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What is a Ball Valve?

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01 What is a Ball Valve?

A ball valve is a type of quarter-turn valve which utilizes a hollow, spherical disc (the ball) to control the flow through it. It is open when the ball’s hole aligns with the flow and closed when it’s pivoted 90-degrees by the valve handle. When the valve is closed, the hole is perpendicular to the ends of the valve, and flow is blocked.

02 How Does a Ball Valve Work?

A ball valve operates by utilizing a rotating ball with a hole, known as a port, through it. The central mechanism of a ball valve is straightforward.
In the “open” position, the port aligns with the inlet and outlet of the valve, thus creating a clear passageway for flows (gas, liquid, or semi-solid). The substance being controlled can effortlessly flow through the hole from the inlet, passing through the inside, and coming out from the outlet.
When you rotate the valve handle a quarter-turn (90 degrees) to the “close” position, the port becomes perpendicular to the flow path. This action blocks the passageway completely, hence terminating the flow. No liquid or gas can pass through because the sealing surfaces close off the port.
The operation is instant, only needing a quick quarter turn to open or close the valve, giving it an edge over other types of valves. Additionally, the handle of the ball valve gives a visual representation of the valve’s status. When the handle lies parallel to the pipeline, it indicates the valve is open, and when it’s perpendicular, the valve is closed.
The design and operation of ball valves provide a reliable and efficient method for controlling flow, making them a popular choice in various industrial and domestic applications.

03 Parts of a Ball Valve

  1. Body: This is the outer casing of the valve and houses the internal parts. It can be made from different materials like brass, bronze, steel,cast iron, or plastic.
  2. Ball: The ball is the central component that gives the ball valve its name. It is a sphere made from durable material, with a hole known as a port running through it. When the ball is rotated, the port aligns or misaligns with the flow of the fluid to regulate it.
  3. Stem: The stem connects the handle to the ball and allows the handle’s turning motion to rotate the ball. It usually features a blowout-proof design to prevent accidental removal or popping out under high pressure.
  4. Seats: Seats are ring-shaped components that serve as sealing surfaces to prevent leakage when the valve is closed. They are normally made from soft materials to ensure a tight seal with the ball.
  5. Power Source:The power source is the force behind the operation of the valve. In some systems, an electric, pneumatic, or hydraulic device may replace the conventional manual handle. This power source enables the valve to operate automatically or remotely without manual intervention.
  6. Bonnet: The bonnet is the top part of the ball valve, which is bolted or screwed into the body. It holds the stem and ball in place and serves as a pressure seal.
  7. Packing: Packing is a seal in the valve around the stem to prevent leaks along the stem when the valve is in use.
  8. Gland follower: The gland follower compresses the packing to make a tight seal around the stem.

Anti Static Design

Live Loaded and Externally Adjustable Gland Flange

Blowout Proof Stem

Integrally Cast ISO 5211 Actuator Mounting Flange

Replaceable Seats

Raised Face Type B Design

Full Port Design

Un-Pigmented PFA Fully Locked in Liner

Polyester Polyurethane Powder Coat per ASTM B117

Metal to Metal Body Half Connection

ASME B16.5 Flange Dimensions

04 End Connections

When it comes to connecting a ball valve to a piping system, there are two common methods:

 

  1. Flanged Connections: This is a popular method often utilized in industrial pipeline systems. In this type of connection, the ball valve is attached via flanges that are connected to the piping system. This type of connection allows for easy disassembly and reassembly when necessary, proving to be highly suitable for large systems requiring regular maintenance.
  2. Threaded Connections: In threaded connections, ball valves are installed through an internal or external threading system. This type of connection is ideal for smaller-scale piping systems for gas or liquid, as it allows for easy installation or detachment without the need for special tools. However, the threaded parts may pose the risk of leakage.

05 Ball Valve Hole Designs

The term “Ball Valve Hole Designs” generally refers to the design of holes or ports in a ball valve. A ball valve is a form of quarter-turn valve that uses a hollow, rotating ball to control flow through the valve. The hole or port is in the middle of the ball and, when aligned with both ends of the valve, enables flow to occur. When the valve is closed, the hole is perpendicular to the valve ends, blocking flow.
A few common types of ball valve hole designs include:
  1. Full Port: A full port ball valve has an oversized ball so that the hole in the ball is the same size as the pipeline. This results in lower friction loss.
  2. Standard Port: In a standard port ball valve, the hole through the ball is smaller than the pipeline. This is a more economical choice but does result in some pressure drop.
  3. V-Port: V-Port ball valves have either a ‘v’ shaped ball or a ‘v’ shaped seat. This allows the orifice to be opened and closed in a more controlled manner with a closer to linear flow characteristic.

06 Valve Body Construction

The construction of a valve body is an essential aspect as it houses the internal parts that regulate the flow of fluid. Valve bodies are typically made from durable materials to withstand high pressures and temperatures. They come in several designs, with each offering unique characteristics. The common types of valve body constructions include:

 

  1. Single-Piece Body: This is the simplest form of valve body construction. It is a one-piece design that offers excellent durability because there are no connections or seams that could potentially leak. However, it could be challenging to maintain or service due to its singular structure.
  2. Two-Piece Body (Split Body): In this design, the valve body is divided into two separate halves. The advantage is that it’s easier to service and maintain since the internal components can be accessed by separating the two halves.
  3. Three-Piece Body: The three-piece design offers even greater ease of maintenance. It consists of two end pieces and a center section containing the valve components. The center section can be removed without having to dismantle the entire valve from the piping system, allowing for easy repair or replacement of internal components.

07 A Comparative Analysis Unveiling the Characteristics of Distinct Ball Valves

In the world of industrial valves, Ball valves have remained an integral player, thanks to their high reliability and versatility. Among the various types of Ball valves, Flanged ball valve, Full-welded ball valve, JIS 10K Flanged Ball Valve, and Ball Check Valve, each come with unique attributes catering to different applications.

 

The Flanged ball valve is characterized by its flanges that connect the valve to its associated equipment, facilitating ease in maintenance and disassembly. Notably, these valves possess an excellent sealing capacity, thereby preventing any leakage, and are often applied in industries like petroleum and natural gas because of their high-pressure handling capability.

 

On the other hand, Fully Welded Ball valves are known for their robust construction, where all valve elements are welded together, ensuring a fully leak-proof mechanism. Their compact and robust nature makes them an excellent choice for use in extreme conditions, such as underground service or in applications with high-temperature variations.

 

The JIS 10K Flanged Ball Valve, designed per the Japanese Industrial Standards (JIS), is typically known for its high reliability and affordability. The numeric ’10K’ stands for the 10 kgf/cm² pressure rating, indicating its ability to handle medium to high pressure applications. Its main applications are in waterworks, shipbuilding, and general industry.

 

Lastly, the Ball Check Valve stands out with its simple yet effective design. These valves play a crucial role in preventing downstream backflow, essentially making them a safety device within piping systems. A specific spherical or ball-shaped closure unit characterizes them, which works on a self-automated system without needing any form of manual operation.
Product Catalog

08 Applications of Ball Valves

Ball valves have a wide array of applications due to their durability, versatility, and ability to control high-pressure, temperature, and flow. They are commonly used across various industries, including:

 

  1. Oil and Gas Industry: Ball valves can handle the high pressures and temperatures associated with oil and gas pipelines, making them an ideal choice for this sector.
  2. Chemical Industry: Ball valves offer excellent sealing capabilities that prevent leaks, a crucial requirement in chemical processing plants where hazardous substances are prevalent.
  3. Water and Wastewater Treatment: Ball valves are widely used in water treatment facilities to control the flow of water and other fluids through the system.
  4. Pharmaceuticals: In the pharmaceutical industry, ball valves are used in process lines to regulate flow. They are particularly beneficial in ensuring sanitary conditions due to their easy-to-clean design.
  5. Power Plants: In both nuclear and conventional power plants, ball valves are predominantly used to control the flow of steam, coolant, and feed water.
  6. Food and Beverage Industry: Ball valves are used in this industry for their quick actuation and the ability to handle a variety of media like steam, water, and other consumables.
  7. Marine Applications: Due to their effective sealing capabilities and durability, ball valves are utilized in various marine applications, including fuel lines, bilge systems, and ballast systems.
  8. Paper and Pulp Industry: The ability to control slurry flow makes ball valves suitable for pulp and paper manufacturing

09 How To Select the Right Ball Valve?

Selecting the right ball valve involves careful consideration of various factors. Here are some steps to help guide you through the process:
  1. Understand the System Requirements: Identify the specific needs of your system, such as the type of fluid, pressure levels, temperature range, and flow rate.
  2. Material of the Valve: The material of the valve should be chosen based on the type of fluid in your system. For instance, stainless steel or brass valves are ideal for water systems, while plastic valves work well for corrosive fluids.
  3. Size and End Connection Type: Before purchasing a valve, it’s important to know the size of the pipe where the valve will be installed. Ball valves come in different sizes and end connections (threaded, flanged, butt-weld, etc.) to fit various pipeline configurations.
  4. Operation Method (Manual or Actuated): Ball valves can either be manually operated or actuated. Manual valves are controlled by a lever and are suitable for simple, on/off applications, while actuated valves can be operated via electric, pneumatic or hydraulic power for more complex or remote applications.
  5. Full Port or Reduced Port: A full port ball valve provides no flow restriction, whereas a reduced port valve has a smaller ball and a correspondingly smaller bore hole. This can slightly reduce flow rates.
  6. Sealing Material: The material of the sealing elements (seats) should be chosen carefully based on operating conditions. Some common materials include PTFE, EPDM, and metal seals.
  7. Certifications and Standards: Ensure the valve meets the necessary standards, codes, and certifications for your application (like ASME, API, or other local standards).
  8. Maintenance and Durability: Consider the durability and whether the valve can be repaired. Some valves are designed for easy maintenance and feature replaceable elements.
  9. Manufacturer Reputation: Consider the reputation of the manufacturer and reviews of past users.
  10. Cost: Finally, compare the costs along with other factors to make an informed decision. The cheapest one may not be the best option if it doesn’t meet your specific requirements.
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