Self Sealing Integral Free Forging Power Station Gate Valve High-Temperature and High-Pressure Large-Diameter Forged Gate Valve

Specification

Execution standards	API, JIS, DIN, BS, ASTM, ANSI, GB, JB, NB, HG
Pressure range	Class150~Class2500Lb(PN16-PN420)
Size range	NPS1/2 “to NPS72” (DN15mm to DN1800mm)
Material scope: Forgings	A105, F91,F11,F22, F5a, F6, LF1,LC2,12Cr1MoV, F36, F304, F316, F321H
Material scope: Castings	WCB, LCB, LCC,WB36, WC6, C5, WC9, C12A, 20CrMOV, CF8, CF8M, 4A, 5A
Operate Type	Manual, electric,pneumatic, gear
Valve type	Power station valves, gate valves, globe valves, check valves
Application	power plants,petrochemicals,refining, natural gas, metallurgy
Connection type	Flange, welding, thread, FM, BW, SW
Customization	OEM/ODM/OSM/OBM

Product Overview

Self-Sealing Integral Free Forging Power Station Gate Valve

I. Product Overview: Reliable Fluid Control for Extreme Conditions

TIANYU’s self-sealing integral free forging power station gate valve is designed for high-temperature and high-pressure conditions in power, petrochemical, and metallurgy industries. The valve body uses integral free forging with a forging ratio ≥5:1, combined with a pressure self-sealing structure that relies on medium pressure for dynamic sealing, eliminating leakage risks from traditional flange connections. Compliant with ASME B16.34 and API 600, it operates stably between -29℃~540℃ and Class 150~Class 2500, suitable for intercepting water, steam, oil, and natural gas. Core advantages lie in the high strength of forged bodies, reliability of self-sealing, and customized design for extreme conditions.

II. Key Attribute Parameters: Comprehensive Technical Specifications

Parameter Category	Technical Indicators
Nominal Diameter Range	NPS 1/2″~NPS 48″ (DN15~DN1200), covering full-size needs from instrument lines to main steam pipes
Pressure Class	Class 150, 300, 600, 900, 1500, 2500 (PN16~PN420), adaptable to different pressure systems
Execution Standards	Design: ASME B16.34, API 600, BS 1873; Face-to-Face: ANSI B16.10; Welding: ANSI B16.25
Material System	– Body/bonnet: A105, F22, F91, WC6, WC9, CF8M, etc.; – Sealing surface: Stellite alloy hardfacing (hardness ≥HRC58)
Operation Modes	Manual (with handwheel/gearbox), electric (explosion-proof optional), pneumatic, hydraulic, supporting remote control integration
Connection Types	Butt Weld (BW), Flanged (RF/RTJ), Threaded, compliant with ANSI B16.5 and other international standards
Temperature Range	Carbon steel ≤425℃, alloy steel ≤540℃, stainless steel ≤200℃, low-temperature steel (LCB) down to -196℃

III. Core Features: Forging Process and Self-Sealing Technology Advantages

Advantages of Integral Free Forging Structure
The valve body adopts integral free forging with a forging ratio ≥5:1, featuring dense and uniform grain structure without casting defects. Compared to castings, tensile strength increases by 30%, impact toughness by 50%, and fatigue resistance by 2x, suitable for frequent start-stop conditions. Ultrasonic testing (UT) shows internal defect rate <0.1%, far exceeding industry standards (≤1%).
Innovative Pressure Self-Sealing Design
The bonnet-body wedge-type self-sealing structure increases sealing specific pressure with medium pressure. At Class 2500, sealing performance is 90% better than traditional flanges, eliminating regular bolt tightening and reducing maintenance. This structure also removes leakage risks from gasket aging, ideal for high-temperature steam and corrosive gases.
Wide-Condition Adaptability Design

Temperature Adaptation: Materials like F91 alloy suit supercritical steam (540℃), while low-temperature steel (LCB) works for LNG terminals (-196℃);
Pressure Fluctuation: The self-sealing structure automatically compensates for ±30% pressure changes, maintaining reliable sealing;
Medium Compatibility: Stellite-alloy hardfaced seals enhance erosion resistance 4x, suitable for particle-laden media (e.g., coal powder, catalysts).

IV. Manufacturing Processes: Precision Control for Quality Assurance

Raw Material Selection and Pretreatment

Forging billets use a dual-process of electric furnace and refining furnace, controlling S/P content below 0.015%, verified by 100% spectral analysis;
Homogenizing annealing before forging eliminates casting stress and improves workability;
Key materials (e.g., F91) undergo intergranular corrosion testing and high-temperature creep strength tests to meet design requirements.

Precision Machining and Surface Treatment

Valve body sealing surfaces are processed by 5-axis machining centers with flatness error ≤0.01mm and surface roughness Ra≤0.8μm;
Sealing surfaces adopt plasma powder surfacing with alloy layer thickness ≥3mm, hardness uniformity within ±2HRC;
Valve stems use rolling strengthening treatment, increasing surface hardness by 20% and significantly improving anti-galling performance.

Full-Process Quality Control

Pressure Testing: Each valve undergoes 1.5x design pressure shell strength test (30-min hold) and 1.1x pressure sealing test (15-min hold);
Nondestructive Testing: 100% radiography (RT) for welds, 100% magnetic particle (MT) for surface defects, 100% ultrasonic (UT) for internal quality;
Life Verification: Sampling for 5,000 on-off cycles with sealing performance decay ≤5%, meeting 20-year design life for power stations.

Valve Details

V. Product Advantages: Core Competitiveness in Industrial Applications

Safety and Reliability
In a 600MW ultra-supercritical unit, the valve operated leak-free for 10 years, extending average service life by 3~5 years compared to similar products, reducing unplanned shutdown risks.
Customized Solutions

Material Customization: NACE MR0175-certified materials for sour gas; duplex stainless steel or Hastelloy for strong corrosion environments;
Structural Optimization: Seismic-designed bodies for earthquake-prone areas, verified by ANSYS FEA to meet GB 50267 seismic requirements;
Functional Integration: Supports intelligent positioners, valve position transmitters, and speed controllers for digital monitoring and regulation.

Full-Cycle Service Support

Rapid Delivery: Standard models within 7 days, non-standard customization completed within 30 days;
Global Service: Overseas warehouses in SE Asia, Middle East, and North America, 48-hour technical response;
Lifetime Maintenance: Provides full-life cycle maintenance plans with regular 回访 to optimize performance.

Application

VI. Application Fields: Solutions for Key Conditions in Multiple Industries

Power Industry

Ultra-supercritical units: Main steam valves, reheat steam valves, boiler feedwater valves;
Nuclear power plants: Secondary circuit main steam isolation valves, containment isolation valves;
Conventional power stations: Turbine bypass valves, drain valves.

Petrochemical Industry

Refining units: High-pressure hydrogen valves for hydrocracking, main air valves for catalytic cracking;
Chemical production: Quench oil valves for ethylene crackers, acetic acid feed valves for PTA plants;
Natural gas processing: LNG terminal cryogenic valves, acid gas treatment intercept valves.

Metallurgy & Steel

Blast furnace systems: Hot blast stove cutoff valves, gas dedusting system control valves;
Rolling mills: Hydraulic system high-pressure valves, reheating furnace fuel cutoff valves.

Other Sectors

Marine engineering: Steam turbine main steam valves, high-pressure valves for seawater desalination;
Municipal engineering: High-pressure water transmission main valves, thermal network high-temperature intercept valves.