1. What is a Flanged Ball Valve?
Flanged Ball Valve is used in flowing on and closing off system application for fluid flow and it refers to a ball valve design that comes with flange connections on both ends. The main function is to control the flow of water, oil, and gas by rotating the ball with a 90-degree quarter turn around the top handle. Flange end ball valve can be made of various material standards such as stainless steel, cast iron, or carbon steel. The material selection is based on the tolerance to temperature and its corrosion-resistant properties.
The flanged ball valve is manufactured following different specification standards and the most common types are JIS, DIN, and ANSI flanges. The different specification with different connection types affects greatly on the scope of application. It is most effective in providing positive leak-tight closure and a flanged ball valve opens and closes the operating fluid flow completely. It is basically not suitable to use in regulating and throttle flow purposes.
The main components of flanged ball valves are the body, ball, seat, and stem. A manually flanged ball valve can operate by positioning its handle at certain angles for open and close positions. Alternatively, it can operate through the use of electric or pneumatic actuators. The flanged ball valve comes with an ISO mounting pad and this allows the installer to mount the actuator directly to the valve without a bracket plate. It helps in a time-saving, hassle-free, and high-cost installation.
2. What is the difference between JIS, ASME, ANSI Flanged Ball Valve?
Flanged ball valve comes with a variety of flange specification standards. There are 3 common flange standards available in our stock:
Japanese Industrial Standards, JIS (JIS10K)
American National Standards Institute, ANSI (ANSI 150#, ANSI 300#)
Deutsches Institut für Normung, DIN (PN10, PN16, PN40)
Each flange standard has its own pitch circle diameter, known as PCD. It is defined as the diameter of the circle that passes through the centre of all the studs. The easier way to measure PCD is by measuring the distance between the two adjacent studs from the centre of each of the flange holes. It is not interchangeable during installation for the above three types of flanges. The nominal pipe size is important to connect with a flanged ball valve.
JIS10K Flange End Ball Valve
ANSI 150# Flange End Ball Valve
PN10/16 Flange End Ball Valve
3. What is a fire-safe Flanged Ball Valve?
Fire-safe flanged ball valves are to maintains their pressure-containing ability during and after a period of fire exposure. There is a possibility of hazardous or flammable fluid leakage from the valve during fire events. Compare to a fire-safe valve design, a non-fire safe valve design has the likelihood to be exposed to a fire pool during an accident. It caused leakage from the valve stem seal and it feeds the fire and makes the fire bigger than before. Therefore, a fire-safe flanged ball valve creates a safe environment when an accident happened. A fire safe flanged ball valve shall be tested and certified according to API 607.
It is important to differentiate between classified fire-safe valves as per below:
A “fire-safe by design” valve is designed to be fire safe and it hasn’t been tested.
A “fire-safe tested” valve might have been tested but it hasn’t been qualified by a governing third party.
A “fire-safe approved and certified” valve is been tested, approved, and certified according to common standard API 607 by a governing third party.
4. How long should a Flanged Ball Valve last?
The lifespan of a flanged ball valve depends on a handful of factors. When it is high-cycle or high-pressure application settings, it requires high maintenance servicing or replacement which compares to those infrequent operations to keep the valve operates.
Media: Media with suspended particulates that are abrasive or grinding in nature can cause the ball valve seals to fail prematurely and cause leakage. It is subjected to the severity of the media characteristics. The operating torque may rise dramatically causing actuation failure in system operation.
Materials: The material of the flanged ball valve body and seals must be compatible with temperature and pressure ratings, together with the chemical makeup of the gas or liquid that will flow through the valve. Material stainless steel is a highly durable and corrosion-resistant material, while metal materials are the best choice for high-temperature applications.
ANSI 150# SS316 Flange End Ball Valve
Temperature & working pressure ratings: In general application, the media temperature will decrease when the media working pressure increases. Both temperature and working pressure media will affect the proper materials, valve design, and valve sealing materials. The overall combination affects the lifespan of a flanged ball valve.
Actuations: Flanged ball valve operates the manual or electric actuator. A pneumatic actuator valve is used in the compressed air system and it provides fast cycle times and high durability. An electric actuator is required in low cycle speeds application and the slow speed helps prevent water hammer in high-pressure applications. A flanged end valve with an actuator will last longer compare to manual valve operation.
Maintenance: A valve designed for serviceability is important to keep the lifespan. Example: three-piece ball valve. These valves centre section and seals can be replaced easily and safely.
5. What is the preparation before the assembly of Flanged Ball Valve?
The plain-end front pipes should be coaxial. This is to ensure the sealing surfaces of the two flanges should be parallel to each other. The pipeline must be equipped with proper support before installation confirmation or should be able to bear the weight of a flanged ball valve.
To remove the internal oil, welding slag, solid materials, and all other impurities present in the pipeline, purge the pipelines before and after the flanged ball valve.
Check the sign of the flanged ball valve and ensure it is fully intact. Opening and closing the valve several times to ensure the valve is working properly.
Ensure the valve specification and working pressure is correct. Do not use the valve at a pressure above its working pressure as it will cause a system burst.
Remove the protective parts such as the cap of the flanged ball valve at both ends of the flange connection.
Check the valve hole to clean the internal diameter. Remove all particles between the valve seat and ball as it may damage the sealing surface.
6. What is the inspection after installation and maintenance steps?
Inspection after installation
Maintenance & Repair
HOW TO INSTALL A FLANGE END BALL VALVE
*** The flanged ball valve with a lever handle can be installed at any position on the pipeline installation in any orientation.
Install the valve on the pipeline as per instruction. Either end can be installed on the upstream end.
Do take note that a flanged ball valve with a pneumatic actuator should be installed upright, eg: installed on a horizontal pipeline and the drive device should be above the pipeline for easy operation purposes.
Install a mechanical seal gasket between the valve flange end and pipeline flange according to the pipeline requirements.
The four to eight bolts on the flange should be tightened symmetrically, successively, and evenly.
Connect the pneumatic actuator pipeline at last in case of a pneumatically driven flanged ball valve.