Regardless of the medium or application, wear and tear are expected. You may extend the life of ball valves by installing them correctly and using the right materials.
Ball valves are great for on/off control of a broad range of media due to their intrinsic design. What should you expect in terms of service life? A fast Google search for “ball valve lifespan” yields a result of 100,000 cycles as a general rule. If only the true answer were so straightforward.
The truth is that the lifespan of your ball valves is determined by a number of variables. Because there are so many elements to examine initially. While the majority of ball valves suppliers do set warranties for the life expectancy of their goods.
Here are five things to consider when it comes to the longevity of your ball valves.
Table of Contents
1. Media
Ball valves have long been used to control the flow of gases and liquids such as water, oil, air, and chemicals.
The presence of abrasive dispersed particles in the media might cause the valve seals to break prematurely. This can manifest as a leak or, depending on the severity of the media properties. Also, a significant increase in ball valve working torque can result in actuation failure.
2. Temperature & pressure ratings
When assessing appropriateness, both the valve media pressure and temperature, also known as pressure/temperature rating, must be taken into account. In general, when the media pressure rises, the temperature of the media must fall, and vice versa.
The materials, valve design, and valve seal materials that you are going to use. All will be influenced by the pressure/temperature rating. This, along with the frequency of the cycle, will also have an impact on the longevity of a ball valve.
A ball valve is used in a pressure/temperature application that is near the rating. It can persist for years if it is cycled (turned on and off) seldom. If a valve is cycled frequently, in the same application, you may need to replace it frequently.
3. Maintenance
When it comes to actuated ball valves, the valve seals are almost often the first to fail. It causes a leak from the stem seal or seats. As evidenced by downstream leaking when the valve is turned off. So, changing the soft seals is a typical way to try to repair the valve.
If you want to maintain the valve in your application, choose a three-piece ball valve that is built for serviceability. These are built so that the valve’s central portion and seals may be replaced quickly and safely. Ball valves, that are one-piece or two-piece, are not meant to be disassembled. You should replace them rather than fix them.
The good news is that a replacement ball valve only accounts for a small percentage of the overall cost. That’s off an actuated ball valve assembly. One actuator can host multiple ball valves before it has to be replaced, depending on the brand and quality of the actuator.
4. Materials
The type of liquid or gas passing through the valve will determine the best materials for your ball valve. Stainless steel, PVC, brass, and bronze are some of the most popular materials used to make ball valves.
The valve body and seals must be made of materials that are compatible with the valve’s temperature and pressure ratings. Also, the chemical makeup of the gas or liquid that will flow through it.
Here’s a deeper look at various types of materials:
- Metals: Stainless steel, bronze, and brass are corrosion-resistant and long-lasting. For high-temperature applications, metal materials are the best option.
- PVC stands for polyvinyl chloride, and it is a kind of plastic that is more flexible than metal valves. PVC, on the other hand, is not as robust as metal and is not suitable for high temperatures (over 140°F). Also for high-pressure applications. PVC ball valves have a shorter lifetime than other valve types.
- PTFE: Polytetrafluoroethylene is used for most ball valve seals. It is compatible with nearly all types of media. Although this material has a high melting point, it is recommended that applications with extremely high temperatures use metal or ceramic sealing.
- Elastomers, such as Viton and EPDM, are also used in the construction of certain ball valves. When utilizing elastomer-based valves, make sure the material is suitable for your application media.
The Cole-Parmer Chemical Compatibility Database is a popular resource for determining chemical compatibility. This is a useful tool for verifying the valve components’ fundamental chemical compatibility with the application medium.
It’s just as vital to know where the supplies originate from. Because some resellers get ball valves from all over the world, there’s always the risk of design discrepancies or functioning difficulties. Domestically manufactured valves are more likely to be dependable and long-lasting.
5. Actuation
A ball valve can be powered in a variety of ways. A lever or handle on top of the valve is used to manipulate manual ball valves. Because these valves need human power, they are not suitable for high-cycle applications or valves in difficult-to-reach locations.
With the addition of a power supply, actuated ball valves may be automated and controlled remotely. You’ll probably see the following choices:
- In situations where compressed air is available, pneumatically operated ball valves are employed. They have quick cycle times and are quite durable.
- In applications that need low cycle rates or do not have access to compressed air. Electric-operated ball valves should be utilized.
- In high-pressure applications, the slower index times can assist prevent water hammers. These are also known as “motorised ball valves.”
Hydraulic actuated ball valves operate similarly to pneumatically actuated ball valves, but with a greater torque output. These are generally more costly than other actuator choices, and effective operation may necessitate the installation of extra components.
Wrapping Up
Regardless of the medium or application, wear and tear are inevitable. However, with appropriate installation and material design, you may extend the life of your ball valves. As a result, get the most bang for your buck.
Last but not least, we hope that the above five factors, covered in-depth in this post, will be of great use. If followed correctly, these variables can extend the life of your ball valves to some great extent.
