1″-2500LB-BW Double Block Gate Valve

Nominal Size 1 inch (DN 25) per valve; assembly size based on common inlet/outlet
Pressure Class Class 2500LB (equivalent to PN 420 bar)
End Connections Butt Weld (BW) – inlet and outlet ends
Configuration Two gate valves welded body-to-body
Structure Type Outside Screw & Yoke (OS&Y), solid wedge or flexible wedge (per service)
Operation Each valve independently operated (handwheels or gear operators as required)

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Technical Data Sheet

Product: Double Block Gate Valve
Model / Size: 1″ – 2500LB – BW
Cấu hình: Two high-pressure forged steel gate valves welded into a single integrated body assembly

Product Description

This valve consists of two forged steel gate valves welded together to form a compact, single-unit double block isolation assembly. The double block configuration provides two independent sealing barriers, ensuring positive isolation even in the event of a single seal failure. This assembly is ideal for critical applications such as high-pressure steam, hydrogen, hydrocarbon, and chemical services where absolute shut-off, safety, and system integrity are paramount. Each valve operates independently, allowing for cavity pressure monitoring, testing, or venting between the two blocks. All connections are butt weld (BW) ends, ensuring leak-free, permanent piping integration.

Basic Parameters

Item	Tham số
Kích thước danh nghĩa	1 inch (DN 25) per valve; assembly size based on common inlet/outlet
Pressure Class	Class 2500LB (equivalent to PN 420 bar)
End Connections	Butt Weld (BW) – inlet and outlet ends
Configuration	Two gate valves welded body-to-body
Structure Type	Outside Screw & Yoke (OS&Y), solid wedge or flexible wedge (per service)
Hoạt động	Each valve independently operated (handwheels or gear operators as required)

Tiêu chuẩn thiết kế

Item	Tiêu chuẩn
Design & Manufacture	API 602 (Compact steel gate, globe, and check valves) – applicable for individual valve design; assembly per manufacturer’s standard
Pressure-Temperature Rating	ASME B16.34
Butt Weld End Dimensions	ASME B16.25 (bevel ends)
Face-to-Face Dimensions	Manufacturer’s standard (assembly length)
Inspection & Testing	API 598 (or ISO 5208); double block isolation tested per API 6D or customer specification
Welding (Body-to-Body)	Per ASME Section IX; 100% NDE of weld

Bill of Materials (Typical Configuration)

Part Name	Material (Typical Options)	Nhận xét
Valve Bodies (x2)	A105 (carbon steel) / A182 F22 (Cr-Mo) / A182 F316 (stainless steel)	Forged steel; welded together to form integral assembly
Wedge (x2)	A105 + 13Cr / F22 + Stellite / F316	Solid or flexible wedge; hardfaced seating surfaces
Seat Rings (x2)	Integral body seat with hardfacing	Stellite 6 overlay for wear and erosion resistance
Stem (x2)	A182 F6a (13Cr) / A182 F304 / A182 F316	Precipitation hardened or austenitic stainless steel
Bonnet (x2)	Same material as body	Bolted bonnet with spiral-wound gasket
Packing (x2)	Flexible graphite with anti-extrusion rings	Low-emission packing system
Handwheel / Operator (x2)	Carbon steel / Ductile iron / Gear operator (optional)	Independent operation
Butt Weld Ends	Bevel ends per ASME B16.25	Inlet and outlet

Dimensions & Weight (Reference)

Item	Value
Overall Length (End-to-End)	Approx. 300 ~ 400 mm (manufacturer dependent)
Overall Height	Approx. 400 ~ 500 mm (including handwheels or operators)
Butt Weld End	1″ Schedule XXS or appropriate wall thickness for 2500LB
Handwheel Diameter (each)	Approx. 150 ~ 200 mm (or larger if gear operated)
Approx. Weight	35 ~ 55 kg (depending on material and operator type)

Note: Dimensions and weights are typical values for welded double block gate valve assemblies and may vary by manufacturer.

Operating Conditions

Item	Tham số
Suitable Media	High-pressure steam, hydrogen, hydrocarbons, corrosive fluids, high-temperature liquids/gases
Temperature Range (Carbon Steel)	-29°C ~ 425°C
Temperature Range (Alloy Steel F22)	-29°C ~ 538°C
Temperature Range (Stainless Steel)	-196°C ~ 538°C
Max. Allowable Pressure	Approx. 42.0 MPa (420 bar) at ambient temperature (38°C)

Testing & Inspection

Test	Requirement
Shell Strength Test (each valve)	1.5 times rated pressure (hydrostatic); no leakage
High-Pressure Seat Test (each valve)	1.1 times rated pressure; zero visible leakage
Low-Pressure Pneumatic Test (each valve)	0.6 MPa compressed air; seat leakage within allowable limits (typically zero for gate valves)
Double Block Isolation Test	Both valves closed; pressure applied between blocks; no pressure rise or leakage observed (per API 6D or customer requirement)
Body-to-Body Weld Examination	100% radiographic testing (RT) or ultrasonic testing (UT) per ASME Section VIII
Operational Test	Full stroke cycling of each valve under rated differential pressure

Features & Benefits

Double Block Isolation: Two independent gate valves in a single welded assembly provide redundant shut-off capability, ensuring absolute isolation for critical systems.
Compact, Leak-Free Design: Welded integration eliminates external flange connections between valves, reducing potential leak paths and installation space.
High-Pressure Capability: Class 2500 rating with forged steel construction ensures reliability in ultra-high-pressure applications.
Permanent Butt Weld Ends: BW connections provide a leak-free, permanent installation ideal for critical and hazardous services.
Cavity Monitoring Capability: The space between the two blocks allows for pressure monitoring, venting, or testing without disturbing system operation.
Fugitive Emission Compliance: Stem packing systems can be designed to meet ISO 15848 or TA-Luft low-emission requirements.
Flexible Wedge Option: For high-temperature applications, flexible wedge design accommodates thermal expansion and prevents binding.

Important Notes

Operation Sequence: When used as a double block assembly, typically the upstream valve is opened first and closed last to protect the downstream valve from full system pressure and flow-induced wear.
Cavity Pressure Relief: A bleed or vent port (optional) should be considered to relieve trapped pressure between the two blocks before maintenance or disassembly downstream.
Butt Weld Installation: Welding must be performed per approved Welding Procedure Specification (WPS) with appropriate post-weld heat treatment (PWHT) when required by material and wall thickness.
Hướng dòng chảy: Gate valves are bidirectional; no specific flow orientation is required unless otherwise specified by manufacturer.
Thermal Expansion: Allow for thermal expansion of piping system; installation should consider proper support and anchoring.
NDE Requirements: Body-to-body weld requires 100% NDE; ensure this is performed and documented as part of quality control.

If you require additional specifications such as NACE MR0175 for sour service, gear operators for high-torque applications, or fugitive emission testing documentation, please let me know and I can supplement the data sheet accordingly.

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