Ball Valve Problems: Are There Substitutes?

Ball valves are essential components in industrial applications. They help to regulate the flow of fluids and gasses through pipes.

While ball valves are generally reliable, they can develop problems that affect their performance and system operation. When a ball valve malfunctions, it can bring your operations to a halt.

In this article, we’ll talk about the most common ball valve problems. We’ll also discuss alternative ball valve options. It’s a must-read for any business that relies on ball valves to keep things flowing.

What Is a Ball Valve?

A ball valve is a flow control device. It uses a pivoting ball to control the flow of fluids and gasses through the valve.

The ball has a hole or bore in its center. When aligned with the valve’s inlet and outlet ports, the ball allows the fluid to flow through the valve. Rotating the ball by 90 degrees closes the valve, blocking the flow of fluid.

Many industrial and commercial applications use ball valves. The valves are durable, reliable, and offer precise control over the fluid flow.

You can find ball valves in a wide range of sizes and materials to suit different applications. They run manually or automatically. The application determines whether you flip a lever by hand or rely on a ball valve actuator.

The oil and gas industry uses ball valves. Chemical, water treatment, and power generation industries also use them.

Common Ball Valve Problems

As mentioned above, ball valves are durable and reliable. They can withstand high pressures and temperatures. That doesn’t mean they’re infallible.

As with any mechanical device, ball valves can develop problems over time. Here are some of the most common issues you may encounter:

Clogging

Particles or debris in the fluid or gas can accumulate inside the valve, causing clogs. Clogging can result in reduced flow rates or even a complete blockage.

If you don’t maintain them, ball valves can become clogged due to buildup of scale, sediment or debris.

Leaking

Ball valves leak due to wear and tear or corrosion. Incorrect installation is another cause of ball valve leaks.

Seizing

A ball valve can seize if the ball or stem becomes stuck. This prevents the valve from turning. Wear and tear, dust and debris buildup, corrosion, and misalignment can cause a valve to seize.

Corrosion

Ball valves can corrode due to exposure to harsh chemicals or environmental factors. Corrosion can weaken the valve’s structure, causing leaks or failure. Moisture and saltwater are just two factors that contribute to corrosion.

Pressure Drops

Pressure drops can sometimes be a problem for ball valves, depending on the application and the specific valve design. Pressure drops can affect the system’s performance and lead to added energy costs.

Solutions to Ball Valve Problems

The good news is that many ball valve problems have simple solutions. Here are a few:

Leaking

Try tightening your connections. You may have a damaged seal or O-ring. In that case, you’ll need to replace the damaged components.

Seizing

You may be able to salvage a seized ball valve by lubricating the ball or stem. Cleaning the valve may help. If neither solution works, you may need a ball valve replacement.

Corrosion

To prevent corrosion, choose materials that are resistant to chemicals and environmental factors. If the valve has already corroded, replace it with a new one made of more durable materials.

Clogging

To prevent clogging, use filters or strainers in the piping system to catch debris before it enters the valve. Once the valve clogs, you’ll need to remove it and clean it.

Pressure drops

To prevent pressure drops, make sure you choose the correct valve for your application. Size matters. An undersized valve can cause an excessive pressure drop, while an oversized valve can lead to flow turbulence.

An ounce of prevention is worth a pound of cure. A good preventative maintenance program helps reduce the risk of problems. If you’re hoping to extend the life of the ball valves used in your operation, routine maintenance is critical.

Impact of Ball Valve Issues

A damaged ball valve can have a significant impact on a business. How much of an impact depends on the severity of the damage and the application of the valve.

If you don’t detect and promptly repair a damaged ball valve, it can lead to several problems, including:

• Downtime
• Safety hazards
• Increased operating costs
• Environmental concerns

Regular inspection and maintenance helps ensure ball valves are working correctly. Repairing or replacing damaged valves helps your business avoid costly downtime.

Are There Ball Valve Substitutes?

Depending on the application and its requirements, you may be able to use a ball valve substitute. Some of the most common ball valve alternatives include:

Gate Valves

These valves have a flat gate that moves up and down to control the flow of fluid. If you have an application that requires a tight shutoff, a gate valve may work.

Butterfly Valves

Butterfly valves have a disc that rotates to control the flow of fluid. Does your application need a quick actuation and a low pressure drop? If so, a butterfly valve can work as an alternative.

Globe Valves

These valves use a disk that moves perpendicular to the flow of fluid to control the flow. They work on applications requiring precise control and regulation of flow.

Needle Valves

Needle valves control the flow of fluid through a long, tapered stem. If you have an application that requires fine flow control, needle valves may work. Needle valves are common in applications requiring fine flow control.

This isn’t a comprehensive list of ball valve alternatives—there may be other substitutes you can use. Fluid, pressure, temperature conditions, and the required flow rate help you decide which valve suits your application.

Need Help Finding the Best Ball Valve Solution?

Even though ball valves are durable, over time, they wear out. Sometimes, they develop problems that require repair or replacement. To avoid ball valve problems, consider beefing up your valve maintenance program.

If you’re in the market today for a ball valve replacement, the team of experts at Everlasting Valve can help. With over a century in the industry, we offer some of the best valve products in the world.

Reach out today to learn more about how we can help you or to ask for a quote.