Many ball valve manufacturers will provide an estimate of the expected lifespan of a ball valve, and proper maintenance can certainly extend this range. However, ball valve lifespan can be influenced by a variety of other factors.
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Actuation
While some ball valves are powered manually, many are operated via automatic actuator. Depending on your system&#;s intended cycle speed, you have your choice between pneumatic (air-powered), electric (motorized) or hydraulic (fluid-powered) actuation. By choosing the appropriate power source for your application, you can reduce maintenance expenses, increase uptime and maximize safety. Pneumatic actuated ball valves are the most durable option in high-pressure environments, provided you have access to compressed air. In most cases, actuators will far outlive the ball valves they control.
Two examples of pneumatic actuated ball valves. The actuator sits on top of the valve body and operates the valve via compressed air.
Design
Ball valves come in one-, two- and three-piece designs, the first two of which do not allow for maintenance and must be replaced when components fail. Three-piece ball valves, however, are designed so that the seats and seals can be removed and replaced quickly and easily without removing the entire valve from the system. Provided the valve is made of durable material, the ability to replace components means that three-piece ball valves can long outlive their one- and two-piece counterparts. For this reason, three-piece ball valves are favored for high-cycle and high-pressure applications that subject the seal components to lots of wear and tear.
Left: A manual two-piece ball valve; Right: A manual three-piece ball valve.
Serviceability
Seals are typically the first component to fail in a ball valve, since they are made of much softer material than the valve body. While one-piece and two-piece ball valves must be replaced when their seals expire, three-piece ball valves allow for easy replacement of seals without removing the valve entirely.
Temperature and pressure rating
Ball valves used in high-pressure or high-cycle settings will need to be serviced or replaced more frequently than those in lower-pressure applications. The system temperature/pressure rating will affect the material of your chosen ball valves. Be aware that the closer the media&#;s temperature/pressure rating is to the ball valve&#;s rating, the more frequently the valve will need to be replaced.
The good news is that the actuator (which is typically the more expensive component in an actuated valve assembly) will normally outlast the ball valve. This means that in most cases the valve can be replaced without replacing the existing actuator.
Media
Ball valves are generally intended for the on/off control of fluids and gases without solid particulates. Any particles in the media can abrade the valve seals, leading to repairs, valve failure or actuator failure. Conversely, lubricative medias such as oils can reduce seal wear and extend the life of the valve even further.
Valve materials
Media is a major determinant of the materials for ball valve bodies and accessories. Ball valves can be made of stainless steel, brass, bronze, or plastic (PVC). While PVC offers flexibility and cost savings, metal ball valves are more durable and able to withstand higher temperatures and pressures. Overall, metal ball valves have a longer lifespan than those made with PVC or other synthetic materials. When in doubt regarding the appropriate valve material, use the Cole-Parmer Chemical Compatibility Database to ensure valve materials are compatible with your specific media.
Left: A manual two-piece brass ball valve; Right: A manual two-piece stainless steel ball valve.
Source
If your plant contains processing equipment made in the U.S., you&#;ll want to source ball valves from domestic manufacturers and suppliers. Some valve retailers source their products from all over the world, but products from overseas carry the risk of incompatibility with products made Stateside. Quality aside, it&#;s best to buy ball valves from domestic sources to ensure longevity and prevent premature replacements.
Regardless of the type of valve, ensuring that you purchase the right size and dimension is necessary to guarantee flow efficiency in your application. The size affects the amount of pressure the valve can support, which may affect the flow rate and control in turn. Finding the right size can save you costs and earn you good returns on investment.
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A general practice to determine the correct valve size is to use the equation Q = Cv&#;(ΔP/G), where Q is the capacity in gallons per minute, Cv is the valve flow coefficient, ΔP is the pressure differential in pound per square inch, and G is the specific gravity of the fluid.
Manufacturers typically have a list of valve flow coefficients for all the models and dimensions of their industrial valves. By finding the Cv required for your application, you can choose a suitable valve size.
DIN valve standards, set by the Deutsches Institut für Normung, are more commonly known as German valve standards. Common standards include DIN EN 488, DIN EN, and more, varying depending on the application type.
BS valve standards are set by the British Standards Institution, the national standards authority of the United Kingdom. Types include BS for ball valves, BS for gate valves, and others.
ISO valve standards, published by the International Organization for Standardization, define the qualifications required for designs, functionality, and other aspects of industrial valves.
ASME valve standards are set and regulated by the American Society of Mechanical Engineers. These standards may detail the pressure and temperature ratings of certified industrial valves.
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Size (Class 150) D L E F G H S 1-inch ball valve dimensions 25 127 108 60 113 185 56 2-inch ball valve dimensions 50 178 152 84 153 300 92 3-inch ball valve dimensions 80 203 191 114 205 355 101 4-inch ball valve dimensions 100 229 229 128 220 355 114 6-inch ball valve dimensions 150 394 279 175 284 680 165 8-inch ball valve dimensions 200 457 343 245 362 750 228 10-inch ball valve dimensions 250 533 406 285What is a standard ball valve size? Depending on the valve class you select, the ball valve standard dimensions will vary. For example, valve diameters may go from 15 to 600 millimeters (mm) for those categorized under Class 150.
If you&#;re asking the question &#;How do I know what ball valve size I need?&#;, referring to the size of your hose or pipe is one way to do it. For instance, a two-inch ball valve may be suitable for a two-inch hose. But this may not be true for reduced bore ball valve dimensions.
On how to measure ball valve sizes, you should consider measuring their diameters. Usually, markings like DNXX can be found on the valves. DN stands for nominal diameter, followed by the valve&#;s diameter size in mm.
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Size A B C D E F G H J K L M N P Q R 3-inch butterfly valve dimensions 10-11/16 6 3-11/16 1-7/8 5-7/8 8 0.561 3-1/4 9/32 6 6 5/8-11 4 3 7-1/2 3 4-inch butterfly valve dimensions 13 7 4-13/16 2-1/8 6-15/16 11 0.686 3-1/4 9/32 6 7-1/2 5/8-11 8 4 9-1/8 3 6-inch butterfly valve dimensions 15-3/16 7-15/16 5-7/8 2-1/4 8-3/4 11 0.811 3-1/4 9/32 6 9-1/2 3/4-10 8 6 11-1/4 3 8-inch butterfly valve dimensions 17-3/4 9-3/16 6-15/16 2-1/2 11 16 0.936 4-3/4 17/32 10 11-3/4 3/4-10 8 8 13-3/4 3 10-inch butterfly valve dimensions 20-1/2 10-1/2 8-3/8 2-13/16 13-3/8 16 1.123 4-3/4 17/32 10 14-1/4 7/8-9 12 10 16 3 12-inch butterfly valve dimensions 23-1/2 12-1/6 9-13/16 3-1/8 16 16 1.247 4-3/4 17/32 10 17 7/8-9 12 12 19 3 24-inch butterfly valve dimensions 40-3/16 19 17-7/16 6-1/8 28-1/4 3 7-1/2 24 29-1/2 1-1/4-7 20 23-1/4 32What is the nominal size of butterfly valves? The most common size configurations available on the market go from 2 to 36 or 60 inches. DN100 butterfly valve dimensions are some of the most common, as well as lug-type butterfly valve bolt lengths.
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Size (in mm) L L2 W W1 H H1 A 2-inch gate valve dimensions 215.9 231.65 200 430 3-inch gate valve dimensions 282.45 298.45 250 555 4-inch gate valve dimensions 304.8 320.55 250 620 6-inch gate valve dimensions 403.35 419.1 350 305 805 835 220 8-inch gate valve dimensions 419.1 434.85 400 305 220 12-inch gate valve dimensions 501.65 517.4 500 460 267 24-inch gate valve dimensions .35 900 610 411Measuring a gate valve involves knowing its hole-to-hole dimensions, stem height, valve travel, and other measures. By gathering this data, you can accurately select the correct gate valve for your application.
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Size (in mm) L H W 2-inch globe valve 203 340 225 3-inch globe valve 241 419 302 4-inch globe valve 292 441 325 6-inch globe valve 406 610 451 8-inch globe valve 495 679 549When picking a globe valve, knowing its Cv rating, or its flow coefficient, would be of help. This is the amount of water in gallons per minute that flows through a valve at 20° C and 1 PSI. If you don&#;t know what a globe valve looks like, a good indicator would be its slightly spherical shape.
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Size (in mm) A B C D E 3-inch foot valve 76 185 (260) 146 18 250 (230) 4-inch foot valve 101 215 (260) 178 18 280 (280) 6-inch foot valve 152 280 (330) 235 18 360 (340) 8-inch foot valve 203 335 (385) 292 18 400 (390) 10-inch foot valve 254 405 (530) 356 22 440 (590)What size foot valve do I need? The rule of thumb in the industry is to select a valve one size bigger than that of the pump discharge pipe. For example, a suitable foot valve for a 4-inch pipe would be a 6-inch foot valve.
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Float valve size Float thread size Float ball size Float ball thread size 1-inch float valve 1 1/4 inches 8 inches 7/16 2-inch float valve 2 1/4 inches 12 inches 5/8When selecting a float ball size, it&#;s important to know the speed of draining and filling of your tank. The rule of thumb is that the faster the rate is, the larger the float ball that you would need to purchase.
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Selecting a solenoid valve is highly dependent on the flow factor, known in the industry as Kv, which details the amount of water passing through the solenoid valve in 60 seconds at room temperature and 1 bar.
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Size (in mm) D C G T L H N-M 4-inch check valve dimensions 229 190.5 157 23.9 292 196 8-19 5-inch check valve 254 216 186 23.9 330 202 8-22Check valves do come in varying configurations, so selecting one that fits your application matters. But what size check valve do I need? To measure the ideal one with the check valve sizing calculation, you must know the floor velocity needed to lift its disc. After this, determine the average flow velocity in your pipes, ensuring that it&#;s either higher or equivalent to the minimum velocity of the valve.
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