How to produce Flange Ball Valves

Producing flange ball valves involves a multi-step process that includes design, material selection, casting or forging, machining, assembly, and quality control. Here's a high-level overview of how they are manufactured:

1. Design & Engineering

Create CAD drawings and technical specifications.

Define valve pressure rating (e.g., ANSI 150/300/600, etc.), material (carbon steel, stainless steel, etc.), size, and standards (API, ASME, DIN).

Design components: body, ball, stem, seats, flanges, handle/actuator.

2. Material Selection

Common materials: ASTM A105, A216 WCB (carbon steel), A351 CF8M (stainless), brass, etc.

Select suitable seat/seal materials (PTFE, RTFE, metal, etc.) based on application.

3. Casting or Forging

Casting: For complex shapes or large volumes.

Sand or investment casting used for valve bodies.

Forging: For high-strength applications.

Forged valve bodies offer better grain structure and pressure performance.

4. Machining

CNC machining for:

Valve body and bonnet.

Ball (must be spherical with mirror-finish surface).

Stem, flange face, and bolt holes.

Precision is crucial for sealing and operational integrity.

5. Surface Treatment

Anti-corrosion treatment (e.g., shot blasting, pickling & passivation, painting).

Internal coatings or linings (if required).

6. Assembly

Assemble ball, stem, seats, seals, and body.

Apply proper torques to bolts and other fasteners.

Use anti-static and blowout-proof designs as required by standards.

7. Testing

Hydrostatic pressure test (shell & seat leakage) – per API 598 or ISO 5208

Air pressure test (seat leakage).

Optional fire-safe, fugitive emission, or cycle life testing.

8. Inspection & Quality Control

Dimensional check.

Material certification (MTRs).

Visual inspection.

Marking per standard (e.g., valve size, pressure class, material).

9. Painting & Packaging

Paint per customer or industry spec (e.g., epoxy, polyurethane).

Protect flange faces with plastic covers.

Pack in crates or boxes to prevent damage in transit.

Optional: Automation

Mount actuator (pneumatic, electric) if needed.

Set limit switches, solenoids, and test the control system.

Compliance Standards to Follow

Design: API 6D, ASME B16.34

Flanges: ASME B16.5

Testing: API 598, ISO 5208

Face-to-Face: ASME B16.10

If you are very interested in our company's products or have any questions, please feel free to contact us.