Ball valves are used in numerous plumbing and industrial systems. People know them by their longevity, tight closure, and fast acting. Ball valves help in controlling the flow of fluids and gases easily. If you want them to function properly and nicely, do take care of their cleanliness. However, these valves are very pivotal in industrial flow control.
In this guide, we will tell you how ball valves function. Also, we will talk about their pros and give you practical tips to keep them functioning well.
A ball valve is a type of valve that contains a ball that has a hole in its center. The ball valve uses this ball to control the flow of fluids and gases. When the hole is lined up with the pipe, fluid passes by it. When we turn the ball 90 degrees, the flow stops. This simple procedure makes the valve easy to operate and trustworthy. That is industrial flow control.
Let’s talk about ball valve benefits now:
Longevity
The materials used in the manufacturing of ball valves are stainless steel or brass. Materials like these make ball valves durable. They are able to control high pressure, high temperature, and even corrosive fluids. However, all this happens without deteriorating.
Fast Performance
One of the optimal attributes of a ball valve is how quickly it functions. When we turn it to 90 degrees, we are able to completely open or close it. This feature is mostly useful in emergency situations, when a quick closure is required.
Leak-Proof Design
Ball valves have phenomenal sealing. The tight fit between the ball and the seats ensures there is no leakage when the valve is not in use.
Low Upkeep
As a comparison between ball valves and other valves, ball valves need very low upkeep. In simple words, you do not need to take care of them much. This is because they contain fewer moving components. However, they are very few chances for them to get damaged or stuck.
Adaptable Use
We see ball valves getting used in numerous substances. Whether it's liquid, oil, gas, steam, or chemicals, their unique structure makes them appropriate for both home and industrial use.
Reasons Upkeep Matters
In spite of needing low upkeep, ball valves still require proper care. Dirt, corrosion, and regular usage can become the cause of poor functioning. If a valve is badly maintained, there are chances that it might become hard to turn, begin leaking, or fail to be turned off fully. Timely upkeep helps avoid these problems. However, it keeps your systems safe and running flawlessly.
To upkeep a ball valve properly, it's helpful to learn about its main components:
• Valve Body: The outer shell that holds everything in one place.
• Ball: A metal sphere with a hole in the center part used to control the flow.
• Seats: Normally made of soft material like Teflon. They hold the ball firmly in its position and cease leaks.
• Stem: A shaft that links the handle to the ball.
• Handle: The lever or knob that we use to turn the valve on or off.
• O-rings and Seals: They prevent leaks that are located around the stem and the body.
1. Regular Visual Examining
Examine the valve on regular basis for indications of failure, rust, or leakage. Inspect the stem, handle, and joints. If the valve is in a critical condition, you should inspect it more often. Also, see if the handle is turning with difficulty. Or, if it's sounding strange.
2. Clean the Valve
Keep the external part of the valve clean by wiping it with a wet cloth. In case the valve gets blocked or hard to operate, you will need to clean the inside as well. To do this, you will need to remove the internal side and clean it thoroughly. Before setting apart each part of the valve, always ensure that the system is powered off. Also, make sure that there is no pressure left inside. Clean the internal components with a soft brush and an appropriate and effective cleaning liquid. However, do not use sharp tools that could scratch or harm the valve walls.
3. Do Oiling of Moving Parts
While many ball valves don't need extra oiling, there are some types, especially those in factories, that work better if they have been oiled. To do the oiling of ball valves, use valve-safe grease to lubricate the stem and moving parts. This will make the valve easier to turn and help minimize wear. However, keep in mind not to use the grease in huge quantities. Or else, there are chances of attracting dirt or gumming up the movement.
4. Replace Worn Seals
The soft seals and O-rings inside the valve can come out with time. If you notice leaking or difficulty in sealing the valve fully, maybe you have to buy new ones. Always use manufacturer-recommended replacement components. This is to ensure the proper fit and working.
5. Keep the Valves in Functioning Order
If a particular valve isn't getting used regularly, there is a chance that it may be stuck. Why? Because it is a universal fact that if you do not use a particular thing on a daily basis, it will stop working. Therefore, checking and running the ball valves on a daily basis can prevent them from many problems. Those issues can be stiff handles and internal sticking. Especially in emergency shut-off valves. It’s because these valves do not get used for months.
6. Do not Over-Tighten
When installing or reassembling a ball valve, do not over-tighten the bolts or connections too much. Why? Because too much tightening can harm the valve or the seals. Use a torque wrench if required. However, always act upon the manufacturer's instructions.
7. Safeguard from Environmental Substances
In outdoor or industrial settings, ball valves face sunlight, dirt, chemicals, and mechanical impacts. Therefore, always cover them with a protective cover to safeguard them from these harmful substances. Also, do not put them where there is a chance for them to accidentally get kicked, hit, or stepped on.
Stiff or Hard-to-Turn Handle
If this happens, there is a chance that the applied grease has been dried out. Or, it could also happen that the stem is worn out. In either of these cases, clean and oil the valves to make them function properly.
Leakage When Shut
This typically means the ball seats are diagnostic. Remove the inner parts of a ball and then take a closer look at them.
Losing or Spinning Handle
In case the handle turns and the valve doesn't open or shut, the internal stem may be broken or disconnected. For this, you will need to open the valve and examine the internal mechanism.
Strange Sounds or Water Hammer
Instant shut-off can be the reason for water hammer, a loud tapping sound in the pipes. Try closing the valve slowly or consider installing a water hammer arrestor in the system.
Sometimes, a valve can't be fixed. If the valve body is cracked, the ball is highly corroded, or even if it leaks, even after replacing the seals, it means you should buy a new one. Also, if your system changes (such as higher pressure or a different fluid), your current valve may no longer be suitable.
• Act upon the manufacturer's instructions for installation and maintenance.
• Use the valve only for what it's meant to be. In other words, don't use it to regulate flow unless it's intended for that.
• Educate the staff team members to operate and keep the valve correctly.
• Maintain a maintenance record to keep track of each valve. In simple words, you will know the time of checking and service of each valve.
Ball valves are easy to use and the most reliable valves out there. With their longevity, fast functioning, and tight sealing, they are used in everything from home plumbing to huge industrial systems.
Act upon these easy maintenance steps, cleaning, oiling, inspecting, and replacing bad components, and increase the lifespan of your ball valves. With the correct upkeeping routine, your ball valves will serve you the best.
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