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Fully Welded Ball Valve

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What Is Fully Welded Ball Valve

Fully welded ball valve also called Welded Body Ball Valve, as the body is fully welded. The fully welded body ensures that no external leakage path from valve body. All welding processes are qualified and performed according to ASME Section IX. The welding for the valve body are to performed with Non-destructive tests.

Fully Welded Underground Ball Valve

GZP Pipeline Ball Valves are manufactured to the latest edition of API 6D and tested to API 6D. Passed API 607 fire test standard for soft seal valves.

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Benefits of Fully Welded Ball Valve

Enhanced sealing performance
Fully welded ball valves feature a welded structure, eliminating the need for sealing gaskets or packing materials found in traditional ball valves. As a result, they offer stronger sealing capabilities, effectively preventing leaks.

Increased pressure resistance
With the adoption of a fully welded structure, fully welded ball valves do not feature threaded connections or sealing gaskets between the valve body and bonnet. Consequently, they can withstand higher pressures, offering superior pressure resistance.

Extended service life
The structure of fully welded ball valves is simpler, without any moving parts or vulnerable components, resulting in a longer service life without the need for frequent part replacements.

Suitable for high temperature, high pressure, and corrosive media
Fully welded ball valves are typically manufactured using materials that are resistant to high temperatures and corrosion. They can adapt to various harsh operating environments, such as high temperature, high pressure, and corrosive media.

Compact structure
Fully welded ball valves feature a simple design with a compact size, making them easy to install and occupying minimal space.

Fully Welded Ball Valves for Heating and Fuel Gas Systems

The following list describes the features of fully welded ball valves used in various heating and gas processing applications.

Ball valves in most gas systems utilize a fixed shaft with a fully welded structure which can reduce or eliminate leakage.

Fully welded ball valves are constructed with fully-forged material to create a compact valve body structure that is lightweight, high-strength, maintenance-free, and can last up to 30 years.

The bidirectional sealing valve (DBB) allows the venting and discharge of the valve chamber at the fully open and closed positions. These specialized valves are extremely useful in pipeline systems that require frequent venting, release, and pressure relief.

● There are two valve seat designs

Single piston effect (standard) to provide the valve cavity overpressure self-discharge function.

The double piston effect provides a double seal barrier.

Fully welded ball valves used for heating and gas systems benefit from low valve torque, meaning they’re easy to open and close.

Finally, these valves are also very useful in systems with flammability precautions. Welded ball valves are tested for the following fire-resistant measures: API, 6FA, and API607.

Functions and Characteristics of Fully Welded Ball Valves

Functions of the Fully Welded Ball Valve

The valve is composed of a fully welded valve body and a carbon-reinforced fluorine gasket, which allows it to operate for a long lifespan under conditions of frequent operation and exposure to impurities and chemicals. The finely ground stainless steel ball ensures years of easy opening and closing, as well as reliable operation.

A spring inside the valve seat ensures that the sealing ring is tightly pressed against the ball. Even under unstable pressure conditions, the valve can still maintain a tight seal.

The anti-leakage structure of the valve stem uses two O-rings, allowing the valve stem to rotate freely while maintaining a tight seal.

Characteristics of the Fully Welded Ball Valve

The fully welded ball valve has an excellent valve seat: A low friction coefficient, small operating torque, a variety of valve seat materials, and a wide range of applications.

The valve stem has an anti-flying-out structure: A step is set at the lower part of the valve stem, and the valve stem is installed from the inside of the valve body to prevent it from flying out.

The fully welded ball valve features an anti-static function: An anti-static spring is installed between the ball and the valve body or stem to discharge static electricity generated during operation.

The fully welded ball valve has a fire-resistant structure: Each potential leakage point is designed with flexible graphite packing or stainless steel with graphite to meet fire-resistant requirements.

The fully welded ball valve adopts a robust support plate structure, which improves the service life of the valve, reduces operating torque, and significantly extends the valve's lifespan.

Some common applications of fully welded ball valves include

Oil and Gas Industry
Fully welded ball valves are widely used in the oil and gas industry for both onshore and offshore applications. They are suitable for high-pressure and high-temperature environments, providing excellent performance in pipelines, refineries, petrochemical plants, and LNG terminals.

Chemical Industry
The chemical industry requires valves that can handle corrosive and aggressive fluids. Fully welded ball valves made from corrosion-resistant materials, such as stainless steel or special alloys, are used to control the flow of chemicals in manufacturing processes and storage facilities.

Water and Wastewater Treatment
Fully welded ball valves are employed in water and wastewater treatment plants to control the flow of water, slurries, and various fluids. They are preferred for their ability to handle high pressures, reduce leakage, and provide tight shut-off, ensuring efficient operation and minimizing water loss.

Power Generation
Power plants, including thermal and nuclear power plants, utilize fully welded ball valves to control the flow of steam, condensate, and other media. These valves can withstand high temperatures and pressures, contributing to the safe and reliable operation of power generation facilities.

Pipeline Transportation
Fully welded ball valves are commonly used in pipeline systems for transporting oil, gas, and other fluids over long distances. Their compact design and high-pressure capabilities make them suitable for buried or underground pipelines, reducing the risk of leakage and ensuring efficient flow control.

Mining Industry
In mining operations, fully welded ball valves are used to control the flow of slurry, water, and chemicals involved in mineral processing. Their robust construction and abrasion-resistant materials enable them to withstand the harsh conditions and abrasive media encountered in mining operations.

HVAC Systems
Fully welded ball valves are applied in heating, ventilation, and air conditioning (HVAC) systems. They are used to control the flow of water and other fluids in HVAC systems in commercial buildings, hospitals, and industrial facilities.

Fire Protection Systems
Fully welded ball valves are crucial components in fire protection systems, including fire sprinkler and fire suppression systems. These valves ensure reliable shut-off and quick response in the event of a fire, preventing the spread of flames and protecting lives and property.

What is the difference between a fully welded ball valve and an ordinary ball valve?

A fully welded ball valve is a type of ball valve, but it is often treated as a separate category of products due to its unique characteristics. Compared to ordinary ball valves, the valve seat of a fully welded ball valve is typically made from carbonized material. It consists of a Teflon sealing ring and a disc spring, which gives it excellent adaptability to pressure and temperature changes. A fully welded ball valve will not experience slippage within its rated pressure and temperature range. The key characteristics of a fully welded ball valve are as follows:

Durability and Resistance
The fully welded ball valve is made from carbon steel seamless steel pipe, which is pressed and formed into a single-piece welded construction. This design allows it to withstand frequent operation in environments with impurities and chemical substances, giving it a long service life.

Low Maintenance and Cost-Effective
It requires no maintenance, adjustment, or lubrication, making it easy to install and ensuring reliable operation at low operating costs over the long term. The surface is treated with plastic spraying technology, which gives it a glossy finish and is at the leading level in China. The valve body is welded, ensuring there is no external leakage. The welded structure makes the valve lightweight and easy to insulate, and the adjustment mechanism is easy to install. The operating handle can be removed and reinstalled in reverse.

Zero Leakage and Long Life
The valve seal is made of a carbon-reinforced PTFE (Teflon) inclined elastic sealing ring, with negative pressure applied to the spherical surface. This design ensures zero leakage and a long service life of the valve.

Self-Sealing Function
The fully welded ball valve uses a floating ball design, where the elasticity of the inclined surface ensures the sealing ring is tightly pressed against the ball. This ensures a tight seal, even when pressure fluctuates.

Compact and Lightweight
The valve has a compact structure and is lightweight, making it easy to insulate and install. It is generally installed horizontally.

Leak-Proof Stem Design
The stem of the fully welded ball valve features a leak-proof structure with two "O" rings that allow the stem to rotate freely while maintaining a tight seal.

Heat Preservation
The stem of the welded integrated ball valve can be lengthened to make heat preservation easier.

Underground Installation
The valve can be persistently buried deep underground. The use of the latest engineering technology minimizes the space required for valve control, greatly saving on construction costs and engineering time. This also helps prevent the risk of gas explosions.

Installation Methods for Fully Welded Ball Valves

Among fully welded ball valves, there is a specific type known as the buried fully welded ball valve. Below is a detailed introduction to the installation method of buried fully welded ball valves.

Installation of Buried Fully Welded Ball Valves

The valve body of a buried fully welded ball valve is installed underground. Typically, an extended rod method is used to position the valve opening above ground. Strict pressure testing should be performed before installation.

Pipeline Valve Pressure Testing
Pipeline valves should undergo a pressure test before installation to ensure the tightness and safety of the valve.

Strength Test
The strength test uses water as the testing medium. High-pressure caps are welded to the sleeves on both sides of the valve. After opening the valve to 45 degrees Celsius, water is injected into the ball valve through the pressure-testing valve on the sleeve. The pressure is then increased to 1.5 times the nominal pressure of the ball valve and maintained for 15 minutes. If no leakage is detected, the valve is considered qualified.

Tightness Test
The tightness test uses nitrogen as the medium. The ball valve is closed, and nitrogen gas is injected into the ball valve through the pressure-test valve on the sleeve. The pressure is then increased to 1.1 times the nominal pressure of the ball valve, and the pressure relief valve in the middle chamber is connected to a water container for testing. The insertion depth should be 1 cm. If no bubbles are generated within 5 minutes, the valve passes the test.

Installation of Fully Welded Ball Valves

Lifting the Valve
The valve should be lifted using the correct method to avoid damaging the valve stem. Do not tie the lifting chain to the hand-wheel, gearbox, or actuator. The protective caps on both ends of the valve sleeve should not be removed before welding.

Valve Welding Process
The connection between the buried fully welded ball valve and the main pipeline should be welded. The weld quality must comply with the Class II film standard for "Radiography of Disc Bend Melt Welding Joints" (GB3323-2005). Typically, one welding attempt cannot fully guarantee the quality of the weld, so when ordering the valve, the manufacturer should provide 1.0-meter-long sleeve pipes at both ends of the valve. This ensures that if the weld is unqualified, the unqualified section can be cut off and re-welded. The valve should be in the fully open position to prevent damage from welding slag splashing onto the valve ball. Additionally, care should be taken to ensure that the temperature of the valve's internal sealing parts does not exceed 140°C. Cooling measures can be taken if necessary.

Install Valve Wells for Pouring
The buried fully welded ball valve adopts a special structural design that requires no maintenance. Before burial, the valve's exterior should be coated with a special anti-corrosion coating. Three injection pipes should be used for emergency grease injection into the valve seat and valve stem. The middle cavity vent pipe and valve stem should be extended according to the burial depth, allowing workers to perform necessary operations above ground. After burial, a small valve hand-well can be built. In contrast, non-fully welded ball valves require a large valve well, which can be dangerous as it creates an enclosed space that hinders safe operation. Additionally, the valve body and the bolt connections between the valve and the pipeline may corrode over time, affecting the valve's service life.

Our Factory

Our company owns a full set of equipment,complete processing and testing methods.The establishing of CAD valve design center and three-dimensional simulated manufacturing experimental design system ensures that new products with high quality can be developed promptly.Implementing perfect quality assurance system,our company is making unremitting endeavor for obtaining API certification on the passing ISO 9001, CE, API 6D International Quality Certification.

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FAQ

Q: What is a welded valve?

A: A fully welded valve is designed with a fully welded and forged body to reduce weight and increase strength while eliminating several potential leak points. They are used to connect and shut off the flow of the medium in many different pipeline systems.

Q: Which is best ball valve?

A: PVC ball valves are durable and can withstand high temperatures and pressures. They are also corrosion resistant and have a long lifespan and are considered as oil and gas valves because they are typically used in industrial applications but can also be used in residential applications.

Q: How long do ball valves last?

A: A ball valve is a shut-off valve capable of preventing or allowing liquid or gas to pass through a fixture. Using the latest and greatest ball valve in your plumbing can help save more water. It also helps you save money while helping the environment. A ball valve life expectancy is about eight to ten years.

Q: Can you weld a ball valve?

A: Valves with extended ends for butt welding to piping or tubing need not be disassembled prior to welding as the extended ends will absorb enough of the heat generated during welding to prevent excessive temperature at the seats and seals.

Q: Can you weld a valve?

A: Weld repairs are usually considered when the valve body has a defect that needs to be addressed. Valve bodies are not readily available as spare parts, and the time to procure a valve body may be prohibitively long. The most common welded repairs are those to valve bodies.

Q: Are ball valves the best?

A: Ball valves have a higher initial cost, but they are the better choice for longevity since they are more durable and highly effective at forming tight seals.

Q: Does a ball valve need to be fully open?

A: That means that your plumbing system will get reactivated with water in an instant. So always avoid turning on the valve fully, and too quickly. Always turn the handle just enough to let the water gently refill the pipes.

Q: What is the longest lasting ball valve?

A: Stainless steel ball valves offer a long-lasting option, even when used in highly corrosive environments; 316 stainless steel is a particularly corrosion-resistant alternative that includes more nickel than standard stainless steel, as well as the addition of molybdenum — a silvery metal with a very high melting point.

Q: Can you overheat a ball valve?

A: Excessive heat can cause the valve's materials to expand. This causes leaks, deformation, or even complete valve failure. Overheating might occur due to factors like high fluid temperatures, inadequate cooling mechanisms, or improper valve selection.

Q: Which is best ball valve?

Q: Do ball valves last longer than gate valves?

A: Frequency of use: Since gate valves wear out quicker, they are often found in applications where they don't need to be adjusted very often. Ball valves are recommended for applications that require frequent, quick control over the flow of liquid.

We're well-known as one of the leading fully welded ball valve manufacturers and suppliers in China. If you're going to buy high quality fully welded ball valve at competitive price, welcome to get more information from our factory.

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