Flanged Butterfly Valve – Custom Valve by Leading Foundry

1. परिचय

A Flanged butterfly valve (FBV) is a quarter-turn valve widely recognized as the workhorse of high-pressure and permanent fluid control systems.

Characterized by their integral flanges that bolt directly to pipeline flanges, they provide a rigid, leak-proof, and structurally stable connection,

a critical advantage over wafer-style valves (space-saving but suited for low-pressure duties) and lug-style valves (moderate pressure, often for non-critical service).

Engineered for medium to large-diameter pipelines, flanged butterfly valves combine तंग शटऑफ़, structural reliability, और रखरखाव में आसानी.

एक ही समय पर, their versatility makes them indispensable in जल उपचार, HVAC networks, and general industrial processing, where their संक्षिप्त परिरूप, cost-efficiency, and adaptability across pressure and temperature ranges deliver long-term operational value.

2. What is a Flanged Butterfly Valve?

Core Definition and Working Principle

ए flanged butterfly valve (FBV) एक है quarter-turn rotary वाल्व designed for regulating or isolating flow in pipelines.

Its defining feature is the integral flanges, which bolt directly to pipe flanges (per ANSI B16.5 or ISO 7005), creating a rigid, leak-tight, and permanent connection suitable for high-pressure service.

The valve operates on a simple principle:

• Fully Open (0°): The disc lies parallel to flow, minimizing pressure loss (typically 1–3 psi for a 6-inch valve at nominal flow).
• Throttling (10–80°): Partial rotation restricts flow; eccentric disc designs provide more linear flow control than concentric types.
• Fully Closed (90°): The disc presses firmly against the seat, achieving tight shutoff. FBVs are bidirectional, handling forward and reverse flows effectively.

Anatomy of a Flanged Butterfly Valve

A flanged butterfly valve is engineered for durability and precision control, typically comprising six core components:

Flanged vs. Wafer vs. Lug Butterfly Valves

The integral flange design sets FBVs apart from wafer and lug types, offering unique advantages for high-demand applications:

3. Design Variations: Concentric vs. Eccentric Flanged Butterfly Valves

Flanged butterfly valves are classified primarily by disc and stem alignment, a critical factor influencing pressure rating, sealing performance, torque requirements, और आवेदन उपयुक्तता.

Concentric Flanged Butterfly Valves (Standard Design)

Geometry: The disc and stem axes align with the valve’s bore center, making the design concentric. During operation, the seat maintains contact across the entire disc surface.

प्रदर्शन मेट्रिक्स:

• Pressure Rating: ANSI Class 150–300 (28–70 bar at 20°C)
• रिसाव वर्ग: एपीआई 609 Class IV (≤0.01% of nominal flow for liquids)
• Torque Requirement: 60–100 N·m (6-inch valve, EPDM seat)
• Cycle Life: 10,000–20,000 cycles (resilient seat limits lifespan)

लाभ:

• Simple, cost-effective design
• Easy maintenance and seat replacement
• Suitable for moderate temperature and pressure fluids

सीमाएँ:

• High disc-seat friction reduces efficiency
• Not suitable for gas service or high-pressure applications
• Limited durability under abrasive or high-temperature fluids

विशिष्ट अनुप्रयोग:

• HVAC chilled water systems
• Municipal water distribution
• Low-pressure, non-critical industrial services

Eccentric Flanged Butterfly Valves (High-Performance Design)

सिंहावलोकन: Eccentric designs offset the disc or stem, reducing disc-to-seat friction and enhancing sealing performance.

These designs are ideal for उच्च दबाव, high-temperature, and gas applications.

Single Eccentric (Offset Disc) Flanged Butterfly Valve

डिज़ाइन: The disc center is offset from the stem axis, which minimizes contact with the seat during rotation, reducing friction.

प्रदर्शन मेट्रिक्स:

• Pressure Rating: ANSI Class 300–600 (70–140 bar)
• रिसाव वर्ग: एपीआई 609 Class V (≤0.001% of nominal flow)
• Torque Requirement: 40–70 N·m (6-inch valve, PTFE seat)—~30% lower than concentric valves

अनुप्रयोग:

• Industrial water treatment
• Low-pressure oil lines
• Applications requiring moderate flow control with improved efficiency

Double Eccentric (Offset Disc + तना) Flanged Butterfly Valve

डिज़ाइन: Both the disc center and stem axis are offset from the bore center. This eliminates disc-seat contact until 80–85% of closure, significantly reducing friction and wear.

प्रदर्शन मेट्रिक्स:

• Pressure Rating: एएनएसआई कक्षा 600 (140 bar at 20°C); up to Class 900 with metal seats
• रिसाव वर्ग: एपीआई 609 Class VI (≤0.00001% of nominal flow) — suitable for gas service, including natural gas pipelines
• तापमान की रेंज: -29° C से 482 ° C से (metal seats)

अनुप्रयोग:

• Chemical processing
• तेल & gas pipelines
• Steam systems
• High-pressure industrial fluids requiring tight shutoff

Triple Eccentric (Offset + Tapered Disc) Flanged Butterfly Valve

डिज़ाइन: Adds a third offset by introducing a conical/tapered disc geometry, achieving a metal-to-metal seal without the need for an elastic seat.

This design enables operation under extreme temperatures and pressures.

प्रदर्शन मेट्रिक्स:

• Pressure Rating: एएनएसआई कक्षा 900 (210 bar at 20°C)
• तापमान की रेंज: -29°C to 650°C (Stellite® or hard metal seats)
• Cycle Life: 50,000-100,000 चक्र (metal seat durability)

अनुप्रयोग:

• Hypersonic vehicle cooling systems
• Power plant superheated steam lines
• Refinery catalytic crackers and petrochemical processing
• Extreme industrial environments requiring zero-leakage and long life

सारांश:

4. सामग्री & Seals of Flanged Butterfly Valve

The performance, विश्वसनीयता, and longevity of double flanged butterfly valves (FBVs) are strongly influenced by material selection for the body, डिस्क, तना, and sealing elements.

Proper materials ensure compatibility with the fluid, संक्षारण प्रतिरोध, high-pressure handling, and suitability for temperature extremes.

Body Materials

The valve body is the primary pressure boundary and must withstand mechanical stress, internal pressure, and environmental corrosion. Common body materials include:

Disc Materials

The disc is directly exposed to flow and often handles अपघर्षक, erosive, or corrosive fluids. Selection is based on यांत्रिक शक्ति, संक्षारण प्रतिरोध, and sealing compatibility:

• 316 स्टेनलेस स्टील: Widely used for general-purpose chemical, पानी, and steam applications.
• Hastelloy C276: Resistant to oxidizing and reducing chemicals; suitable for aggressive acids.
• Ductile Iron with PTFE Coating: Low-friction, corrosion-resistant option for water and mild chemicals.
• तारामंडल®-Clad Discs: High-temperature and high-wear applications, including superheated steam and petrochemicals.

Design Note: The disc may be concentric, eccentric, or triple-offset, with metal or resilient coating to improve sealing and reduce wear.

Stem Materials

The stem transmits torque from the actuator or handwheel to the disc and is exposed to mechanical stress, दबाव, and fluid contact. Common materials:

Seat Materials and Seal Types

The seat forms the critical sealing interface with the disc, determining leakage class, torque requirement, and service life. Selection depends on fluid type, दबाव, और तापमान.

Gaskets and Actuator Interfaces

• Flange Gaskets: Graphite, पीटीएफई, or nitrile gaskets ensure leak-proof flange connections between the valve and pipeline.
• Actuator Seals: O-rings or PTFE bushings prevent fluid leakage along the stem while enabling smooth torque transfer.

5. उत्पादन & Foundry Methods of Flanged Butterfly Valves

The production of flanged butterfly valves (FBVs) requires high precision, robust materials, and strict adherence to international standards such as API 609, आईएसओ 5752, and ANSI B16.5.

Valves designed for high-pressure and high-performance applications—like oil & gas pipelines, रासायनिक संयंत्र, and power generation—must exhibit आयामी सटीकता, संरचनात्मक अखंडता, and leak-tight performance.

Casting Butterfly Valve Components

Casting is the primary method for shaping valve bodies and discs, allowing complex geometries and cost-effective production. For large valves (typically over 12 इंच), सैंड कास्टिंग is widely used.

इस प्रक्रिया में, molten metal (1450–1550°C) is poured into resin-bonded sand molds.

Sand casting offers tolerances around ±0.5 mm, making it suitable for carbon steel or ductile iron valves used in municipal water or low-pressure industrial pipelines.

For small-to-medium valves (2–12 inches) requiring high dimensional precision and corrosion resistance, धातु - स्वरूपण तकनीक (lost wax method) is employed. Wax patterns are coated with ceramic shells, melted out, and replaced with molten metal.

This method achieves tight tolerances (±0.1 मिमी) and smooth surfaces, enabling precise features such as double eccentric disc hubs.
Investment casting is ideal for 316L stainless steel, hastelloy, or other corrosion-resistant alloys.

फोर्जिंग: High-Strength Components

Forging is the preferred method for critical, high-pressure components such as bodies, निकला हुआ किनारा, and stems, because it produces superior grain structure and higher tensile strength.

Heated metal (1100-1200 ° C) is shaped under hydraulic presses or dies, resulting in 20–30% stronger parts than equivalent castings.

Forged components are typically used in ANSI Class 600 or higher valves for oil & gas pipelines, power plants, and other demanding industrial applications.

Forging methods include open-die forging for large custom parts, closed-die forging for medium-sized components with precise dimensions, and upset forging to reinforce critical junctions like disc hubs.

मशीनिंग: Precision Finishing

After casting or forging, सीएनसी मशीनिंग ensures high dimensional accuracy, सतह खत्म, and proper alignment:

• Flange faces are milled to achieve flatness within 0.1 mm and bolt hole alignment per ANSI B16.5 standards, ensuring leak-free connections.
• Seat bores are honed or machined to Ra 1.6–3.2 μm to allow proper seat bonding and effective sealing.
• Discs and hubs, especially eccentric designs, are finished with 5-axis CNC milling to maintain flatness within 0.05 mm for tight shutoff.
• Stems and bearings are turned and milled with precision to guarantee smooth rotation and correct torque transfer.

उष्मा उपचार: Mechanical and Corrosion Properties

Heat treatment improves strength, कठोरता, and corrosion resistance depending on the material used:

• कार्बन स्टील (डब्ल्यूसीबी): Quenched at 850°C and tempered at 650°C to achieve tensile strength ≥485 MPa.
• 316एल स्टेनलेस स्टील: Solution-annealed at 1050–1100°C followed by water quenching to restore corrosion resistance and homogenize microstructure.
• दोहरा 2205: Solution-annealed at 1020–1080°C to achieve a balanced austenite/ferrite ratio (50:50), optimizing both strength and corrosion resistance.

सतह का उपचार: Longevity & संक्षारण प्रतिरोध

Surface finishing ensures durability in harsh environments:

• अदा करना for 316L stainless steel enhances the natural chromium oxide layer, improving corrosion resistance by up to 20%.
• एपॉक्सी कोटिंग्स of 100–150 μm protect carbon steel bodies in oil & gas pipelines from soil and atmospheric corrosion.
• Electropolishing is used in sanitary applications (खाना, पेय, दवाइयों) to achieve Ra ≤0.8 μm, eliminating microscopic crevices and bacterial dead zones.

विधानसभा & गुणवत्ता आश्वासन

After machining and surface treatment, valves undergo assembly and rigorous quality control:

• Seat and disc integration: Seats are bonded or pressed, and eccentric discs are carefully aligned for precise shutoff.
• Stem installation: Bearings, packing, and O-rings are fitted, and torque is verified.
• Hydrostatic or pneumatic testing: Confirms leak-tight performance under design pressure.
• गैर विनाशकारी परीक्षण (एनडीटी): Methods such as X-ray, अल्ट्रासोनिक, or dye penetrant inspections detect internal defects.
• Actuator calibration: Manual, इलेक्ट्रिक, वायवीय, or hydraulic actuators are tested for torque and stroke accuracy.

6. Pressure Ratings, Sizes & मानकों

Flanged butterfly valves (FBVs) are designed for reliability across a wide range of pressures, आकार, and industrial standards.

Proper selection ensures safety, दीर्घकालिक प्रदर्शन, and compatibility with pipeline systems.

Pressure Ratings

Standard Sizes

Face-to-Face Dimensions: Usually conform to ISO 5752 Series 10 or API 609 for easy interchangeability.

Key Standards & Certifications

7. Actuation & Control Systems

Flanged butterfly valves are quarter-turn devices requiring actuators capable of 90° rotation.

Actuator selection depends on valve size, torque requirement, fluid type, and control sophistication.

Common Actuator Types and Specifications

Key Accessories for Enhanced Control

• पोजिशनर्स: Provide precise modulating control (±0.5% accuracy), crucial for applications like HVAC chilled water, chemical dosing, or industrial process lines.
• Torque Switches: Protect the disc and seat from over-torquing, preventing premature wear or damage.
• Limit Switches: Deliver open/closed position feedback to SCADA or DCS systems for remote monitoring and automated safety protocols.
• Solenoid Valves & Air Filters (for pneumatic actuators): Ensure rapid, reliable actuation while protecting internal actuator components from contaminants.

8. Flanged End Geometry & Interface

The flanged end design is the defining characteristic of butterfly flange valves, ensuring a rigid, secure, and leak-tight connection to pipeline systems.

The geometry is standardized globally to allow full interchangeability across manufacturers.

Flange Standards & Compatibility

Flanged butterfly valves are machined to match pipeline flanges in dimensions, bolt-hole patterns, and pressure ratings. The most common standards include:

Dimensional Geometry

The flanged end geometry typically includes:

• Raised Face (आरएफ): Standard sealing surface, 2–6 mm raised area around the bore, ensures even gasket compression.
• Flat Face (FF): Used with cast iron pipelines to avoid overstressing flanges.
• Ring-Type Joint (RTJ): Machined grooves for metal gaskets, suited for high-pressure/high-temperature services (तक 210 छड़, 650° C).

9. Industrial Applications of Flanged Butterfly Valves

Flanged butterfly valves are बहुमुखी, high-performance quarter-turn valves widely used across industrial sectors due to their reliability, संक्षिप्त परिरूप, and adaptability to a broad range of pressures, temperatures, and fluids.

जल और अपशिष्ट जल उपचार

• आवेदन: Flow isolation, chemical dosing, and backwashing systems.
• लाभ: Tight shutoff, low-pressure drop, corrosion-resistant seats for treated water or chemical additives.
• उदाहरण: Municipal water distribution networks employ butterfly flange valves for diameters exceeding 12 इंच, ensuring maintenance-friendly operation.

तेल व गैस उद्योग

• आवेदन: Crude oil pipelines, refined products, gas distribution, and offshore platforms.
• लाभ: High-pressure tolerance (एएनएसआई कक्षा 600 और ऊपर दिए गए), bidirectional flow capability, compatibility with hydrocarbons and corrosive fluids.
• उदाहरण: Double or triple eccentric flanged butterfly valves control oil and gas pipelines where minimal leakage and high reliability are mandatory.

विद्युत उत्पादन

• आवेदन: भाप, cooling water, and feedwater systems in thermal and nuclear plants.
• लाभ: उच्च तापमान सहनशीलता, tight sealing for steam lines, rapid quarter-turn actuation for safety.
• उदाहरण: Triple eccentric butterfly flange valves handle superheated steam at 482°C in power plant feedwater lines.

Chemical and Petrochemical Processing

• आवेदन: Aggressive chemicals, अम्ल, and high-temperature processes.
• लाभ: Material versatility (316एल, hastelloy, दोहरा 2205), precise throttling, minimal friction for controlled flow.
• उदाहरण: Eccentric flanged butterfly valves with metal seats prevent leakage in sulfuric acid or caustic soda lines.

गरम करना, Ventilation, and Air Conditioning (एचवीएसी) and Industrial Chilled/Hot Water Systems

• आवेदन: Flow regulation in chilled water loops, cooling towers, and heating systems.
• लाभ: प्रभावी लागत, lightweight, low-pressure rating suitable for non-critical applications, easy maintenance.
• उदाहरण: Concentric butterfly flange valves regulate building-wide chilled water distribution efficiently.

खाना, Beverage, and Pharmaceutical Industries

• आवेदन: Sanitary processing lines, CIP (Clean-in-Place) प्रणाली.
• लाभ: Electropolished stainless steel, FDA-approved seats, smooth surfaces eliminate bacterial growth zones.
• उदाहरण: Flanged butterfly valves with EPDM or PTFE seals ensure hygienic flow control in beverage bottling plants.

Mining and Slurry Handling

• आवेदन: Tailings pipelines, slurry transport, and water control.
• लाभ: Robust construction, abrasion-resistant discs and seats, compatibility with viscous or particle-laden fluids.
• उदाहरण: Carbon steel double flanged butterfly valve with hardened seats handle mineral slurries without rapid wear.

10. Comparison with Other Valves

11. निष्कर्ष

The flanged butterfly valve is a versatile and cost-efficient solution for fluid control, offering a balance of compact design, high flow capacity, and reliable sealing.

Its adaptability to different materials, pressure classes, and actuation methods makes it indispensable across industries ranging from municipal water to petrochemicals.

For engineers and procurement teams, selecting the right FBV involves evaluating media compatibility, operating conditions, performance metrics, and lifecycle costs.

With ongoing advances in materials and automation, flanged butterfly valves will remain a cornerstone of industrial flow control.

Custom Valves from DEZE Foundry

From water treatment plants and HVAC systems to oil & gas pipelines, chemical reactors, and power generation networks, flanged butterfly valves deliver precise flow regulation and tight shutoff under demanding conditions.

Their quarter-turn operation, compact structure, and wide material options enable customization for specific fluids, pressures, and temperatures.

As a professional valve foundry and supplier, we provide custom-engineered flanged butterfly valves and precision-cast components, meeting international standards (एपीआई, आईएसओ, ANSI) while ensuring cost-effective performance.

Whether your project requires large-diameter high-pressure service, corrosion-resistant alloys, or optimized designs for maintenance efficiency, our manufacturing expertise ensures reliable solutions tailored to your industry.

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पूछे जाने वाले प्रश्न

Can flanged butterfly valves handle high-pressure gas service?

Yes—double/triple eccentric flanged valves with metal seats (एपीआई 609 Class VI leakage) and ANSI Class 300–900 ratings are suitable for high-pressure gas (उदा।, प्राकृतिक गैस, नाइट्रोजन).

Ensure compliance with ISO 15848-1 Class AH for low fugitive emissions.

What is the maximum size of a flanged butterfly valve?

Most manufacturers offer flanged butterfly valves up to 48 इंच (1200 मिमी) in diameter, suitable for large water treatment plants and oil & gas pipelines.

Custom designs can reach 60 इंच (1500 मिमी) for specialized applications.

How do I prevent flange gasket leakage?

Use gaskets compatible with fluid/temperature (उदा।, graphite for steam, PTFE for chemicals); tighten bolts in a crisscross pattern (per ASME PCC-1) to uniform torque (उदा।, 70 N·m for 6-inch ANSI 300 निकला हुआ किनारा); replace gaskets annually.

Are flanged butterfly valves suitable for sanitary service?

Yes—select 316L bodies with electropolished surfaces (Ra ≤0.8 μm), PTFE seats, and tri-clamp flanges (3-A/EHEDG compliant).

These valves are used in dairy, पेय, and pharmaceutical manufacturing.

What is the difference between ANSI Class 300 और 600 flanged valves?

एएनएसआई कक्षा 300 valves handle up to 70 छड़ (20° C), while Class 600 handles up to 140 छड़ (20° C).

Class 600 valves have thicker bodies (20–30 mm vs. 15–20 mm for Class 300) and stronger flanges, making them suitable for high-pressure applications like refineries and offshore pipelines.