What is a Flanged type Ball Valve? - Plumberstar

A ball valve is an isolating type of valve. It is used to allow & prohibit the process media flow through the piping system. Ball valves come in different styles and are usually made of other materials. This affects how they can be used. A flanged ball valve is a ball valve designed to have flanged ends. One can use it for shutoff applications. The usage is in hydraulic circuits. A flanged-type ball valve allows the operating fluid to flow when needed. It is very effective in providing positive leak-tight closure. For regulating or throttling purposes, a flanged-type ball valve is not suitable.

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The flanged ball valve is made of carbon steel, stainless steel, or brass. These materials are perfect for temperature tolerance and corrosion resistance, making them robust. This ball valve is a control component in the piping flow system. A spin of 90 degrees with a small torque is enough to close the valve.

Industries use flanged-type ball valves to transport water or other liquids at low to high pressures. Flanged ball valves can start and stop the flow of fluids. They also provide the facility to change pipes without disrupting the entire line.

This type of ball valve is only different from other ball valves on the exterior. Besides the flanges, these valves contain a ball with at least two holes or ports. The standard primary ball valve has one inlet and one outlet with a hole. When rotated 90°, the hole moves vertically to the passageway and blocks the flow.

L-type ball valves have two short bored holes and meet at a right angle in the middle. The ball can be revolved a quarter turn and connect the inlet to the outlet. When the ball rotates a quarter turn in the other direction, it will connect to a second outlet. T-type flanged ball valves have three holes, which meet in the center to form a T shape.

The current can move into both outlets or to one or the other. The ball can differ in size. A complete port ball valve has a ball more prominent than the passage’s size, and the hole is the same diameter as the pipe. There is no flow limit for valves of this kind because the pipe walls are flush with the hole. Compact port balls have small balls with even smaller holes that make it hard to move around.

Components of a Flange-Type Ball Valve

• Body
• Cap
• Ball
• Seat
• Joint gasket
• Seat rings
• Stem Packing
• Gland Nut
• Stem
• H-spring Washer
• Handle Nut
• Nut
• Spring Washer
• Handle Cover
• Thrust Washer
• Locking Device

Flange Ball Valve Operation

• When the valve is used within its rated range, you can maximize its operational life.
• Keeping the flange ball valve in throttled position is not always good, and it may cause damage & seat life.
• A gear unit or an actuator (electric/hydraulic/pneumatic) helps the flange-type ball valve rotate a quarter-turn.

Gear Unit: The clockwise operation of a flange-type ball valve is for closure. The anti-clockwise is for the opening of the valve. It is possible by using the location indicator, which is on the side of the gear panel. Forcing the handwheel or the chain wheel alongside the stops will not provide a suitable valve shutoff and may damage the gear unit.

Actuator: The actuator controls the gear assembly and rotates the shaft. Electrically actuated valves are fixed for manual control. The pneumatic/hydraulic actuators are fitted directly to the valve without a gear connection.

Handling:

• Before moving the valve, it must be correctly stayed and protected. Otherwise, damage to the valve and property may occur.
• The valve should not be dragged to the ground during any movement. A minimum height should be maintained.
• One must not hang the crane wire around the actuator/gear unit. When handling the valve, you should ensure that no external load acts on the actuator/gear unit.
• One should not handle the valves with the handwheel fixed to the gear unit. We should disassemble the handwheel before handling and transporting the valve.

Storage:

• The valves must be kept in a safe environment. Dust and humidity may damage them, so the area should be well-ventilated.
• Before installing the valve, you must ensure that the end protectors are in place. Otherwise, dry pollutants like dust, sand, and grit can scratch the metal surfaces and parts of the seats, causing leaks when the car is being serviced.
• One should keep the valve at a temperature higher than the dew point temperature at the storage location. This will help prevent the increase in water droplets on the valve sheet.
• It is against the law to leave the valve on the floor. We can put it on a wooden pallet just above the floor. We must always avoid damaging protruding parts of the adaptor, gear unit, or actuator during storage.
• Incompatible grease or any other material inside the valve is prohibited. It may malfunction the valve.
• The steel valves were coated with a nontoxic Manganese Phosphate, which slows down the formation of rust during storage. Stainless steel valves, with their natural finish, can also be used. They may not require any additional protection because of their natural finish.

Instructions for Using Flange Ball Valve

• The assembly and disassembly of flange-type ball valves depend on the relief of the upstream and downstream pipes. One should remove non-metal parts instantly after cleaning. These should not be drenched for a long time in the cleaning agent, which should be well-matched with the rubber parts, plastic parts, metal parts, and working medium like gas. We can use gasoline as a cleaning agent for metal parts when the working medium is fuel gas. Using grease is compatible with flange ball valve metal materials.
• The bolts on the flange must be tightened correspondingly & steadily.
• We can submerge all parts of the flange ball valve in cleaning solutions. A clean silk cloth soaked with a cleaning agent can scrub the non-metallic elements. Washing the parts in cleaning agents for an extended period is not good. It may rust. Grease, dirt, glue, dust, etc., adhering to the wall should be removed while cleaning. 
• Non-metallic parts are susceptible. Pure water or alcohol can be used to clean non-metal parts. We should be conscious while disassembling and reassembling the flange ball valve to prevent damage to the sealing surface of the details.
• During assembly, metal debris, fibres, grease, dust, and other foreign impurities should not contaminate the surface of the parts. The inner cavity of the valve should also be monitored.

Installation of Flange Ball Valve

Before installing a Flange Ball Valve, we should be concerned about the following necessary steps:

• The front and rear pipes should be coaxial. The sealing tops of the two flanges should be parallel. The pipeline should be able to bear the weight of the valve. If it is impossible, the channel must be equipped with proper support.
• We should run an expulsion procedure of the channels to remove oil, welding slag, and all other impurities present in the pipeline. 
• The flange ball valve should be fully intact. For this, we can check the sign of the flange ball valve and make sure. We should also make sure that the valve is working correctly. We can check it by opening and closing the valve several times.
• Eliminate the protective parts of the flange ball valve at both ends of the connecting flanges.
• Check the valve hole to eliminate and clean any possible filth. Even small foreign particles between the valve seat and the ball may harm the sealing surface of the valve seat.

From Process Systems

Installation Procedure:

• A handle drives the flange-type ball valve. The handle can be installed anywhere on the pipeline. Sometimes, a flange ball valve is driven by a gearbox or has a pneumatic drive. The pneumatic drive should be installed upright or on a horizontal pipeline. The driving device should be straight above the channel.
• A gasket needs to be installed between the valve flange and the pipeline flange according to the pipeline design requirements.
• The bolts on the flange should be tightened symmetrically and consecutively.

Inspection

• To inspect, operate the valve with a driving tool to open and close the flange ball valve several times. This operation should be flexible. We have to confirm that the valve is working appropriately.
• A proper flange joint between the pipeline and the flange ball valve is necessary. It should be according to the channel’s design requirements.

Maintenance & Repair of Flange Ball Valve

To get a longer service life and maintenance-free period for flange-type ball valves, we should maintain a good temperature/pressure ratio. The following provisions should be taken while carrying out the repair and maintenance of the Flange Ball Valve:

• Ensure fluid is under pressure inside the valve even after shutting off the flange ball valve.
• Discharge the line pressure and open the valve before servicing the flange ball valve.
• Separate the power or air supply from the driving mechanism before repairing the flange ball valve.
• Detach the actuator from the bracket before maintenance.
• Discharge only the upstream and downstream pipelines of the flange ball valve before disassembly.

Replacement of seats and seals

• Ensure that the pipeline has been reduced, depressurized, and emptied.
• Loosen and remove the flange screws and nuts.
• Spread the flanges using a proper tool and remove the valve.
• Close the valve.
• Loosen and remove the hexagon nuts from the stud bolts.
• Eliminate the body connector from the body.
• Eliminate seats, ball, and body seal. Be careful about any damage.
• Eliminate the handle nut/screw and hand lever.
• Take off the gland flange and disk spring washers and remove the gland.
• Push the stem into the valve body and remove it carefully.
• Eliminate the thrust washer and primary sealing from the branch.
• Remove the stem packing and thrust washer.
• Clean all parts, especially the sealing surfaces of the ends.

Assembly of Flange Ball Valve

• Clean and review all the removed parts.
• The seals, valve seat, and bonnet gasket are suggested to be substituted with a spare part.
• Tighten the flange connection bolts crosswise with the indicated torque.
• Tighten the stem nut with the listed torque.
• After installing the actuator, put the corresponding signal. It helps to rotate the valve core. 
• It will be good to have a pressure seal and performance test on the valve, which should occur according to related standards.
• The packing should be leak-free. If it is, the stem nut must be locked again or replaced with the valve seat and seal.

Disassembly of Flange Ball Valve

• Stay the valve in the half-open position to flush. Eliminate the dangerous substances that may exist inside and outside the valve.
• Eliminate the connecting bolts and nuts on the flanges on both sides. Then, remove the valve entirely from the pipeline.
• Take the drive device actuator, connecting bracket, anti-loosening washer, valve stem nut, butterfly spring, wear plate, and valve stem packing.
• Remove the body cover connecting bolts and nuts. Detach the valve cover from the valve body and remove the valve cover gasket.
• Ensure the flange ball valve is in the “off” position. The valve body can now be easily detached. After that, the valve seat should be removed.
• Push the stem lightly through the hole in the valve body until it is completely removed. After that, remove the O-ring and the packing under the branch.

Application & Use of Flanged Ball Valve:

A ball valve is usually used to turn a pipe on and off. The pipe contains solids, slurries, liquids, or gases in suspension. Ball valves are also used extensively in tubing systems, equipment, and tools to move fluids. They are everywhere, from the factory floor to your house. Manufacturing, mining, oil and gas, agriculture, heating and cooling, plumbing, water, consumer goods, construction, and other industries use them.

Advantages of Flanged Ball Valve:

In the industrial piping systems, the flange ball valve plays a crucial role in ensuring efficient flow control, safety, and ease of maintenance. From oil and gas pipelines to chemical processing and water treatment facilities, flange ball valves are prized for their robust design, reliable shut-off capabilities, and operational simplicity. This article will provide an in-depth exploration of flange ball valves, covering their design, advantages, materials, and applications, while also highlighting the strengths of Tanggong Valve Group’s flange ball valve offerings.

What is a Flange Ball Valve?

A flange ball valve is a type of valve that utilizes a ball with a hole (bore) in its center to control the flow of fluids. The valve is named after the flanged ends that are used to connect it to a pipeline. These flanges allow the valve to be securely bolted between two sections of pipe, providing a reliable seal and enabling easy removal or maintenance. The ball itself, when rotated 90 degrees, allows or blocks fluid flow, making it ideal for on-off applications.

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How Does a Flange Ball Valve Work?

This image shows a sectional drawing of a flange ball valve, illustrating its main components and how it operates. Here’s a basic explanation of how the flange ball valve works:

Flange Ball Valve Diagram

Components Overview:

• Handle (13): Used to manually control the valve position.
• Ball (2): The main element that controls the flow of fluid.
• Valve Seat (7): Creates a seal with the ball to prevent leakage.
• Valve Stem (8): Connects the handle to the ball, allowing for rotational movement.
• Valve Body (1): Encloses the internal components and provides the flange connection points.

Working Principle

Open Position:

When the handle (13) is turned 90 degrees counterclockwise, it rotates the valve stem (8) and the attached ball (2). The ball has a hole (bore) through its center. In the open position, this bore aligns with the inlet and outlet ports of the valve body (1), allowing fluid to flow freely through the valve.

Closed Position:

When the handle is rotated 90 degrees clockwise, the ball rotates such that the solid portion of the ball blocks the flow path. The valve seat (7) seals against the surface of the ball, preventing any fluid from passing through.

Sealing and Operation:

• Packing (9) and Packing Press Cover (10) help to maintain a seal around the valve stem to prevent leaks from the top.
• Limiter (12) prevents over-rotation of the handle, ensuring precise control over opening and closing.
• Bolts (5) and Nut (4) secure various components together to maintain structural integrity and prevent leakage.

Material List of Flange Ball Valve

No. Part Name Material 1 Valve Body Cast Stainless Steel (ASTM A351 CF8M) or Carbon Steel (ASTM A216 WCB) 2 Ball Stainless Steel (SS316 or SS304) 3 Intermediate Washer PTFE (Teflon) or Graphite 4 Nut Stainless Steel (SS304 or SS316) 5 Bolt Stainless Steel (SS304 or SS316) or Alloy Steel 6 Valve Cover Cast Stainless Steel or Carbon Steel (matching valve body) 7 Valve Seat PTFE (Teflon), Reinforced PTFE, or RPTFE 8 Valve Stem Stainless Steel (SS316) 9 Packing PTFE (Teflon) or Graphite 10 Packing Press Cover Stainless Steel (SS304 or SS316) 11 Inner Hex Screw Stainless Steel (SS304 or SS316) 12 Limiter Stainless Steel (SS304 or SS316) or Carbon Steel 13 Handle Carbon Steel with Vinyl Coating or Stainless Steel

This table provides a concise view of the different materials used for each part of the flange ball valve.

Technical Parameters of Flange Ball Valve

Parameter Description Nominal Diameter (DN) Typically ranges from DN15 to DN600 (1/2″ to 24″). Pressure Rating PN10, PN16, PN25, PN40, Class 150, Class 300, etc. Temperature Range -29°C to 200°C (depending on materials used). Connection Type Flanged (RF – Raised Face, FF – Flat Face, RTJ – Ring Type Joint). Operation Type Manual, Pneumatic, or Electric Actuator. Body Material Stainless Steel, Carbon Steel, or other alloys. Ball Material Stainless Steel (SS304/SS316). Seat Material PTFE (Teflon), Reinforced PTFE (RPTFE), or Metal. End Connection Standard ANSI B16.5, DIN, JIS, GB, etc. Leakage Class ANSI FCI 70-2 Class VI (soft seats), Class IV (metal seats). Flow Characteristics Full bore or reduced bore (to control flow rate). Seal Type Soft seal (PTFE) or Metal-to-Metal. Face-to-Face Dimension As per ASME B16.10 or DIN EN 558-1 standards. Testing Standard API 598, EN , or ISO . Actuation Torque Varies depending on valve size and pressure, typically measured in Nm (Newton-meters).

These parameters cover the important specifications needed to understand the performance, application suitability, and operational aspects of a flange ball valve. The exact values may vary depending on the valve design, manufacturer, and the specific application.

Key Features and Benefits of Flange Ball Valves

Flange ball valves are highly regarded for their versatility and functionality in industrial applications, combining key features such as simple operation, excellent sealing capabilities, and low maintenance. Here are some of the essential features and benefits that make flange ball valves a popular choice in fluid control systems.

1. Full-Bore Design and Flow EfficiencyOne of the primary advantages of flange ball valves is their full-bore design, which allows fluid to pass through the valve with minimal resistance. The full-bore construction ensures that the internal bore diameter matches that of the pipeline, eliminating flow restrictions, minimizing pressure drop, and reducing the risk of erosion. This feature makes flange ball valves particularly suitable for applications where high flow rates with low turbulence are critical, such as in oil and gas transportation, refining, and water supply systems.
2. Robust Construction and Material VersatilityFlange ball valves are available in a variety of body materials, including carbon steel, stainless steel, and nickel alloys. This versatility in material selection enables the valves to be used in diverse environments, from low-pressure water lines to highly corrosive chemical processing systems. Stainless steel is often preferred for its superior corrosion resistance, while nickel alloys provide exceptional strength at high temperatures. Depending on the nature of the media, the valve seats are often made of PTFE, RPTFE, or even metal-to-metal for demanding applications.
3. Reliable Sealing PerformanceFlange ball valves employ wedge-shaped seals that are pressed firmly against the ball, providing an excellent sealing surface even under varying pipeline pressures. Additionally, the valve’s self-cleaning mechanism ensures the continuous removal of any buildup on the sealing surface, which enhances longevity and reduces maintenance costs. This self-cleaning effect occurs when the ball tilts away from the seat, causing the fluid to flush across the sealing surface evenly, thus extending the life of the valve.
4. Ease of Operation and MaintenanceThe quarter-turn operation of flange ball valves makes them incredibly easy to use, enabling quick opening or closing of the flow line with a simple 90-degree turn of the handle or actuator. This feature is particularly advantageous in situations where rapid shutoff is required, such as emergency isolation in industrial settings. Furthermore, many flange ball valves come with swing-out body construction, which allows for easy maintenance without completely removing the valve from the piping system. This reduces downtime and facilitates cost-effective maintenance.

Applications of Flange Ball Valves

Flange ball valves find extensive applications across a wide range of industries, thanks to their robust design, versatility in material options, and ability to provide precise flow control. Here are some key application areas and associated benefits:

1. Oil and Gas IndustryFlange ball valves are integral to the oil and gas industry, where they are used in upstream, midstream, and downstream operations. In upstream processes, they are installed at wellheads to control the flow of crude oil and natural gas. During midstream transportation, they regulate the movement of these fluids through pipelines, ensuring safe and efficient delivery. In downstream processes, such as refining and petrochemical production, flange ball valves help in isolating different sections of the refinery and managing fluid flows between units. The ability of flange ball valves to withstand high pressures, up to Class , and extreme temperatures makes them highly suitable for these demanding environments.
2. Chemical and Petrochemical IndustryIn chemical processing, flange ball valves are utilized for their excellent chemical resistance. The wide variety of materials available—such as stainless steel, nickel alloys, and titanium—makes them compatible with corrosive chemicals and volatile substances. The use of specialized materials like PTFE and PEEK for valve seats provides broad chemical compatibility, while the full-bore design reduces pressure drop and helps minimize the risk of erosion when handling aggressive chemicals. Furthermore, the availability of different configurations, such as three-piece designs, makes maintenance easier, which is essential in a chemical plant where operational downtime must be minimized.
3. Power GenerationThe power generation industry relies heavily on flange ball valves for various steam, water, and fuel control applications. They play a crucial role in managing the flow of water and steam in boilers, as well as controlling the fuel supply in power plants that use coal, oil, or natural gas. Flange ball valves with reinforced PTFE seats or high-temperature-resistant thermoplastics can withstand the intense conditions found in power generation, such as high-temperature steam environments. The robust sealing mechanisms in these valves ensure minimal leakage and efficient shutoff during operations.
4. Water and Wastewater TreatmentFlange ball valves are widely used in municipal and industrial water treatment facilities. They serve to isolate sections of a pipeline for maintenance and regulate the flow of treated water. The corrosion resistance of materials like stainless steel and brass makes these valves ideal for handling treated and untreated water, including those with sediments or chemicals. The full-bore design of these valves ensures minimal flow resistance, which is essential for efficient water distribution across treatment facilities.
5. Food and Beverage IndustryIn food and beverage applications, the materials used for flange ball valves must comply with sanitary standards to prevent contamination. Stainless steel grades like 316 are commonly employed due to their non-reactivity with food products and resistance to corrosion. Flange ball valves are used to control the flow of liquids, such as juices, milk, and water, as well as in clean-in-place (CIP) processes where sanitation is critical.
6. HVAC SystemsHeating, Ventilation, and Air Conditioning (HVAC) systems also make extensive use of flange ball valves. These valves are employed to control the flow of refrigerants, cooling water, and other fluids in HVAC systems. The simplicity of quarter-turn operation allows for rapid on-off control, which is particularly useful in balancing and isolating different zones in HVAC systems to maintain optimal temperature control.
7. Pulp and Paper IndustryIn the pulp and paper industry, flange ball valves are used to manage the flow of water, chemicals, and pulp slurry. The durability of these valves ensures reliable performance, even in conditions involving abrasive pulp slurries. The use of full-bore valves helps maintain a consistent flow rate with minimal obstruction, reducing energy consumption in pumping systems.

Overall, the wide range of available materials, robust sealing mechanisms, and various design configurations make flange ball valves an excellent choice for numerous industrial applications. They are highly effective in handling different types of media, from gases and liquids to chemicals and slurries, and are designed to offer reliable performance in both standard and challenging conditions. Their versatility, ease of maintenance, and ability to provide precise flow control have cemented their place as an essential component in industrial flow systems.

Ball Valve Air Tightness Test

Below is a video demonstrating the testing process of a flange ball valve, showcasing its performance under operational conditions. This visual representation will give you a better understanding of the valve’s sealing capabilities, pressure handling, and overall reliability, which are crucial factors for industries that demand safety and efficiency.

Conclusion

Flange ball valves are an indispensable component in modern industrial piping systems, providing reliable shut-off, ease of operation, and minimal maintenance requirements. Whether in the oil & gas sector, chemical processing, or water treatment, these valves play a key role in ensuring safe and efficient operations. Tanggong Valve Group is committed to delivering high-quality flange ball valves that meet the diverse needs of our customers, backed by our expertise, quality standards, and dedication to customer satisfaction.