Specification

DN100 PN40 Carbon Steel SS304 Manual Metal Seal Float Flange Ball Valve

I. Product Overview

Newway DN100 PN40 carbon steel and SS304 manual metal seal floating flange ball valve is a precision flow control device engineered for high-temperature, high-pressure industrial pipelines. As a floating ball design, it leverages media pressure to press the ball against the metal seat, achieving reliable sealing. Combining carbon steel (WCB) for structural strength and SS304 (CF8) for corrosion resistance, it handles media like oil, gas, steam, and industrial fluids. Equipped with manual operation and flange connections, it complies with international standards, serving as a durable shut-off solution in demanding industrial systems.

II. Key Attribute Parameters

Size Range: DN15-DN600 (1/2″-24″), covering small to large-diameter pipelines to meet diverse flow requirements from equipment interfaces to main industrial networks.

Pressure Rating: PN16-PN40 (Class 150-Class 300), with PN40 (6.4MPa) as standard, suitable for medium to high-pressure systems like boiler feed lines and process pipelines.

Temperature Range: -29℃ to 425℃, with metal-sealed structure maintaining integrity in high-temperature environments (e.g., superheated steam) where soft seals would degrade.

Material Configuration:

Body: Carbon steel (WCB, ASTM A216) for high structural strength, tensile strength ≥485MPa, yield strength ≥250MPa.

Ball & Stem: SS304 (ASTM A182 F304) for corrosion resistance, with ball surface precision-ground to Ra ≤0.8μm.

Seal: Metal-to-metal (SS304/Stellite alloy), ensuring tightness under thermal cycling and pressure fluctuations.

Connection Type: Flange (RF, ANSI B16.5), with bolt hole alignment matching pipeline standards for secure, leak-free integration.

Operation: Manual worm gear, reducing operating torque by 60% compared to direct lever operation, enabling easy handling even for large-diameter valves.

Standards Compliance: Design per API 608, ASME B16.34; testing per API 598; materials certified to ASTM standards, ensuring compatibility with global industrial systems.

Product Overview

III. Structural Features

Floating Ball Design: The ball is not fixed to trunnions but “floats” within the body. When media flows, pressure pushes the ball against the downstream seat, creating a self-tightening seal. This design eliminates complex trunnion structures, reducing weight while ensuring sealing reliability under varying pressures.

Metal-to-Metal Sealing: The ball and seat feature precision-machined, lapped metal surfaces (Ra ≤0.8μm). SS304 or Stellite-coated seats resist wear, corrosion, and high temperatures, outperforming soft seals in steam, abrasive, or chemical environments.

Manual Operation System: Equipped with a worm gearbox (cast iron housing) with a 30:1 transmission ratio, lowering manual force required to operate large-diameter valves. The handwheel (cast iron with anti-slip coating) includes position indicators for clear open/close status.

Safety Enhancements:

Anti-blowout stem: Stem bottom features an inverted seal structure, preventing ejection under high pressure (API 600 compliant).

Anti-static device: Stainless steel spring connects ball and body, dissipating static (resistance ≤10⁶Ω) to avoid sparks in flammable media.

IV. Manufacturing Processes

Material Selection & Inspection: Carbon steel and SS304 raw materials undergo spectral analysis to verify chemical composition (e.g., SS304: 18-20% Cr, 8-10.5% Ni). WCB forgings are ultrasonic-tested to eliminate internal defects.

Precision Machining:

Ball & Seat: CNC grinders achieve ball roundness ≤0.01mm and surface finish Ra ≤0.8μm; seats are lapped to match ball contours, ensuring uniform contact.

Body & Flange: CNC lathes machine flange sealing faces to flatness ≤0.05mm, with bolt holes drilled to ±0.1mm tolerance for pipeline alignment.

Assembly & Testing:

Seal Assembly: Metal seats are pre-loaded with springs to compensate for thermal expansion, ensuring consistent contact with the ball.

Performance Testing: Each valve undergoes:

Hydrostatic shell test (1.5×PN40 for 30 minutes) with no leakage.

Gas tightness test (0.6MPa nitrogen) with leakage ≤0.1×10⁻⁶ mL/s.

Operation test (100+ cycles) to verify smooth gear operation and position accuracy.

Surface Treatment: Carbon steel bodies are sandblasted (Sa 2.5) and coated with high-temperature anti-rust paint (dry film thickness ≥80μm); SS304 components are passivated to enhance corrosion resistance.