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Implementing ball valves within industrial processes is an inextricable part of the fluid constraint. These valves have earned a reputation for their uncomplicated nature, user-friendly operation, and dependability. However, if you&#;re not familiar with the determinants that dictate their output, choosing the appropriate industrial ball valve China can be an overwhelming and arduous task.
Fluid management can be a complex process, and it involves the use of valves that play a crucial role in regulating the flow of fluids. This object can function as a full port or reduced port, which allows it to reach its maximum capacity. Port valves with full-size dimensions are designed to match the inner diameters of nearby pipelines. Standard port valves are also known as reduced port valves. They have a width of one-half of the pipe&#;s internal dimensions.
A reduced port ball valve with a nominal width of 1 inch can be used as an example. This valve can be operated using a ball with a diameter of 3/4 inches. This demonstrates the level of precision needed for effective fluid flow management. In this blog, we will discuss the eight questions that you need to ask to make the right choice when buying an industrial ball valve in China.
Ball Valves: Advantages and Categories
The usage of ball valves is quite everywhere in industrial applications, owing to their popularity in various fields like petrochemicals, water treatment, and many other areas. They are deemed preferable over other valve categories, presenting numerous perks that are too advantageous to overlook. The ensuing discourse scrutinizes the merits of ball valves and their assorted groupings.
Advantages of Ball Valves:
- Leak-tight seals:
Ball valves offer a leak tight seal, which guarantees that no fluid or gas can escape through the valve.
- Quick opening and closing:
When compared to other industrial valves, ball valves have a distinct advantage due to their ability to open and close quickly and precisely. This feature makes them highly suitable for applications.
- Durability:
The durability and long-term life expectancy of ball valves are a hallmark that sets them apart from other types of industrial valves. This type of valve is capable of enduring severe temperatures and pressures, thus making it appropriate for challenging and rigorous environments.
Categories of Industrial Ball Valve China
There exist multiple criteria to categorize ball valves, each with the distinct features that set it apart from others. Below are the most frequently used classifications:
Valve design is based on the movement of a ball.
- Floating valves:
Floating valves are designed with a structure that allows the ball inside the valve body to move freely without any restriction. The seat rings are accountable for securing the ball&#;s position while simultaneously maintaining the valve&#;s hermeticity upon ball closure.
- Trunnion-mounted valves
:
The implementation of fixed support or trunnion at the height and depths of the sphere ensures that its stationary position is sustained. This engineering approach affords supplementary reinforcement to the orb, rendering it apt for employment in contexts of heightened pressure.
Body style
There are various types of ball valves, each with its own set of distinctive features.
Single-body ball valves can either be made from one piece or two pieces.
Maintenance is easy with top-entry ball valves
To form a 3-piece valve, three sections are bolted together.
Ball valves with welded bodies offer a tight seal against leakage.
It is important to choose the correct design when choosing a ball valve.
Industrial engineers must make several crucial inquiries before buying ball valves. These questions will help you navigate the complex process of choosing the right valve for your piping system.
Here are eight questions to assist in making the appropriate choice:
What Is the Material of the Valve Body?
What is the valve&#;s size and pressure rating?
What Is the Type of Connection?
What type of valve actuator do I need?
What is the valve&#;s temperature range?
What is the valve&#;s flow coefficient (Cv)?
What are the valve&#;s end connections?
What certifications should the valve have?
What Is the Material of the Valve Body?
When it comes to selecting an industrial ball valve, the material of the valve body is an indispensable aspect that must be taken into account. The primary component of a valve is its valve body. It houses the ball and controls fluid flow. Valve bodies are made of common materials such as stainless steel, brass, and bronze.
Stainless steel is the most commonly used material for valve bodies in industrial applications. It is highly durable, resistant to corrosion, and can withstand high temperatures and high pressures. However, stainless steel can be expensive, especially if it has to be used for large valves.
Valve bodies are often made from brass and bronze. They are less expensive than stainless steel and can be used in low pressure applications. They are less durable than stainless steel, and they are more susceptible to corrosion.
Cast iron is another material that can be used for valve bodies. It is strong and durable, but it is not suitable for applications that involve high temperatures or corrosive fluids.
What Is the Size of the Valve?
It is important to take into account the size of the industrial ball valve when choosing one. There are many sizes of ball valves, from tiny 1/4 inch valves to larger 24 inch ones. The valve size will depend on the size and flow rate of the fluid.
The pipe&#;s size and fluid velocity are directly related to the flow rate of fluid through pipes. Although a larger valve allows for a higher flow rate, it can lead to greater pressure drops and energy losses. Selecting the appropriate valve size is crucial for maintaining fluid flow in your application. Additionally, the valve&#;s pressure rating is equally vital, as it must stand up to the pressures of any process it encounters.
What Is the Type of Connection?
The variety of connection is also a significant factor to consider when choosing an industrial ball valve. Ball valves can be connected using different methods, such as threaded, socket weld, or flanged connections. The type of pipe and pressure requirements of your system will determine the type of connection that you make.
Threaded connections are suitable for low-pressure applications and are easy to install. Socket weld connections are ideal for high-pressure applications and can stand up to high temperatures. Flanged connections are also suitable for high-pressure applications and are easy to install and maintain.
What type of valve actuator do I need?
The valve actuator serves as the pivotal element that controls the opening and closing mechanism of a valve. This vital component comes in various forms, such as manual, electric, pneumatic, and hydraulic, each providing a unique set of advantages and limitations depending on the operational requirements.The type of actuator you choose will depend on several factors, such as the valve size, operating pressure, and frequency of use.
Manual valve actuators are simple to operate and require no outer power source.
They are ideal for smaller valves or applications where the valve is rarely used. Electric valve actuators, on the other hand, are powered by electricity and are suitable for applications where the valve needs to be frequently operated or remotely controlled.
They are ideal for applications where a compressed air source is readily available and are often used in industrial settings. On the other hand, hydraulic valve actuators employ hydraulic fluid to run the valve and are fitting for high-pressure applications that call for precise regulation.
What is the valve&#;s temperature range?
The temperature range of the valve stands as another pivotal aspect to inspect when making a choice of the industrial ball valve. Different valves are designed to operate within specific temperature ranges, and exceeding these limits can cause significant damage to the valve and potentially harm the surrounding equipment.
For instance, if the valve will be employed in a high-temperature application, it is vital to opt for a valve that can withstand extreme temperatures.
The valve&#;s temperature range is specified by the manufacturer and can be found in the valve&#;s technical specifications.
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What is the valve&#;s flow coefficient (Cv)?
The flow coefficient (Cv), a standard measure of a valve&#;s ability to control fluid flow, is known as the flow coefficient. It can be used to compare different valves&#; flow capacities and is important when choosing an industrial ball valve. The Cv value can be determined by the size and shape of the valve and the internal design of the valve. It is the flow rate of water through the valve at a pressure drop equal to one pound per square inch (psi).
It is important to select a valve that has the correct Cv value in order to achieve optimal performance and avoid issues like excessive pressure drop. So, The manufacturer will usually specify the Cv value, and it can be found in the technical specifications.
What are the valve&#;s end connections?
The end connections of the valve refer to the way the valve is connected to the covering piping system. The type of end connection used will depend on the specific application and the piping system requirements. Common types of end connections include threaded, flanged, and welded connections.
Threaded connections are commonly used in smaller valves and low-pressure applications. Welded connections are often used in applications where a permanent connection is required and are commonly founded in industrial settings.
It is important to choose the right type of connection when selecting an industrial ball valve in China. This will ensure that it is appropriate for covering piping systems. The manufacturer will usually specify the end connections and these details can be found in scientific data.
What certifications should the valve have?
Selecting the appropriate ball valve for a specific application requires a complete ranking of their certifications. Different industries have their own set of regulations and standards to ensure that their products meet health and safety requirements. Therefore, it is crucial to determine the suitable certifications that a ball valve should have.
- ANSI certifications:
When you choose ball valves, it is important to consider the pressure and temperature ratings of the pipe flanges, which are determined by ANSI certifications.
- NEMA certifications
are the standards that define the design describes ball valves that can be electrically actuated.
- NSF certifications
are crucial guidelines for choosing ball valves in production services that produce food, drinks, and drugs.
It is important to verify that the ball valves selected have the required certifications for the fluid applications used in your facility. In this blog, we&#;ll explore in depth the importance of certifications in valve selection and the specific certifications required for different industries.
Conclusion:
Selecting the appropriate industrial ball valve is of utmost importance in verifying that your system operates efficiently and safely. By asking the right questions and considering factors such as material, size, connection type, pressure rating, temperature rating, flow rate, and type of ball valve, you can make an informed decision when choosing an industrial ball valve in China. It is crucial to select a well-respected supplier, such as EG Valves when you choose industrial ball valves. EG Valves is a respectable and well-known manufacturer and also supplier in this industry. They are also known for their high-quality products, reliable services, and reputation.
EG Valves is a well-respected manufacturer of high-quality ball valves that are durable, reliable, and efficient. So, The company offers a wide range of ball valve types, including floating ball valves, trunnion-mounted ball valves, top entry ball valves, and fully welded ball valves. Their valves are constructed using diverse materials like carbon steel, stainless steel, and alloy steel.
As a manufacturer of high performance and engineered ball valves, we are often asked about what industry standards affect ball valve products and what should be referenced when specifying and ordering. The answer to that question is not nearly as straightforward as with the gate, globe, and check valves that have historically been the primary go-to valves in refining. With the more common &#;rising stem&#; valve types, standards such as API 600, API 602, API 603, etc. have taken a lot of the guesswork out because much of the design and sealing methods are well defined. However, as ball valves become more prevalent due to better sealing and reduced emissions, reliance on standards alone is not sufficient. Assurance that the installed product meets process requirements relies on much more.
There are several standards that influence the design and performance of ball valves. At a basic level, ASME B16.34, ASME 16.10 and others govern the dimensions and wall thickness (among other things) of most all valves used in the refining and chemical industries. Standards like API 641 (emissions for quarter-turn valves), API 607 (fire testing for both &#;soft&#; and metal seated quarter-turn valves), and API 608 (requirements for metal ball valves generally up to NPS 24 and class 600 rating) guide the industry.
However, none of these standards address the suitability of sealing materials for individual processes. Since these valves are typically used in applications where sealing is critical to the process, there are several open questions that must be addressed when specifying ball valves.
- What is the pipe specification or process requirement?
This is almost always clearly stated and will help determine the body material of the valve.
- What is the valve process?
Valve &#;trim&#; material determined by valve process. Internal components must be compatible with the process to resist attack, and it must have the mechanical integrity to operate safely and reliably.
- What are the process conditions?
Because seat and seal material must be compatible with the process conditions, these must always be confirmed with the end user.
- What is the pressure / temperature?
Seat rating acceptability is determined by pressure & temperature.
Guideline Considerations for &#;Soft Seated&#; Ball Valves
By at least a 10:1 ratio, &#;soft seated&#; ball valves dominate the refining and chemical markets. Although this is evolving as the costs of metal seated valves come down, soft seated ball valves will likely continue to be the most cost-effective solution in relatively clean services under 450ºF.
There are a wide array of options for seating material in these valves. The vast majority used in the refining and chemical industry are based on a form of Teflon &#; / PTFE. Apart from the base material, there are molecularly enhanced versions and compounds filled with glass, carbon fiber and/or graphite. One problem that exists in many specifications for these types of valves is the vague term &#;RPTFE&#; which (not so simply) indicates reinforced PTFE. Without information on the type of reinforcement, this can be misleading. For example, if a request is made for RPTFE in a plant with HF Acid (which dissolves glass) and a valve with glass-filled PTFE is installed, the results will be very undesirable.
In addition, manufacturers offer seat and seal materials like PEEK, Nylon, PCTFE, etc. for specific process requirements. All have certain properties that, when combined with specific seat designs, create allowable maximum (and minimum) temperature ranges and differential pressure.
It is well past the scope of this article to provide an application guide to all these seat types, but if you&#;re involved with selection or specification of these seat and seal materials, here are some guidelines to consider:
- Always verify that the seat and seal materials are rated for the maximum or minimum design temperature, and the maximum differential pressure in the system where the valve is to be installed. All reputable manufacturers publish this information.
- If specifying reinforced PTFE seat material, note any material limitations or requirements around the &#;filler&#;.
- If automating, confirm the torque requirements of the specific seat material provided. This can vary greatly.
- Whenever possible, include the design temperatures and pressures in the specifications. This is especially important in cryogenic or other extreme conditions.
What is a Severe or Critical Service Application?
A very common question asked in the valve and automation industry is: what is considered a severe or critical service valve application? There are several groups, MSS in particular, that are working on a more objective standard to provide guidance on this question.
As it pertains to ball valves in the refining and chemical industry, the question becomes: when should a severe or critical service metal seated ball valve be considered? This is a rapidly expanding segment of the market that is widely misunderstood. The correct answer to this question is: when process requirements exist calling for ball valves that operate and seal in conditions outside the range of typical products, test protocols and industry standards. This can mean many things to many people, and one must take care to not simply throw money at a problem hoping it goes away.
Choose a Metal Seated Valve for These Applications
In the petrochemical, chemical, and refining industries, some examples of applications where metal seats would be the preferred choice are:
- Coking services
- High pressure hydrogen and gas isolation
- Catalyst handling
- Reactor isolation (manual and automated)
- &#;High cycle&#; ball valves
- Heater isolation or&#;
- Places where reliable tight shut-off is important and soft seated&#; valves will not function due to high temperature, pressure, wear, solids, etc. For example, ball valves that have a pressure rating Class 900 or above, or valves with a design temperature requirement exceeding 450ºF, could be considered a metal seat application.
It is important to understand that metal- to-metal sealing in ball valves is a misnomer. If uncoated metal balls and seats are in direct contact, they would be damaged due to galling when operated and would never seal well. In reality, it is the ball and seat coatings that provide the sealing and allow the valve to cycle without galling. These coatings are generally lapped for tight shut-off and must resist chemical and thermal attack from the process in which the valve is installed.
The key to reliability of &#;metal seated&#; valves in any process application is the selection of the right coating, and the lapping / grinding process to &#;mate&#; the sealing surfaces.
A Deep Dive into Modern Coating Technology
There is simply no &#;one size fits all&#; for &#;metal-to-metal&#; sealing. Coatings are extremely application dependent. There are literally hundreds of material options and combinations, although certain technologies are more common.
Some of the more standard coating options are:
- High Pressure-HVOF
- &#;Spray and Fuse&#;
- Cobalt Overlays
- Chrome Plating
- Surface treatments like Nitriding that are more of a surface hardening than a true coating.
All have their positives and negatives in terms of performance in given applications and cost. The Cobalt overlays (commonly referred to as Stellite&#;) and Chrome Plating are still widely used in ball valves, as well as other valve types.
The most common ball and seat coating in severe service is the HP-HVOF process in which the coating mechanically bonds to the substrate material. In this process, a robotically controlled &#;gun&#; creates high kinetic energy allowing the coatings to be applied in a compressive state. The mechanical bond created is > 12,000 PSI bond strength for carbides, 5,000 &#; 7,000 PSI for chrome oxide ceramic. Some downsides to this process are that even at the lowest porosity, there is still poor sealing on gas applications. In addition, any carbon content makes these coatings susceptible to oxidation.
In the spray & fused process, the ball and seat surfaces are coated with a relatively thick layer of hardening material, then the part is heated to &#;fuse&#; (similar to welding) the coating to the base material for the highest possible bond strength and lowest porosity. This process is best for small molecule gas and particles.
Finally, is the plasma coating process where the specialty coatings are brought to a very high temperature prior to being robotically applied to the metal. This again creates a good bond strength, and coupled with the ceramic-like materials applied, creates a very corrosion resistant surface.
In Conclusion
Ball valves have been around for many years and represent a very large portion of our industry, but they still require attention to detail and an understanding of the applications in which they will be installed. While there is no such thing as &#;zero leakage&#; in valves, by clearly defining the process objectives and properly specifying these products, the greatest reliability can be achieved.
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About the Author
Barry Hoeffner, Director of Quarter Turn Products at Ladish Valves has over 30 years experience in the Chemical and Refining Industries. As a Chemical Engineer, Barry brings a unique perspective to the Flow Control space. His focus for the years in the Valve Industry has been in application engineering and development of severe service and engineered ball valves
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