The floating ball valve vs the trunnion mounted ball valve

&#;&#;Floating ball&#;&#; and &#;&#;trunnion ball&#;&#; are concepts which are used generally. But what are the exact difference between these two designs and when to use which one?

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The most important difference between these two design is the construction of the ball and the way in which it is assembled inside the valve body. A trunnion ball is attached and centred inside the valve body through both a top shaft -the valve stem- and a bottom shaft &#; the trunnion. A floating ball is attached to the valve body only through the valve stem. As a result, the floating ball &#;&#;floats&#;&#; in the valve seats.

In a floating ball design the ball is pushed against the downstream seat by the in-line pressure, resulting in tightness. When operated from closed to open position, the ball is to be rotated against both the in-line pressure (&#;p) and the friction of the seats. In other words: the torque needed to operate the valve is created by both in-line pressure and the nature of the valve seats. The amount of torque required increases significantly when operating pressure (&#;p) and/or valve size increase, and/or whenever the nature of the seat is made more robust. The latter applies in case of a metal seated valve design.

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 centred. The inline pressure presses the seats against the ball, causing the 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 is solely needs to be rotated against the pressure of the seats.

As a result, the required torque of a trunnion mounted ball valve is generally lower than the torque required of a comparable floating ball valve. For example: a DN200 metal-seated floating ball valve would require a significantly larger actuator than a DN200 comparable trunnion valve, leading to significantly lower costs of the overall package. Also, in general the trunnion seat design offers higher stability which makes it more suitable for extreme conditions and especially varying pressure levels.

So, the trunnion-mounted ball valve is more suitable for high pressure applications and bigger dimensions compared to the floating ball. Another advantage of the trunnion design vis-à-vis the floating design is the fact that a trunnion generally is included with a drain or bleed connection, making it suitable to function as a dual safe device. Furthermore, it functions as an relief valve automatically whenever the pressure in the central cavity is higher than the spring force of the seats. When this happens, the seat springs relieve automatically in order to drain the excess pressure back into the main line. Because of these reasons, the trunnion is commonly used in offshore- & oil & gas applications, where extreme conditions pose the standard.

Off course, a large disadvantage of the trunnion compared to the floating design is associated with its costs; which are significantly bigger. Because of these costs, trunnions are used solely when they have to be used.

Our specialist happily assist you in advising the right ball valve design for your application.

A trunnion ball valve is an industrial valve that has been designed to regulate the flow of fluids specially in high-pressure and high-temperature areas. It has a central hole through which it consists of a spherical sealing mechanism widely called the &#;ball&#;. This hole aligns with the pipeline for fluid flow when the valve is open, and when closed, the ball is turned 90 degrees to block it.

The difference between this type of ball valve and other types lies in its support structure. Ball valves are fitted with either trunnions or shafts at their top ends as well as at their bottom ends that are then anchored on the body of the valve. Furthermore, this design provides extra stability and also lowers operating torques needed to turn these valves hence being suitable for use in high pressure applications.

Additionally, there may be two or more ports, inlets/outlets on a typical valve body; and its inside ball may be constructed from different types of materials such as metals or even reinforced plastics depending on application requirements. The shut-off function is accomplished by utilizing elastomeric or metallic seals allowing no leakage under extreme conditions.

Thus these valves find wide application in industries like oil & gas, petrochemicals processing units, power plants and water treatment owing to their need for accurate control over fluid motion and reliability aspects. Their resistance to high pressures makes them appropriate for critical services like pipelines as well processing plants that require robust construction. Additionally automation can be done with them so as they can be operated remotely thereby increasing efficiency proceeds with safety stipulations in industrial processes.

How Does a Trunnion Ball Valve Work?

At its nucleus, a trunnion ball valve works on the simplest yet effective principle to handle fluid flow. The main elements consist of a hollow, perforated spherical closure method commonly referred to as ball which is in a housing called valve body with inlet and outlet ports. What happens is that when the valve is open, there is bore through the centre of the ball that coincides with the pipeline thereby allowing passage of fluid. But on the contrary, when closed, this 90-degree rotation makes it block flow by lining-up solid part of it with ports.

Trunnion mounted design constitutes one distinguishable thing about trunnion ball valve. It&#;s like as if top and bottom supports are here for balls or shafts, which are firmly held by a retainer in place screwed into the body of the valve. This arrangement provides stability and decreases torque required for operating valves even during high pressures.

In most cases, operation of this valve is controlled using levers, gears, actuators among other automated devices. Whenever it opens or closes due to triggering either through operator or control systems such as actuator moving mechanism causes rotation of balls within bodies containing them.

Sealing also plays another important role in making sure that trunnion ball valves carry out their functions well enough. Seals made from resilient elastomers or solid metals materials are employed by these valves in order to have tight shut-off and no leakage when they work. These seals keep integrity between a ball and itself maintaining even under challenging conditions.

Trunnion ball valves come off best in applications where precise control over flowing fluids , high pressure operations and dependability mean everything. Such industries as oil & gas, petrochemicals , power generation , water treatment rely heavily upon these fittings for their vital procedures . Moreover , they can be easily automated thus improving operational efficiency thus safety especially at far flung places or where there may be danger.

The functionality behind a properly functioning trunnion ball valve is based on its rugged design, fine-tuned performance and reliable sealing which have all made these valves to become the backbone of fluid control systems in many industries.

What Is The Main Features Of Trunnion Ball Valve?

Trunnion-Mounted Design

In these valves, the ball is supported by trunnions at its top and bottom ends that are firmly fixed into the body of the valve. This prevents shifting, and thereby reduces torque requirements for operation while improving overall reliability, especially under high pressure conditions.

High Pressure Capability

Trunnion ball valves are designed to endure high pressures. Due to their robust build and trunnion-mounted design they can safely handle fluid pressures higher than that which we would have expected in other styles of ball valves.

Accurate Flow Control

The quarter turn operation and tight sealing mechanism allow these valves to provide accurate flow control. These can easily modulate fluid flows with precision required by processes needing fine control.

Bidirectional Sealing

Generally, trunnion ball valves are capable of bidirectional sealing meaning they can effectively seal against flow from either side. This allows them to be used reliably in different flow regimes.

Durable Construction

These types of valves are made using durable materials such as stainless steel, carbon steel or other alloys to resist against corrosion, wear, erosion among others. With this feature intact also comes long-term performance life in tough industrial environments.

Multiple Port Configurations

They come full port or reduced port options enabling experts select an appropriate configuration depending on their need for flow rate and system limitations.

Wide Range of Sizes and Pressure Classes: To fit various applications within industries, trunnion ball valves have been manufactured in many sizes and pressure classes. It does not matter whether it is a small bore pipeline or a full scale industrial process; you will find a suitable trunnion ball valve that meets your needs.

Optional Automation: By use of gears, actuators or pneumatic/hydraulic systems one can manually operate or automate these types of valves. This makes them to be more efficient in operations, ensures remote control and also allows integration into advanced process control systems.

Fire-Safe Design: Most of the trunnion ball valves are made to satisfy fire-safe requirements by having additional metal-to-metal second sealing or blowout-proof stem for integrity protection during fire outbreaks.

Having a grasp of these features gives professionals the ability to choose wisely when specifying or purchasing trunnion ball valves for industrial use and this leads to peak performance, dependability and safety.

Structure Of Trunnion Ball Valve

The structure of a trunnion ball valve is intricately designed to withstand high pressures, temperatures, and demanding operating conditions. Below is an elaborate description of its main parts:

Valve Body

This typically forms the bulk of the valve&#;s anatomy like forged or cast metals and serves as the primary structural member. This part houses inlets and outlets through which fluid passes. The valve body also accommodates other internal components such as ball and stem.

Ball

Within the trunnion ball valve, it acts as the foundation for this mechanism, being a spherical closure with a hole (bore) right through its center. It revolves in the valve body for controlling fluid flow. In order to resist erosion and corrosion, balls are usually fabricated from strong materials such as stainless steel, carbon steel or other alloys.

Trunnion Mounting

An important feature that has made major contributions to designing these valves is known as trunnion mounting .There are trunnions or shafts at either end that support the ball within firmly anchored bases in the valve body. Stemming from this aspect of design is that there is less torque required to move the ball so it stabilizes its position very well hence precise control over movement of the valve can be achieved.

Stem

The stem links up with either actuator or handle thereby transmitting rotational movements necessary to open/close respective valves. It extends through a stem bore in this mainframe before sealing against loss of fluids into/onto environment of operation. Frequently stems come equipped with anti-blowouts for enhanced safety measures.

Seats & Seals

For positive shutoff purposes and sealing off leakages at any point on fluid passage way, sealing elements have been quite vital aspects about this sort of technology .The majority of these seals bear resemblance by having elastomers like Nitrile or Viton used while others may be made using metallic PTFE (Teflon) or graphite.

Actuator

An automated trunnion ball valve usually has an actuator which is attached to the valve body for remote control purposes. Depending on types of actuators, positioners and response times can be precise in terms of whether the latter are pneumatic, electric or hydraulic. For the manual ones, handles as well as gear mechanism might be included too.

Bonnet & End Connections

A device&#;s bonnet encloses internal components and enables ease of maintenance or repair .Different connections at end such as flanged, threaded or welded union ensure that valves fit into plumbing system without any issues.

Optional Features

Based on the specific application requirements, trunnion ball valves may include additional features like fire-safe designs, anti-static devices, cavity relief mechanisms and special coatings for better corrosion resistance.

In general, a trunnion ball valve has a precisely engineered structure with extreme durability so that it can provide exceptional service within wide range of industries where accurate fluid flow management applications are necessary.

Types of Trunnion Ball Valve

There are so many varieties of trunnion ball valves, each one made specifically to serve certain application demands and operating environments. The following are some types that are well-known:

Floating Trunnion Ball Valve

In this valve type, the ball is supported by trunnions allowing it to float a little bit within the valve body which therefore reduces friction during operation resulting in lower torque requirements as well as improved sealing performance. Floating trunnion ball valves are best suited for applications where pressure is moderate to high.

Fixed Trunnion Ball Valve

The trunnions hold the ball in place in fixed trunnion ball valves unlike floating ones that allow lateral movement. This makes it more stable and resistant to side loads making it ideal for high pressure and temperature applications where accurate control is vital.

Double Block and Bleed (DBB) Trunnion Ball Valve

Double block and bleed capabilities of DBB trunnion ball valves are provided by two seating surfaces. What this means is that they can cut off both upstream and downstream flow as well as relieve any trapped pressure between their seals. Wherever safety and reliability take precedence over everything else, DBB valves have become very common.

Full Bore Trunnion Ball Valve

A full bore trunnion ball valve has a bore diameter equal to that of the pipeline thereby allowing unrestricted fluid flow through them. Consequently, this design minimizes turbulence and reduces pressure drop hence suitable for continuous processes with large flow rates that do not require much energy loss.

Reduced Bore Trunnion Ball Valve

These may also be called reduced port or standard port, but their bore diameter sizes are smaller than those of pipelines they go into so what happens? Reduced bore trunnion ball valves may offer less capacity compared to full bore ones but they tend to be much cheaper hence better for low-flow conditions.

Top-Entry Trunnion Ball Valve

Unlike other designs, top-entry valves make it possible to access the inside elements of valve; including the ball and seats without necessarily taking them out of the pipeline. As a result, servicing is simplified and downtime is minimized during maintenance activities. They are used in applications that require frequent maintenance.

Split Body Trunnion Ball Valve

The split body valves have two or three pieces making it easy for you to separate the valve into different parts thus facilitating installation and maintenance with better access inside components. These valves are found in situations where space availability as well as ease of servicing matter; therefore, they can be excellent options.

There are many other types of trunnion ball valves besides those mentioned above. Therefore, each type has different characteristics and benefits suited to specific industries considering optimal performance, safety, and reliability in fluid control systems.

Trunnion ball valve advantages

High Pressure and High Temperature Capability: Because they can tolerate extremely high pressures and temperatures, trunnion ball valves are used in applications where there is a need to work with oil and gas, petrochemicals, power generation.

Excellent Sealing Performance

Good sealing performance even at high pressure levels is guaranteed by the design of the ball on trunnion. This results in safety through tight shut-off hence reducing the loss of important fluids through leakage.

Low Operating Torque

The presence of a trunnion mounted ball means that there will be minimum friction between it and the valve body thereby reducing the operating torque required. It is easy to operate them as well as ensuring that wear on components of these valves is minimized hence extending their lifespan.

Stability and Reliability

Irrespective of how difficult or complicated the situation may appear, better stability provided by trunnion mounted balls withstand side loads. Consistent sealing and exact flow control are also benefits derived from this feature.

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Versatility

Trunnion ball valves come in different sizes, pressure classes and materials thus offering versatility for various uses. They can be adjusted to suit certain project specifications making them adaptable for use across many industries.

Bi-directional Sealing

Usually sealed from both sides, trunnion ball valves provide tight shut off in either direction of flow. As a result, flexibility is enhanced while installation can be done in any direction along the pipeline.

Minimal Maintenance Requirements

Trunnion ball valves require less maintenance over time due to their strength and reliable ways of closing up securely . Industrial installations become more cost-effective when downtimes are reduced because repairs have been limited or eliminated altogether.

Automation Compatibility

Using pneumatic , electric or hydraulic actuators ,trunion ball valves can easily be automated enabling remote operation and integration into advanced control systems . Automation increases efficiency by cutting down manual error during operations and improving accuracy in managing flow patterns.

Long Service Life

Built using strong materials and with a tough construction, the trunnion ball valves will last for many years hence no need of replacing or repairing them frequently.

Overall, these advantages make trunnion ball valves an integral part of fluid control systems in various industries where safety, reliability and efficiency are the most important factors.

Where is Trunnion Ball Valve Used

Fluid control is necessary in a variety of industries and applications, which explains why trunnion ball valves are so widely employed. The following are some areas where trunnion ball valves are commonly used.

Oil and Gas Industry

Trunnion ball valves are common in oil and gas industry upstream, midstream and downstream activities. Pipeline transportation, refining processes, storage tanks, wellhead control etc. use them. These valves can withstand the high pressures and temperatures that are usual with this kind of work.

Petrochemical Industry

Petrochemical plants heavily rely on trunnion ball valves to direct the flow of diverse chemicals and hydrocarbons around their system. Cracking, reforming isothermally or adiabatically operated distillation stills or batchwise distillation process and polymerization stages constitute some of these processes. In petrochemical environments that tend to escalate into harsh corrosive atmospheres, the resilient nature of trunnion ball valves makes them ideal for such situations.

Power Generation

Fossil fuel power plants including nuclear power stations as well as renewables have applications for trunnion ball valves. They regulate the flow of steam, water and other fluids in boiler systems (e.g., economizers), cooling circuits (e.g., wet-surface air coolers) or steam turbine control systems (gland condensers). The ability of these Valves to handle the high pressures and temperatures they operate under therefore remains an essential part towards effective power generation.

Water and Wastewater Treatment

Water treatment plants desalination facilities as well as waste water treatment systems employ Trunnion Ball Valves. They regulate fluid flow in different treatments including filtration excretory system disinfection sedimentation among others where fresh water brine chemicals sludge etc pass through different channels respectively.

Mining and Minerals

Mining operations utilize trunnion ball valves when handling process fluids like abrasive slurries, plus chemicals among many others. The mining of minerals and metals is usually done through a combination of extraction, beneficiation and mineral processing where these valves have been installed in pipelines, flotation circuits as well as various process plants.

Chemical Processing

Chemical industries employ trunnion ball valves in the production line to control the flow of acids, solvents, polymers, and other chemicals. These are required in reactors such as distillation columns and mixing tanks across different chemical manufacturing areas including storage facilities for their raw materials.

Pipeline Transportation

Long distance pipelines convey oil, natural gas, refined products and other fluids which rely heavily on Trunnion Ball Valves. Over several hundreds or even thousands kilometers the pipeline can be shut-off at key control points with reliable shut-off devices and operated at high pressures up to ANSI Class # which guarantees fluid transportation safety across continents.

General Industrial Applications

Pulp & paper industry; food & beverage; pharmaceuticals; among others all find applications for Trunnion Ball Valves. Precise fluid handling demands are part of various industrial processes that require fluid distribution control systems or simple closing off mechanisms throughout their operation.

To sum up then, trunnion ball valves remain an important part in numerous industries and applications providing efficient, reliable yet safe fluid control solutions.

Comparison of Trunnion Ball Valve and Floating Ball Valve

Trunnion ball valves and floating ball valves are both widely used in industrial applications for fluid control, but they have distinct differences in terms of design, operation, and application. It is shown below:

Design

Trunnion Ball Valve: Trunnion ball valves come with a fixed ball supported by trunnions or shafts at the top and bottom ends, which are anchored to the valve body. The design supports the ball better and ensures it moves precisely with reduced torque.

Floating Ball Valve: Floating ball valves do not fix the ball in place but allow it to float slightly within the valve body. The pressure of the fluid holds the ball while downstream seat pressing against it provides typical sealing mechanism. This means that floating balls require more operating torque compared to trunnion balls.

Sealing Mechanism:

Trunnion Ball Valve: The sealing mechanisms employed in most trunnion ball valves include soft-seated or metal-to-metal seals. These seals around the periphery of the ball and inside its housing provide tight shut-off, preventing leakage even under high pressures.

Floating Ball Valve: In such valves, a seal against a floating valve seat is created by using downstream seat as separation between them. As pressure increases, so does force exerted on the ball supporting this seal. Nevertheless, over time these types of balls may suffer from seat wear causing them to leak.

Pressure and Temperature Rating:

Trunnion Ball Valve: Due to their heavy duty construction and superior sealing mechanisms, trunnion ball valves are suitable for high-pressure, high-temperature applications. They can handle various levels of pressure as well as temperature without fear of any damages arising from leakage.

Floating Ball Valve: Normally floating type is applied to low or moderate pressure/temperature conditions but still they can withstand significant pressures unlike trunnions that cannot stand up against harsh environmental conditions.

Applications:

Trunnion Ball Valve: Industries such as oil &gas, petrochemicals, power generation, and mining use trunnion ball valves for accurate flow control at very high pressures with reliable operation. Also these valves are the preferred choice when tight shut-off and long life are paramount in critical applications.

Floating Ball Valve: Floating ball valve is used in water and wastewater treatment, general chemical processing and HVAC systems among others where moderate pressure temperature condition and cost-effective is crucial factor.

To sum up while both trunnion ball valves and floating ball valves serve similar purposes in fluid control, their design differences make them suitable for different operating conditions and applications. Trunnion ball valves offer excellent control and reliability in extreme high pressure/high temperature environments whereas floating balls are more commonly found in lower-pressure services where low costs have highest priority.

What are the advantages of using a trunnion ball valve?

Trunnion ball valves are beneficial since they offer:

Stability with minimum operating torque due to their trunion mounted design.

Good sealing performance even at high pressure and temperature.

It is capable of handling different types of fluids such as corrosive, abrasive among others.

This is important for it guarantees that the vital industrial process keeps on going without any interruptions in case there are any technical malfunctions which are unavoidable.

What industries commonly use trunnion ball valves?

Some areas where companies use trunnion ball valves include:

Oil and gas sectors like pipeline transport, refinery processes and well heads control

Petrochemicals which deals with chemicals, hydrocarbons and refining processes

Power generation plants involving steam, water and coolant control systems

Water and wastewater treatment, mining, chemical processing among other general industrial applications

How does a trunnion ball valve differ from a floating ball valve?

Design and operation differentiate between Trunnion Ball Valves (TBVs) and Floating Ball Valves (FBVs):

While TBVs have balls that remain fixed by means of a trunion to minimize torque needed for closing their FBV counterparts allow free movement of the balls within their body.

Trunnion Ball Valves depend on metal-to-metal or soft seating while Floating Ball Valves rely on downstream seat pressure for sealing.

Trunnion Ball Valves find application in high pressure &#; high temp services while Floating Ball Valves are used mostly in low pressure areas.

What key considerations should be made when selecting a trunnion ball valve for an application?

Depending on what you want to do with your app; some things to keep in mind when choosing this kind of equipment include:

The fluid used must be compatible with the material used making the valve. Corrosive or erosive media must be avoided.

The capacity of the valve and its corresponding size should be in line with the flow requirements. Operating conditions like presence of harsh chemicals or whether it will be exposed to harsh weather must also be considered while selecting this kind of equipment.

Adherence to industry benchmarks as well as regulatory bodies is another decisive criterion for purchasing such equipment. Long term reliability, maintenance and/or life cycle cost.

Summary on Trunnion Ball Valve

Fluid control systems in many industries rely on trunnion ball valves because these valves have a robust design, are very accurate and reliable. In them, the closure is spherical (ball) which can rotate about its axis to open or close the valve. The liquid flows into the pipe when it is open and stops when it is closed. In addition to holding the ball in place while opening or closing, trunnions provide support and help reduce operating torque.

In various industries such as oil and gas, petrochemicals, power generation and mining among others, one of the major advantages of using trunnion ball valves is that they can withstand high pressures and temperatures. They have good sealability even under severe conditions to ensure tight shut-off and prevent any leakage. Trunnion ball valves handle a wide range of fluids including corrosive media and abrasives.

Moreover, apart from reliability and performance, long-term durability without servicing are other merits for which trunnion ball valves are selected. It makes them ideal for critical applications requiring nonstop operation due to their strong constructional parts in connection with various types of sealing devices. Selecting a trunnion ball valve should take into account factors such as fluid compatibility with the system&#;s pressure, temperature requirements, environmental issues as well as compliance with industry codes.

Ultimately in various industrial operations where there is need to regulate movement of fluids by most efficient means possible; therefore consider utilizing trunnion ball valves which form highly efficient solutions for fluid transport systems specifically designed for safe use within different industrial environments.

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