TYPES OF BALL VALVES (FLOATING, TRUNNION)

A ball valve features a spherical disc to open and close the flow of the fluid. They are the industry standard for pipeline shut-off
applications, as their design guarantees very tight and leak-free sealing even after years of operation. The two key types of ball
valves are the floating and the trunnion designs (side or top entry). The body can be cast or forged and monolithic or split (in 2
or 3 pieces). The API 6D and ASME B16.34 are key specifications.

WHAT IS A BALL VALVE?

Ball valves are key devices to shut-off and regulate the flow of a fluid (oil, gas, steam, etc) in the petrochemical industry.

ADVANTAGES AND DISADVANTAGES OF BALL VALVES

This type of valve has the following advantages:

 can be quickly opened and closed with a quarter turn movement

 ensure a very tight seal without the need for high torque forces

 have a compact design (this is the main difference between a ball valve and a gate valve – which are both on/off
devices)

The disadvantages are:

 valve has poor regulating and throttling capabilities, as it is designed for pipeline shut-off instead of flow modulation
(this is an ideal function for globe valves): throttling causes the partially exposed seat to erode because of the high-
velocity flow and pressure experienced by the valve. The wear may lead to a leakage of the valve progressively.
 valve can’t be used for slurries, as the accumulation of suspended particles and debris would make the valve
leak. These particles may solidify in the cavities in the proximity of the ball and seats.  Ball valves are way more very
efficient with gases and other liquid fluids (even challenging chemicals as dry chlorine, hydrofluoric acid or hydrochloric
acid, and oxygen).
 may be difficult to clean (except for top entry design)

The open, close or partially open position of the valve can be detected by looking at the position of the lever:

 when the lever is aligned to the pipe, the valve is open; when it is perpendicular to the pipe, the valve is closed;
 when it is any other position, the valve is partly open (or partly closed) and is modulating the flow.

These valves belong to the family of “quarter turn” valves or “1/4 turn valve” (together with butterfly and plug valves), as the
opening and closing operations are executed by turning a lever connected to the disc by 90 degrees.
The key ball valve specifications are the API 6D, BS 5351 (forged) and ASME B16.34 (pressure and temperature ratings), ASME
B16.5/B16.47 (flanged ends) and ASME B16.25 (butt welding ends).

DSEIGN STANDARD-

 ISO 17292- Specifies the requirements for a series of metal ball valves suitable for petroleum, petrochemical,
natural gas plants, and related industrial applications

 BS5351- Specification for steel ball valves for the petroleum, petrochemical and allied industries

 API 6D - Pipe line valves, end closures, connectors and swivels.

 API 608-Metal Ball Valves-Flanged, Threaded and Butt-Welding Ends (150&300)

API-608 is ball valves only.  6D is ball, gate, check, etc.

API-608 covers up to NPS 20 size, 6D up to NPS 60.

API-608 has up to class 600 flanged, and class 800 thread and weld end.  6D goes much higher class ratings

608 requires conformance with ASME B16.34.  6D does not require it, but suggests it as an optional standard.

608 has requirement for strength of ball to stem connection and location of weakest part of stem.  6D regulates
strength of stem only.

608 requires adjustable packing glands.  6D does not.

For potential pressure increase from liquid trapped between the seats, 608 refers to ASME B16.34.  6D defines a
performance test and acceptance limit.

608 defines allowable distruptions on the flange gasket face.  6D does not.

608 tests the valve per API-598, which suggests only low pressure tests recognizing the limitations of soft-seated
floating ball valves.  API-6D requires seat testing at 1.1 times rated pressure.

**API 6D (commonly used for Ball Valves more  than 4") Trunnion mounted. ISO 17292 (upto 4").

TESTING STANDARD

 API 598- Valves inspection and test.

 ISO 5208-Pressure testing of valves

FIRE TESTING STANDARD

 BS 6755 part 2 : Testing of valves. Specification for fire type-testing requirements

 API 6FA: Specification for Fire Test for Valves

 API 607: Fire test for soft seated ball valves

HOW DOES IT WORK?

The ball inside the valve has a hole through which the flow passes freely when it is fully aligned with the two ends of the
valve. When the hole is completely perpendicular to the ends of the device, the valve is perfectly sealed.

Otherwise, when the hole is in any other position (perpendicular to the valve ends for instance) the flow is totally or partly
interrupted.

Ball valve vs gate valve

This valve absolves the same function as a gate valve (shut-off). The difference between a ball valve and a gate valve is that the
former uses a spherical ball to open/close the flow, the latter uses a disc sitting on a seat. The difference between these two
valves is therefore in design and compactness.

Ball valve vs globe valve

These valves are not as precise as globe valves to throttle the fluid flow, as they generally have positive (at 0, 45 and 90
degrees) instead of incremental positions. Further, the valve would be damaged by partial open positions (or repeated
open/close operations) in the long run (not an issue for globe valves).

BALL VALVE TYPES

Ball valves can be classified according to multiple criteria:

 Design: floating, trunnion mounted and double bleed and block

 Number of ports: the standard type is with 2 ports design (1 inlet, 1 outlet), but 3-ways design is also available (1 inlet
and 2 outlets or vice-versa)
 Bore size: full bore or reduced bore (FB vs. RB), and V-notch
 Body assembly: unibody (the ball body is made out of one single piece of cast or forged steel), 2 pieces or 3 pieces (the
body results from the assembly of two or three different parts)
 Ball access: side entry or top entry (depending on the fact that the ball can be accessed, for maintenance, from the side
of the valve or from its top)
 Seat type: metal or soft (Teflon)

FLOATING BALL VALVE

In a floating valve, the ball is suspended in the flowing fluid and is kept in position by the compression of two elastomeric seats
against it.

The shaft is connected at the top of the ball and allows the switch from an open to a closed position with a quarter turn
movement (90 degrees).

When the shaft is moved, a load is applied to the ball which gets pressed against its seats.

This design, which is lightweight and economic, suits bore sizes up to 10 inches: above this bore size, the seats of the valve
would not be able to withstand heavier and heavier balls and the valve would not operate safely and efficiently.

Floating valves allow a bi-directional shut-off of the flow (as the trunnion type).
TRUNNION BALL VALVE

Trunnion valves have been introduced to cope with the size limitations of standard floating valves outlined above. Indeed, in this type of
valves the shaft, the ball, and the supporting trunnion act as a single solid assembly able to withstand the heavy loads generated by balls of
large dimensions.

Besides a size flexibility advantage, a trunnion valve features a lower operating torque compared to a floating valve design (which can become
a benefit when the valve needs to be actuated, as smaller and economical actuators can be fitted to operate the valve).

SIDE ENTRY VS. TOP ENTRY

What is the difference between a side entry and a top entry ball valve?

These terms relate to the way by which the ball of the valve and its internal parts can be accessed, from the side (side entry) or
from the top (top entry)

floating and trunnion-mounted ball valves are available with a “side entry” and “top entry” design.

The top entry design is specified when frequent inline maintenance activities are expected on the valve.
This is due to the fact that top entry ball valves allow easier and faster access to the ball and the valve trim compared to side
entry valves (which require more maintenance time and space for the same operations).

The main differences between these two ball valve design are:

 Top entry ball valves are manufactured, generally, with cast steel bodies; side entry valves are manufactured with
(robust) forged steel bodies
 Top entry ball valves have a monolithic structure (are made by one single piece); side entry valves have a two or three
piece assembly
 Top entry ball valves require more non-destructive tests than side entry due to their cast bodies;
 Side entry ball valves are easier to assemble and manufacture than top entry, which requires long experience and
craftsmanship to work properly
 Top entry ball valves are generally more expensive than side entry ones and have longer lead times due to the casting
operations required to manufacture the body

3-WAYS

Generally, a ball valve has two entries (or “two ways”).

However, for some applications, a 3-way ball valve may be specified. A 3-way ball valve has 3 ports (entries), instead of only
two.

FULL PORT VS REDUCED PORT

These concepts refer to the relation between the bore diameter of the valve and the connected piping system. More in detail:

 The “Full port” (FB) type features a bore size (the hole of the ball) matching the bore size of the connected piping. Full
port ball valves minimize the pressure drop that is generated by reduced port valves but they are of course more bulky,
heavy and expensive. FB ball valves are better suited, than RB ball valves, for throttling applications.
 The “Reduced port” ball valve (RB) type has a bore size that is smaller than the bore size of the connected piping (for
example a tube). The media flowing through the valve is, in this case, limited to a percentage (generally between 70
and 80%) of the full flow in the pipeline. Reduced port ball valve creates a pressure drop in the pipeline.

MATERIALS

This type of valve is available with cast or forged body materials (monoblock, or split).

Generally, valves below 2 inches of diameter have 2 pieces of three pieces forged bodies (the most common is ASTM A105 for
high-temperature service, ASTM A350 LF2 and LF3 for low-temperature service and ASTM A182 F304, F316 for stainless steel
valve or higher grades, such as duplex valves ASTM A182 F51 and super duplex ASTM A182 F53/F55).

Forged bodies are also used for high-pressure valves of higher bore sizes (with 2 or 3 pieces split body construction).

Examples of forged ball valves (small size and stainless steel valve with a forged body, trunnion mounted).

Valves of sizes above 2 inches have a cast body (the most common grades are ASTM A216 WCB for high temp. service, ASTM
A352 for low-temperature service and ASTM A351 CF8, CF8M for cast stainless steel valves).

BALL VALVE GUIDELINES

Based on the body construction the valve could be classified as:
• Single piece design
• Two piece design
• Three piece design
• The short pattern
• The long pattern
• Sandwich design.
• Flush bottom design.

 In the single piece design valve, the body will be cast/forged as one piece. The insertion of the ball will be through the
end of the body and is held in position by body insert. This design restricts the valve to be of regular port only.

 In two piece design, the body is constructed in two pieces and the ball is held in position by body stud. There can be
full port or regular port design possible in this construction. In case of three piece construction, the body has two end
pieces and one centre piece. These are held by body studs.

 The three piece construction permits in line servicing without disturbing the existing pipe work.If the valves have
socket weld, screwed or butt welding ends, this design totally dispenses with the necessity of companion flanges.

 The short pattern and the long pattern of the body is on the basis of the end dimensions Normally short pattern body is
adopted by the manufacturer upto 300 NB valves for 150 LB class. In case of 300 NB to 400 NB class 150 short pattern
valves, the ball may protrude beyond the body and flange faces when the valve is in closed position.

 The sandwich design is the flangeless design adopted by some manufacturers. This is to confine the use of the high
cost exotic materials like Alloy-20. Hastelloy-B. Hastelloy-C etc. To the wetted areas only. The valve is designed to fit
between the flanges. The body cover gets bolted to body with studs or hexagonal head screws.

 The seat rings are renewable in the ball valves except for those having one-piece sealed body construction. The two
different types of seat construction are possible, viz. The fire safe design and the non-fire safe design. In the fire safe
design, a secondary metal seat will be provided so that when the soft seat is fully burnt, the ball will shift its position
and seat against secondary metal seat and arrest full leakage.

 In an actual fire, the heat intensity of the fire could be so different that it is impossible to ensure that elastomer seats
are fully damaged during fire. If the seats are only partially damaged, the ball cannot take seating against the
secondary metal seat and hence the valve would leak. Hence, in my opinion, none of the soft seated ball valves can
be declared fire safe since the valves are bound to leak in case of partially damaged seats. The manufacturers have
come up with metal seated ball valves which are fully fire safe. Here the elastomer seats are replaced by metal seats
which could even be deposited with high temperature resistant materials. The fire safe design should also ensure that
any development of static electricity should be fully discharged by proper design and manufacture of valve. Such an
arrangement is called the ‘Anti-static’ design. This ensures to have a discharge path from ball to the spindle and from
spindle to the valve body with an electrical resistance of not greater then 10 ohms when the valve is new. A typical
method of achieving earthed continuity is to provide stainless steel spring loaded plungers, one fitted between the
stem tongue and ball and second fitted between stem and body.

 The ball could be of full bore or a reduced bore. The design aspect of the same has been explained earlier. The ball at
the bottom end of the body could be supported fully by the seat or it could be trunnion supported. The ball can be
solid ball or of hollow construction with cavity. The cavity is to be sealed when the valves are used in volatile liquid.
This design of the ball is called sealed cavity design.

 The gland shall be bolted type or screwed. Internally screwed stuffing box is not allowed by code. Bellow sealed
bonnet is also provided in case of valves used in lethal services. There are two basic bellow seal designs available. The
same is explained under plug valves.

 The valves shall be operated by wrench or by hand wheel with gear arrangement. The wrench shall be designed so
that it is parallel to the flow passage of the ball. The valve shall be closed, by turning the wrench or the hand wheel in a
clockwise direction. The length of the wrench or the diameter of the hand wheel shall be such that the minimum force
is required to operate the valve under the maximum differential pressure.

Ball valves are a low torque quarter turn valve, with low resistance to flow, suitable for many on-off
utility and process services. They have a straight through configuration. They have a good control
characteristic (equal percentage), but is not generally used for throttling applications in their
standard form because of the potential for seat damage and cavitation (high pressure recovery).
Designs include floating ball and trunnion mounted ball types. Most designs are double seated, but
there are some special single seated designs e.g. eccentric ball (Orbit) types.

a. The majority of valves have soft seat inserts and elastomer or polymer seals. Such valves are
recommended for clean service only and are unsuitable for dirty/abrasive service or high temperatures.
Hard metal seated designs are suitable for abrasive and scaling service and versions having graphite
stem, etc. seals can be used at elevated temperature.
b. Reduced opening valves should normally be specified for lines which do not have to pass pigs and if the
increased velocity and pressure drop can be accommodated. They are not recommended for fluids
containing solids in which the resulting high velocity could cause erosion.
c. Levers should be mounted such that in the open position, the lever is parallel to the pipe axis.
Because smaller valves are lever operated (fast open/close), the possibility of accidental operation
should be considered.
d. If “water hammer” would be unacceptable on liquid systems, valves should be gear operated.

Body design
There are three basic body designs:
• End or side entry (ball fitted through body ends).
• Top entry.
• All welded design.
All may be obtained in full opening (full bore) or reduced opening (reduced bore) versions.
End entry valves may comprise a single piece body (usually small, low pressure designs with a threaded
seat retainer.

Floating ball valve (single piece body) Floating ball valve (three piece body)

a. The removal of the central section of three piece valves is only recommended in small sizes/low pressures.
b. If larger size (e.g. > DN 150 (NPS 6)) end entry valves are manufactured to order, at least one valve
of each unique size and rating should be hydro-tested with blank flanges or welded end caps so as to
load the body joints. Bolting torque for other valves should then be confirmed to be identical.
Top entry designs (See Figure ) have the advantage of only a single leak path to the environment which
is not subject to piping loads and offer the possibility of in-situ maintenance. In practice, in-situ
maintenance may be limited by the valve location, weight of ball, availability of lifting, etc. equipment and
removal of the complete valve is often necessary.

Top entry trunnion mounted ball valve End entry trunnion mounted ball valve
c. Hard metal seated designs having all welded bodies should normally be avoided because of the
risk of experiencing seat sealing problems during FAT which may necessitate cutting open the welds.
All welded body valves have the fewest potential leak paths to the environment, but usually have to be
returned to the manufacturer for maintenance.

Ball Valve trim materials

a. Unplated valve balls should be stainless steel (normally 316 grade). Chrome plated carbon steel balls and
stems should not be used because of the danger of pitting corrosion caused by test water, etc. Electroless
nickel (ENP) plated carbon steel balls (and stems, if integral with the ball) may be used for non-corrosive
service or if water may be present for only a limited period (e.g. line test water). If valves are being
refurbished, a proprietary ENP containing chrome carbide particles may be used to increase wear resistance
(Hychrome).
b. The manufacturer should normally be allowed to choose the soft seat insert material.
Three materials are commonly used :
• At low pressure – virgin PTFE.
• At medium pressure – filled PTFE or nylon.
• At high pressure – PEEK.
c. Virgin PTFE should never be used at high pressure and PEEK should never be used at low pressure.
Nylon should not be used if there is water present in the working fluid or if prolonged exposure to test
water is likely followed by service at a temperature above 70°C (158°F).
d. Valves incorporating soft seals should be fully rated up to their maximum temperature limit.
Pressure/temperature ratings of soft seated valves are limited. The same is true of all ball valves
incorporating soft seals. Some standards (e.g. ISO 17292) allow the manufacturer to reduce
maximum operating pressures below those in the ASME B16.34 rating tables.
e. Metal seated ball valves require the use of hard coatings. If operating temperatures are below 150°C
(302°F) the coating should normally be tungsten carbide although other carbides (e.g. chrome
carbide) are sometimes used for specific applications.
f. At elevated temperatures (e.g. in refinery applications) alloys from the Stellite or Colmonoy range
should be chosen (with a suitable differential hardness between ball and seat to prevent galling or
seizing).
g. Metal seated ball valves should always be chosen for dirty or abrasive service.
h. For high temperature service (> 200°C (392°F), metal to metal seats and graphite stem/body seals
should be specified. Trunnion mounted designs are normally not suitable.
i. Brass or bronze materials for bushings or other wetted parts are not acceptable.