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Before selecting an engineered solution for any fluid control application, it is important to understand the unique application and overall value provided by each ball valve. Ball valves come in a variety of styles, materials, and drive types, each of which provides different results.
This is a guide to help you understand what you need to know to ensure that the correct type of valve is used to execute the project to improve operational efficiency.
How does the ball valve work? The ball valve is a right-angle rotary valve that uses a ball with a hole to control the flow of the medium. This hole is called a port or orifice, and when opened, it aligns with the valve body to allow flow.
The ball is contained in the valve body and is held in place by two cup-shaped seals commonly called valve seats. To allow the medium to flow through the valve, rotate the ball 90 degrees to align the port parallel to the valve body. To close the flow, the ball is rotated backwards so that the port is perpendicular to the valve body. These rotations (called cycles) can be triggered manually by using a handle or automatically by using pneumatic, electric or hydraulic actuators.
Let's start with the two-way ball valve used for traditional on/off control. These are the most commonly used and lowest cost ball valve types. These valves are ideal for a variety of original equipment manufacturer (OEM) and end-user applications, including testing, fluid filling, dosing, and discharge.
The following are the advantages and disadvantages of this ball valve:
Advantages: It can be cycled quickly (open or closed), especially pneumatic or hydraulic drive.
Advantages: Provide effective long-term sealing for medium and low pressure applications.
Disadvantages: Not suitable for applications requiring precise control of medium flow: only suitable for on/off control.
Disadvantages: The design is not suitable for repairability.
The three-way ball valve is the most popular type of multi-way ball valve. This style is usually used for applications that have multiple media sources or redirect the media in two different directions. According to the flow direction, the three ports are designated as one outlet and two inlets, or one inlet and two outlets. They are designed for applications such as process control, sterilizers/autoclaves, and bottling and dispensing.
Advantages: the same fast cycle as the two-way ball valve.
Advantages: the ability to provide mixed media types (select valves).
Advantages: Provides the ability to divert the flow of media (diverter valve).
Disadvantages: more expensive than two-way valves.
Disadvantages: Most models are only used as a diverter valve or selection valve, and cannot completely shut off the flow of the medium.
The three-piece ball valve has a main body and two pipe connectors, which are threaded or welded to the pipe. The 3-piece design allows the valve to be easily disassembled and repaired without removing the pipe connector from the pipe. Three-piece ball valves are ideal for high cycle and/or heavy pressure applications that experience a lot of wear.
Advantages: easy to disassemble and maintain.
Advantages: Provide a variety of connection types.
Advantages: Long-term cost savings can be achieved in applications susceptible to extreme wear.
All ball valves are powered manually or by automatic energy sources. The actuator or manual handle is installed on the valve stem and acts as a control mechanism to open or close the valve. Using the power supply that is right for your project, you can reduce maintenance costs, increase uptime, and maximize safety.
Pneumatically actuated ball valves use compressed air to automatically control the medium. Pneumatically actuated ball valves are usually used in OEM equipment that can obtain compressed air, such as liquid filling equipment or automotive liquid filling systems. They also exist in factories and manufacturing facilities.
Advantages: resistance to overheating and humidity.
Advantages: The size of the double-acting model is much smaller than the industry standard electric actuator.
Disadvantages: need compressed air or gas to run.
Disadvantages: Short cycle time will increase the risk of water hammer.
Other key considerations for pneumatic valve actuators include:
Electric ball valves, also known as electric ball valves or rotary ball valves, are the most popular choice for ball valve automation. This type of ball valve uses an electric motor to operate the ball valve and control the flow of the medium. OEM as well as industrial and commercial applications use electric ball valves.
Advantages: The slower cycle time is less likely to cause water hammer.
Advantages: No need for compressed air operation.
Advantages: Rotation and linear options are provided.
Disadvantages: Compared with pneumatics, the cycle time is slower.
Disadvantages: Fail-safe options are not widely available.
Other key considerations for electric valve actuators include:
Hydraulically actuated ball valves are similar to pneumatic actuators, except that they use pressurized fluid instead of air or gas. Fluid (water or oil) is delivered to one or both sides of the piston to produce movement. Due to the use of incompressible fluid instead of compressed air, hydraulic actuators can provide much greater force/speed than pneumatic actuators.
Advantages: It can provide greater force than pneumatic actuators.
Disadvantages: easy to leak hydraulic oil and reduce efficiency.
Disadvantages: prone to pollution problems.
Disadvantages: Need a lot of operator support.
Due to its versatility, ball valves are one of the most widely used industrial equipment. When choosing the right option for your intended application, each ball valve and actuator type has advantages and disadvantages that need to be considered. It’s best to determine your constant needs before deciding which additional features are best for your application.
—George Packard (George Packard) is Gemini Valve's vice president of marketing, Gemini Valve is an American family-owned manufacturer of automatic and manual ball valves.
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