Learn how to specify a valve for your application

Learn how to specify a valve for your application

Learn About Valve Options

Mounting: The standard mounting types in the industry are typically ANSI 150 # and DIN drilling, commonly used for heavy-duty and high-performance valve models. For applications that require quick clamps, they work well for pressures up to 30PSI (2bar) and port sizes of up to 10 inches. For VB ball valves ranging from 1 inch to 3 inches, options for NPT, socket weld, and tri-clamp connections are available. 

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It is important to note that some valves may include blind tapped holes, which can create challenges if the valve needs to align with existing blind tapped holes. An alternative solution is to choose oversized flanges that permit through holes. For valves serving regular duty, relying on ANSI and DIN bolting specifications might be excessive, and other bolting patterns can be explored.

• No Clamps
• ANSI 150#
• Tri Clamps
• Gemco Mounting
• DN PN10
• Cover Clamps
• NPT
• Socket Weld Connections

Seats: Using metal seats is advisable for highly abrasive materials, as they typically outperform the more common reinforced Teflon seats in terms of lifespan and tolerance to higher temperatures. Metal seals can withstand high heat but the shut-off sealing performance is limited to dust tight, ANSI class IV, or ANSI class V standards. Reinforced Teflon seats are capable of operating up to 450 degrees F (230 C) and provide superior Class VI shut-off capabilities.

• Teflon
• Metal
• Inflatable Seat

Service: For most gravity-feed powder applications that are not subject to vacuum or pressure, dust-tight seals are commonly employed.

• Dust Tight
• Liquid Tight
• Vacuum
• Low Pressure
• Pressure
• High Pressure

O-Ring Material: The typical choice for O-rings is silicone, while Viton and Teflon encapsulated silicone are preferred for specific chemical resistance requirements. Other material options are available upon request.

• Silicone
• Viton
• Teflon encapsulated

Operators (Actuators): For optimal reliability, speed, weight, and cost-effectiveness, double-acting pneumatic operation is the favored choice. However, levers and gear drives are also available. Actuation options include pneumatic operators in double-acting or single-acting (spring return) fail-safe modes, though spring return models tend to be slower, bulkier, and heavier.

As is typical with quarter-turn valves, options for actuation include levers, gear drives, or chain operators. Both pneumatic and hydraulic operators can be configured for double-acting or fail-safe purposes. Considerability must be given to price, reliability, and speed when determining the best pneumatic operation. In instances where solid materials are handled, a higher safety factor is utilized when calculating seat torque requirements, typically being 1.5 instead of the standard 1.25 used for liquid and gas valve calculations.

For solid materials that may set or harden, oversized actuators and specially designed discs that can break through the hardened material are often employed. Actuators are generally designed for 80-PSI (5.3 bar) pressure, thus adjustments must be made if the available supply air pressure is consistently above (100 to 120PSI) or below (40 to 60 PSI) this standard.

When exploring fail-safe operations, spring return actuators are the common choice. When such an actuator is implemented, it is often designed to account for the spring as well as the unseating, running, and seating torque necessary for the valve’s operation. This can potentially lead to complications regarding weight, space, and additional costs. An alternative fail-safe mechanism is employing a double-acting actuator with a suitably sized pneumatic accumulator to close the valve in the event of pressure loss. In this case, a pressure switch will engage the accumulator to operate the valve.

• No Operator
• Manual Lever
• Air - Double acting
• Air - Spring Return

Control: Commonly, single solenoid (spring return) valves are configured to fail closed upon loss of control signals. Fast acting quarter-turn valves are especially well-suited for solid flow control. Both pneumatic (3 to 15 PSI) and electro-pneumatic (4 to 20 milliampere) positioners can accept signals from manually adjusted pressure regulators or from computer controls. Pneumatic positioners are ideal for manually operated filling setups, while electro-pneumatic positioners are preferred in systems requiring variable discharge, commonly seen in automatic loss-in-weight systems.

• No control required
• Solenoid
• Pneumatic Positioner
• Electro-Pneumatic Positioner

Feedback: Automated valves typically feature two mechanical limit switches that indicate fully open and fully closed positions, accompanied by a visual beacon indicator.

• Position Indicator
• Visible Beacon

Electrical Classes: Standard classifications include NEMA 4/IP64 for wash-down applications and explosion-proof ratings such as NEMA 7 and 9. Additional classifications such as IS Intrinsically Safe can be provided as engineered options.

• Wash Down
• X-Proof
• Intrinsically Safe

Voltage: The specified voltage for an electrical appliance indicates the designed operating voltage, with single solenoid appliances typically rated at 7.2 Watts. The current consumption at this voltage is noted on the rating plate on the appliance.

• 24V DC
• 120V 60
• 240V 50 Hz

Clean in Place (CIP): For automatic cleaning, consideration should be given to the use of spray balls or jets, with an additional option being the Sani K Valve, which can be dismantled manually for thorough inspection and cleaning. Due to safety concerns, the size of such valves is typically restricted to an 8-inch port diameter to manage the weight of individual components.

CIP ports utilize a 1-1/2 inch ferrule featuring a Teflon plug, cap, and quick clamp. A spray ball is provided with a cap and plug for use in instances when the spray ball is removed between cleaning cycles.

• No CIP required
• CIP port
• CIP Spray Ball

Ball valves are adaptable flow control devices ideal for a wide range of industrial applications. They come in a variety of sizes and designs, making them suitable for numerous sectors including sanitary, petrochemical, and cryogenic applications.

The functionality of these valves revolves around controlling the flow of fluids via a hollow, pivoting ball, which may feature either a full or reduced port design. Full port valves possess dimensions equal to the internal diameters of adjacent pipelines. On the other hand, reduced port (standard port) valves have diameter measurements that are one pipe size less than those of adjoining pipes. For example, a 1 inch reduced port valve will actually use a ball with a ½ inch port diameter.

Ball valves boast several advantages over alternative industrial valves, with key benefits including:

• They provide leak-tight seals.
• They can open and close swiftly.
• They offer greater durability compared to most other types of industrial valves.

Valves can be categorized in various ways, with each classification impacting the valve’s performance characteristics. These classifications include:

• Valve design according to ball movement: floating versus trunnion mounted
• Port design: full port, standard, or V-port valves
• Body style: single body, split, top-entry, three-piece, or welded body

Before selecting ball valves, industrial engineers must seek answers to critical questions. The responses guide them through the intricate valve selection process, ensuring they choose reliable ball valves that meet the specific needs of their piping system. What questions should be addressed?

1. What type of media will flow through the ball valve?

Engineers must first analyze the type of fluid flowing through the pipeline. Is it a liquid, gas, or semi-solid (slurry)? Understanding the physical and chemical configurations of the fluid is essential, as this impacts its behavior when passing the valve. The nature of the service fluid is crucial in making informed decisions regarding valve materials, port designs, and sizes. For instance, when selecting a gas ball valve, it is vital to consider performance and reliability factors when working with combustible gases such as hydrocarbons, liquified natural gas, or chemical vapors.

2. Which actuation methods will you use?

Pipelines necessitate specifying the appropriate actuation method that aligns with flow control requirements. Some systems demand frequent valve activation with high precision, while others may only require one-time activation of the ball valve. Designers must assess the valve operation frequency, energy consumption, and the complexity of chosen actuation technologies. Actuation options for ball valves can include:

• Pneumatic
• Electric
• Manual
• Hydraulic

Additional actuation options such as spring return or double-acting actuators must also be evaluated. Understanding the impact of add-ons like limit switches or pilot valves on the reliability of valves is equally important.

In processes that necessitate rapid cycle times, pneumatic actuation is often the most effective choice. Engineers can position manually operated ball valves at strategic points in the pipeline for isolation during maintenance or inspections. Such low-cycle valves usually see usage only a few times each year.

3. What are the temperature and pressure ratings of the pipeline?

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Identifying the pressure and temperature conditions of the service fluid and surrounding environment is crucial when selecting ball valves. Fluctuations in service fluid temperatures can weaken mechanical strength in valves. Excessive temperature changes can lead to uniform expansion and contraction, potentially resulting in surface fractures over time.

Ball valves must also endure the pressure sustained within the service fluid. Surpassing designed pressure thresholds can negatively influence sealing quality and contribute to premature wear. Always opt for a ball valve rated for the temperature and pressure on par with or exceeding those of the pipeline.

4. What are the estimated annual cycles?

The durability of a ball valve is influenced by its cycling frequency. Engineers should project annual operating cycles to assess the longevity of various ball valves within the piping system. Additional factors like maintenance routines and media abrasion can affect the valves' reliability throughout their operational lifespan.

Designers must estimate the life expectancy of ball valves before determining the actuation method. If appropriately specified, ball valves have the capacity to endure tens of thousands of cycles without failure. Upon understanding the cycling needs, engineers can select pneumatically actuated valves, which generally offer superior durability and dependability over electrically actuated alternatives.

5. How do you intend to use the ball valve?

Numerous types and brands of ball valves exist within the market, each tailored for specific application areas. For instance, a steel ball valve tailored for a chemical processing facility may not be adequate for use in sanitary applications. Ball valves are designed to provide shut-off capabilities for pipelines while also facilitating directional flow control. When selecting application-specific valves, designers should clarify whether:

• The valve solely halts fluid flow.
• The valve alternates flow between different sources.
• The valve splits flow from one source to two distinct destinations (applicable to 3-way ball valves).

Industrial applications function under varying pressure and temperature conditions. Compliance with strict emission and leakage regulations is essential across different classes of ball valves. Be sure the selected ball valve meets all system specifications and regulatory standards.

7. Which materials are used to manufacture the valve?

The choice of valve materials is fundamental to the properties of the service fluid. When assessing valve materials, engineers must validate:

• Compatibility with service media
• Corrosion resistance
• Cost considerations

Common materials for ball valve construction include brass, stainless steel, plastic, Monel, Inconel, Molybdenum, Chromium alloys, nickel alloys, or copper. Severe service applications often necessitate materials with enhanced strength and corrosion resistance properties, such as Monel or Inconel.

When inspecting valve materials, attention should also be directed towards the composition of sealing materials. Soft-seated ball valves frequently utilize rubber or PTFE seals, while extreme fluid services warrant metal-to-metal seating in ball valve designs.

Which testing and quality assurance procedures does your valve vendor use?

When collaborating with manufacturers or vendors, request detailed information about testing protocols and quality assurance measures in place. Testing protocols assess the performance of various ball valves, including leak, emission, and pressure tests to guarantee the suitability of valves for specific applications.

Avoid making purchases based merely on initial pricing. It is important to evaluate quality assurance metrics and standardization marks on the valve construction or packaging. Bulk purchasing ball valves is futile if they fail after only a few operational cycles.

8. What certifications should the valve have?

Ball valve applications reach across various industries, with designated organizations certifying products to uphold health and safety regulations. According to application types, ball valves, and their actuators may require different certifications, including:

• ANSI certifications: Establishes pressure and temperature ratings for pipe flanges.
• NEMA certifications: Defines standards for the design of electrically actuated ball valves.
• NSF certifications: Offers guidelines for ball valve selections in food, beverage, and pharmaceutical production sectors.

Ensure that the selected ball valves possess certifications that are relevant to the fluid applications you are managing within your facility.

9. What are the maintenance requirements for ball valves?

Ball valves generally do not necessitate extensive maintenance, owing to their straightforward flow control functions and lowered failure likelihood. Nonetheless, industrial valves may require maintenance from time to time. Establish a systematic plan for inspection and upkeep while keeping an essential inventory of repair and replacement components, such as seals for valves and actuator consumables. Manual ball valves may demand fewer maintenance interventions compared to actuated valves.

Conclusion

The process of selecting ball valves for diverse industrial applications can be intricate. It demands a meticulous examination of the technical specifications of the pipeline, judicious choice of manufacturing materials, and an understanding of valve industry codes and standards. By addressing the questions posed, engineers and pipeline designers can make educated choices, selecting reliable ball valves that ensure lasting performance.

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