DN2550 and DN1800 Metal-Seated Valves Successfully Applied in Ethylene Cracking Units
Recently, automatic plasma powder cladding equipment for eccentric butterfly valves, independently developed and manufactured by Shanghai Duomu Industrial Co., Ltd., successfully supported Wuxi Intelligent Control Engineering Co., Ltd. in the delivery of two large-diameter triple offset butterfly valves (DN2550 and DN1800).
The delivered products are bi-directional, fully metal-seated triple offset butterfly valves, installed at the compressor inlet of an ethylene cracking unit, one of the most critical positions in petrochemical plants. These valves provide tight shut-off of cracking gas media, ensuring safe and reliable operation under extreme process conditions.
Large-Diameter Triple Offset Butterfly Valves for Severe Service Applications
The DN2550 triple offset butterfly valve, weighing more than 15 tons, adopts an advanced triple offset design and features:
• Bi-directional metal-to-metal sealing
• High overall structural rigidity
• Wide operating temperature range
• Extended service life under severe conditions
These characteristics ensure zero leakage shut-off of hazardous media such as cracking gas, safeguarding the safe, stable, and long-term operation of ethylene cracking facilities.
The successful delivery marks a major technological breakthrough for Wuxi Intelligent Control in the development and manufacturing of large-diameter, high-parameter special valves, and represents a significant milestone in the localization of critical valves for China’s ethylene cracking units.
Automated Plasma Cladding Solves Manufacturing Challenges of Large Valves
Compared with conventional valves, large-diameter triple offset butterfly valves present significant manufacturing challenges due to:
• Large sealing surface width
• Complex offset angles
• Extremely heavy valve bodies and discs
• High sensitivity to heat input during hardfacing
During hard alloy cladding, improper heat control can easily cause cracking or unstable metallurgical bonding. To overcome these issues, Wuxi Intelligent Control adopted automated plasma powder cladding technology provided by Shanghai Duomu Industrial, enabling:
• Precise control of heat input
• Stable and repeatable alloy deposition
• Effective suppression of cladding cracks
• High-quality, dense, and uniform cladding layers
This advanced process ensured the reliable reinforcement of sealing surfaces and the on-time delivery of the large-diameter valves.
Industry Trend: Conventional Manufacturing No Longer Meets Severe Service Requirements
As industries such as energy, petrochemical, shipbuilding, and long-distance pipeline transportation continue to demand higher levels of reliability, sealing performance, and service life, traditional manufacturing methods—including:
• Integral casting
• Conventional welding or overlay processes
are increasingly unable to meet the requirements of high temperature, high pressure, corrosive media, and frequent operation, especially for large-diameter triple offset butterfly valves and ball valves.
Plasma Powder Cladding: A Core Technology for High-End Valve Manufacturing
The application of plasma powder cladding technology for sealing surface reinforcement of large-diameter triple offset valves enables precise and efficient deposition of high-performance alloy coatings, fundamentally improving:
• Wear resistance
• Corrosion resistance
• High-temperature performance
• Long-term sealing reliability
As a result, plasma cladding has become a core enabling technology in the manufacturing and remanufacturing of high-end industrial valves.
Long-Term Value Far Exceeds Initial Investment
Although plasma powder cladding requires higher initial equipment investment and alloy powder costs, the overall lifecycle value is substantial:
• Extended Service Life
Valve service life can be increased by 3 to 5 times, significantly reducing shutdown frequency and replacement costs.
• Enhanced Safety
Early sealing surface failure and leakage risks are effectively eliminated, improving operational safety and environmental protection.
• Lower Total Cost of Ownership
Reduced maintenance and improved operational continuity deliver significant economic benefits over the valve’s lifecycle.
Conclusion: Mastering Core Technology for Sustainable Valve Development
With its high precision, efficiency, and flexibility, plasma powder cladding technology successfully addresses the challenges of sealing surface reinforcement for large-diameter triple offset valves operating under extreme conditions.
This technology not only represents a pinnacle achievement in high-end valve manufacturing, but also supports green manufacturing and circular economy practices by extending the service life of high-value critical equipment.
Mastering plasma cladding technology means gaining a key competitive advantage in enhancing valve reliability, extending service life, and enabling domestic substitution of high-end industrial valves.
Post time: Dec-20-2025