Manual 2 Piece Flange Stainless Steel Cryogenic Ball Valve Liquid Nitrogen Oxygen

Specification

OEM Manual 2-Piece Flange Valve: A Reliable Solution for Industrial Fluid Control

I. Product Core Overview

The TIANYU OEM Manual 2-Piece Flange Valve is a high-performance shut-off valve designed for industrial pipeline systems. It features a classic two-piece structure (split body and bonnet design) connected by bolts to ensure reliable sealing and convenient maintenance. As a core control component for industrial pipelines, this valve is suitable for shutting off or regulating fluids such as water, oil, steam, and corrosive media. Widely used in petrochemical, power metallurgy, water treatment, food & pharmaceutical industries, it supports multi-standard customization (API, DIN, JIS) to provide efficient and durable fluid control solutions for global industrial clients.

II. Key Attributes and Technical Parameters

(A) Structural Design

Two-Piece Split Structure: The body and bonnet are bolt-connected, allowing separate disassembly of the bonnet for seal or disc replacement during maintenance without pipeline disassembly, significantly reducing downtime (e.g., only 20 minutes for seal replacement on DN100 models);
Flange Connection Standards: Supports international standards such as ASME B16.5 (US), DIN EN 1092-1 (EU), and JIS B2220 (Japan), with flange types including RF (Raised Face) and RTJ (Ring Type Joint) to adapt to different pipeline systems;
Manual Operation: Standard handwheel drive (optional gearbox speed-up device), operating torque ≤150N·m (DN100), supporting live loading operation, ideal for remote scenarios without power/gas or emergency shutdowns.

(B) Material and Application Compatibility

Component	Standard Materials	Special Application Materials	Applicable Media	Temperature Range
Body/Bonnet	WCB (Carbon Steel), CF8 (304 SS)	Duplex 2205, Hastelloy C-276	Water, oil, steam, weak corrosives	-29℃~427℃
Disc/Seat	304 SS, 316L SS	Stellite 6 (Cobalt-Based Alloy)	High-wear media (e.g., slurry)	-196℃~650℃
Seals	NBR, EPDM	Viton, PTFE	Strong acids/alkalis, food-grade	-40℃~260℃
Fasteners	A193 B7 (Alloy Steel Bolts)	Inconel 718 (Superalloy Bolts)	High-pressure/high-vibration	-162℃~540℃

(C) Performance Parameters

Pressure Rating: Class 150 (PN16) to Class 2500 (PN420), suitable for medium-to-high pressure systems (max 42MPa);
Sealing Class: Bidirectional bubble-tight sealing (leakage rate ≤5×10⁻¹⁰Pa·m³/s), compliant with API 598 Class IV, supporting Double Block and Bleed (DBB) function;
Size Range: DN15 (1/2″) to DN300 (12″), offering full-bore/reduced-bore designs with flow coefficient ≤0.8 (DN100 full-bore), reducing pumping energy consumption by ~10%;
Operation Life: Simulated 100,000-cycle testing (under pressure) with sealing performance retention ≥95%, far exceeding industry standards (50,000 cycles).

Product Overview

III. Manufacturing Processes and Quality Control

(A) Core Manufacturing Techniques

Precision Forging
- 800-ton hot forging presses produce carbon steel/stainless steel bodies (forging ratio ≥4:1) with ASTM No.8+ grain size, ultrasonically tested (UT) for defects (sensitivity ≥Φ1.2mm) to ensure pressure components are crack-free;
- Stainless steel bodies use vacuum induction melting (VIM+VAR) with sulfur content ≤0.005%, suitable for high-purity food/pharmaceutical applications (FDA 21 CFR 177.2600 compliant).
High-Precision Machining
- 5-axis CNC machines mill flange sealing surfaces to ≤0.003mm flatness and Ra≤1.6μm roughness, ensuring leak-free flange connections;
- Valve body interiors are honed to ≤0.02mm cylindricity, and disc guiding surfaces are lapped to Ra≤0.8μm roughness, reducing operating torque and enhancing sealing precision.
Automated Assembly and Testing
- Smart torque wrenches control bolt preload (±2% accuracy) to avoid seal over-compression;
- 100% hydrostatic/gas testing:
  - Hydrostatic Test: 1.5x rated pressure (water, 30-minute hold), pressure drop ≤0.3%;
  - Gas Test: 1.1x rated pressure (air/helium), bubble detection or helium mass spectrometry (leakage rate ≤5×10⁻⁹Pa·m³/s).

(B) Surface Treatment Solutions

Standard Conditions: Carbon steel bodies coated with epoxy powder (200μm thickness), passing 1,000-hour salt spray test;
Corrosive Environments: Stainless steel bodies electropolished (Ra≤0.4μm) or PTFE-coated (100μm thickness) for acid/alkali resistance;
Marine/Outdoor Use: Zinc-rich primer + polyurethane topcoat (300μm total thickness), resisting ≥2,000-hour salt spray.

Valve Details

Product Description and Applications

(A) Core Advantages

Easy Maintenance: Split design enables “no-pipeline-disassembly” maintenance, reducing repair time by 70% compared to integral valves, ideal for continuous production;
High-Pressure Adaptability: Forged steel body + metal hard seal (e.g., Stellite 6) ensures stable operation under Class 2500 (42MPa) pressure and 540℃ high temperature;
Flexible Customization: Supports OEM designs like extended stems (buried installation), blowout-proof stems (explosion-proof), and special coatings (abrasion-resistant/adhesion-resistant).

(B) Typical Applications

Petrochemical Industry
- Upstream Gas Production: Sulfur-resistant valves (NACE MR0175 certified) with duplex 2507 bodies for ≤1,500ppm H₂S environments, lasting 8 years;
- Chemical Reactors: DN200 valves control polymer slurries, with quick-open bonnets enabling 10-minute screen replacement to minimize downtime.
Power & Energy Sector
- Power Plant Steam Pipelines: High-temperature valves (F91 chromoly steel bodies) withstand 540℃, passing 100,000 load cycles with ≤5% pressure drop variation;
- LNG Terminals: Cryogenic valves (-162℃) with F316L SS bodies + cryo-rubber seals, API 6A PR2-certified to prevent ice blockages in LNG transport.
Water Treatment & Environmental Engineering
- Wastewater Plants: DN300 valves with tungsten carbide-coated discs last 7 years in 15% solids-laden sewage, cutting replacement costs by 40%;
- Pure Water Systems: Sanitary valves (316L electropolished) meet 3A/EHEDG standards, with Ra≤0.2μm interiors for CIP/SIP cleaning and contamination prevention.

V. OEM Customization and Certifications

(A) Customization Options

Functional Customization: Can integrate limit switches, position transmitters (for remote monitoring), or flow-through designs (reduced pressure drop);
Branding & Packaging: Custom engraving of logos, compliance marks (e.g., API 6D, CE-PED), and wooden case packaging for ocean transport;
Industry-Specific: Mirror-polished + clamp connections for food/pharmaceuticals, seismic designs (IEEE 344 compliant) for nuclear applications.

(B) International Certifications

Basic Certifications: ISO 9001, CE-PED, API 6D;
Special Certifications: ATEX (Ex II 2G Ex db IIC T4), TR CU, DNV GL (marine applications).

VI. Quality Commitment and Services

TIANYU offers full lifecycle support:

Warranty: 3-year guarantee, free replacement for material/process defects;
Global Service: 6 regional service centers in North America, Europe, and Southeast Asia, with 48-hour emergency delivery and on-site installation support;
Sustainability: 100% recyclable body materials, 40% lower forging energy vs. casting, supporting client ESG goals.