Forged Steel Floating Ball Valve

Forged Steel Floating Ball ValveZeco’s  forging ball valve has a floating ball supported by two valve seats.

Principle: 

This kind of forging ball valve has a floating ball supported by two valve seats. Under the medium pressure effect, a certain displacement can be generated by the ball itself so as to be pressed onto the seat seal ring at the outlet, guaranteeing tightness at the outlet.

Features：

1. Simple structure with good tightness and small torque;

2. Have reduce bore type and full type with the minimum flow resistance(zero actually);

3. Low emission packing;

4. Fire safe, anti-static and anti-blow out stem design;

5. Optional locking device.

Product Range:

Body material: carbon steel, stainless steel, alloy steel

Nominal diameter:1/2″～6″（DN15~DN150）

End Connection: RF, RTJ, BW, THR, SW

Pressure range: Class150 – 2500（PN16~PN420）

Operation : wrench, worm gear, electric, etc

Brand	Zeco
Valve Type	Forged Steel Floating Ball Valve
Valve Material	Cast steel, stainless steel, special alloy, etc
Valve Test	100% quantity tested before delivery
Valve Guarantee	18 months from the date of dispatch ex works, or 12 months from date of commodity installation.
Valve Painting	Customer request
Valve Package	Wooden case
MOQ	No requirement
Valve Certificate	API 6D/CE/ISO9001/ISO14001
Delivery Detail	Shipped in 4 or 6 weeks after payment
Port	SHANGHAI
Payment Terms	L/C, D/A, D/P, T/T
Certificate Offered	Packing List, Commercial Invoice, Test Reports and Material Certificates, Certificate of quality and quantity, Seller’s Certificate of Guarantee

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What is a Trunnion Ball Valve?

Trunnion mounted ball valves are quarter-turn valves used to stop the flow of medium in pipelines. These valves feature a round or spherical disk in the center that rotates to start or stop the flow. This disk is called a ball and it features a hollow center. Ball valves are extremely versatile and are commonly used in industrial applications where tight shut-off is required.

Trunnion mounted ball valves feature additional support for the ball. This support is in the shape of a shaft and is called a trunnion. The trunnion absorbs any added pressure from the flow, reducing stress on the ball and seats of the valve. Trunnion mounted ball valves are used in high-pressure, large-scale applications where low operating torque is required.

How does a Trunnion Ball Valve work?

Trunnion ball valves are quarter-turn valves. This means you need to turn the actuator on a 90-degree angle to turn the valve on or off. Once the actuator is turned the ball rotates so that the bore faces the pipeline and the medium can flow freely. Another turn of the handle moves the ball so that the bore faces away from the pipeline stopping the flow.

In a trunnion design, the ball is inserted in a central bottom shaft which is called the trunnion. The ball is fixed between the stem and the trunnion, which inclines that the ball is not floating but fixed and centered. The inline pressure presses the seats against the ball, causing tightness. This inclines that during operation, the ball does not have to be rotated against the in-line pressure (∆p) and the valve seats, but that it solely needs to be rotated against the pressure of the seats.

Types of Trunnion Ball Valves

Based on Body Structure

The valve body of a trunnion ball valve can have one or more pieces joined together through welded joints. There are two kinds of trunnion ball valves based on their number of pieces.

Two Piece Trunnion Ball Valve

This valve features two pieces of housing that are connected to each other through threaded connections. It is easy to open up one piece of housing to access the valve for cleaning or repair. However, the valve has to be disengaged from the pipeline before the housing can be removed.

Three Piece Trunnion Ball valve

The three-piece trunnion ball valves are a step ahead of its two-piece version. They’ve got three bits of the casing that are bolted together. You should remove one section to access the inside of the valve for maintenance and repair. However, there is no need to disconnect the valve from its pipeline to remove it for maintenance.

Based on Body Configuration

The body configuration features tell how a ball valve can be used and the ease of repairs and maintenance. Based on these parameters, three types of trunnion ball valves will be examined:

Top Entry Trunnion Ball Valve

This type of ball valve has a removable bonnet cover on the top of the valve. The internal parts of the valve can be easily accessed by removing the bonnet. These valves are easy to assemble and disassemble. You can repair or maintain different parts of the trunnion valve without removing them from the pipeline.

Side Entry Trunnion Ball Valve

This type of design is also referred to as the split body trunnion mounted ball valve. It assembles its ball from the side. They are often made out of forged metal. In this design, the body is often divided into three or two pieces that are joined together like extensions. A piece of the body is most often bigger than the rest of the design. This larger piece holds the stuffing that winds around the ball and the ball itself. For this design, they are easily repairable and can be inspected as the smaller piece can be pulled out to access the valve.

Based on Bores

A bore in a ball valve is the hole present in the ball’s center. There are two types of this design for trunnion ball valves based on bore size.

Full Bore Trunnion Ball Valve

In full bore valves, the size of the diameter of the bore matches that of the connected pipeline. When the valve is open, the medium can flow freely without restriction through the bore. This type of ball valve is used in chemical, petrochemical, and refining industries. They are also used in applications where pigging is required.

Reduced Bore Trunnion Ball Valve

A reduced bore valve is a design that has a bore size lesser than the connected pipeline’s diameter. The flow path of the channel is limited and results in greater energy loss. They are applicable to the gas and oil industry.

Applications of Trunnion Ball Valves

Oil and gas industries

Trunnion ball valves are perfect for a wide range of applications in several oil and gas industries. Examples of oil and gas industries that utilize trunnion ball valves include gas feed lines, field gas plants, industrial gas processing plants, oil refinery feedstock lines, and crude oil plants.

Pipeline industries

The ability of trunnion ball valves to handle several different applications such as gasses, slurries, and liquids makes them highly valuable in the pipeline industry.

Hydrocarbon industries

Because trunnion ball valves are useful for the facilitation of hydrocarbon processing, they are extremely popular among hydrocarbon industries.

Power Industries

Trunnion ball valves are suitable for numerous applications such as turbines, skids, generators, and compressors which are integral to the operation of power industries.

Chemical industries

Offering incredible safety, durability, and sealing capabilities, trunnion ball valves suit a wide variety of chemical industries where such competencies are imperative.

Features of Trunnion Ball Valves:

• EMERGENCY STEM SEALANT INJECTION: This standard feature allows the valve’s stem housing to be adapted with a grease fitting to inject sealant during emergency scenarios, providing protection against unplanned spikes in operating conditions.
• EMERGENCY SEAT SEALANT INJECTION: This optional feature allows the valve’s end connections to be adapted with a grease fitting to inject sealant. This creates a positive seal in the case of seat leakage due to service impurities or unplanned spikes in operating conditions.
• DRAIN AND VENT PORTS: Drain ports located at the bottom of the valve release any fluid trapped in the body cavity of a closed valve. Vent ports located at the top of the body cavity eliminate any gas trapped in the body cavity of a fully closed valve. Both play a key safety role in the double block and bleed and/or double isolation and bleed valve configurations.
• DOUBLE BLOCK AND BLEED: This safety feature eliminates the buildup of pressure due to high-pressure media trapped in the valve’s body cavity, even while the valve is in the fully closed position.
• FIRE SAFE DESIGN: Secondary metal seat design provides a fire-safe shut-off per API 607. Additionally, secondary graphite body seals and flexible graphite packing prevents leakage through the body joints and stuffing box, respectively.
• INTERNAL TRUNNION DESIGN: Upper and lower bearing plates hold the ball in place, preventing the ball from floating axially and avoiding excess load on the seats. External trunnion design is available in certain sizes.
• PRESSURE ENERGIZED STEM PACKING: Our proprietary energizer ring, located above the primary o-ring stem seal, provides insurance in the rare event that the O-ring is damaged by using the media pressure to create an upward compressive force on the packing. This upward force on the packing combined with the downward compressive force created by tightening the packing gland results in a larger net compressive force on the packing and a better seal than a typical packing design.
• DOUBLE SEALS ON BODY JOINTS: Primary elastomeric seals ensure zero leakage in standard operating conditions. Secondary graphite seals ensure proper body joint sealing per API 607 in extreme temperature scenarios.
• ANTI-STATIC DEVICES: Standard anti-static devices ensure electrical continuity between the ball, stem, and body, eliminating the possibility of sparks within the valve created by static electrical charges.
• VALVE POSITION INDICATION: Clear stamping on the outer diameter of the mounting flange identifies the open or closed position of the valve based on the stem key orientation.
• BLOWOUT-PROOF STEM DESIGN: Valves are designed with stem/body connection to prevent stem blowout under line pressure.

Product Overview of Trunnion Ball Valves

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What is a Three Piece Ball Valve?

Again, as the name suggests, three-piece ball valves consist of three pieces: two end caps and a body. The end caps are typically threaded or welded to the pipe and the main body section may be easily removed for cleaning or repair without removing the end caps. This can be a very valuable option because it prevents a line shutdown if maintenance is required.

Features of Three Piece Ball Valves

Three piece ball valve is a high-performance ball valve, ideal for a wide variety of services. Designed for simple, in-line maintenance, and long, reliable service life, this resilient-seated ball valve offers sophisticated technical features that enable superior performance at an economical cost.

The advantage of the three-piece ball valve is that it is easy to disassemble. So that the central body can be maintained and cleaned without affecting the entire pipeline. For example, when the valve body is blocked, we only need to untie the bolts of the ball valve, take out the actuator and the center body, and then clean and maintain it. After cleaning, we can put the center body and the end cap together with bolts. We do not need to disassemble the entire valve from the pipeline, which greatly reduces our maintenance costs. Secondly, most of the three-piece ball valves are full-bore designs, which can allow more flow to transport.

Material of Three Piece Ball Valves

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What is a Bronze Ball Valve?

The bronze ball valve means that the body, bonnet and ball as well as the inner parts are made of bronze. Commonly used in corrosive resistant environments, such as seawater conditions.

What is Bronze Material?

Bronze is a copper-based alloy that typically consists of approximately 88% copper and 12% tin. Trace amounts of other metals, such as aluminum, manganese, phosphorus, and silicon, may also be present in the alloy.

The bronze material can be classified as Aluminum Bronze, Aluminum-nickel Bronze, Aluminum-silicon Bronze and Manganese Bronze and so on. The most commonly used grades are ASTM B148 C95800, ASTM B62 C83600, ASTM B283 C61900, etc.

Advantages of Bronze Material

• Excellent thermal conductivity
• Resistance to saltwater corrosion
• High ductility

Applications of Bronze Valves

Bronze valves are commonly used in the petrochemical industry and in high-performance use cases, particularly in marine environments where low levels of corrosion are a requirement.

What is a Forged Ball Valve?

ZECO forged ball valve is divided into forged two-piece ball valves and forged three-piece ball valves, as well as small diameter forged ball valves and large diameter forged ball valves, which are widely used in various high-pressure industrial conditions. Usually pressure at 600 lb, 800 lb, 900 lb, 1500 lb, working temperature in various pipeline – 46 ℃ ~ 425 ℃.Of course, 150LB and 300LB of low pressure are also frequently used in the list of users. Its materials also include ASTM A105, ASTM A182 F304, ASTM A182 F316, ASTM B283 C61900, ASTM B148 C95800 and other forging materials.

Features of Forged Ball Valve:

• ZECO forging ball valve has double piston effect seats which are pressure energized in both directions. So the seat rings are always pushed against the ball by the pressure from upstream/downstream or from the cavity. If the upstream seat fails, the downstream seat can still ensure a tight seal. Widely used in specific applications or for some pipe pressure testing. Since double piston effect valves do not have the self-relieving function, the automatic cavity-pressure relief valve shall be provided, unless otherwise agreed;
• ZECO forging ball valve has one self-relieving seat. If the force created by the body cavity pressure is greater than the preloaded spring force plus the force created by the pressure from pipeline, the cavity pressure releases via the self-relieving seat, the double piston effect seat still functions a tight seal;
• ZECO forging ball valve is available in additional configurations upon request, like Delta ring seat design, it’s easier to seal;
• ZECO forging ball valve is available in additional configurations upon request, like Lipseal design, it’s easier to preserve.

Material of Forged Ball Valve:

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What is a Two Piece Ball Valve?

ZECO two piece ball valve is divided into two piece trunnion mounted ball valve and two pieces floating ball valve. The two-piece floating ball valve is called because, the ball is floating, under the pressure of the medium, the ball will produce a certain displacement and the sealing surface of the outlet end can be kept tight contact to ensure the seal; The two-piece trunnion mounted ball valve is suitable for long-distance pipeline and general industrial pipeline, trunnion mounted ball valve because the ball will not move to the ball because of the pressure of the medium but will transfer the pressure of the medium to the bearing, so the torque of the trunnion mounted ball valve will be much smaller than the floating ball valve, and the life longer.

Two Piece Ball Valve Parts

• Ball
  • The highly polished solid ball has a pressure relief hole in the stem slot in order to avoid pressure build-up in the body cavity. This ensures a tight shut off and long service life.
• Stem
  • The valve stem assembly has a blow out proof construction and a square top connection. A PTFE thrust washer seal helps to achieve a low operating torque.
• Seats
  • A flexible seat design provides tight shut off at high and low pressures. The specical seat construction limits wear to a minimum and ensures low torque values under all operating conditions. Standard seat material is a high grade PTFE TFM1600. Besides the proven mechanical and chemical properties of PTFE, this chemical reinforced version offers suitability for a wider range of applications in respect to pressure and temperature.

Description of 2PC Ball Valves

• 2 piece full bore ball valves
• Carbon steel and stainless steel
• Flange connections ASME B16.5
• Pressure Rating from ASME CLASS 150 to ASME CLASS 2500
• Size 1/2″ – 16″
• Design ASME B16.34, API 608, API 6D
• Face to Face length ASME B16.10 long pattern
• ISO 5211 direct mount
• API 607 6th Edition Fire safe certified
• Anti-static device

Features of 2PC Ball Valves

• The valve seat of ZECO two piece ball valve is adopted with front design structure, this structure have both-side sealing capacity and self-relieving function. Composite material seat is floating, it loaded with spring. When it is at Close position, sealing face keeps close contact with ball to make sure there is no leakage between high pressure and low pressure;
• ZECO two piece ball valve design with emergent sealing system-assistant seat. Once sealing is damaged or sealing face capacity is damaged, injection of sealant to assistant system will be able to seal it emergently. Emergent sealing device will also be able to be used to clean or lubricate. Stem is also designed with emergent sealing system;
• According to wording conditions, ZECO two piece ball valve has been designed to be fire-proof structure. This design is as per API 607, once fire occurs, fire-proof structure will be able to prevent mass leakage;
• When valve is under close status, seat blockades fluid, dregs accumulated on body cavity will be able to relieved by the relieving device.

Material of Two Piece Ball Valve:

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What is 12″ Inch Ball Valve?

ZECO 12 inch ball valve can choose floating ball valve, trunnion mounted ball valve or top entry ball valve. As one of the only ball valve manufacturers in China with a history of nearly 30 years, ZECO, with the historical mission of continuous innovation and technological innovation, successfully sent the ball valve products of ZECO to one after oil companies, offshore platforms, and industrial projects, and was fully recognized by the owners. ZECO is dedicated to product performance research and development and product material research and development and is committed to building an internationally renowned Chinese valve manufacturer.

Dimensions & Weight of 12 Inch Ball Valve

Specification of 12″ Ball Valve

Features of 12 Inch Ball Valve:

• ZECO 12 inch ball valve has a metal-to-metal seat design. When the ball valve is applied in the high abrasive or high temperature service, the metal-to-metal seat shall be chosen;
• ZECO pays attention to the flow coefficient of the valve because this is the index that measures valve current capacity, flow coefficient is bigger the pressure loss that shows medium flows through the valve is smaller. ZECO will regularly test the flow coefficient of the newly developed products and old products of each series and each diameter to ensure that users will not incur extra costs due to the valve flow when using ZECO products;
• ZECO pays attention to the research of product materials and will confirm the information needed by customers before confirming the order. The degree of pressure and temperature tolerance of the ball valve is not only related to the shell material but also related to the seat, packing, gasket, and other seals, seals can try polymer materials, graphite asbestos, or rubber; Sealing material depending on the medium in the pipeline;
• ZECO 12 inch ball valve has low emission control. Low emission packing is assembled whose max leaking rate of design and test stands at 100PPM.

Material of 12 Inch Ball Valve:

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What is a 2 Piece Ball Valve?

2 piece ball valves are some of the most common ball valves used. As the name suggests, the two piece ball valve consists of two pieces, one piece that has one end connection and the body. The second piece fits into the first, holds the trim in place and includes the second end connection. Once installed these valves typically cannot be repaired unless they are removed from service.

ZECO Ball valve is the same to the ordinary that trim spring with the stem to reach the purpose of open/ close, it is mainly adopted to cut off medium on pipe. It features for simple structure, good sealing capacity, flexibility, small blockage coefficient, easy operation etc. ZECO is the global supplier of 2PC ball valves, which can be divided into 2 piece floating ball valves and 2 piece trunnion mounted ball valves.

Construction of 2 Piece Ball Valve

The Ball Valves are of a two piece construction and have a solid full bore ball. Relevant design standards are EN ISO 17292, EN 12516, ASME B16.34 and API 608.

Applications of 2 Piece Ball Valve

The 2 piece ball valves are designed to be used as shut-off valves for corrosive and non-corrosive liquids, gases, vapours and loose materials. Medium may fl ow in both directions through the ball valves.

Features of 2 Piece Ball Valves

• As the moving parts of valve, ball, valve stem and handle are an assembly unit. The head of valve stem is shaped a diploid, thus to easily distinguish whether valve is in the “ON” position from handle position. When handle or stem diploid is in parallel with the pipe axis, valves is in “ON” position, when handle or stem diploid is vertical to the pipe axis, valve is in “OFF” position;
• When the medium go through the valve, the pressure in middle cavity would pull out the stem. In order to prevent the occasion from happening, a convexity is designed. At the same time, a lubricator device has been added, so even if the fire damage would happen to damage the o-ring, the lubricator device would inject sealing oil to prevent medium from leaking;
• When operating the valve, the friction between the ball and the nonmetal seat, like PTFE or etc. will produce electrostatic charge that can be accumulated on the ball, To prevent static spark, an anti-static device is placed on the valves to derive the electric charge accumulated in the ball from the static channel between the ball and the stem, or between the stem and valve body;
• In order to prevent the mal-operation of the valve, the open/close position can be equipped with lock device, especially when they are used outdoor or process forbidden the malfunction.

Material of 2 Piece Ball Valves

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What is a 2″ Stainless Steel Ball Valve?

ZECO stainless steel ball valve is widely used in pipelines with corrosive media. Stainless steel materials can protect the ball valves in its specific media with anti-corrosive properties for a long time to prevent the valve body, ball and sealing surface from being severely corroded due to corrosive media, resulting in failure to seal or even leakage. ZECO has a specific incoming inspection process for all stainless steel raw materials. Through spectral analysis, it can be determined that the materials are in conformity with international standards before they are put into storage and processed. In addition, ZECO has traceability records for the raw materials after inspection. When the product is delivered to users, it will be displayed and sent to users through MTC.

Applications of 2″ Stainless Steel Ball Valve

• Heating-cooling lines
• Food facilities
• Chemical industry
• Shipbuilding
• Paper mills

Features of 2″ Stainless Steel Ball Valves:

• As the moving parts of stainless steel ball valve, ball, stem and handle are an assembly unit. The head of valve stem is shaped a diploid, thus to easily distinguish whether valve is in the “ON” position or “OFF” position from handle position. When handle or stem diploid is in parallel with the pipe axis, valve is in “ON” position; when handle or stem diploid is vertical to the pipe axis, valve is in “OFF” position;
• Although ZECO stainless steel ball valve can resist corrosion, it is basically used in corrosive medium, which is hard to avoid corrosion. Therefore, ZECO will leave a certain amount of corrosion margin when designing the thickness of the valve thickness, so as to ensure the long-term service life of the product free from the influence of corrosive medium;
• ZECO stainless steel ball valve can also be processed in accordance with NACE MR0175 standard according to the requirements of users, and the quality control and testing are strictly carried out in the manufacturing process to meet the technological requirements of sulfide environmental conditions;
• ZECO stainless steel ball valve also has fire protection construction and anti-static structure.

Material of 2″ Stainless Steel Ball Valves:

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What is an Motorized ball valve?

The working of an motorized ball valve is similar to its manual counterpart but in this valve, an electric actuator is mounted instead of a lever to drive the stem (which is connected to the ball) which in turn, rotates the ball to provide the desired operation. As the electric actuator receives a signal from remote control location depending on its position it will rotate to start or stop the flow of fluid through the ball valve.

An motorized ball valve can be designed to change positions based on sensor readings. A sensor can detect and report changes in temperature or pressure. The motorized ball valve is triggered when the sensor reaches a predetermined point set by machine management staff. This could perform important functions, such as keeping more process fluid from reaching an area that is already full. When the sensor detects that the area is available for more fluid, it activates the motorized ball valve, which changes position to allow process fluid to reach that location.

How does an Motorized ball valve work?

Motorized ball valves is mainly composed of two parts, namely electric actuator and valve. After certain installation and debugging, the switch of the equipment can be adjusted and controlled normally. The motorized ball valves mainly relies on the motor to drive and execute the operation, the size of the opening can also be adjusted according to the actual situation, so as to control the flow of equipment intermediary, is a very humane operating system.

What are Motorized ball valves used for?

On/Off Control

Motorized ball valves can be switched from open to fully closed without any stops at any position in between. Every time the actuated ball valve finishes the cycle of opening and closing, the electric motor will switch off through internal cams, which strikes the limit switches.

For instance, when the electric motor receives a signal of closing the motorized ball valve, the motor is energized, rotating in order to close the ball valves. Subsequently, the limit switches travel on the cam as the internal cam rotates on the shaft until the lobe makes the switch to stop the electric motor, breaking the circuit.

Positioning Control

Another type of application requires the motorized ball valves to open or close partially, detecting and responding to the various conditions of water flows. In this case, the goal can be achieved through the incorporation of a digital position sensor.

Depending on the special flow requirements, the external control command signal will be created. This input signal will be compared by the actuator of the motorized ball valves consistently to the actual position through the output feedback element. Subsequently, the actuated ball valves will be driven to balance the commands and reach the required position. A signal of approximately 4mA or 0V is typically used to close the motorized ball valves.

Applications of Motorized ball valves

Motorized ball valves introduce into the systems to control valve opening and closing. To measure flow, they are often equipped with gauge monitors or flow meters. Industrial processes, manufacturing factories, chemical handling, food, and beverage equipment, mining operations, power plants, and the energy sector uses actuated ball valves. They’re also used in wastewater treatment, municipal treatment centres, clean water generation, aquariums, aquatics and animal care, chemical production, metals and plating operations, and chemical synthesis.

Features of Motorized ball valves:

1. When medium passes through the valve, the pressure in valve body may possibly push the stem out, or when the valve in repair, if there is pressure in the middle cavity, the stem or medium seems to easily fly out upon disassembling the valve, which can cause injuries to human beings. To prevent these possibilities, a dummy club is placed at the lower part of the stem. In this way, even if there is fire, packing and thrust bearing are burned or packing is damaged due to other causes, the pressure of medium in valve body will make the dummy club of valve stem in close contact with the upper seal face of valve body, thus to prevent medium leaking out from the damaged packing position;
2. ZECO motorized ball valve can be operated remotely, simple and fast;
3. The standard of ZECO motorized ball valve’s electric actuator is AUMA electric actuator. Other types of electric actuators can be selected according to customers’ requirements;
4. ZECO motorized ball valve can choose forged body or cast body, ZECO is very strict in the control of raw materials, no matter what material material can fully meet the requirements of international standards and chemical analysis.

Material of Motorized ball valves:

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