How Superior is Trunnion Ball Valve Compare to Floating Ball Valve?

Ball valve is one of the essential mechanism for industrial needs, particularly used to regulate the variety of flows such as liquids, gases, and solids. It allows the through-bore to either fully open or fully block to regulate the fluid flow.

Ball valves are separately categorized into two types: Trunnion ball valve & floating ball valve are both classified under the same mechanic category of ball valve, but these two has the differences in terms of their design, purpose, and operation. However, one of these two types of ball valves is often utilized by every sectors to fulfill their needs and solving their problems efficiently.

To understand why every sectors prefer trunnion ball valve as a superior mechanical device than floating ball valve, these are the key points for why the trunnion ball valve is much more of a top-notch mechanism for industrial sectors than the floating ball valve.

1.   Durability

Even trunnion ball valve is generally more expensive than floating ball valve, but in terms of durability, trunnion ball valve is last longer than floating ball valve because it has the superior materials as the resistancy shield to wear and tear, that’s why it made trunnion ball valve much more costly. But from the business perspective, it’s a cost-saving mechanism that has a longer duration of utilization.

2.   Pressure Application

Trunnion ball valve is able to operate both high and low pressure applications, while floating ball valve is only able to operate in low pressure applications. Trunnion ball valve plays a critical role for absorbing the pressure from the fluid within pipeline. For example, in oil & gas fields, trunnion ball valve can operate for oil refinery feedstock lines which has the compression amount of approximately between 25-65 PSI.

3.   Efficiency

Trunnion ball valve has its trunnion stem for reduced the operating torque to either open or close the ball valve, which enable the operation smoothly. Even trunnion ball valve is designed for low-torque operation, it can reduced the strain on the actuator, prolonged the valve’s lifespan, and maintained precisive control over the fluid flow on the pipeline. This will create the efficiency as the beneficial advantage from the mechanical device.

4.   Versatility

Similar to point No. 2 (Pressure Application), trunnion ball valves are suitable for various applications in a wide range of sizes & materials. Due to its versatile function, trunnion ball valve can also operate in various applications such as oil and gas pipeline, petrochemical plant, power station, and water treatment system.

5.   Reliability

With the robust design and construction for mechanism support, trunnion ball valve has the resistancy against corrosion and erosion. The innovative design for trunnion ball valve at both ends is to enable the mechanic device in order to withstand the forces generated by high fluid flow and pressure rates which it make much superior and reliable in terms of operartion performance.

In conclusion, the crucial role of trunnion ball valve for industrial applications such as oil and gas, petrochemical, and other sectors is remarkably essential in terms of superiority qualities, functionally advanced, & much beneficial for its design & materials. In most cases, every industrial sectors were most likely to choose trunnion ball valve as the effective mechanism for the application need like pipeline than floating ball valve.

For More Information

References :

Welsford, Gilbert. 2022. Selecting the Right Ball Valve: Floating Versus Trunnion. Opflow.

Chen, Sheng-Tan & Huang, Wen-Yi & Xing, Chen. 2015. The Designing of Trunnion Mounted Ball Valve for Oxygen Working Conditions.

Wang, Jialun & Zhang, Yefeng & Tang, Hesheng. (2024). Erosion wear characteristics of metal seal floating ball valve in gas–solid–liquid three-phase flow. AIP Advances.

The Essence of Operating Type for the Valve

In order to operate the valve, we need to understand the actuation system that operate the valve from within. First, what is valve? It’s a mechanism to regulate, direct or control the flow of fluids such as gases, liquids, and solids by either open, close, reduce or increase the flow. The main question is, how the operating type works to operate the valve?

The main purpose is to activate the valve by actuating the system that enable or disable the mechanical device to regulate the flow and pressure on its system, whether it operates manually or automatically. The mechanism can also relieve pressure from a piping system or from pressurized vessels. There are 4 operating types for the valve:

1.   Handwheel

A common type of manual actuation that can be used to override the valve’s pneumatic machine to either the fully open or closed positions. It may also assert a limit stop to the valve stem which prevent stem motion beyond a certain position.

2.   Lever

A manual actuation that can be actuated by hand to direct compressed air and simply control the flow in quick response times. It’s easy to install on various industrial applications and durable to withstand hazardous condition.

3.   Gear

Unlike handwheel type, the gear converts the turning force to rotate the stem and it make much simple to control the flow. Gear is generally less expensive if it compared to actuator and much more immune in a fragile environment.

4.   Actuator

A non-manual actuation that directs force when a various elements are usually supplied to the valve’s system. Actuator provides precise control of the valve without the requirement of manual operation and made it as an integral part of the piping system from within. It has a variety type of actuators such as electric, pneumatic, hydraulic, and electro-hydraulic.

The valve cannot be operate on its own without its actuating device so that the mechanism can maintained the piping system from within. It’s very crucial for the valve to operate by manual-backed or electric-backed actuating system in order to control the valve.

For More Information

References :

Aghazadeh, Fereydoun & Al-Qaisi, Saif & Hutchinson, Francis & Ikuma, Laura. 2012. Handwheel valve operation: Assessment of four opening methods in terms of muscle loading, perceived comfort, and efficiency.

Kumar, Shrawan. 2001. Industrial handwheel actuation and the human operator: a review. International Journal of Industrial Ergonomics.

Aziz, Musadiq. 2013. Valve Actuator.

What Are the Type of Materials to Required for Manufacturing the Valve?

Valves are the backbone for many industries such as oil and gas, petrochemical, electric, water, and other sectors. This mechanical device is to regulate and control the flow of fluids like liquids, gases, and solids. However, it would not be possible to operate if it wasn’t for the materials within the valve, it depends on condition process and functions.

To classified what kind of materials to be considered as a requirement for manufacturing the valve, we have to understand each of various materials that can be materialized for the valve. These are the raw materials for the valve and how they were worked on different circumstances.

1. Carbon Steel

Carbon steel is commonly used in a normal condition and it comes in multitude of grades, it comprised of iron ore, coal, and limestone. This type of material steel is equipped as the resistant to the corrosive element of water and other liquids. There’s also another type of carbon steel such as low temperature carbon steel, but the difference is it only operate for low temperature applications.

2. Alloy Steel

Alloy steel is an alloyed material that contains such variety of elements such as manganese, nickel, chromium, vanadium, molybdenum, and among others. These elements help to increase the strength of alloy steel from within. It has a various types of alloy steel with different appliances and requirements in terms of condition. For example, if the alloy content is low, it would be categorized as low alloy steel and it can be applied for pressure piping and pressure vessels.

3. Stainless Steel

Stainless steel is much frequently used in industrial sector, manufacturing, and construction due to its resistancy against the corrosion, high temperature, and high pressure environment. The composition of chemical content on stainless steel contains <10% chromium and >0,2% carbon. It has a variety of classification type that categorized as stainless steel based on different characterizations. For example, stainless steel ball valve is suitable for petroleum refineries that is usually under the extreme circumstance due to its corrosiveness level.

4. Austenitic Stainless Steel

Similar to stainless steel, austenitic stainless steel is categorized as the stainlesses material. But in terms of conformability, this non-magnetic steel offers practical machining and wide range of temperatures. The composition of chemical content on austenitic stainless steel comprised 16-25 % of chromium and 8-20 % of nickel. It cannot be hardened by heat treatment since the steel is independent from the temperature at which it’s treated. It is widely used for a variety type of valves due to its superior mechanical component, corrosion resistance, and versatility. For example, gate valve is often made of austenitic stainless steel which provide the resistance shield against corrosion in the corrosive environment.

5. Ferritic Stainless Steel

Unlike austenitic stainless steel, ferritic stainless steel has the magnetic detection to determine which elements can be considered safe, it can be hinted if one of the material sticked into the steel. This stainless steel is known as direct chromium stainless steel that contains 10,5-30 % of chromium while it has a decreasing rate of carbon content. Ferritic stainless steel can achieve higher ductility and resistance in annealing. It’s frequently used for basic material to manufacturing the valve and it made applicable for the various industrial applications including chemistry, water processing, and paper.

6. Bronze

Bronze is a flexible alloy metal that contains mostly of copper, with the addition of other metals such as tin (12-12,5 %), aluminium, manganese, zinc, and nickel. Due to its higher tin content, it enhanced higher yield and tensile strength to the valve. Bronze can be used as a valve material for a wide variety of industrial applications such as plumbing, HVAC, marine, and other sectors

7. Brass

Similar to bronze, brass is contains of copper but what makes it differ from bronze is the presence of tin element on brass while bronze comprised of zinc. Brass offers high mechanical strength for the valve and it’s widely used in industrial applications such as oil and gas, plumbing, automotive, HVAC, and other sectors.

8. Cast Iron

Cast Iron is a mixture material of various metals that comprised of iron, carbon, silicon, and manganese. This predominantly iron alloy material has the resistance shield against corrosion, abrasion, high temperature, and high pressure due to its durable component. In terms of usage, cast iron can be used in a wide range of industrial applications such as water supply, air conditioning, sewage system, and other sectors. It has a variety type of cast iron based on different chemical component and characterizations. For example, cast iron gate valve can be used for transporting crude oil since the mechanism has its durable component to withstand the liquids within pipeline.

9. Cast Steel

Cast Steel is a steel material that contains of carbon and steel alloys which can withstand the high pressure and temperature. With the combination of tough component and tensile strength, cast steel is commonly used for high pressure and high temperature applications in various sectors. Due to its beneficial advantages, cast steel can be applied to a wide variety type of valves such as gate valve, globe valve, and check valve.

10. Monel

Monel is an alloy material that contains of nickel, copper, iron, manganese, and among others. These compounds can added to the resistance against corrosion and increasing the strength of nickel alloy component. With its durability and versatility, monel can be applied to various type of valves for industrial sectors such as oil and gas, maritime, and chemical. Monel valve can be utilized in the high temperature and high pressure applications such as hydrofluoric acid, sea water, dry chlorine, and other chemicals.

To summarized it, each materials has a wide variety of elements for different purpose and requirements when it comes to condition, circumstance, and process. Material can affect the valve’s performance to operate and utilize in the industrial sectors. With these different classification on each materials, the industries will able to recognized the various materials based on condition process and function for manufacturing the valve.

For More Information

References :

ASTM International. 2024. Standard Specification for Castings, Austenitic, for Pressure-Containing Parts.

ASTM International. 2024. Standard Specification for Carbon Steel Forgings for Piping Applications.

ASTM International. 2024. Standard Specification for Stainless Steel Bars and Shapes.

ASTM International. 2024. Standard Specification for Alloy-Steel and Stainless Steel Bolting for Low-Temperature Service.

Understanding the Role of Valve Actuator and Its Type

Valve Actuator is a mechanism that used for move or control the valve. It’s a component that produce forces when an electrical, pneumatic, or hydraulic input is supplied to the actuating system. It can move the valve based on commands so that the valve can open, shut, or regulate fluid flow as desired. The mechanism can be activated by using a mechanical arm that is usually driven by an electric motor, which is controlled by a programmed automatic control media including a microcontroller.

There are 2 working conjunction component parts of the actuator, valve body & valve pilot. There’s also a several parts of the components inside the mechanism device itself such as bonnet, engine valve spring or diaphragm, yoke, clutch block, drive indicator, upper spindle, vent plug, & adjusting crew.

In terms of functionality, the valve actuator has a variety of important functions to enable the operation of its device. It can be used for moving the valve, controlling the fluid flow, maintaining the precision and the accuracy, provide the responsiveness, & optimize the system’s safety. There are several types of the actuators that commonly equipped for the valves.

1.   Diaphragm Actuator

This type of valve actuator is used air pressure from within the diaphragm housing in order to push the actuator rod down. This process is known as “direct-acting,” which results in air compression. It usually used for control valve to regulate the fluid flows in order to adjust pressure, temperature, and flow rate.

2.   High Pressure Actuator

Similar to diaphragm type, it’s also used air pressure as well. But on this type of mechanism, it’s designed to work with high pressure. It’s generally used for industrial applications that required high pressure and faster movement. For example, higher pressure application can make it much difficult to operate the mechanism, so it has to required high pressure actuator to achieve the torque performance.

3.   Pneumatic Actuator

This piston shaped mechanism that is used to move various mechanical components, such as valves, conveyors, and other equipment. It provides enough force power to control the movement of these components in various industrial applications. One such case for example, it can be used for mining industry where pneumatic actuator drive the valve to regulate the pressure within the nozzle on the stone washing line.

4.   Electric Actuator

A mechanism that is used electric as a power source to move the valve. It can enhance rotational movement which is converted into linear motion by using mechanism, i.e., screws or gears. For the valve operation, it able to facilitate the valve to control the flow of fluids within pipeline.

5.   Electro-Hydraulic Actuator

Combining the electromechanical and hydraulic components, it used an electric force to drive a hydraulic pump then push hydraulic fluid in order to move the valve. For purpose, it aims to replace hydraulic system with standalone actuator operated solely by electrical power. Aircraft control surface required the precise control over motion, in order to operate the application, electro-hydraulic actuator provide proportional control of force to the automotive application, this would made the operation much smoothly.

For the advantages of the valve actuator, it has a responsiveness, precision control, more durable, non-dependent on external power sources, & able to withstand the heavy loads. But on its disadvantages, it much more costly, require more maintenance, require electric force, complex to control, & much heavier by design.

The vital role of actuator in the industrial sectors is crucial for assisted the valve to operate for the various industrial applications such as oil and gas, petrochemical, energy, and other sectors. It enable the operation process for the valve and it makes much easier for every sectors to achieve the efficiency.

For More Information 

References :

Aziz, Musadiq. 2013. Valve Actuator.

Kovalenko, Aleksandr. 2017. Numerical model of the pneumatic diaphragm actuator. Mechanics and Advanced Technologies.

Enoksson, Peter. 2002. A high-stroke, high-pressure electrostatic actuator for valve applications. Sensors and Actuators A: Physical.

Ali, Hazem & Noor, Samsul & Bashi, S. & Marhaban, Mohammad Hamiruce. 2009. A Review of Pneumatic Actuators (Modeling and Control). Australian Journal of Basic and Applied Sciences.

Cococi, Valentin & Constantin, Calinoiu & Safta, Carmen-Anca. 2021. Pneumatic Actuator Controlled by Proportional Valve. Experimental results. E3S Web of Conferences.

Kivanc, Omer & Ustun, Ozgur & Tosun, Gurkan & Oguz, Ender & Mutlu, Yasar. 2019. Design and Implementation of an Electric Actuated Valve for Precise Fluid Control. Gazi University Journal of Science.

Bing, Xu & Shen, Jun & Shihao, Liu & Qi, Su & Zhang, Junhui. 2020. Research and Development of Electro-hydraulic Control Valves Oriented to Industry 4.0: A Review. Chinese Journal of Mechanical Engineering.

Why It's Important to Required Safety Kit on the Workplace?

While working at the workplace or factory plant, every workers, employees, or staffs must have one of the key major requirement for work, industrial safety kit. This kit isn’t just only for protection, it’s a multi-disciplinary requirement for maintain the worker’s safety and prevent the potential danger or accident risk while working at the site.

This requirement is part of ensuring compliance with working regulation so that the sectors can assured each worker’s safety during the operational hours. It’s a crucial part for every single worker to maintaining their well-being while working. These are the safety equipment for working in the factory area:

1.   Safety Helmet

Safety helmet is a protective kit to protect the head from injury at the workplace. This head protection shielded the head part from the falling object and minimalized the untoward injuries or impacts.

2.   Safety Shoes

A steel-toe boot shoe is aims to minimize foot injuries caused by dropped potential hazard substances. This foot protection typically has a steel-toe cap that cover the toes from being crushed or injured.

3.   Safety Gloves

The main purpose of this hand kit is to prevent injuries and it protect hands from cuts, abrasions, burns, chemical exposure and other harm substances. This is one of the crucial requirement to ensuring the safety of each workers.

4.   Safety Jacket

A safety code dress is the first line of defense for the workers by providing visibility and protection from potential hazards. Safety jacket reduced the accident risk by ensuring the safety of the workers who wore it. It also designed with reflector to the jacket which gave the signal of the user’s presence while at the workplace or at the life-threatening potential situation.

5.   Safety Glass

Safety glasses are designed to protect the eyes against any light to moderate impact and flying particles. This eye protection prevent any potential harm and illnesses that could impact the eye vision.

It’s very crucial for workers, staffs, & employees to prioritized their safety. That’s why each workers required to wear industrial safety kit while working in the factory area. The benefit of the safety kit is a visibility and protection, it can also prevent potential accident or injuries. It’s what K3 stands for “Kesehatan & Keselamatan Kerja”, it is part of the protocol for every industrial sectors to comply in order to ensuring the worker’s safety.

For More Information

References :

Sowmiya, S.. 2023. Industrial Hygiene and Safety. Louis Savenien Dupuis Journal of Multidisciplinary Research.

Guney, E., Altin, H., Esra Asci, A., Bayilmis, O. U., & Bayilmis, C. (2024). YOLO-Based Personal Protective Equipment Monitoring System for Workplace Safety. JITSI : Jurnal Ilmiah Teknologi Sistem Informasi.

Breaking Down the Comparison Between Trunnion Ball Valve & Floating Ball Valve

A ball valve is a mechanism that uses a rotary ball to control the flow of fluids such as liquids, gases, and solids. It allows the through-bore to either block, open, or partially open in order to regulate the fluid flow.

Ball valves are typically categorized into two types: Trunnion ball valve and floating ball valve are both classified under the same category of ball valves, but these two types are differ in terms of their design, purpose, and operation.

1. Trunnion Ball Valve

This type is designed to control the flow of fluids within a pipeline. It features a fixed ball connected to a shaft, called the trunnion, on one end, ensuring the ball is securely held in place. This design enables the valve to maintain a proper seal on both sides of the ball simultaneously.

2. Floating Ball Valve

Similar to the trunnion ball valve, it's primarily used to control the flow of fluids through a pipeline. However, it features a floating ball within the device mechanism, which allows for quick and efficient operation when opening or closing the valve. The primary function of this valve is to achieve a bidirectional seal within the pipeline.

Both types each have their unique functions and components, but they also share several similarities. Below are the key point similarities and differences between these two different types of ball valves.

Similarities

• Both types utilize a spherical element, or ball, to regulate the flow.
• They both offer minimal flow resistance.
• Both types are actuated with a quarter-turn rotation.
• Each valve includes a seal between the stem and the external environment, which is subject to wear and tear over time.
• Both designs are engineered to prevent stem leakage by halting media from escaping the piping system.

Differences

• A trunnion ball type is connected inside the valve through both on top and bottom shafts, whereas a floating ball type is only attached through its stem.
• The trunnion ball type is generally more expensive than the floating ball type.
• A trunnion ball type has both fixed upper and lower stems, while the floating ball valve features a movable ball.
• Floating ball types are more challenging to operate in high-pressure applications compared to trunnion ball types which able to operate in both high-pressure and low-pressure applications.
• In a floating ball type, the ball is pushed against the downstream seat by in-line pressure to create a tight seal. In contrast for trunnion ball type, its ball fixed between the stem and trunnion, requiring only rotation against the seat pressure to achieve sealing. 

Despite their differences, both trunnion and floating ball valves are crucial for industrial applications such as oil and gas, petrochemical, and other sectors. Their unique characteristics and functions make them as essential components for regulating the fluid flow within pipelines.

For More Information

References :

Welsford, Gilbert. 2022. Selecting the Right Ball Valve: Floating Versus Trunnion. Opflow.

Chen, Sheng-Tan & Huang, Wen-Yi & Xing, Chen. 2015. The Designing of Trunnion Mounted Ball Valve for Oxygen Working Conditions.

Wang, Jialun & Zhang, Yefeng & Tang, Hesheng. (2024). Erosion wear characteristics of metal seal floating ball valve in gas–solid–liquid three-phase flow. AIP Advances.