Working Principle and Application of Pneumatic Ball Valve

Pneumatic ball valve is evolved from plug valve. It has the same 90 degree rotation action. The difference is that the plug body is a sphere with a circular hole or passage through its axis. Its working principle is to make the valve unblocked or blocked by rotating the valve core.

Pneumatic ball valve has light switch, small in size, and it can be made into a large caliber. The seal is reliable, the structure is simple, the maintenance is convenient, and the sealing surface and the spherical surface are often in a closed state. It is not easy to be eroded by the medium, so it is widely used in various industries. Pneumatic ball valve and plug valve belong to the same type of valve, but its closing part is a ball. The ball rotates around the center line of the valve body to open and close.

The pneumatic ball valve is mainly used to cut off, distribute and change the flow direction of the medium in the pipeline.

Advantages of Pneumatic Ball Valve

• 1. The fluid resistance is relatively small, and the resistance coefficient is equal to the pipe section of the same length.
• 2. Simple structure, small volume, and lightweight.
• 3. It is tight and reliable. At present, the sealing surface material of ball valve is widely used in plastic, with good sealing performance, and also widely used in vacuum systems.
• 4. It is easy to operate and it can be opened and closed fast. It only needs to rotate 90° from full open to full close, which is convenient for the remote control.
• 5. The maintenance is convenient, the structure of pneumatic ball valve is simple, the sealing ring is generally movable, and the disassembly and replacement are relatively convenient.
• 6. When the valve is fully open or closed, the sealing surface of the ball and the valve seat shall be isolated from the medium. When the medium passes through, the corrosion of the valve sealing surface will not be caused.
• 7. It can be widely used, ranging from several millimeters to several meters in diameter, from high vacuum to high pressure.
• 8. The power source of pneumatic ball valve is gas, generally 0.2-0.8mpa pressure, which is relatively safe. If the pneumatic ball valve leaks, the gas can be discharged directly compared with the hydraulic and electric ones, which has no pollution to the environment. It is of high safety.
• 9. Compared with the manual and turbine ball valves, the pneumatic ball valve can be configured with large caliber. (the manual and turbine ball valves are generally under DN300 caliber, and the pneumatic ball valve can reach DN1200 caliber at present.)

Pneumatic ball valve has been widely used in petroleum, chemical industry, power generation, papermaking, atomic energy, aviation, rocket, and other departments, as well as people’s daily life.

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I. Overview of Pneumatic Ball Valve

Pneumatic ball valve is a ball valve equipped with a pneumatic actuator, the execution speed of which is relatively fast with the fastest switching speed of 0.05 seconds / time, so it is also referred to as pneumatic quick cut-off ball valve.

Basically, the pneumatic ball valve employs magnetic valve, air source treatment triplet, limit switch, positioner, control box and other fittings to realize local control and remote centralized control. It allows the valve to be opened and closed in the control room without manual operation at the site or at high altitude and dangerous areas, which saves time and human resources, and improves safety to a great extent.

II. Classification of Pneumatic Ball Valves

1. Trunnion Mounted Ball Valve

The ball of pneumatic ball valve is fixed and will not move after pressure acts on it. While the floating valve seat it employs will move under the medium pressure to allow the sealing ring being pressed in tight against the ball to ensure seal. Equipped with bearings on the upper and lower shafts with low operating torque, fixed ball is suitable for high-pressure and large-diameter valves.

In order to reduce the operating torque of pneumatic ball valve and increase the reliability of sealing, oil sealed ball valve appears, that is, special lubricating oil is injected between sealing surfaces to form an oil film, which not only enhances the sealing performance, but also reduces the operating torque, which is more suitable for high-pressure and large-diameter ball valves.

2. Floating Ball Valve

The ball of pneumatic ball valve is floating. The medium pressure acts upon the ball and the ball moves with a certain displacement and is pressed tightly on the sealing surface of the outlet end to ensure its sealing.

The floating pneumatic ball valve has simple structure and good sealing performance, but all the load of the working medium borne by the ball is transmitted to the outlet sealing ring. Therefore, it is necessary to consider whether the sealing ring material can withstand the working load of the ball medium. This structure is widely used in medium and low pressure ball valves.

3. Elastic ball Valve

The ball of pneumatic ball valve is elastic. The ball and valve seat sealing ring are made of metal materials with large sealing pressure ratio. The pressure of the medium itself can not meet the sealing requirements, so external force must be applied. This valve is well suited for high temperature and high pressure medium.

Elasticity is attainable from an elastic groove at the bottom of inner wall of the ball. When the passage is closed, the wedge head of the valve stem permits the ball to be expanded and pressed against the valve seat tightly to achieve sealing. Loosen the wedge head before rotating the ball, and the ball will return to its original size, resulting in a small gap between the ball and the valve seat, which can reduce the friction on the sealing surface and operating torque.

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Which working conditions should pneumatic valves be used?

Here are some suggestions from pneumatic ball valve manufacturers.

Compared with electric valves, pneumatic ball valves are more suitable for explosion-proof applications. The main reason is that the driving source of pneumatic ball valve is air source. There are no electronic components in the pneumatic actuator. When used in flammable and explosive occasions, even if there is a fault, it will not be as easy to generate sparks as the electric valve. So it will not bring about potential safety hazards. According to these working conditions, explosion-proof electric valves have been produced. However, from the point of view of price and performance, if there is air source on the working site, the pneumatic valve should be selected for use. Corrosion-resistant pneumatic valves should also be chosen when you are transporting toxic and dangerous media, because pneumatic ball valves have the function of fault reset. Customers choose switch pneumatic valves when ordering. In case of failure or gas source breakdown, pneumatic ball valves can automatically restore full shutdown or full open state according to user’s needs to protect the safety of working conditions. This is not available in general electric valves.

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What is a Pneumatic Ball Valve?

Pneumatic ball valves are used to control the flow of a media, liquid, or gas, by means of a rotating ball with a bore. The rotating ball is controlled by a pneumatic actuator that is capable of turning it.

How do Pneumatic Ball Valves work?

The most common mechanism for a pneumatic actuator for ball valves is the rack and pinion mechanism. This comprises the rack (a linear gear) and the pinion (a circular gear). The rack is attached to a piston which is pushed by compressed air to achieve linear motion. This linear motion is converted to circular motion by the pinion. The pinion drives the stem of a ball valve to open and close positions.

To control the pneumatic actuator for ball valves, the compressed air is regulated by solenoid valves. Electrical signals from the controller energize the solenoid valve to either open or close positions allowing compressed air to flow through to both piston sides of the pneumatic actuator. The piston pushes the rack which turns the pinion connected to the stem of the ball valve.

Types of Pneumatic Ball Valve

Select and buy a pneumatic ball valve online for your application. Pneumatic ball valves are used to control the flow of a media, liquid, or gas, by means of a rotating ball with a bore. The rotating ball is controlled by a pneumatic actuator that is capable of turning it. A ball valve is one of the most common valves due to its simple operation, reliability, long service life, and wide range of application uses.

• 2-way pneumatic ball valves have 2 ports, an inlet, and an outlet. The media flows from one direction to the other and the valve is used to open or close the flow. A 2-way ball valve is commonly called a shut-off valve.
• 3-way pneumatic ball valves have 3 ports. The bore in the ball is not straight, but rather in an L or T formation. This allows for various circuit functions (flow directions) for the valve. It can be used to distribute, mix, or divert flow in the desired direction. Therefore, any of the 3 ports can be an inlet or an outlet.
• Pneumatic ball valve accessories include ball valves with an ISO-top (suitable for a pneumatic actuator).

How to Install Pneumatic Ball Valve?

How is the pneumatic ball valve installed? Can the pneumatic ball valve be installed vertically?

Vertical installation of pneumatic ball valves is possible. Generally, installation on the pipeline can be divided into parallel installation and vertical installation, which is based on the actual situation of customers. But we recommend that it is generally best to install in parallel so that it can be easily maintained and it is very beautiful. But in many special cases, pneumatic ball valves can also be installed vertically. Customers said that if the pipeline space of the parallel installation is not enough, then it will be installed vertically, which will not affect the service life.

Sealing position of Pneumatic Ball Valve

Pneumatic ball valve seal generally consists of four seals: 1. Stem seal ring 2. Midway seal ring 3. Two seals on both sides. The stem seal ring refers to the seal ring where the valve stem operates, generally with tetrafluoro (PDFE) and flexible graphite; the middle seal ring refers to the middle connection valve body seal, generally with tetrafluoro (PDFE) and graphite metal composite gasket; the two sides of the seal ring are: the ball core on both sides of the import and export seal ring. It is generally sealed with tetrafluoro (PDFE) and PPL (high-temperature resistant sealing ring).

Pneumatic Ball Valve Actuator

The pneumatic ball valve consists of two main parts: actuator and valve. The actuator has two kinds: single-acting and double-acting.

So how to make your pneumatic ball valve easy to use and has a long life? The service life of pneumatic ball valves is determined by the on-site use of customers.

To prolong the service life of pneumatic ball valves, the first thing is to keep the gas source stable. The stable gas source can directly affect the speed of the valve switch and the life of the valve sealing ring. It is better to install a couplet on each actuator. This couplet can not only provide stable air pressure but also regularly refuel the cylinder. It can also discharge moisture from the air, which greatly improves the life of the cylinder. The life of the valve is determined by the medium used in the field.

Professional pneumatic actuator ball valve manufacturers and high-quality ball valves will make its life longer. Among various pneumatic ball valve manufacturers, ZECO Valve is the best choice for you. ZECO Valve provides you with high-quality pneumatic ball valve products.

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Pneumatic control valve accessories help ensure optimal performance and are an essential component in a pressure control system. Electric switches help bridge the communication gap between a valve operator and control system, helping to control accuracy. Various styles of operators allow for manual and pneumatic actuation of control valves and mounting brackets are used to mount directional control valves to machinery.

Purpose of Pneumatic Valve Accessories

There are five basic reasons that accessories are added to a control valve:

• Improve process control
• Improve safety for the process or personnel
• Improve valve performance or speed of response
• Monitor or verify the valve responsiveness
• Diagnose potential valve issues

Pneumatic Accessories For Pneumatic Actuator

Electro-pneumatic valve positioner:

The valve positioner is the main accessory of the pneumatic actuator. It is used in conjunction with the pneumatic actuator to improve the position accuracy of the valve, overcome the influence of the friction force of the valve stem and the unbalanced force of the medium, so as to ensure that the valve is realized in accordance with the signal from the regulator position it correctly.

Under the following circumstances, a positioner is required:

1. When the medium pressure is high and the pressure difference is large;
2. When the caliber of the regulating valve is large (DN>100);
3. High temperature or low-temperature control valve;
4. When it is necessary to increase the operating speed of the regulating valve;
5. When using standard signals to operate non-standard spring actuators (the spring range is outside of 20～100KPa);
6. When used for split-range control;
7. When the valve realizes the reverse action (the air-to-close type and the air-to-open type are interchanged);
8. When the flow characteristics of the valve need to be changed (the positioner cam can be changed);
9. When there is no spring actuator or piston actuator, it is necessary to achieve proportional action;
10. When using electrical signals to operate pneumatic actuators, power must be distributed to the pneumatic valve positioner.

Solenoid valve:

When the system needs to achieve program control or two-position control, it needs to be equipped with a solenoid valve. When the solenoid valve is selected, in addition to considering the AC and DC power supply, voltage, and frequency, the relationship between the solenoid valve and the regulating valve must be paid attention to. It can be used as “Normally open” or “normally closed”. If you need to increase the capacity of the solenoid valve to shorten the action time, you can use two solenoid valves in parallel or use the solenoid valve as a pilot valve in combination with a large-capacity pneumatic relay.

Air filter pressure reducing valve:

The air filter pressure reducing valve is an accessory in the industrial automation instrument. Its main function is to filter and purify the compressed air from the air compressor and stabilize the pressure at the required value. It can be used for various pneumatic instruments, solenoid valves, Air supply, and voltage stabilizing devices for cylinders, spraying equipment, and small pneumatic tools.

Travel switch (responder):

The travel switch reflects the two extreme positions of the valve switch and sends out an indication signal at the same time. Based on this signal, the control room can betray the switch state of the valve in order to take corresponding measures.

ZECO Valve is a professional pneumatic ball valve manufacturer, if any inquiries, please be free to contact us,

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