Specification

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

I. Product Core Overview

The Newway 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

(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.