DN200 PN100 A105 Forged Plug Valve Delivery

1. Overview of Forged Plug Valves

As key control components in industrial pipeline systems, forged plug valves occupy an important position in many fields such as petroleum, chemical industry, and electricity with their excellent sealing performance, high pressure resistance and long service life. Compared with traditional cast valves, plug valves produced by forging technology have higher structural strength and better mechanical properties, and are particularly suitable for fluid control under high pressure, high temperature and harsh working conditions.

ZZJG recently successfully delivered a batch of DN200 PN100 A105 Forged Plug Valves to a large energy company, fully demonstrating our technical strength in the field of high-end valve manufacturing. This article will comprehensively introduce the production process, performance characteristics and applicable scenarios of forged plug valves, and focus on recommending high-quality products produced by our company.

2. Production Process of Forged Plug Valves

2.1 Raw material selection and forging process

The forged plug valves produced by our company are strictly made of ASTM A105 high-quality carbon steel materials, which have excellent mechanical properties and forgeability. The forging process adopts advanced die forging technology, and through precise control of temperature (usually within the range of 950-1250℃) and deformation, the metal grain structure is made denser, internal defects are eliminated, and the impact resistance and pressure resistance of the valve body are significantly improved.

2.2 Precision machining

After rough machining, the forged blank enters the finishing stage. Our company has introduced a five-axis linkage CNC machining center, and the machining accuracy of the valve body sealing surface can reach 0.01mm, and the surface roughness Ra≤0.8μm. The taper of the plug and the valve body are matched with a 1:6 taper. Through precision grinding, the contact area is ensured to reach more than 95%, which is the key to achieving zero leakage.

2.3 Heat treatment process

For A105 material, we use normalizing + tempering heat treatment process to make the valve obtain the ideal hardness (HB160-190) and toughness combination. A computer temperature control system is used during the heat treatment process, and the temperature fluctuation is controlled within ±5℃ to ensure stable performance between batches.

2.4 Surface treatment and assembly

All processed parts are sandblasted to remove the surface oxide scale and improve the adhesion of the coating. Our company uses electrostatic spraying technology, the coating thickness is uniform, and the corrosion resistance is excellent. The assembly process is performed by experienced technicians, who use torque wrenches to accurately control the bolt preload to ensure that the valve can operate reliably for a long time under a working pressure of 100kgf/cm².

3. Technical Characteristics & Advantages of Forged Plug Valves

3.1 Excellent sealing performance

The forged plug valve produced by our company adopts a metal hard seal structure, which has a longer service life than soft seal valves. The unique cone seal design can achieve self-tightening sealing under the pressure of the medium, and can maintain excellent sealing even under high pressure fluctuation conditions.

3.2 Excellent pressure resistance

The tensile strength of the forged valve body can reach more than 485MPa, which is much higher than the same specification cast valve. The PN100 pressure rating means that the valve can safely withstand a working pressure of 100kgf/cm², and the short-term pressure resistance can reach 150kgf/cm². The minimum wall thickness of the valve body has been strictly calculated and pressure verified, and the safety factor is more than 4 times.

3.3 Smooth media channel

The full-bore design makes the valve flow resistance coefficient as low as 0.05, which will hardly cause additional pressure loss to the pipeline system. The actual flow diameter of the DN200 valve reaches 200mm, which is completely matched with the inner diameter of the pipeline, and is particularly suitable for conveying high-viscosity media or working conditions requiring low flow resistance.

3.4 Convenient operation performance

Gearbox, electric or pneumatic actuator options are available according to customer needs. The manually operated valve adopts a high-strength chrome-molybdenum steel stem, and the switching torque is 30% lower than that of ordinary carbon steel stems, which can be easily operated even under large-diameter and high-pressure conditions.

4. Applicable Industries

4.1 Oil and gas industry

In oil and gas gathering and transportation systems, our company's forged plug valves are widely used in wellhead devices, gathering and transportation stations and long-distance pipelines. The good sulfur resistance of A105 material makes it suitable for hydrogen sulfide-containing media, and can withstand the acidic environment specified by NACE MR0175 standard.

4.2 Industrie chimique

Applicable to various corrosive media transportation systems. Through lining special materials or surface treatment, it can be extended to strong corrosive conditions such as hydrochloric acid and sulfuric acid. At the PN100 pressure level, it can be safely used in the feed control system of high-pressure reactors.

4.3 Power industry

Especially suitable for high temperature and high pressure occasions such as power station boiler water supply system and steam pipeline. A105 material can maintain good mechanical properties in the temperature range below 425℃, which fully meets the operation requirements of conventional power stations.

4.4 Other industrial applications

Including high-pressure fluid control systems in metallurgy, shipbuilding, papermaking and other industries. The DN200 specification is particularly suitable for the key control points of the main process pipeline, taking into account flow requirements and control reliability.

5. ZZJG Product Advantages & Service

5.1 Strict quality control system

From raw materials entering the factory to finished products leaving the factory, we implement 18 quality inspection processes. Each DN200 PN100 valve undergoes:

- 100% radiographic flaw detection (in accordance with JB/T4730 standard)

- 150% rated pressure shell test

- High-pressure gas sealing test

- Operating torque test

- Full inspection of appearance dimensions

5.2 Perfect after-sales guarantee

We provide:

- 36-month quality assurance period

- 48-hour emergency response service

- Free technical consultation and selection guidance

- On-site installation and commissioning support

- Lifetime maintenance service

5.3 Customized production capacity

In addition to standard products, we can provide according to customer's special needs:

- Different end face connection forms (RF, RTJ, BW, etc.)

- Special surface treatment (hard chrome plating, nickel-phosphorus plating, etc.)

- Special anti-sulfur treatment

- Enhanced low-temperature impact toughness

- Fire safety design

6. Conclusion

As the "safety guard" of the high-pressure pipeline system, the quality of the forged plug valve is directly related to the safe operation of the entire industrial device. With mature forging technology, precision machining technology and strict quality management system, our company provides customers with valve products with excellent performance, safety and reliability. The recently delivered DN200 PN100 A105 forged plug valve project has once again verified our ability to meet the needs of the high-end market.

ZZJG VALVE welcome you to inquire and negotiate. We will provide the best solution for your fluid control system with professional technical solutions, high-quality product quality and perfect after-sales service. Choosing our forged plug valve means choosing safety, reliability and efficiency!