Ball valves are versatile flow control devices suitable for extensive industrial applications. They are available in different sizes and designs, making them adaptable to diverse sanitary, petrochemical, and cryogenic applications.
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These valves control the flow of fluids through a hollow, pivoting ball that is either a full or reduced port. The dimensions of full port valves are equal to the internal diameters of the adjacent pipelines. The dimension of a reduced port (standard port) valve diameter is one pipe size less than the internal size of the adjacent pipe. For example, a 1&#; reduced port valve will actually use a ball with a ¾&#; port diameter.
Ball valves have several advantages over other industrial valves, with the most notable being:
There are several ways to categorize valves. Each category or design determines the performance characteristics of the valve. The categories include:
There are a few questions that industrial engineers must ask before choosing ball valves. Finding answers to these questions guides the experts through the challenging valve selection process and helps select reliable ball valves that satisfy the requirements of the piping system. What are these questions?
The first question that the engineers must address is the type of fluid that passes through the pipeline. Is it a liquid, gas or semi-solid (slurry)? Understanding the physical and chemical characteristics of the fluid helps analyze its behavior as it flows past the valve. Understanding the nature of the service fluid is vital for making decisions about valve materials, port designs and valve sizes. For example, when choosing a gas ball valve we must take into account its performance and reliability issues when working with combustible gases, like hydrocarbons, liquified natural gas or chemical vapors.
Pipeline designers must specify the type of valve actuation that will complement flow control operations. There are piping systems that require frequent valve operation and high precision levels. Other flow operations require a one-off activation of the ball valve. When choosing ball valves, the designer needs to quantify the frequency of valve operations. They also need to evaluate the energy requirements and complexity of actuation technologies. The available actuation methods for ball valves include:
Evaluate additional actuation options like spring return or double-acting actuators as well. Understand the impact of add-ons like limit switches or pilot valves on the reliability of valves.
In processes that demand fast cycle times, pneumatic actuation for ball valves seems to be the most suitable choice. Engineers can install manually-operated ball valves in strategic pipe locations to facilitate pipeline isolation for maintenance or inspection. These low-cycle valves require operation a few times a year.
Specifying the pressure and temperature conditions of the service fluid and the working environment is critical when selecting ball valves. The temperature ranges of the service fluid can alter the mechanical strength of the valve. If the temperature fluctuations are too high, the valve experiences non-uniform expansion and contraction that may lead to surface fractures with time.
Ball valves should sustain the pressure of the service fluid. Exceeding the designed pressure limits affects sealing quality and can cause premature wear. Select a ball valve with temperature and pressure ratings equal or higher to the ratings of the pipeline.
The frequency of valve cycling affects the durability of a ball valve. Engineers should estimate annual operating cycles to determine the durability of different ball valves in the piping system. Other factors like maintenance and media abrasion affect the reliability of valves throughout their lifecycle.
The designers should estimate life expectancy of ball valves before choosing the actuation mechanism. If properly specified, ball valves can survive several tens of thousands of operations without failure. After understanding the cycling requirements, the engineers may settle on pneumatically actuated valves that guarantee better durability and reliability than electrically actuated counterparts.
While there are different types and brands of ball valves in the market, each has a definite application area. For instance, a steel ball valve for a chemical processing facility may not meet the specifications for use in a sanitary application. Ball valves provide shut-off for pipelines and can also provide directional control of fluids. When making selections for application-specific valves, the designer should understand whether:
Industrial applications operate under different pressure and temperature conditions. There are strict emission and leakage control requirements attached to diverse classes of ball valves. When selecting the ball valve, ensure that it meets minimum system requirements and regulatory specifications.
The type of valve materials comes down to the properties of the service fluid. When evaluating valve materials, engineers should verify:
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The most common materials for ball valve bodies are brass, stainless steel, plastic, Monel, Inconel, Molybdenum, Chromium alloys, nickel alloys or copper. Severe service ball valves require materials with better strength and corrosion resistance values like Monel or Inconel.
When examining valve materials, the designers should pay attention to the composition of seal materials. Soft-seated ball valves may use rubber seals or PTFE seals. For extreme fluid service, the ball valves feature metal-to-metal seats.
Which testing and quality assurance procedures does your valve vendor use?
When working with vendors or manufacturers, the company should request information about testing protocols and quality assurance measures that they use. Testing procedures analyze the performances of different ball valves, leak and emission tests and pressure tests to ensure valves are safe for specific applications.
Do not purchase ball valves because they are the cheapest in the market. Take an extra step to evaluate the quality assurance criteria and standardization marks on the valve body or packaging. There is no point in purchasing ball valves in bulk, only for them to fail after a few working cycles.
The application of ball valves spans different industries. In each sector, appointed organizations certify products to verify compliance with health and safety regulations. Depending on the type of application, ball valves and their actuators are subject to the following certifications:
Ball valves should have certifications relevant to the fluid applications you are running within the facility.
Ball valves do not typically require a high volume of maintenance interventions. They have simple flow control mechanisms and are less likely to fail. However, that does not preempt the fact that industrial valves, at times, will require maintenance. When selecting valves, establish a plan for inspection and maintenance. Maintain a lean inventory of repair and replacement parts like seals for valves and consumables for actuators. Manual ball valves may require fewer maintenance interventions than actuated valves.
Slanted seat check valves are engineered for enhanced water hammer resistance. The valve has a double eccentric shaft position and an increased seating angle. This design reduces the valve stroke, reducing closure time.
Hydraulic dampers are recommended, especially for installations on pumping stations with frequent valve opening and closing. The damper provides controlled valve closure by dissipating kinetic energy, significantly reducing the risk of water hammer. The valve disc closes quickly over the first 85% of its angular travel before meeting the hydraulic damper. The damper then dissipates the kinetic energy of the disc and forces it to open slightly. The disc closes until it gets in contact with the damper again, and this cushions the disc until it returns to its fully closed position, sealing the valve.
For additional details please refer to our slanted seat check valve product information.
Nozzle check valves are designed with the disc connected to a central stem, moving along the horizontal axis. A spring is positioned between the disc and the diffuser sleeve. When flow enters the valve, the hydraulic force exerted onto the front face reacts against the spring, causing it to compress and allow the valve to open. When the flow stops, the spring forces the disc to return to the closed position.
Due to the spring-assisted closure and the short linear valve stroke, the nozzle check valve is one of the quickest acting check valves available and is commonly used in pumped systems where water hammer is a potential concern. The disc is constantly present in the flow stream which can result in slightly higher head loss compared to swing check valves.
For additional details please refer to our nozzle check valve product information.
Choosing the ideal check valve for your application depends on several selection criteria. No single type of check valve suits every situation, and the following factors are essential to consider. However, they may not be equally important for all applications. By evaluating these factors in relation to system requirements, you can select a check valve that ensures reliable performance, minimal maintenance and long-term operational efficiency.
All check valves referred to in this article are designed for water and treated wastewater. However, for raw wastewater or sewage the presence of solids may impact valve performance, requiring careful consideration of design and material compatibility.
Rapid closure of a check valve can protect upstream equipment such as pumps from damage. However, the rapid closure will not protect against the surges caused by pumps being started and shut down. If the valve opens (and closes) quickly, the flow will change rapidly and thus increase likeliness of surge occurrence. Consider the flow dynamics of your system to choose a valve that mitigates these risks effectively.
Head loss is influenced by fluid velocity and valve design. Valves with unrestricted openings minimise head loss, whereas designs with narrower bores increase fluid velocity and, consequently, head loss. There are a number of values for head loss, among others zeta values, Kv and Kvs values.
The total cost for your check valve is much more than the purchase price. Long-term costs such as maintenance, equipment protection and energy costs may be just as important as purchase price and installation costs.
A simple valve construction generally requires less maintenance, and the higher the Kv value, the lower the energy consumption.
If you are looking for more details, kindly visit ANSI Standard Flange Check Valve.