Forged Steel A105 Stainless Steel 304/316 CF8 WCB Cast Steel Gate Valve

Specification

TIANYU Custom Forged Steel/Stainless Steel Gate Valves: Multi-Application Industrial Flow Control Solutions

I. Product Overview

TIANYU custom forged steel/stainless steel gate valves feature A105 forged carbon steel, 304/316 stainless steel, and CF8/WCB cast steel materials. With nominal diameters ranging from DN50 to DN400 (2″ to 16″) and pressure classes PN16 to PN100 (1.6MPa to 10.0MPa), these valves operate in -46℃ to 600℃ temperature ranges. The wedge gate design with hydraulic actuation ensures precise on-off control, combining the high strength of forged steel with the corrosion resistance of stainless steel for demanding industrial applications in petrochemical, power, and shipbuilding sectors.

II. Core Technical Parameters

Specifications & Pressure-Temperature Range
- Nominal Diameter: DN50/80/100/150/200/300/400 (customizable up to DN600)
- Pressure Class: PN16/PN25/PN40/PN64/PN100 (1.6MPa to 10.0MPa)
- Temperature Range: -46℃ to 230℃ (stainless steel), -29℃ to 425℃ (carbon steel), -196℃ to 600℃ (special alloys)
Materials & Sealing System
- Body/Gate: A105 forged carbon steel (tensile strength ≥485MPa), 304/316 stainless steel (ASTM A351 CF8/CF8M)
- Sealing Pair: Metal hard seal (STL alloy overlay) + auxiliary PTFE soft seal, leakage rate ≤0.1% (API 598)
- Stem: 2Cr13 stainless steel (HRC30-35 hardness), chrome-plated surface
- Connections: Flanged (ASME B16.5/GB/T 9113), butt-welded (BW), threaded (NPT)
Actuation & Operation
- Actuation: Hydraulic drive (standard), optional pneumatic/electric/manual
- Operation Time: ≤5 seconds (DN100 hydraulic drive)
- Protection Grade: IP67 (body), Ex d IIB T4 (explosion-proof electric actuator)

III. Structural Design & Technical Features

Forging Process Optimization
- Integrally forged body eliminates casting defects, with grain flow following structural contours, enhancing fatigue resistance by 30%.
- Double-eccentric wedge gate design auto-compensates sealing specific pressure (≥15MPa) via medium pressure for bidirectional bubble-tight sealing.
Multi-Temperature Adaptability
- Low-temperature: LCB forged carbon steel (-46℃) with extended bonnet to prevent cold transfer.
- High-temperature: A105 material tempered at 650℃, maintaining creep strength ≥180MPa at 425℃.
Hydraulic Drive Advantages
- Servo hydraulic system provides constant driving force, overcoming on-off resistance under high pressure differential.
- Integrated accumulator design supports emergency shut-off (ESD function) during power outages.

Product Overview

IV. Manufacturing Processes & Quality Control

Precision Forging Flow
- Free forging/die forging process, blank dimension tolerance ≤±0.5mm, ultrasonically tested (UT) for internal defects.
- Stainless steel parts solution treated at 1050℃, grain size ≥Grade 5 for excellent intergranular corrosion resistance.
Surface Treatment Technology
- Carbon steel body with three-layer anti-corrosion system:
  - Zinc-based epoxy primer (80μm) + fiberglass intermediate layer + weather-resistant polyurethane topcoat (100μm)
- Stainless steel electrolytic polishing (Ra≤0.8μm), passivated for salt spray test ≥1000 hours.
3D Quality Inspection
- Hydrostatic test: 1.5x working pressure for shell (30min hold), 1.1x for sealing (zero leakage).
- Spectral analysis: Element deviation ≤0.05% per heat, traceable to heat number.
- SIL certification test: Meets Safety Integrity Level SIL 2/3 requirements.

Valve Details

V. Core Product Advantages

Multi-Scenario Industrial Adaptability
- Petrochemical: 316 stainless steel + Hastelloy seal resists H2S (≤100ppm), suitable for FCC units.
- Power generation: A105 carbon steel gate valves operate leak-free for 8 years in 425℃ superheated steam.
- Marine engineering: 316L stainless steel + fluororubber seal resists seawater chloride (Cl-≤20,000ppm).
Full-Life Cycle Cost Optimization
- Replaceable seat design reduces on-site maintenance costs by 50%.
- Hydraulic system maintenance cycle up to 5 years, saving 30% on 运维 costs vs. pneumatic drives.
Global Certification Support
- Certified to SIL 2/3, API 6D, CE-PED 2014/68/EU.
- Provides API 598 test reports, Material Test Reports (MTR), and third-party inspection services.

Application

VI. Application Fields & Cases

LNG receiving station: DN300 PN40 304 stainless steel gate valve in -162℃ LNG pipeline, extended bonnet prevents frosting, 4-year fault-free operation.
Refining integration project: DN200 PN64 A105 gate valve controls 380℃ residue oil in atmospheric-vacuum unit, STL seal wear ≤0.1mm/year.
Offshore platform: DN150 PN25 316L gate valve in marine atmosphere, anti-corrosion coating remains intact for 5 years, compliant with NACE MR0175.

VII. Customization Services

Material Upgrades
- Super duplex steel (2507): Suits harsh conditions with Cl-≤30,000ppm.
- Titanium alloy (TA2): Resists seawater and strong oxidizing acids, 57% lighter than stainless steel.
Functional Enhancements
- Fire-safe design: Complies with API 6FA, maintains sealing for 30min during fires.
- Intelligent monitoring: Integrates pressure/temperature sensors, supports 4-20mA output and remote communication.
Special Interface Customization
- Socket-weld (SW): DN≤50mm, meets ASME B16.11.
- Vacuum flanges: DN80-DN300, leakage rate ≤1×10⁻⁶Pa·m³/s.