Your Complete Guide to Ball Valves

Like most mechanical parts that keep our lives running smoothly, most people don’t know what a ball valve is until they run into a problem with one. But ball valves are quietly and efficiently doing their job in almost every aspect of American life.

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Ball valves are used in manufacturing, the food industry, health care operations, and many appliances found in homes. These valves are used to keep liquids and gases flowing in the right direction, many without the need for sophisticated technology.

This guide will provide detailed information about a variety of ball valves and their uses, including how they work and what purposes they serve.

What Is a Ball Valve?

A ball valve is a type of shut-off valve. It consists of a ball that has had a borehole drilled through the center and a handle. You use the handle to rotate the ball up to 90 degrees, which allows liquid or gas to flow through the borehole. When the valve is in the closed position, the solid part of the ball effectively creates a seal, keeping whatever is in the pipe trapped behind it.

Versatile and long-lasting ball valves can be made of many different materials and come in a variety of sizes. Their simple design means that you can easily have them custom-fitted. The main limiting factor for a ball valve is the specific application you need it for. A PVC ball valve may work just fine for low pressure and low-temperature applications, but you may need a stainless steel ball valve to stop the flow of materials that are at high temperatures or under a great deal of pressure.

Not all ball valves are manually operated. Some, like the electric ball valve, open and close when electrical current is passed through them. These motorized ball valves are used in high-pressure applications where the ball valve is open and closed frequently and continuously.

How does a ball valve work?

The basic concept of a ball valve is simple. A ball that matches the shape and size of the pipe is fitted into the valve. This ball has a bore hole that runs through its core and a handle or gear that moves it on its axis.

In the closed position, the solid part of the ball seals the valve shut. When rotated, the contents of the pipe flow through the valve until it is returned to its closed position. At a 90-degree rotation, the entire borehole is exposed, allowing for the full flow of the pipe’s contents. The flow can be controlled by partially rotating the ball valve handle.

Ball check valves work on the same principles as other ball valves except that they have a means, usually a flap or disk, of preventing backflow. This type of ball valve shuts off flow when the pressure decreases. When opened, the pressure of the medium flowing through the pipe pushes the disk or flap out of the way. When the pressure flowing forward decreases, the flap or disk falls back into place to keep the contents of the pipe from flowing backward. This happens regardless of whether the ball valve is open or closed.

What does a ball valve do?

A ball valve is a shut off valve. It is used to start and stop the flow of liquids or gases through a pipe or other confined space. Water ball valves can be found in almost any home or business with running water.

Do ball valves control pressure?

You can use ball valves to control the pressure in a pipeline or other confined space. By only opening the ball valve partially, you can control how much of the pipe’s contents flow through it. If you open it slightly, the amount flowing will be small and move at lower pressure. If you open the valve fully, both the flow and the pressure will be higher.

Traditional sink taps use ball valves to control the flow of water. By adjusting the taps, you move a ball valve and control how much water comes out of the tap.

Your Quick Guide to Ball Valve Markings

Ball valve markings are labels or tags placed on the pipe that houses the valve. They provide vital information for anyone who needs to perform maintenance on the valve or the pipe that contains it.

The coded information on these labels or tags tells you many things, including information about the valve itself, the type of medium flowing through it, the pressure that contents are likely to be under, the temperature of the medium, and whether or not the contents are flammable or in another way dangerous.

This labeling system, set by the American National Standards Institute (ANSI), is vital to the health and safety of those working on the pipes. It also ensures that those who do the work are prepared with the correct gear and tools before the job begins.

ANSI is one of the three organizations that regulate the labeling, use, and maintenance standards for ball valves.

• ANSI. This organization is responsible for setting voluntary safety standards for many industries in the United States, including the manufacture and use of ball valves. They created the labeling standards for valves and work to ensure that these standards are met.
• Uniform Plumbing Code (UPC). Set by the International Association of Plumbing and Mechanical Officials (IAPMO), this code was created to ensure the safety of both plumbers and consumers through a consistent and regulated code of conduct. The UPC includes the requirements that pipe and valve labels follow the ANSI standards.
• Underwriters Laboratories (UL). This is a global nonprofit organization devoted to promoting safe practices in industries around the world. In addition, this organization is responsible for testing the proper functioning of many of the mechanical parts, including ball valves, that all industries rely on to function.

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Common ball valve sizes

Although ball valves can be custom made to fit any application, there are standard sizes designed to fit most needs. The most commonly used sizes are:

• 2 inch ball valve
• 1 inch ball valve
• ¾ ball valve
• ½ ball valve
• ⅜ ball valve
• ¼ ball valve

Each of these sizes serves a specific purpose, from bathroom sinks to garden hoses to boiler steam pipes. The size of the ball valve should be listed in the valve label or tag.

There are some other important pieces of information that you can find on valve labels.

PN: Pressure Nominal Classes

The PN Class number lets you know how much pressure the valve is designed to withstand. The PN is designated by bars, with each bar representing 14. pounds of pressure. This means that a valve label with 3 bars would indicate that the underlying valve could withstand pressures of up to 43. pounds.

PSI Rating

PSI stands for pounds per square inch and is a standard measurement for pressure in any circumstance. When listed on a valve tag or label, it indicates the pressure of the liquid or gas that is flowing through the pipe. The higher the PSI rating, the more durable the ball valve must be to withstand the force applied against it.

What does CWP mean on a ball valve?

CWP stands for cold working pressure. This value on a valve label or tag is used to indicate the maximum pressure the valve can withstand at temperatures between –20 degrees and 100 degrees Fahrenheit. This temperature range is considered to be the cold range. For example, a 680 CWP would mean that the labeled valve can withstand 680 PSI at temperatures within the cold range.

This means that you can count on a ball valve with a high CWP to perform well at the lower temperatures found in dairies, food processing plants, and anywhere else that cold media is traveling through the valve.

What does SWP mean on a ball valve?

SWP stands for steam working pressure. It may also be labeled WSP for working steam pressure. Either way, it means the same thing. It indicates the pressure the valve will continue to function at even in the highest temperature range.

Ball valves with a high SWP are essential for pipes that carry steam, lubricants for engines, and hydraulic systems where friction may heat the oil. They have many industrial uses.

The 10 Most Important Types of Ball Valves

Ball valves are simple to repair and replace, long lasting, and highly effective. Because of these advantages, we use them in almost every home, business, and manufacturing plant. Anywhere you find pipes, you will find ball valves controlling the flow of the medium inside of them.

How many types of ball valves are there?

Over time, many types of ball valves have been developed to meet specific needs. In the following list, you will find the 10 most important types of ball valves and some of their common uses.

1. Sanitary Ball Valve

These valves are designed for use in the food industry, pharmaceutical manufacturing, and anywhere that sterilization is required. They come in many different configurations and sizes and may be manual, mechanical, or electric actuated ball valves. They all share the ability to be sterilized by heat or chemicals, and they have smooth, polished surfaces to prevent the build-up of debris.

2. V-Port Ball Valves

Unlike most ball valves, the V-port ball valve does not have a ball with a bore hole but rather a floating ball that is compressed when the valve is open. When the valve is closed, the ball expands and blocks both the in and out ports of the valve. This feature creates a tighter seal.

3. Full Port Ball Valve

A full port ball valve has a borehole with the same diameter as the pipe leading to the valve. When fully opened, this type of ball valve allows for the free flow of the pipe’s contents without bottlenecking in the valves. These valves are most often found in situations where the medium in the pipes must flow at a steady pace or when high-pressure ball valves are used.

4. Multi-Port Ball Valve

These valves may be 3-way ball valves or have more connectors that allow the flow of the medium to be diverted in different directions as needed. They can be made so that the flow travels in only one direction at a time or designed so that multiple connectors can be opened simultaneously.

5. Standard Port Ball Valve

The bore holes on standard port ball valves have a smaller diameter than the pipes leading into them. They are usually less expensive and more durable than full bore ball valves, but they will restrict the flow of the pipe’s contents even when they are fully opened.

6. Reduced Port Ball Valve

Reduced port ball valve is another name for the standard port ball valve, which is explained in number 5.

7. True Union Ball Valve

These ball valves have double unions with the pipes that contain them. The unions can be sealed at either end of the valve, which allows you to completely remove them for repair or replacement.

8. Manually Operated Ball Valve

Many different configurations of ball valves may fall into this category. As the name implies, you manually control these valves using a handle mounted outside of the pipe.

9. Electric Ball Valves

Electric ball valves are opened and closed by an electrical current instead of a handle.

10. Motorized Ball Valves

These valves are electric ball valves. They use an electrically powered motor mounted over the valve that opens and closes it as needed. Motorized ball valves are commonly found in automated factories and manufacturing plants.

Conclusion — Who Makes Quality Ball Valves?

Regardless of the application, your best chance of long-term success is to get your valves from a respected and reliable source. There are many ball valve manufacturers, but few offer the quality, variety, and customer satisfaction levels of Adamant Valves.

Since , Adamant Valves has been working to improve ball valve design, manufacturing, and materials to create reliable, long-lasting, and economical choices. Adamant Valves manufactures a large range of sizes and can supply you with a custom fit if a standard size does not work. Adamant Valves has quickly gained a reputation for high-quality valves delivered quickly and has become a leading supplier of valves to food manufacturing and distribution plants, cosmetics manufacturers, pharmaceutical companies, and many other industries.

Choosing the right ball valve size is pivotal in ensuring that your piping system operates efficiently and effectively. Ball valves help maintain optimal flow rates, pressure control, and seamless system operations when sized correctly. The right valve allows fluids to move through the system without resistance, ensuring smooth functionality, reducing wear and tear, and preventing energy losses.

What is Ball Valve Sizing and Why Does it Matter?

Defining Ball Valve Size

Ball valve sizing refers to the process of determining the appropriate valve dimensions required for a particular piping or fluid control system. It’s not just about picking a valve that physically fits, but rather selecting one that can effectively handle the system’s flow rates, pressures, and specific operational demands. The critical dimensions and parameters you’ll need to consider when measuring ball valve size include:

Valve Bore Size: The valve bore (also known as the port size) is the internal opening through which the fluid flows. The bore size directly impacts the flow capacity of the valve and is often the most important factor in sizing a ball valve.

Nominal Pipe Size (NPS) and Diameter Nominal (DN): These two measurements refer to the size of the pipe the valve is designed to fit into. NPS is commonly used in the United States, while DN is the metric equivalent used in other parts of the world. These measurements are key to ensuring that the valve connects seamlessly to the piping system.

Valve Body Size: The valve body size refers to the overall size and shape of the valve housing. This dimension affects how well the valve fits within the system and influences factors like weight, material selection, and flow dynamics.

Flow Coefficient (Cv): The Cv value indicates the valve’s flow capacity. It measures how much liquid (usually water) can pass through the valve at a specific pressure drop. Cv is critical in determining whether the valve will be able to handle the required flow rate without causing pressure loss or other system inefficiencies.

Pressure Rating: Each ball valve is designed to handle a specific range of pressures. Choosing a valve that aligns with your system’s pressure requirements is essential to prevent over-pressurization or valve failure.

Valve Seat and Stem Dimensions: The valve seat and stem work together to create a seal that controls the flow. The size and configuration of these parts can affect how tightly the valve seals and its overall performance, especially under high pressure or extreme conditions.

Understanding these key dimensions helps in accurately sizing the valve for your system, ensuring that it functions efficiently, maintains pressure, and supports the flow requirements.

The Role of Ball Valve Sizing in Fluid Control Systems

Proper ball valve sizing plays a critical role in ensuring smooth and efficient operation within any fluid control system. The size of the valve determines its ability to regulate flow, maintain pressure, and perform under different operating conditions. Here’s why ball valve sizing is so crucial:

Ensuring Optimal Flow Rates: Ball valves are often used to control the flow of fluids in pipelines. If the valve is too large or too small, it can either restrict flow or allow too much fluid to pass through, which can create system imbalances, energy inefficiencies, or even damage to equipment downstream. Proper valve sizing ensures that the fluid moves at the right speed and volume, minimizing energy waste.

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Maintaining Pressure Control: In pressurized systems, the size of the valve directly impacts the pressure drop (the reduction in pressure as the fluid passes through the valve). Incorrectly sized valves can cause excessive pressure loss, which can damage equipment or disrupt operations. A properly sized ball valve ensures that the pressure remains within acceptable limits and that the system operates safely and efficiently.

Preventing System Strain and Damage: An oversized valve can lead to unnecessary wear, while an undersized valve can place strain on the system as it tries to force fluid through a restrictive passage. Both scenarios increase the likelihood of leaks, equipment failure, and costly repairs. Correct sizing keeps the entire system in balance, reduces maintenance, and prolongs the life of components.

Ensuring Compatibility with System Requirements: Fluid control systems often have unique requirements based on the type of fluid being transported, the temperature, and the pressure conditions. Ball valve sizing ensures compatibility with these variables. For example, the size of the valve may need to be adjusted depending on whether the fluid is a liquid, gas, slurry, or corrosive material.

How to Measure Ball Valve Size: A Step-by-Step Guide

Step 1: Measure the Valve Bore Size (Flow Path)

The first and most critical measurement when determining the size of a ball valve is the valve bore size. This refers to the internal diameter of the valve’s ball or flow path. The bore size dictates how much fluid can pass through the valve at a given time and is directly linked to the valve’s flow capacity.

To measure the valve bore:

Remove the valve from the system: If possible, remove the valve to measure it accurately.

Measure the internal diameter: Using calipers or a micrometer, measure the inner diameter of the valve’s opening (also known as the port size or flow path). This size is usually given in inches or millimeters, depending on the valve’s specification.

Consider the flow rate: Larger bore sizes allow for higher flow rates, making this an important factor if you need the valve to handle large volumes of fluid.

Choosing the correct bore size ensures that the ball valve can handle the system’s required flow rate without causing unnecessary pressure loss or restriction.

Step 2: Determine the Nominal Pipe Size (NPS) vs. Diameter Nominal (DN)

After measuring the valve bore, the next step is to determine the Nominal Pipe Size (NPS) or Diameter Nominal (DN). These terms are used to describe the size of the pipes that the valve will connect to and ensure compatibility between the valve and the piping system.

Nominal Pipe Size (NPS): This is the standard measurement used primarily in the United States. It refers to the approximate internal diameter of the pipe and is usually given in inches (e.g., 1-inch, 2-inch, etc.).

Diameter Nominal (DN): This is the international standard measurement used in metric systems. It corresponds to the same general size as NPS but is given in millimeters (e.g., DN 50 for a 2-inch pipe).

To measure NPS or DN:

Check the pipe’s specification: Review the piping system’s documentation or measure the internal diameter of the pipe using calipers.

Verify compatibility with the valve: The NPS or DN of the pipe should roughly match the valve size to ensure a proper fit. In some cases, slight variations in diameter may be accounted for by using adapters or flanges.

Correctly matching the NPS or DN ensures a leak-proof connection between the valve and the pipe.

Step 3: Measure the Valve Inlet and Outlet

The valve inlet and outlet dimensions refer to the openings where the fluid enters and exits the valve. These are crucial for ensuring the valve is properly sized to connect with your piping system.

To measure the inlet and outlet:

Measure the diameter of each opening: Using a tape measure or calipers, measure the inner diameter of both the valve inlet (where fluid enters) and the outlet (where fluid exits).

Check for consistency: The inlet and outlet should generally be consistent with the nominal pipe size (NPS/DN) of the valve. If they differ, adjustments (such as adapters or reducers) may be needed to maintain system flow.

The inlet and outlet measurements are essential for maintaining consistent flow and pressure throughout the system. Mismatched sizes could lead to turbulence, pressure drops, or inefficiencies.

Step 4: Check Valve Pressure Rating and Compatibility

Each ball valve is designed to withstand a certain pressure rating. The pressure rating tells you the maximum pressure the valve can handle safely without risk of failure. Selecting a valve with the correct pressure rating is critical to preventing leaks, burst valves, or other operational failures.

To check the valve’s pressure rating:

Locate the pressure rating on the valve body: Most manufacturers will mark the pressure rating (e.g., 150 psi, 300 psi, etc.) directly on the valve’s body. It may also be listed in the valve’s technical specification sheet.

Consider the system pressure: Ensure that the valve’s pressure rating exceeds or matches the maximum pressure expected in your system.

Check the material compatibility: The material of the valve (e.g., stainless steel, brass) must be able to handle the pressure and the type of fluid being transported. For high-pressure or corrosive systems, ensure you select a valve made from a durable, pressure-resistant material.

Matching the valve’s pressure rating to the system’s needs helps avoid pressure-related failures and ensures safe operation.

Step 5: Assess Valve Seat and Stem Size for Precision

The valve seat and valve stem play a key role in controlling the flow of fluid through the valve. Proper sizing of these components ensures that the valve operates smoothly and maintains an effective seal. The stem size and the seat configuration determine the precision and reliability of the valve’s on/off function.

To assess the valve seat and stem size:

Check the valve seat: The seat is the area where the ball makes contact to form a seal. It should be sized to fit snugly around the ball to prevent leakage. The material of the seat should be compatible with the type of fluid being used, such as metal or soft-seated options.

Measure the valve stem: The stem connects the actuator (manual or automated) to the ball inside the valve. It should be appropriately sized to handle the mechanical force needed to open and close the valve without causing wear or sticking.

Consider the valve type: Depending on the type of valve (e.g., full port or standard port), the seat and stem dimensions may differ. Full port valves have larger openings and typically require a different seat configuration.

How to Calculate the Correct Valve Size for Your System

Valve Size Calculation: How to Match Valve to Pipe Size and Flow Rate

Selecting the right valve size involves carefully matching the valve to both the pipe size and the flow rate requirements of your system. This ensures that the valve operates efficiently, without causing excessive pressure drops or restricting fluid flow.

Step 1: Match Valve to Pipe Size (NPS or DN): Start by determining the Nominal Pipe Size (NPS) or Diameter Nominal (DN) of your system. These measurements give you the general size of the pipe and indicate the size of the valve needed for the connection. Typically, a valve should match the pipe size closely to maintain a smooth flow of fluid.

Step 2: Calculate the Required Flow Rate: The flow rate is the amount of fluid that needs to pass through the valve within a given time, typically measured in gallons per minute (GPM) or liters per minute (LPM). To calculate this, you need to understand the fluid’s velocity, which depends on the type of fluid and the system’s design. A flow rate that is too high or too low can result in system inefficiencies.

Step 3: Use Flow Coefficients (Cv) to Adjust Valve Size: The Cv value (flow coefficient) helps determine the valve’s capacity to allow fluid flow at a specific pressure drop. By using the required flow rate and Cv, you can calculate the exact valve size needed to achieve the desired flow under the given system conditions.

By aligning these factors—pipe size, flow rate, and Cv—you can calculate the correct valve size that balances flow capacity and pressure control for your system.

The Role of Pipe Diameter and Pressure Drop in Valve Sizing

Understanding the pipe diameter and pressure drop is essential for accurate valve sizing, as these factors directly influence how the valve will perform in the system.

Pipe Diameter and Flow Velocity: The diameter of the pipe plays a key role in determining the required valve size. A larger pipe diameter typically requires a larger valve to ensure adequate flow. The flow velocity within the pipe should also be considered, as too high of a velocity can cause erosion or increased friction, leading to a greater pressure drop across the valve.

Pressure Drop and System Efficiency: Pressure drop refers to the reduction in pressure that occurs as fluid flows through the valve. If the valve is too small, it will create a significant pressure drop, which can reduce system efficiency and increase energy consumption. A larger valve may not restrict flow as much, but if it’s too large, it can result in excessive fluid velocity or turbulence, which could cause wear or loss of control.

When selecting the valve, you need to ensure that the pressure drop remains within acceptable limits for the system’s operation, ensuring the system maintains efficiency without excessive energy usage.

Flow Rate and How It Affects Valve Selection

The flow rate is perhaps the most critical factor in valve sizing because it determines the amount of fluid that will pass through the valve and how much resistance it will encounter. To ensure smooth, efficient operation, you must match the flow rate to the valve size.

Determining Flow Requirements: The required flow rate will depend on the application. For instance, high-flow systems such as those used in industrial manufacturing will require larger valves to accommodate the large volumes of fluid moving through them. Smaller systems, like residential plumbing or smaller HVAC systems, will require valves that can regulate lower flow rates efficiently.

Impact of Flow on Valve Size: If the valve is too small for the required flow rate, it will result in a flow restriction, leading to pressure drops, reduced system efficiency, and potential damage to the valve. Conversely, if the valve is too large, it may not provide the necessary control over the flow, which could result in poor system performance and wasted energy.

To calculate the correct valve size, you’ll need to use the Cv value in conjunction with your system’s flow rate. The Cv value tells you how much flow the valve can handle at a certain pressure drop, helping you select the optimal valve size to achieve your desired flow rate without unnecessary energy loss or inefficiency.

Hydraulic Valve Sizing Explained

Hydraulic systems, which rely on pressurized fluids, require careful valve sizing to ensure consistent pressure, flow, and control throughout the system.

Understanding Hydraulic Valve Sizing: In hydraulic applications, valve sizing is more complex due to the higher pressure and variable flow conditions. The pressure rating of the valve must be matched to the system’s maximum operating pressure, and the valve must be sized to handle the required flow rate without causing excessive turbulence or fluid resistance.

Calculating Hydraulic Valve Size Using Cv and Pressure: When sizing hydraulic valves, the Cv value is just as important as in other systems, but you also need to factor in the specific pressure conditions of the hydraulic circuit. Hydraulic systems often operate under high-pressure conditions, so ensuring the valve is rated for the necessary pressure is critical. Additionally, valve design features such as throttling capability and flow control are essential in achieving smooth, consistent performance.

Consideration of Fluid Viscosity: The viscosity of the fluid being used in a hydraulic system affects the flow rate through the valve. Thicker fluids (higher viscosity) will require larger valve sizes to ensure adequate flow and reduce frictional losses. For such systems, valve sizing calculations must account for the fluid’s viscosity to avoid issues like flow restriction or excessive energy consumption.

Conclusion

In conclusion, accurate ball valve sizing is essential for achieving optimal system performance, extending equipment lifespan, reducing costs, and enhancing safety. By carefully measuring the right dimensions and using the right tools, you can ensure that your fluid control system runs smoothly, efficiently, and safely for years to come.

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