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    Ball valves are used for many purposes, from cutting water usage to liquid flow. They have a role as shutoff valves that can control the flow of fluids and gases through a unit. Conventional ball valves are inappropriate for process installations that wash in place. The area between the ball and seal face is not cleaned due to inner-body cavities.

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    Ball valves are used for many years for controlling media in plant piping. A ball valve may lasts for 8-10 years if you follow the bellow tips about its management.

    What Are Ball Valves?

    Ball valves are created for controlling different types of media. Ball valves offer continuous, smooth flow paths with tiny pressure drops. Ball valves are an easy-to-use mechanical device used in the water gas and oil industries. To allow or prevent flow, they have a rotary ball with a bore that you can open or close often.

    The food product is transferred into the cavity when the valve is worked from its open. When the ball valve is turned open from its closing position, the food trap is in the space and not removed. As a result, dust or debris deposit in the inner cavity and cause damage or blockage. 

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    How Do We Protect The Ball Valve For A Long Time?

    If you want to protect the ball valve for a long time, you should keep the ball valve maintained. 

    Does regular maintenance significantly affect the lifespan of your ball valve? Here are some steps you should notice during the maintenance program.

    •  Proper installation

    When your ball valve is installed in the correct position, there is a lower chance of replacement. Ensure the experts have experience in ball valve maintenance and installation. 

    • Valve Lubrication

    Lubrication helps your ball valves from working and prevents erosion. It also helps to increase the efficacy of the valve seals. Choose synthetic, oil-based water-insoluble lubricants and avoid solid lubricants. Make sure you should choose a lubricant that is compatible with the media. 

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    • Regular Cleanings

    Cleaning your valves will last longer, but if you do not clean for a long time, it affects the system’s efficiency. You can use a towel to remove the valve’s oil, dirt, or dust. Also, you can use cleaning agents that would not react with the valve materials. Compressed air cleaners work well for metal elements, and water-based cleaners are used for non-metal parts. At least once a year, you should clean your ball valves.

    • Routine Operated

    On a routine basis, you should check your valve with an expert. For most ball valve applications, you should need to do often inspections. Some inspections are explained below:

    1. Leak hazards
    2. Position indicator accuracy 
    3. Tightness of bolts, nuts, and other parts
    4. Proper opening and closing of valves
    5. The presence of corrosion or mineral buildup
    6. Proper air filtration in the area

    When Should We Replace The Ball Valve?

    When you see your ball valve get worn out due to constant rotation. Now you need to replace your ball valve. You know, ball valves are an essential part of both piping and plumbing systems. They are usually the most stable and prevent leaks and damage. Once you understand the proper steps, replacing the ball valve is a simple process. 

    For the first part of the process, you need tools only that are adjustable wrenches and a cloth. After, you may need to have screws, a screwdriver, and lubricating oil according to the situation. Once you have gotten these tools, you should follow the below-listed steps for ball valve replacement.

    1. Turn off Water Supply

    In the first step, you need to turn off the water supply so the replacement can quickly be done. Rotating off the water supply ensures you do not waste more water than has already been destroyed because of the broken ball valve.

    Drain excess water and dry off the valve with a cloth after the water has been cut off. Remove the handle to check where the ball valve is held together by screws. Then use a suitable wrench to remove it. You will easily be able to remove the ball valve, showing the source of the problem.

    stainless ball valve with blue handle. industrial valves for special purposes.

    2. Remove and Disassemble The Ball Valve

    Operation is the key to completing the further step of the process. When removing the ball valve ensures to keep all the parts are together. If parts are misplaced or lost, it will be more challenging to find the problem. This will lead to confusion and even cause you to pay more money. 

    Every type of ball valve has different from another valve. They have different parts to fulfill additional requirements. But you will check four other details if you work with a compact PVC ball valve. These are the double stem O-ring, handle, joint end more O-rings, and the sphere ball valve.

    3. Examining Ball Valve Parts

    Checking the ball valve parts, you should be able to find wear, cracks, or tear that have led to the leaking. If you find a problem with a specific part but notice that the rest parts like to be expected, the best solution is to the replacement part.

    Once you have replaced the worn part, use screws and the lubricating oil to match the parts. When you notice a problem with many parts of your ball valve, you will need to get a new ball valve.

    4. Replace Ball Valve

    If, after completing the steps to fix a ball valve, you will find that you need a total ball valve replacement. Check out some high-quality ball valves that last for a long time. If you want versatility, look at the ball valve with removable ends and its design.

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    What causes the ball valve to fail?

    Several factors will affect the ball’s longevity of the ball value e. which is why most manufacturers don’t set lifespan guarantees. Every design, environment, and use will be different from others.

    What is the material construction of the ball valve? 

    The liquid or gas you use determines the right materials for your ball valve. The valve body must be created of compatible material, the pressure rating. If the material is other than metal, elastomeric, and polyvinyl chloride, it may cause damage.

    Media are you working

    Ball valves provide on/off control for gases and liquids, such as water, oil, chemicals, and air. It’s best to avoid abrasive media or media with suspended particulates. The abrasiveness of the media can result in premature valve seal failure, which can cause leaks. The valve operating torque could also rise and cause the actuator to fail. 

    Here are a few causes why ball valves leak on the outer body and packaging. These causes are explained below: 

    • Manufacturing defects
    • Packed gland deflection
    • Frequent switching off and on
    • Failure to install as per the given instructions
    • Insufficient and Invalid packing

    Usually, valves can leak completely or be damaged for many reasons. The media or fluid can leak out if the valve is not closed due to the carelessness of debris. Old, worn-out valves also start leaking, signaling for replacing a valve. Even zero-leakproof valves may often leak if they are not closed entirely. Sometimes, valve leaks occur when an application is unsuitable for the system. 

    A common cause of ball valve issues occurs due to incorrect installing parts with valves. For example, you need to check valve seats to check which ones will stand up to the specific combination of pressure and temperature. You should also take care of ball valves after they are disconnected. It is easy for pieces to get cracked from place to place. You will want to see breaks before you hit the valve back on.

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    What happens if the ball valve is not protected daily?

    When the ball valve is not protected or maintained daily, it causes many failures. One of the most common ball valve failures is a deposit of dirt and sediment within the valve. These dirt particles make it difficult to open and close the valve. Using cement glue solvent can also block the ball, causing it to stick to the inside of the valve. You must remove the valve and clean any dirt with a towel if this occurs.

    Another failure occurs in the ball valve when the elastic is used to seal the valve. It gets worn down over time by gas-liquid getting pushed through it. You will want to remove the elastic when you see any leakage or cracks. Moving down the intensity of liquid flowing through the valve can also boost lifespan.

    Make sure to look for leak points at the nuts bearing the bolts. Shows that the nuts or bolts are too loose to need realignment. Damage to O-rings around the nuts can also cause leaks.

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    Summary

    Failure also occurs when the actuator starts to fail, as this piece helps control the flow of media via the valve. Picking the suitable actuator is essential here, as different actuators handle different speeds. 

    To prevent these problems, the best solution is to calculate the average life of your ball valves. All above, we have explained how to improve the long life of the ball valve. Also, you have learned the causes or failure of the ball valve. If you have any questions about ball valve replacement, contact us. 

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