The Leading Manufacturer and Supplier of Ball Valves

Apart from the usual two-port ball valves, there are also multi-channel ball valves.

They can either be:

• 3-way (most common)
• 4-way
• 5-way
• 6-way

Rarely will you find ball valves with more than six channels?

Here is all you should know:

Side Entry Ball Valve

This type of ball valve has its ball assembled from the side. Usually, it is made in either two or three pieces of the body.

Each part, or piece, is assembled using a stud or a bolt. The assembly is similar to joining two pieces of flanges.

Notably, side entry ball valves are made from forged metal. Each piece is developed independently, and then later, the pieces are joined together.

Some advantages of side entry ball valves include:

• Easy assembly and alignment
• Minimal defects

Top Entry Ball Valves

Top entry ball valves have their balls assembled from the top side. Unlike the side entry ball valves, it is made from casting metal.

You can compare these valves to a globe valve which has a bonnet and a body. Top entry ball valves have one body.

Due to the casting design of these ball valves, the valves need to undergo NDE tests to ensure that they have no defects.

Also, they require minimal disassembly. Due to this feature, its use is preferred in high-pressure systems.

An outright advantage of the top entry valves is that they are less susceptible to leaks. It is because their design permits for minimal thread connection.

Bottom Entry Ball Valve

Bottom entry ball valves are also referred to as filling valves. They have an arm and afloat and are designed to fit cisterns.

Their operation is relatively straightforward. It is open and closes with the aid of an arm, a ball, and a diaphragm which cuts off the water supply.

Some of the most common configurations include:

One-Piece

The installation of a one-piece ball valve is as a unit. The retainer holds the ball and the seal.

Typically, one-pieces ball valves are threaded. These types of ball valves are firmly fixed to the pipes using the threads.

Notably, the retainer has to secure the entire joint between the pipe and the ball valve. So that the joint does not wear out unevenly.

These types of ball valves are inexpensive and are generally not repaired.

Two-Piece

Two-piece ball valves have two separate body parts with flanges. Notably, these parts are easily assembled. Their assembly simply involves joining the two parts with bolts (for flange design).

Also, their different design makes servicing the valves easy. What’s more, the entire servicing procedure can be done in-line.

Usually, two-piece ball valves use floating balls to regulate media flow.

One drawback of the two-piece ball valves is that the tightness of the joint can be altered by force and pressure. Hence, they are susceptible to leakages.

Three-Piece

A three-piece ball valve consists of three main parts, a body, and two end caps. The end caps can either be threaded, flanged, or welded.

Maintaining a three-piece valve is easy, making them preferable for applications that critically require valves. Assembling and disassembling the three-piece valves is relatively easy.

The 3-piece ball valves are majorly used in manufacturing facilities for the following reasons:

• They are easy to disassemble for maintenance.
• They come in complete port design; hence they do not hinder flow.
• Unlike the two and one-piece ball valves that may require entire replacement, 3-piece valves only require the replacement of worn-out parts.

Three Piece Ball Valve

The top advantages of three-piece ball valves are that:

• They are cost-effective in the long run since they do not require entire replacement.
• They are easy to disassemble and reassemble.
• There is no need for line shutdown during replacing the various parts (seats and seals majorly).

Ball valves come in different types.

First, ball valves can be classified in terms of the ball port orientation and the number of ports, as below:

• Full-port Ball Valve
• Standard (Reduced) port Ball valve
• V-port Ball Valve
• Multi-port Ball Valve
• True Union (Trunnion) Ball Valves
• Vented Ball Valves

Alternatively, the ball valves can be grouped in terms of their connection type as follows:

• Threaded (Standard) Ball valves – Which can either have male or female threads.
• Flanged Ball valves.

Also, ball valves can be classified according to their operating mechanisms. These include:

• Manual Ball Valves
• Hydraulic Ball Valves
• Pneumatic Ball Valves
• Electric Ball Valves

Lastly, ball valves can also be grouped as per the number of pieces:

• One-piece ball valves
• Two-piece ball valves
• Three-piece ball valves

Floating Ball Valve

Notably, the floating ball is the most common design in ball valves. As the name suggests, the ball is floating, i.e., not fixed to the stem.

Consequently, it offers extensive freedom.

In floating ball design, a seal is created using the upstream pressure, which pushes the ball back against the downstream or rear seat.

Floating  Ball Valve

Trunnion Ball Valve

Unlike in the floating ball design, a trunnion design features a pin that holds the ball in place to prevent it from being dislodged.

This design is ideal mainly for high-velocity piping systems.

Notably, the ball in the trunnion ball valve is specially segmented.

The ball is supported with a shaft on one side and another shaft or post on the opposite side.

The shaft can either be separate or joined to the ball.

Trunnion Ball Valve

Lastly, there is little friction between the ball and the seal of the trunnion ball valves.

Ball valves feature various operating mechanisms. Lets’ look at the different working mechanisms.

Manual

The valve is turned on or off by manually rotating the handle at 45 degrees angle. Notably, when the valve is at a 90-degree angle, it is closed.

On the other hand, when the handle is parallel to the pipe, the valve is open.

Electric

For an electric operation mechanism, an electric actuator is fixed directly to the stem of the ball valve.

The actuator can cause a quarter of the stem.

This type of operation mechanism allows for remote control of the ball valve.

Also, the ball valve will be more efficient since it will be either fully closed or fully opened.

Hydraulic

The hydraulic operating mechanism is somehow self-sufficient.

This operation does not require any external pressure or electricity.

The opening and closing of the ball valve are entirely dependent on the pre-determined flow, level, or pressure.

Pneumatic

Like the electric operating mechanism, the pneumatic mechanism features actuators attached to the stem of the ball valve.

Commonly, pneumatically controlled ball valves employ a rack (linear gear) and pinion (circular gear) mechanism.

First, linear motion is achieved by attaching the rack to a piston pushed by compressed air.

The piston pushes the rack, which in turn pushes the pinion resulting in a circular motion. Since the pinion is attached to the stem, the circular motion causes the opening or closing of the ball valve.

Spring-loaded

Spring-loaded ball valves mostly feature springs and other actuators (primarily electric) for regulating media flow.

Commonly, they are used for fail-safe reasons or energy conservations.

Its operating mechanism is that the spring triggers the closing or the opening of the ball valve while the actuator holds the stem in place.

The common parts of all ball valves include:

1. Valve Body – The part that contains all the components of the ball valve.
2. Rotary Ball – It acts as the barrier that permits or blocks media flow.
3. Seats – They lie in between the body and the ball. They offer support to the ball and, at the same time, create a seal.
4. Stem – Usually attached to the rotary ball to control its movement.
5. Packing – Located around the stem. It offers a seal that prevents the fluid from escaping.
6. Bonnet – It hosts both the packing and the stem.
7. Handle or actuator – Located on the outer part. It is attached to the stem to control the movement of the stem, which in turn controls the rotary ball.

Parts of a Ball Valve

For versatility, ball valves are manufactured from a range of materials. The materials commonly used are as follows:

Polyvinyl Chloride (PVC)

As many refer to it as plastic, PVC is among the popularly used materials to manufacture ball valves.

PVC is flexible and smooth. Consequently, it allows for easy movement of the ball valve’s parts.

CPVC

CPVC is simply chlorinated PVC.  This additional property makes it tolerant to high temperatures. Thus can be used to manufacture ball valves used to transport hot media, such as hot water.

Bronze and Brass

Both bronze and brass are metal alloys, with each having copper.

Notably, they are used for ball valves designed to operate under medium or low-pressure conditions.

Also, they have a significant level of corrosion resistance.

Stainless Steel

Most ball valves intended for use in the food, beverages, and pharmaceutical industries are made from stainless steel.

It is because stainless steel is less susceptible to contamination.

Also, stainless steel has bot high corrosion resistance and durability.

Iron

The popularity of iron in making ball valves lies in its ability to withstand a wide range of temperatures and pressure.

However, it is not flexible compared to other materials such as PVC.

Stainless steel ball valves differ from brass ball valves in 4 main ways:

1. First, stainless steel ball valves have a higher price tag compared to brass ball valves.
2. Additionally, unlike brass ball valves, stainless steel ball valves usually have FDA approval. Brass ball valves can only get FDA approval if the brass used is lead-free.
3. Also, brass ball valves are more accessible to weld compared to steel ball valves. Brass ball valves are directly welded, unlike steel ball valves which mostly require you to break down its oxide layer.
4. Lastly, stainless steel all valves have higher corrosion resistance as compared to brass ball valves.

Despite the differences, both ball valves will efficiently perform their roles when applied in the right environment.

Brass Ball Valve

Stainless Ball Valve

The working principle of a ball valve is centered on its various parts.

The rotary ball has a hollow that permits media flow. With a quarter turn on the handle, the stem moves, resulting in the rotary ball’s movement.

When the hollow is in line with the flow, the media will be allowed to flow. If the ball’s hollow part is not aligned to the media flow, then the flow will be obstructed.

Ball valves are commonly used:

• As on/off stop-valves since they offer a bubble-tight shut-off.
• You may use it in gaseous, air, vapor, and hydrocarbon systems.
• It is n instrument tubing to connect instruments.
• Another use is in high temperature and pressure conditions, especially the metal seated valves.

The advantages of ball valves include:

• The packing seal lasts longer since the stem is not turned multiple times, i.e., only a quarter-turn is required.
• Full-bore balls offer zero flow resistance, with the other bore orientations offering minimal flow resistance.
• jmmIt is easy and fast to operate the ball valves since a 90-degree turn is enough to close or open the ball valve.
• Ball valves have a simple structure and are relatively small in size, making it easy to disassemble and reassemble them for repair and maintenance.
• Ball valves are versatile and have a wide range of applications.

Ball valves also have few disadvantages, including:

• Some types of ball valves, such as one-piece ball valves, may be challenging to clean, resulting in contamination.
• Generally, ball valves are poor when it comes to throttling.

• Generally, ball valves can be installed with your desired orientation. However, you will be forced to install larger ball valves with actuators vertically.
• Before installation, ensure there are no defects on the part of the ball valve. Also, check what material the valve’s seat, ball, and body are made from.
• Ensure that the ball valve’s pressure rating is in line with the system’s pressure rating.
• Also, the temperature rating of the valve should be ideal for the application.
• Check that the ball valve’s connection type (threaded, flanged, or weld) is compatible with the piping system.
• If the ball valve needs welding, complete all the welding work before installing and clean any welding residue.
• After ensuring the ball valve is clean, clean the pipe thread or flange end to be connected to the ball valve. You can use mild detergent and water if necessary.
• Support the valve to ensure there is no strain caused on the piping system.
• You may need to install a pipe union for 2-way and 3-way valves to allow for easy maintenance.
• For threaded connection, insert the male end to the female end and tighten. You can use a sealant if necessary.
• For flanged connection, tighten one bolt at a time. It is to apply even pressure, consequently forming a seal.
• After completing the installation, ensure the valve is good to go by turning it on completely and closing it multiple times.

• Clean and repair the ball valve at least once a year
• Ensure you activate the ball valve once a year to prevent it from getting stuck
• Do not use the ball valve for throttling. Instead, you should fully open or fully close it.
• Before maintaining the ball valve, ensure you relieve the system pressure.
• Ideally, you should replace valve seals and seats by removing the endplates. Check that you used only the approved lubrication for the seals.

Some of the most common end connections include:

Threaded

A threaded connection is the most common end connection since it offers a streamlined and compact connection between the ball valve and pipe.

Ball valves can either have male or female thread end connections.

Regardless of the type of thread (tapered or straight), they must adhere to specific standards. These standards are:

• National Pipe Thread Tapered (NPT) – This is the US standard for tapered threads used in fittings and pipes.
• British Standard Pipe Taper Threads (BSPT) – It is similar to NPT with only a variation in the angle of the thread flanks.
• British Standard Parallel Pipe Threads (BSPP)

Notable tapered threads form a tighter seal compared to the straight or parallel threads. As such, you may need to use a soft seal in the parallel threading connection.

Flanged Connection

Flanges are also a popular end connection for ball valves.

Flanged connections adhere to the standards set by the American National Standards Institute (ANSI) and the American Society of Mechanical Engineers (ASME). Other standards are by the DIN and SAE.

The most common flange connection used in ball valves is the four-bolt flanges.

Weld Or Soldered

Ball valves can also be welded to the pipe. The common types of weld include:

• Socket weld – Where the pipe is inserted into the ball valve’s socket and welded.
• Buttweld – Typically used for small size ball valves, less than 2 inches in size.
• Soldered – Commonly used in residential plumbing and is similar to socket weld. The only difference is that in this case, the connection is soldered, not welded.

Push-in

Push-in end connection is mainly used in ball valves used in residential plumbing.

Ball valves with a push-in end connection have an O-ring slightly smaller than the pipe’s outer diameter. Consequently, when the pipe is inserted into the ball valve, the o-ring gets stretched around the pipe, forming a seal.

Barbed Hose

Ball valves with barbed hose end connections feature long end connections with barbs on them.

The hosepipe is then stretched over them, forming a connection.

Notably, this type of connection is used for low-pressure systems.

Note: Ball valves with thread end connections can also be attached to the pipe using unions or connection nuts.

All valves’ temperature and pressure ratings vary depending on their class classifications.

Typically, a ball valve can operate under a minimum temperature of -55^oC to a maximum of 300^oC.

A ball valve may have a pressure rating of up to 2250 psi depending on the end connection type and the valve’s body material.

Globe Valve VS Ball Valve

The table below gives out the main distinctions between ball valves and globe valves.

Although ball valves are durable and require minimal maintenance and repair, you may need to carry out repairs once in a while.

Below are some tips to guide you as you repair your ball valve:

• First, you need to shut off the media supply to the affected area to avoid wastage.
• Familiarize yourself with the fitting the valve uses and remove it.
• Proceed to disassemble the parts orderly to ease the reassembly process.
• Meticulously inspect each part, placing keen attention on wear and tear, stiffness, or any signs of leaking.
• If only one component is damaged, you can proceed to replace it.
• However, if multiple components are damaged or damages are hard to visualize, you should preferably replace the entire ball valve.
• You will then reassemble and fix the now repaired old valve. Alternatively, you will fix a new ball valve.
• Lastly, turn back on the media supply and ensure the valves are fully functional.

There are some considerations you need to make before purchasing an industrial ball valve. We will group this into two: Product specifications, and supplier considerations

Under product specifications, you will consider:

1. Materials – The ball valve material should not be reactive to the media that will flow through it.
2. Applications – Ball valves are majorly used as shut-off valves and not for throttling purposes.
3. Actuation – Industrial applications may need automated actuators as opposed to domestic applications, which will perform quite okay with manual handles
4. Temperature and pressure ratings – The ball valve should operate efficiently under the prevailing temperature and pressure in the piping system.
5. Media – The ball valve should be able .to to control the media (gas or liquid) flow efficiently.
6. Life expectancy – Ensure that the ball valve will be operating for a long time. You can check the ball valve’s warranty period to estimate the lifespan.
7. Cost – How much a ball valve costs should also be at the back of your mind. Do not overstretch your budget.

Here, you will be concerned with:

• Where the supplier sources their material.
• Whether the supplier offers a discount on bulk purchase,
• The company’s authenticity, concerning how long it has been operational.
• The testing and quality assurance that the ball valves undergo.
• The certifications that the supplier has.
• After-sale support that the supplier offers.
• The delivery time upon purchase.

Below is a comparison table showing the difference between an actuated valve and a solenoid valve:

Rangeability is the flow rate (maximum to minimum) that the ball valve can control. It depends on the design and the actuator of a brass ball valve.

To determine the rangeability, you divide 100 by the non-accuracy level (%) of the valve. For example, a valve that is not accurate at 10% stroke has a rangeability of 10:1.

The higher the rangeability, the less sensitive the closing element is when it is near closed and more sensitive when the valve is open. It enables the valve to control a broader range of flow rates.

Notably, the highest rangeability in ball valves is in the v-notched ball valves, 200:1.

The ball valve size is usually indicated on the body, usually in nominal diameter (DN) or inches. For example, DN20 is equivalent to 34 inches.

There are two main common types of ball valve handles:

• Lockable Handle – That can be locked using a padlock or any other locking equipment.
• Ball valve Handwheels – These are circular handles, similar to steering wheels.

For standard valves with manual handles, you will know if it is opened when the handle is in line with the pipe. If the handle is at a right angle, it means the ball valve is closed.

Spring actuated or spring-loaded ball valves use a spring to open and close the ball valve.

A spring-loaded valve also has either an electric or a pneumatic actuator to hold the valve in place once closed or opened.

Usually, spring-actuated ball valves are used as a fail-safe mechanism and for energy conservation.

Commonly, ball valves will fail due to:

• Damaged seals
• Presence of debris in the valves
• Poor fixing of the ball valves
• Passing media that corrodes the valve
• Failure to occasionally maintain the ball valve

An essential role of the valves seats is to provide a seal, thus making the valve leak-proof. Valve seat materials can either be fluoropolymers or metals.

The material you will choose for the valve seat will depend on:

• Operating conditions, i.e., pressure and temperature.
• Desired operating torque
• The fluid being passed on the valve

You can choose from the below primary materials:

• Carbon
• Metals
• Polyether ether ketone (PEEK)
• PTFE
• Carbon fiber filled PTFE
• Acetal
• Ultra-high molecular weight polyethylene (UHMW)

These types of ball valves have soft seats made from thermoplastic materials such as PTFE. They offer a tight seal and are compatible with most chemicals.

However, soft seats can break down when the fluids being passed are abrasive or dirty.

Soft Seated Ball Valve

Unlike soft seats, metal seats can withstand high temperatures and adverse conditions. They can resist abrasive fluids, severe shock and flashing, and corrosion, among other states.

Also, they can be hardened by applying coatings such as chromium carbide, spray coating, tungsten carbide, etc.

Metal Seated Ball  Valve

Below are some of the important quality certification s ball valves ought to have:

• National Electrical Manufacturers Association (NEMA) certification – For electrically actuated ball valves.
• ANSI/ASME certification – This prescribes the pressure and temperature ratings for various flanged ball valves.
• National Sanitation Foundation (NSF) certification – Indicates if the ball valve is suitable for use in the food and beverage industry.

The lining or coating in the lined ball valves is non-reactive. As such, the lining protects the valve from exposure to corrosive fluids.

Also, it prevents any contamination of the fluid by the ball valve’s body material.

Lastly, it improves the flow by reducing any friction.

The specifications for the various ball valves vary. Outlined below are some of such specifications:

• For Flanged ball valves – The specifications include ANSI/ASME B16.5 and DIN 1092-1/ISO7005 standards.
• For NPT threaded ball valves – Specifications are defined by ANSI/ASME standard B1.20.1
• For BSPP threaded ball valves– Specifications are defined by 1S0 228-1:2000

Water hammer occurs when fluid flow is abruptly disrupted leading to excessive pressure build-up. Excessive pressure can result to damage or even bursting of the system.

To prevent water hammer, you can do the following:

• Install a water hammer arrestor to absorb the excess pressure and reduce the shock impact.
• Install a pressure regulator before the valve to check the pressure
• Increase the diameter before the valve to reduce pressure.

The valve positioner is equipment designed to improve the valve’s sensitivity and precision. It is commonly used in ball valves with electric actuators.

Simply put, a valve positioner amplifies electrical or pneumatic signals by adding its pressure to the signal.

Valve positioners can be pre-installed in a ball valve by the manufacturer. Alternatively, you can buy it separately.

If the valve positioner comes separately, it comes with a braided connection or a mounting kit for installing it.

The prices of ball valves vary depending on:

• Valve’s material
• Size
• Actuation
• Type of ball valve