant aluminum bronze body and hygienic seat materials ensure that there is no contamination of the food products. It can also be used in cleaning and sanitation systems, handling cleaning agents and hot water.
Pharmaceutical Industry: In pharmaceutical manufacturing, the valve is suitable for controlling the flow of pharmaceutical fluids, solvents, and cleaning agents. The precision – control capabilities of the electric actuator are valuable for accurate dosing, and the corrosion – resistant materials ensure product purity throughout the manufacturing process.
Chemical Industry: For handling a wide range of chemicals, the aluminum bronze body and PTFE seat combination offers excellent chemical resistance. The valve can be used in processes such as chemical synthesis, where precise flow control and reliable shut – off are required.
Water and Steam Systems: In industrial water supply and steam distribution systems, the valve can be used to regulate the flow. The EPDM seat option is well – suited for handling water and steam, ensuring tight sealing and durability.