The ball valve is a versatile flow control device used in various industrial applications. Different sizes and designs make them suitable for diverse sanitary, petrochemical, and cryogenic applications.
They control fluid flow through a hollow, pivoting ball with a full or reduced port. Full port valves have dimensions equal to the internal diameters of adjacent pipelines. Reduced port (standard port) valve diameters are one pipe size smaller than adjacent pipe diameters. For example, a 1″ reduced port valve uses a ball with a 34″ port diameter.
There are several advantages to using ball valves over other industrial valves, including:
- They provide leak-tight seals.
- They can open and close quickly.
- Most industrial valves are not as durable as these.
Valve types can be categorized in several ways. A valve’s performance characteristics are determined by its category or design. Among the categories are:
- Valve design based on ball movement: Floating and trunnion mounted
- Port design: full port, V-port valve, or standard.
- Body style: single body, top-entry, 3-pieces, split, or welded body.
Industrial engineers should ask a few questions before choosing ball valves. The answers to these questions guide the experts through the valve selection process and help them select reliable ball valves that meet the piping system’s requirements. What are these questions?
1. Through the ball valve, what type of media will flow?
First, engineers must determine the type of fluid that passes through the pipeline. What kind of liquid, gas, or semi-solid is it? Analyzing how the fluid behaves as it flows past the valve requires an understanding of its physical and chemical characteristics. When choosing valve materials, port designs, and valve sizes, it is crucial to understand the nature of the service fluid. Gas ball valves play an important role when dealing with combustible gases, such as hydrocarbons, liquefied natural gases, or chemical vapors.
2. Which actuation methods will you use?
It is important for pipeline designers to specify the type of valve actuation that will complement flow control operations. In some piping systems, valves need to be operated frequently and with high precision. There are other flow operations that require a one-time activation of the ball valve. A designer must quantify the frequency of valve operations when choosing ball valves. In addition, they need to evaluate the energy requirements and complexity of actuation technologies. Among the actuation methods available for ball valves are:
- Pneumatic actuation
- Electric actuation
- Manual operation
- Hydraulic actuation
Consider other actuation options, such as spring return or double-acting actuators. Know how add-ons like limit switches and pilot valves affect valve reliability.
Pneumatic actuation of ball valves seems to be the most suitable choice in processes that require fast cycle times. To facilitate pipeline isolation for maintenance or inspection, engineers can install manually-operated ball valves at strategic locations. It is necessary to operate these low-cycle valves a few times a year.
3. What are the pipelines that have a temperature and pressure rating?
It is important to specify the pressure and temperature conditions of the service fluid as well as the working environment when selecting ball valves. Valve mechanical strength can be altered by the temperature range of the service fluid. Over time, the valve may experience non-uniform expansion and contraction as a result of temperature fluctuations.
The pressure of the service fluid should be sustained by ball valves. Pressures that exceed the designed limits can adversely affect sealing quality and cause premature wear on the seals. You should choose a ball valve whose temperature and pressure ratings are equal to or higher than those of the pipeline.
4. What are the estimated annual cycles?
Ball valve durability is affected by valve cycling frequency. It is important for engineers to estimate annual operating cycles when determining whether different ball valves will last in a piping system. Throughout the lifecycle of a valve, other factors such as maintenance and media abrasion can affect its reliability.
To determine the actuation mechanism for ball valves, it is important for designers to estimate their life expectancy. It is possible for ball valves to survive several tens of thousands of operations without failure if they are properly designed. When engineers understand the cycling requirements, pneumatically actuated valves provide better durability and reliability than electrically actuated valves.
5. Which materials are used to manufacture the valve?
The type of valve material depends on the properties of the service fluid. Engineers should verify the following when evaluating valve materials:
- Compatibility with the service media
- Resistance to corrosion
- Cost
Brass, stainless steel, plastic, Monel, Inconel, Molybdenum, Chromium alloys, nickel alloys, or copper are the most common materials for ball valve bodies. Materials with higher strength and corrosion resistance values, such as Monel or Inconel, are needed for severe service ball valves.
In examining valve materials, designers should pay attention to seal materials. Rubber seals or PTFE seals may be used on soft-seated ball valves. The ball valves feature metal-to-metal seats for extreme fluid service.
What testing and quality assurance procedures does your valve vendor use?
When working with vendors or manufacturers, the company should inquire about their testing protocols and quality assurance measures. Various ball valves are tested for performance, leak and emission tests, and pressure tests to ensure their safety.
6. How do you intend to use the ball valve?
Despite the fact that ball valves come in a variety of types and brands, each has a specific application. It may not be possible to use a steel ball valve for a chemical processing facility in a sanitary application, for example. In addition to shutting off pipelines, ball valves can also provide fluid directional control. During the selection process for application-specific valves, the designer should consider:
- The valve exclusively shuts off the flow.
- The valve switches flow between sources.
- A three-way ball valve splits flow between two different destinations (applicable to three-way ball valves).
Different pressure and temperature conditions are encountered in industrial applications. Ball valves of various types are subject to strict emission and leakage control requirements. Ensure that the ball valve meets minimum system requirements and regulatory requirements.
7. What certifications should the valve have?
There are a variety of industries that use ball valves. Each sector has appointed organizations that certify products to verify compliance with health and safety regulations. The following certifications for ball valves and their actuators, depending on the application:
- ANSI certifications: Determines pipe flange pressure and temperature ratings.
- NEMA certifications: Provides standards for electrically actuated ball valve design.
- NSF certifications: In food, beverage, and drug production facilities, guidelines should be provided for selecting ball valves.
Your facility should have ball valves that are certified for the fluid applications you run.
8. What are the maintenance requirements for ball valves?
Most ball valves do not require a significant amount of maintenance. Simple flow control mechanisms make them less likely to fail. Industrial valves can, at times, require maintenance, however, so that does not preclude their use. Establish a plan for inspection and maintenance when selecting valves. Maintain a lean inventory of repair and replacement parts, such as seals for valves and consumables for actuators. In comparison to actuated valves, manual ball valves may require fewer maintenance interventions.
Conclusion
The selection of ball valves for different industrial applications is not an easy task. An expert review of the technical specifications of the pipeline, a balanced selection of manufacturing materials, and an understanding of the different valve industry codes and standards are all required. Engineers and pipeline designers can make informed decisions based on the answers to these questions and choose reliable ball valves that will provide long-term service.
Aira Euro Automation is a leading actuated ball valve suppliers in India. We have a wide range of industrial valves.
Also, check List of Valves Which are Use in the Oil & Gas Industry