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Industrial Ball Valves
Valveforce provides specialist industrial ball valve solutions for commercial and industrial applications where reliability, process performance and operational continuity are critical.
Working with established valve manufacturers including Broen, Klinger and Somas, we support customers with engineered valve solutions across industrial, energy, utilities and building services environments.
Our approach focuses on helping clients specify and source the correct valve technology for each application, balancing performance, maintainability and whole-life value.
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Industrial Ball Valves Explained
What is a Ball Valve?
Named after the spherical ball which acts as the moving element (or obturator) to isolate the flow, the ball valve is the perfect valve for isolation purposes which is why it is so frequently employed for this purpose in a multitude of applications. The ball has its cylindrical flow port drilled though its centre, which is turned by a quarter turn (or 90°) to be in-line with the flow (in the open position) or perpendicular to the flow (in the closed position).
The seat material, in conjunction with the rotating ball face provides the seal on both the upstream and downstream side of the ball. The relative force on each seat (which in combination with the application media and pressure effects the required actuation force) is largely dependent on the type of ball valve used. There are typically two main styles employed. These are, floating ball valves and trunnion mounted ball valves.
Comprehensive Industrial Ball Valve Range
Valveforce offers a broad portfolio of industrial ball valve solutions to support a wide range of operating conditions and system requirements.
Our range includes solutions from recognised manufacturing partners, allowing us to support both general industrial duties and more demanding process applications.
Available configurations include:
- Full bore ball valves
- Reduced bore ball valves
- Stainless steel ball valves
- Carbon steel ball valves
- Flanged ball valves
- Threaded ball valves
- Weld-end ball valves
- Manual and actuated ball valves
- High temperature applications
- Process isolation solutions
- Severe service valve applications
Types of Ball Valves
Floating Ball Valves
Floating ball valves have the ball mechanically disconnected from any other parts in the valve. The shaft which turns the ball is sitting within a groove cut into the top of the ball. This groove is orientated so it is perpendicular to the flow direction. This enables the shaft to hold the ball when the valve is open. When the valve closes the upstream pressure pushes against the closed face of the ball and the ball can move freely and seal itself against the downstream seat.
Floating ball valves are the most widely used ball valve as they are relatively inexpensive and suited to lower pressure applications for a wide range of isolation purposes. Because the floating ball uses the line pressure to seal against the downstream seat, the floating ball type may be less suited to very low pressure applications with very tight shut off requirements. It is important to remember, the required actuation force increases as the operating pressure increases.
Full Bore and Reduced Bore Ball Valves
Ball valves may also fall under two other configuration types which are known as full bore, or reduced bore ball valves.
Full bore ball valves have a flow port with an internal diameter equal to the pipeline inner diameter. This results in a physically larger ball being required, increasing valve size and material costs, but the benefits are that there is a minimal pressure drop as the flow is unimpeded through the valve. There is also no induced process turbulence. The other advantage of the full bore valve is the ability to facilitate pig or cleaning rod access through the pipeline.
Reduced bore ball valves are used where cost is more critical factor than pipeline pressure loss. Typically the ball is 1 size less than the pipeline diameter. This results in smaller and lighter valves, but will increase the flow velocity and hence increase the pressure drop across the valve.
Ball Segment Valves
Ball segment valves are the valve of choice if you are looking for high capacity, free flowing valves with tight shutoff capability. The ability to handle larger flows reduces the need for larger valve bodies, offering cost and space saving advantages. When combined with the V-port ball segment, slow opening characteristics mean the quarter turn valve can be adapted to meet the most demanding control and isolation requirements in a single valve.
As the ball segment moves completely out of the flow of the valve when open, the valve is suitable for abrasive, adhesive or more viscous media where maintaining a free flowing product is of upmost importance.
The reduced size means reduced material weight, allowing for a smaller line size and more optimised pipework support structure.
There is also the option for noise reduction ball segments and a multitude of body and seat materials, meaning we can match up the perfect valve for your application.
Trunnion Mounted Ball Valves
Trunnion mounted ball valves are fixed in position and so only move on their own axis of rotation. The seats are spring loaded so they press against the sealing faces when closed. This means the trunnion mounted ball valves are more suited to larger diameters and higher pressure applications, where if they were floating, the upstream pressure could cause excessive force on the seat and deform the seat due to the larger surface area upon which the upstream pressure acts.
The sealing forces are much lower in trunnion mounted ball valves for higher operating pressures, The sealing areas is also smaller resulting in lower actuation forces being required, meaning that when compared with floating ball valves, smaller actuators or gearboxes can be used.
The spring loaded seats also make trunnion mounted ball valves more suited to low pressures, where in the floating ball design there would not be enough force generated to seal the valve effectively.
Typically, trunnion mounted ball valves are more expensive than their floating ball counterparts.
Unlike floating ball valves, where the upstream pressure pushes the ball against the downstream seat, trunnion mounted ball valves require different strategies to adequately seal against leakage. The most common types (as part of API 6D) are either “single piston effect” or “double piston effect”.
Industrial Ball Valve Services
Specification & Design
Selecting the Correct Ball Valve
Industrial valve selection should consider more than connection size alone.
Our technical support team assists customers in reviewing:
- Operating pressure and temperature
- Media compatibility
- Isolation requirements
- Material selection
- Flow characteristics
- Automation requirements
- Service life expectations
- Access and maintenance considerations
Correct valve selection improves reliability, reduces maintenance requirements and supports efficient long-term operation.
Valve Sizing and Type
Correct Sizing: Valveforce ensures the valve size matches the flow requirements of your system to avoid issues like cavitation, excessive velocity, or pressure drops.
Appropriate Valve Type: We select the type of ball valve (full port, reduced port, etc.) based on your application's specific needs, ensuring optimal performance and efficiency.
Budget: We can also select a valve to suit your budget requirements.
Actuation Method
Choosing the Right Actuation: Valveforce helps you decide on the appropriate actuation method (manual, pneumatic, electric, hydraulic) based on your application's requirements for control, speed of operation, and fail-safe positions, ensuring precise control and reliability.
Pressure and Temperature Ratings
Meeting Operating Conditions: Valveforce ensures the valve's pressure and temperature ratings meet or exceed your system's maximum operating conditions, considering factors like steam hammer and thermal expansion to guarantee safety and durability.
Installation & Commissioning
Orientation and Positioning
Proper Installation: Valveforce installs the valve in the correct orientation according to the manufacturer's instructions, ensuring proper function.
Ease of Access: We position the valve for ease of access for operation, maintenance, and potential future replacements, facilitating long-term serviceability. We consider the need for isolation valves to facilitate maintenance without shutting down the entire system, ensuring minimal downtime.
Leakage and Seal Performance
Choosing the Right Actuation: Valveforce helps you decide on the appropriate actuation method (manual, pneumatic, electric, hydraulic) based on your application's requirements for control, speed of operation, and fail-safe positions, ensuring precise control and reliability.
Overhaul & Repair
Wear and Tear
We address the natural degradation of internal components, replacing worn seals and the ball as necessary, to prevent leaks and ensure the valve can fully shut off the flow.
Corrosion
Utilising corrosion-resistant materials and protective coatings, Valveforce combats the effects of corrosive condensate, preserving the integrity of the valve body and internal components.
Scaling
Our descaling procedures remove mineral buildup, ensuring the valve operates smoothly without interference, maintaining a tight seal and unobstructed flow.
Thermal Expansion
Valveforce implements solutions to accommodate thermal expansion and prevent misalignment or seal damage, ensuring consistent valve operation and sealing integrity.
Steam Hammer
Valveforce’s system design and operational recommendations help mitigate the effects of steam hammer, protecting valve components from excessive force and potential damage.
Erosion
Addressing erosion from high-velocity steam, we focus on areas susceptible to damage, employing erosion-resistant materials and design adjustments to enhance durability and performance.
Maintenance & Service
At Valveforce, we understand the critical role that process ball valves play in regulating flow in a variety of industrial applications. Known for their durability and reliability, ball valves are vital in maintaining efficient system performance. However, over time, even the most robust ball valves require regular maintenance and overhauls to ensure optimal operation and prevent costly breakdowns.
With Valveforce’s comprehensive maintenance and overhaul services, you can rely on our expertise to keep your process ball valves in top condition, extending their lifespan and ensuring continuous, trouble-free operation.
Why Regular Maintenance of Process Ball Valves is Important
Process ball valves are exposed to a wide range of conditions, including corrosive media, high temperatures, and constant cycling, which can lead to:
Wear and tear: The constant movement of the ball and seats can cause wear, reducing the valve's sealing capability.
Corrosion and scaling: Exposure to aggressive fluids can lead to corrosion or the build-up of deposits, affecting valve performance.
Leakage and inefficiency: Over time, improper seating or degraded seals can result in leakage, compromising process efficiency and safety.
Regular maintenance helps to:
Ensure reliable operation: Keep your ball valves functioning smoothly, reducing the risk of operational interruptions.
Prevent costly downtime: Early detection and resolution of minor issues can prevent unexpected valve failures and minimize downtime.
Extend valve lifespan: Routine maintenance prevents excessive wear, extending the life of your process ball valves.
Maintain safety standards: Ensure your ball valves continue to meet safety and operational standards, even in harsh conditions.
Don't wait for a valve failure to disrupt your operations - contact Valveforce today to schedule regular maintenance and servicing for your process ball valves. Trust us to keep your valves working smoothly and efficiently for years to come.
Comprehensive Overhaul Services for Process Ball Valves
At Valveforce, we offer specialized overhaul services for process ball valves, restoring them to their original performance levels. Our overhaul process includes:
Detailed Valve Inspection
We begin with a comprehensive inspection to assess the condition of the valve body, ball, seats, and seals. This allows us to identify any signs of wear, corrosion, or damage.
Disassembly and Precision Cleaning
The valve is carefully disassembled, and all components are cleaned to remove any debris, scale, or build-up that may affect performance.
Component Repair and Replacement
Worn or damaged parts such as seats, seals, or bearings are repaired or replaced with high-quality components, ensuring reliable performance and a tight seal.
Reassembly and Testing
After reassembly, the valve is tested for leaks and operational efficiency to ensure it meets your system’s pressure and flow requirements.
Calibration and Certification
We provide full calibration to guarantee that your valve performs accurately within its specified parameters, offering certification that confirms compliance with industry standards.
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