In October 2020, during a visit to Huawei’s Longgang campus, Mr. Zhang, a lead engineer, tapped a butterfly valve in the pipeline. “The last supplier’s batch nearly brought the whole project to a halt,” he recalled. “A single industrial butterfly valve, no bigger than your fist, left over 200 of us idle for three days. Every minute of that time was money.” He then knocked on the body of one of our emergency-delivered valves. “Thankfully, we found you. We installed these and moved straight to the next phase.”

⊙  The Challenge: A Critical Lug Butterfly Valve Installation Failure

On March, 2020, a cooling system upgrade project at Huawei faced a critical setback. A batch of DN150 lug style butterfly valves from the original supplier failed during lug type butterfly valve installation due to a flange hole pitch deviation. The measured Pitch Circle Diameter (PCD) was 152.4mm, outside the required 152±0.5mm tolerance specified in their lug type butterfly valve dimensions chart.

Furthermore, the perpendicularity of the threaded holes deviated by 0.8°, far exceeding the ≤0.5° requirement set by the GB/T 12238 standard. This geometric inaccuracy in the butterfly lug type body made it impossible for 12 sets of valves to align with the standard ASME B16.5 flanges. This is a common issue when there's a poor understanding of the difference between wafer vs lug type butterfly valve design for dead-end service.

The project team calculated that each day of delay would incur ¥56,000 in idle labor costs, putting the entire project timeline at significant risk.

⊙ JRVAL’s Rapid Response: The Reliable Choice from Tianjin’s Valve Industry Hub

Upon receiving the urgent request, JRVAL committed to and completed the production of 200 DN150 stainless steel lug butterfly valves within 48 hours. This was achieved through a meticulous, three-stage process:

1. Casting Stage: Foundation of Quality

• Raw Material Control: We exclusively used S30408 stainless steel ingots from Baosteel Special Steel. Every batch was accompanied by a Material Test Report (MTR) certifying key element content (e.g., Carbon ≤0.08%, Nickel 8%-11%).

• Lost-Foam Casting: 3D-printed EPS (Expanded Polystyrene) patterns were used to ensure exceptional cavity accuracy. The pouring temperature was precisely controlled at 1560℃ ±10℃.

• Stress Relief: A documented heat treatment process, verified by temperature curve charts, was performed to eliminate internal stresses and ensure long-term dimensional stability.

2. Machining Stage: The Pursuit of Perfection

• Rough Machining: Face cutting was performed on a vertical lathe, leaving a precise 0.5mm allowance for the finishing pass.

• Precision Finishing: A DMG MORI CTX beta 800 5-axis CNC machining center executed the final machining of flange faces and holes, guaranteeing geometric accuracy.

•  Three-Stage Manual Tapping: Using an M20×1.5 tap, our technicians performed a rigorous three-step process for each threaded hole:

• Rough Tapping: To remove the cast oxide layer.
• Finish Tapping: To correct the thread form and positional tolerances.
• Calibration Tapping: To ensure 100% pass rate with a go/no-go gauge, compliant with the GB/T 3934 standard.

3. Testing Stage: Three Tiers of Rigorous Validation

⊙ Conclusion: Professionalism is the Ultimate Respect for a Client’s Time

When JRVAL’s 200 lug butterfly valves arrived at the Huawei project site, the installation was seamless. The precise hole spacing and perfect perpendicularity of the threads allowed every bolt to be inserted and tightened effortlessly. The stalled workflow was instantly revitalized, putting the entire project back on track.

Engineer Zhang’s simple statement, “We installed them and moved straight to the next phase,” is the ultimate endorsement of JRVAL’s core philosophy: Precision Manufacturing, Reliable Delivery.

In the era of industrial automation and precision engineering, a minute flaw in a single component can trigger a system-wide chain reaction. At JRVAL, we understand that we deliver more than just a butterfly valve; we deliver certainty for our clients’ projects, confidence for their engineers, and a commitment to their valuable time.