SIO manufactures top-quality ball valves that clients can freely customize. Ball valves are a form of shut-off valves that will control the flow or either gas or liquid. This can be done by using a rotary ball that has a bore. By turning the ball 90 degrees, the gas or liquid is blocked or allowed to flow through. They are known to provide stable sealing even when they are not used for a period of time. They also feature a longer lifespan. In addition, they have better resistance to contaminants making them a more popular choice among other valves.
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Ball valves are fast-acting quarter-turn valves that use a rotating ball in transferring media flow through a system. Thanks to their tight shut-off feature, they are gaining significance in multiple industries. They are used in oil and gas industries, petrochemicals, power industry, pipelines, and practically any application that requires fluid shut-off.
Ball valves come in different types and have different add-ons, which can be overwhelming to take in. Also, while ball valves are mainly used for on/off applications, some types have become useful for throttling applications. All of these make it challenging to choose which ball valve type best suits your application.
Since ball valves are so complex, we have broken down all the essentials to give you a better understanding of this valve type. This guide will help you determine which ball valve will deliver you desirable results.
Before buying a ball valve, it is essential that you understand the specific requirements of your application. This is for the ball valve to function efficiently, safely, and have a long service life. To guide you, here are the important factors that will help you select the right valve that will serve you for many years.
The characteristics of the process media have significant effects on the entire system, including how the ball valve operates. It is essential that you determine them to make sure you use the right ball valve for your application. The factors you need to take into account include, but are not limited to:
Ball valves may need to perform other functions depending on the application. The range of ball valves available means they are well-suited for a variety of operations.
For example, should the valve completely start and stop the flow or is it also used for throttling? Does it need to regulate or release system pressure? How much leakage can the system tolerate? How accurately should the valve be able to control the flow? Identifying the specific functions of your ball valve will lead you to the right type that will deliver safely and effectively.
The shut-off feature of ball valves is also used to manage hot and cold liquids. It is equally important you identify the temperature of the process media as this will help you choose the appropriate make of your ball valve. Different materials are used in the manufacture of industrial valves including stainless steel, carbon steel, PTFE, PVC, etc. Each one of them is fitted for specific temperature ranges.
The shut-off features of ball valves are designed to handle different pressures of liquid. It is important that you determine the pressure range that will flow through the ball valve. This allows you to choose the appropriate size and maximum pressure capacity to handle such an application.
Maintenance and cleaning requirements are also important since they affect the operation of the entire system. Is it easy to clean the valves? How regularly do the valves require maintenance? These questions help you determine whether the valves are ideal and practical for the overall application.
When choosing a ball valve, you also need to consider how well it will work with the other components of the system. For example, larger valves are capable of higher pressures but they are not suitable where there is limited space.
Other specific conditions refer to the nature of the operation and the required standards of the industry. For example, your application may need strict hygiene guidelines that would affect the function of your ball valve. Other conditions may include the following:
This is a stopper that only allows a 90-degree rotation. It is often used in industrial applications, such as petrochemical and chemical, plumbing services, human workstations, and other essential machinery to regulate flow accurately. It also functions as a safety feature as it ensures that the flow is completely shut.
A swing check provides a ball valve the function of a check valve. This prohibits media flow from moving back into the system.
An anti-static device prevents a buildup of static electricity due to valve friction. A static buildup is a fire hazard, particularly if the media flow is flammable.
A fire-safe design provides a back-up metal seat for the ball valve. This is useful, especially when the system temperature goes extremely high that can damage the soft seat. When the soft seat softens or melts, the backup seat will provide support to prevent leakage that could result to an accidental fire.
These dimensions conform to ASME standards that will make the valve easy to modify and replace with valves from other manufacturers.
A position indicator is used to indicate the direction of the flow. It is placed on top of the ball and is commonly used in multi-port ball valves. It is also used to ensure the proper alignment of a ball valve. In industrial processes, it is vital to have full awareness of valve operations to avoid damages and serious injuries.
A blow-out proof stem contributes to safe and smooth industrial operations. It is an excellent addition that ensures the valve stem will not fly or blow out when the ball valve is receiving too much pressure.
Before buying a ball valve, it is essential that you understand the specific requirements of your application. This is for the ball valve to function efficiently, safely, and have a long service life. To guide you, here are the important factors that will help you select the right valve that will serve you for many years.
Ball valves might serve the same function of providing a positive shut-off. However, they are not all the same and each is specifically designed to function with certain materials, pressure rating, temperature, etc. To help you understand which ball valve you need, here is a breakdown of the different ball valve types.
An electric ball valve is a type of valve that is automatically operated to provide a secure and safe working environment for operators. It is supplied with an electric actuator that will automatically control the opening and closing of the valve. It comes with an ISO 5211 industry-standard mounting pad to put the actuators in place.
Also known as a motor-operated ball valve, it is usually made from stainless steel, PVC, and brass and can either be 2-way or 3-way depending on its function. It is often used in process control plants to provide safe and reliable releasing and sealing of process media.
The highlight of using an electric ball valve is it is quiet, efficient, and non-toxic. It is also an economical solution for valve automation. Since it operates slowly when opening and closing media flow, a motor-operated ball valve reduces the risks of water hammer.
A pneumatically-controlled ball valve provides easy, safe, and secure operations to the system. This valve is equipped with an actuator that uses compressed air to control media flow remotely. The actuator, either spring-opened or spring-closed, creates torque to provide rotary motion so as to operate the ball valve.
Automatic ball valves, including the electric- and pneumatically-operated, are commonly used in plumbing, chemical fields, HVAC systems, and other industrial applications.
Using air-actuated ball valves promotes safety during the entire operation. Since they use air to function, these valves are safe to use, non-flammable, and are not vulnerable to short circuit. They are also ideal for longer use as they are not prone to overheating even when used excessively.
A manual ball valve is a hand-operated valve that uses a lever, gear, or wheel to open or close media passage. It is often made from stainless steel, carbon steel, cast iron, brass, and certain types of plastics.
Because of its durability, a manual ball valve is suitable for critical service conditions, such as high-pressure applications. It guarantees accurate releasing and blocking of media flow and allows you to control the flow easily and whenever you want.
Using a manual ball valve creates a low-pressure drop and is less prone to system wear due to lower velocity. It also provides high flow capacity since the operator can directly control the system flow.
There are two ways to manually control valves:
A lever handle is used to manually operate ball valves and indicate whether the valves are open or closed. A ball valve is open when the lever is aligned with the pipe, while it is closed if the lever is perpendicular to the pipe.
A lever handle is difficult to operate in larger valves, making it more suitable for low-pressure applications. This design promotes easy indication of the position of a ball valve, promoting safety and precise opening and closing of media flow.
A gear-operated ball valve is manually controlled into open and closed positions by turning a wheel or gear. It is usually made from metal so it can endure severe conditions and hazardous media. Using a gear makes it easier for a ball valve to open and close, making it ideal for highly-stressful applications.
A stainless steel ball valve is a type of valve known for its durability and excellent corrosion resistance, making it suitable for a spectrum of applications. These include severely high temperatures and pressures, extremely low pressures, and cryogenic applications. It is also useful in handling chemicals that could corrode other substances present in the system.
Because of its strength and high endurance, a stainless steel ball valve can work with different properties of liquid and gas flow and can guarantee a tight sealing with zero leaking. It is widely used in the oil and gas industries, petrochemical and chemical industries, power generation plants, and more.
Because of its many features, a stainless steel ball valve is the most cost-effective and reliable choice for industrial applications. It can handle the most demanding applications and requires less maintenance.
A forged steel ball valve is made from forged steel, which is an alloy of iron and carbon compressed under extreme pressure. This type of material makes ball valves hard and strong, making them ideal for an array of industrial services.
This ball valve is suitable for providing positive shut-off in severe working conditions. These include pipelines, processing plants, and other major industrial applications, both with critical and non-critical properties.
A major benefit of using a forged steel ball valve is it has zero to low flow resistance. It provides reliable sealing as the valve seat is usually made from PTFE elastomer, allowing the valve to provide positive sealing even under severe temperatures and pressures.
A cast steel ball valve is a valve made from different types of steel which gives it excellent strength and shock resistance. A cast steel valve is initially made from liquid state to metal to which valve components are molded and made.
Due to its strength, corrosion-resistance, and temperature tolerance properties, a cast steel ball valve can handle a range of pressures and temperatures. It is commonly used in major industrial applications such as petrochemical plants, refineries, and pipelines in oil fields.
A significant benefit of cast steel is its design flexibility that creates valves in different sizes and shapes. Therefore, it is ideal for customized ball valves as it can easily be formed and produced to meet specific requirements, especially unique designs and intricate shapes.
A cast iron ball valve is made from cast iron, a hard material that should not be bent. This material is made from 96% – 98% iron, 2% – 4% carbon, and some silicone. This type of ball valve is known to tolerate intense vibrations.
Since a cast iron ball valve has excellent temperature tolerance, it is used in extreme industrial applications with temperatures up to 2,100°F (1,150°C). It is also strong, but its maximum working pressure will depend on its size, pressure class, and type of end connections. It is often used in water and wastewater, oil and gas, and chemical applications.
The main advantages of using cast iron for ball valves include high-corrosion resistance and durability. Since this ball valve will be exposed to liquid with various properties, cast iron is excellent in protecting the valve from reacting to prolonged exposure to different flow media.
A trunnion mounted ball valve is a ball valve held in place with its extra anchoring system found at the top and bottom of the valve. With this feature, there is a significant reduction of friction and relief from excess pressure. This promotes safe and stable operation of the entire system and longer service life for the trunnion ball valve.
The bubble-tight sealing feature of a trunnion ball valve makes it well-suited for an array of industrial applications. These will include gas processing plants, LNG plants, petrochemical and chemical industries, and hydrocarbon processing.
The major advantage of using trunnion mounted ball valve is the guarantee of a safe and stable operation. It provides positive sealing with zero chances of leakage, which also helps in prolonging the lifespan of the ball valve.
A floating ball valve is a ball valve that does not have the extra anchoring system found in trunnion ball valves. This allows the ball to “float” instead of holding it in place. The ball moves down slightly depending on the pipeline’s flow pressure until it comes in contact with the opening. This creates a tight seal, preventing the media flow from passing through.
This type of ball valve has smaller diameters, making it suitable for low-pressure applications. It is commonly used in oil and gas, food and beverage, petrochemical, and hydrocarbon industries.
Using a floating ball valve ensures a really tight and strong shut-off as the pressure forces the ball against the downstream seat. This promotes a safe and effective working environment for both the operator and the entire system.
A double block and bleed (DBB) ball valve is equipped with three valves in one manifold or unit – two isolation valves and one vent valve. Since it serves the functions of three different valves, it reduces work during installation, cleaning, and maintenance.
A DBB ball valve is ideal in critical applications wherein equipment maintenance, repair, or replacement does not disrupt the entire system. It is often used in oil and gas operations, chemical applications, and industrial processing plants.
The importance of a double block and bleed ball valve is it maintains the integrity of the process media by depressurizing the area that needs work. It prevents contamination by providing a tight shut-off that guarantees safe and smooth operations of the rest of the system.
A full port ball valve provides unrestricted flow of the valve and is ideal for any application that requires free flow and positive shut-off. It has a large ball with a hole that has a similar diameter with the pipeline resulting in lower friction loss.
Also known as a full bore ball valve, it is widely used in applications where low flow resistance is important. It is also used in media flow that contains mixed solids and liquids where flow restrictions can separate materials that could lead to clogging and buildup.
A full bore ball valve provides a small pressure drop and maintains a consistent flow rate. This helps maintain the integrity of the ball valve so it can function effectively for a long time.
A reduced bore ball valve means it has a standard ball with a hole smaller than the pipe it connects which creates more pressure drop. It has a straight flow path wherein the ball valve becomes more restricted on the inside.
A reduced bore valve is ideal for applications where an increased pressure drop does not affect the entire operation. It is also used in situations where the valve size and cost are important factors.
The main advantages of a reduced bore is its compact size and affordable cost. When the pressure drop is not a concern, a reduced bore valve is often used since it provides the same function as the full bore valve.
A v-notch ball valve has either a “v”-shaped seat or a “v”-shaped ball designed to meet the requirements of piping. This allows the opening or cavity to open and close in a more controlled manner. This ball valve is also called a control valve since the flow velocity is controlled depending on the application.
A v-port ball valve is used in a range of industrial applications to open/shut or control media flow. These will include food and beverage processing, water treatment, bleach chemicals, waste processing, agricultural applications, and petrochemicals.
The highlight of a v-port ball valve is its robust construction to handle higher velocities of media flow. It controls flow rate efficiently and has less cavitation, corrosion, vibration, and noise.
A two-way ball valve is the most common ball valve that shuts off pressure flow in both directions. It has two ports or openings – the inlet and outlet ports.The ball in a two-way ball valve has a single straight hole to where gas or liquid passes through.
A two-way ball valve is commonly used in almost every industry that requires effective gaseous and fluid control. It is suitable for basic on/off applications but can also be used in complex flow controls.
This type of ball valve comes with a straightforward design, easy operation, and efficient functionality, which makes it safe, reliable, and effective for almost any application.
A three-way ball valve is a type of multi-port valve that consists of three ports or openings, one inlet port and two outlet ports. It provides a better solution for complex flow controls than a two-way ball valve.
Because of its reliable sealing and compact design, it is typically used in process applications in the oil and gas industries and power generation plants. It is also used in other industrial applications that need to divert pressure flow.
The structure of a three-way ball valve allows it to be cleaned, repaired, or maintained in-line, which means system operation can continue uninterrupted. It is also easy to operate and has low torque thanks to the special design of its stem. It allows the ball valve to completely open and shut quickly with its 90-degree turning feature.
A one-piece ball valve has a solid cast body installed as a single unit where the retainer keeps the ball and seal in place. This assembly type cannot be separated during maintenance or repair. But thanks to its single-unit design, it promotes reliable tight sealing and reduces the chances of the valve needing repair.
This assembly type is typically used in ball valves that require to provide positive shut-off at an economical cost. A one-piece ball valve is typically employed in light-duty applications that handle a non-critical environment.
The main advantage of a one-piece ball valve is its robustness and low cost. When the application is not demanding and does not need the valve to work excessively, this ball valve is an excellent choice.
A two-piece ball valve has a floating ball and a body that consists of two pieces that are joined together with bolts and flanges. The two-piece design has more variations when it comes to sizes and connection types compared to one-piece designs. It’s the most commonly used assembly for industrial ball valves.
It is widely used in low-pressure and low-temperature applications to maintain positive sealing. It is used in many industries, including the oil and gas industries, hydrocarbon processing, water and wastewater treatment plants, chemical applications, and more.
A significant advantage of a two-piece ball valve is It provides easier assembly and operation wherein the procedure, such as maintenance, can be performed in-line.
A three-piece ball valve consists of three components – two end caps and one body where the end caps are usually welded or threaded to the pipe. When an application requires heavy demands from the valve, this assembly type is more effective than the one-piece or two-piece design.
A three-piece ball valve is well-suited for demanding applications that involve different process temperatures, pressures, conditions, and flow rates. It is also used when an application has special requirements, such as sanitation, cryogenic applications, and piggable services.
An important benefit of having a three-piece design is it provides easy and quick access during valve maintenance without shutting down the process line. During the procedure, the main body area may be pulled out easily without removing the end caps. This allows convenient disassembly, reassembly, and servicing without performing major cutting to the system.
A top-entry ball valve has a ball assembled at the top part and consists of a bonnet and body. It is designed to function in critical service conditions and usually come with a fire-safe design, anti-static device, and a double block and bleed feature.
It is commonly used in high-pressure applications that require minimum disassembly during in-line maintenance. These include oil and gas industries, water services, chemical industries, and other general industries that require reliable sealing.
With its durability and high endurance to severe conditions, a top-entry ball valve provides a positive shut-off with no chance of leaking. The top-entry design allows simple and convenient in-line inspection, maintenance, and repair, which promotes safety and efficiency of the overall system.
A side-entry ball valve usually comes with a two-piece or three-piece body wherein the ball of the valve is placed at the side part. It is made from durable materials, such as stainless steel, carbon steel, or cast iron so it can endure demanding environments of different applications.
With its robust design, a side-entry ball valve is well-fitted for a variety of industrial applications. These will include extremely high pressures and temperatures, and severely low pressures and cryogenic applications.
The main benefit of a side-entry ball valve is it provides a safe and reliable working environment. Even in critical conditions, this ball valve can provide a positive shut-off. It may come with a double block and bleed function so system operation can continue without any disruptions during equipment replacement, repair, or maintenance.
A flanged ball valve has end connections that are in the form of flanges, which are connected using nuts and bolts. Flanged connections are the most used method of joining valves, regardless of the valve size and pressure level.
A flanged connection is commonly used in gas, petroleum, water, and transport services. It is also used in applications that deal with hazardous media, such as in the oil and gas industries, power generation, and petrochemical and chemical industries.
The primary benefits of using a flanged end ball valve include having a low-pressure drop, quick and easy turning operation, and positive sealing. All of these contribute to the integrity of the system.
A welded ball valve means the valve is welded to the pipe directly. The welding process provides a leak-proof feature that prevents any chance of leaking. The seal ring and spring are usually made from carbonized Teflon, allowing the ball valve to adapt to changes in temperature and pressure.
This type of connection is commonly used where positive shutoff of leaks is critical, such as high-pressure and high-temperature pipeline systems. It is also used to meet certain sanitation guidelines in the food and beverage industries and cosmetic industries.
A welded connection provides a compact casing, which promotes enhanced strength without compromising the weight. Since the ball valve has similar materials as the pipe, there are minimal chances of deformation and uneven stress caused by accidental and natural disasters.
There are two types of welded connections:
The welded end of the ball valve is in the shape of a socket, where the pipe is inserted and welded into the ball valve. This connection method is mainly used for small valves that don’t exceed two inches.
The pipe and valve ends are joined together and then welded to produce a connection. Both butt edges are slanted for jointing. This type of connection is suited for any valve size.
A threaded ball valve is a ball valve directly connected to the pipeline through pipe threads. This connection method is mainly used for small valves that are less than two inches with a pressure level of 1 MPa or lower.
Although the installation is simple, a threaded connection still needs to comply with certain standards to be effective. For example, the pipe and valve threads should be made observing the same standard so they can produce a proper connection.
Thread valve end connections are ideal for low-pressure piping systems and plumbing applications, such as in water and wastewater applications.
A significant advantage of a threaded connection over other connection types is it does not need small parts, like nuts and bolts to connect. This makes the threaded ball valve economical and easy to install. Moreover, the direct and compact connection of a threaded ball valve to a pipeline ensures minimum chances of leakage.
There are two types of threading – male and female threads, and parallel and tapered threads:
You can identify the gender of pipe threads by locating the threads. Male threads are found outside, while the female threads are found inside the hex nut.
Source: RG Group
Parallel threads have a similar diameter from both ends, which means they maintain a straight shape all the way down. Meanwhile, tapered threads have an increased diameter on the male end and a decreased diameter on the female end.
A metal-seated ball valve has a seat made of metal, such as Monel and 316 stainless steel. It is typically used in applications with extreme conditions. These could include high pressures and temperatures, low pressures and temperatures, and cryogenic conditions. It is also suitable for applications that deal with corrosion and erosion. It is mostly found in oil and gas industries, power generation, and refining plants.
Using a metal-seated ball valve means it can endure high temperatures up to 1,000°F and critical service conditions. It can also withstand hydraulic shock, extreme flashing, and abrasive process media. A metal-seated ball valve is designed to promote efficiency, safety, and longer service life for the ball valve.
A soft-seated ball valve has a seat usually made from thermoplastic materials, such as PTFE (polytetrafluoroethylene) or NBR (nitrite butadiene rubber). It provides positive sealing with its quick-acting 90-degree rotation with low turning torque.
A soft-seated ball valve is well-fitted for applications wherein chemical compatibility is critical and positive sealing is important. It works well with different types of media including solvents, gas, water, acids, methane, oxygen, ethylene, etc. The properties of the soft seat do not react to the chemical characteristics of the media flow.
The advantages of using a soft-seated ball valve include its simple and lightweight design, easy and convenient operation, and affordable cost.
A high-pressure ball valve is designed for more durability, safety, and reliability to withstand high-pressure applications. It is made from robust materials, such as stainless steel and carbon steel.
A high-pressure ball valve is equipped with accessories to increase its efficiency and reliability. These will include an anti-static device, fire-safe design, extended stem, etc. It is usually manually-operated for a more precise shut-off, but can also be supplied with actuators if automation is required.
It is widely used in service conditions that deal with extreme pressures and temperatures and corrosive and abrasive media. These will include oil refineries, hydrocarbon processing, manufacturing of chlorine, cosmetic industries, power plants, and more.
Since a high-pressure ball valve is highly durable and can endure different media flow properties, it can guarantee positive sealing with absolute zero leaks. It is a very reliable way to ensure that all system operations go smoothly. It promotes a safe, secure, and effective environment of the entire application.
A high-temperature ball valve is engineered to endure demanding services from various high-temperature and highly-abrasive applications. It is designed to give the ball thermal expansion without damaging, even at severe temperatures. The valve seat sealing ring is made of various metal sheets on both sides for enhanced durability.
Because of its excellent temperature tolerance, a high-temperature ball valve is used in almost any industry. It is suitable for demanding services in petrochemical, petroleum, wastewater and other related services that involve slurries and media containing solids.
A high-temperature ball valve features both the functions of soft sealing and metal sealing. This means that the ball valve can regulate or control the media flow whether it has a relatively low or extremely high temperature.
A cryogenic ball valve is a type of ball valve that is specifically designed to handle applications with extremely low temperatures. It has an extended stem and bonnet that position the stem packing on top of the cryogenic fluid. This provides an area of warmer vapor to insulate the stem seal from the effects of cryogenic conditions.
It is widely used in applications dealing with Liquefied Natural Gas (LNG) and Compressed Natural Gas (CNG). It is also used in other cryogenic services, such as tank applications, low-pressure trailers, and cryogenic pumps and pipelines.
A cryogenic ball valve maintains a tightly closed position to keep cryogenic media contained securely and safely. It ensures a positive shut-off and typically has a large flow diameter to provide quick opening and closing times.
A fire-safe ball valve is a spring-loaded ball valve that is thermally actuated. It is made up of a fire-safe seating surface, graphite body seal, and stem packing that will prevent internal and external leakage. In case of an accidental fire, the ball valve will automatically close and obstruct the media flow.
A fire-safe ball valve is widely used in applications that deal with severe service conditions and hazardous process media. These include chemical process lines, high-pressure applications, high-temperature medium, cryogenic services, and fugitive emission applications.
The fire-safe design guarantees the operational integrity of the valve during a fire. It also promotes reliable operations and safe working environments for the system, operator, and other personnel.
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