The type of valve used in the industrial sector is very important, in regard to efficiency in the flow control, reliability of the valve in question, and durability of the valve at a given cost. Plug valves and ball valves are two of the most widely used types and each has an edge over the other depending on the application. This article gives a detailed comparison of plug valve vs ball valve in terms of efficiency, its uses, and even the cost basing the information from the leading manufacturers of ball valves.
Understanding Plug Valves
Plug valves are designed in such a way that there is a cylindrical or conical plug that rotates in the body of the valve to regulate the flow of the fluids or gasses. The plug has an opening extending in the flow direction when the valve is open, and turns to cover the flow when closed. This design enables the valve to be operated with a quarter turn like the ball valves though there is a slight difference in the application and operation of the two valves.
Plug valves are specially built and very useful in those industries where the valves are subjected to heavy usage. They are especially suitable where close tolerance and low head loss are desired. These valves can be applied in chemical processing, oil and gas and water treatment industries to name but a few because it is important that no leakage occurs in the system. But there is a flaw in the plug valves, and this is the friction between the plug and the valve body which causes wear if the valves are used in abrasive or corrosive environment. To counter this, plug valves are known to be somewhat more challenging to maintain and need frequent greasing than ball valves. However, because of these features, they offer a tight seal and can be used in high pressure systems, and for this reason, they are commonly used in industries.
Exploring Ball Valves
It is a well-known fact that ball valves are highly usable and can be applied in a lot of situations. These valves have a round ball with an orifice centered through the ball so as to be in line with the pipeline and open for flow but is turned to normal in case of closure. Ball valves are similar to plug valves in terms of the fact that they also function through a quarter-turn and are also somewhat more versatile than plug valves.
These valves have been designed to accommodate a range of fluids, pressures and temperatures by manufacturers for use in many industries including the oil and gas, heating and ventilation, water treatment, and food industries. Ball valves are another type of valve that can ensure a very tight shut down without much force and hence, the stress exerted on the parts will also be less. This results in improved reliability of the equipment and reduced costs of maintenance, particularly in high cycling operations. Furthermore, ball valves are less likely to leak compared to plug valves and this is because when the ball seats are in the valve body they fit tightly so as to minimize the chances of leakage. This makes them particularly ideal for use in areas where leakages should be prevented as in the case of chemical industries, or a natural gas distribution system.
Efficiency and Applications
Comparing between the plug valve and Ball valve in a factor of efficiency, it is important to consider sealing capability, ease of operation, and the durability of the two valves. Ball valves are usually considered as being more efficient in terms of their lower operating torque and minimal friction between the valve components. This makes ball valves quite operational, particularly in high pressure and in the long-run, does not put a severe strain on the parts of the valve.
It should be noted that plug valves are quite rugged and durable; however, this type of valve may experience higher friction between the plug and the valve body and therefore, will experience higher operational resistance and wear. That is why, in certain applications, where the ability to provide a perfect sealing and the minimum pressure drop is critical, plug valves can still be used effectively if only they are properly maintained from time to time. Ball valves are more general in their use, and can be found in a wider range of applications. Their simplicity coupled with their versatility in handling all kinds of media make them suitable for use in HVAC systems, food and beverage processing, water supply and treatment and many others.
Problems
There are several pitfalls which may result in either suboptimal performance of the plug or ball valve and / or additional costs: One fairly common mistake is choosing a valve only by its purchase price not taking into account the future maintenance and profitability of usage. While plug valves can be suitable for some applications, there are some disadvantages, such as higher maintenance to increase the operating costs in the long run.
Another weakness in valve selection is inability to determine the type of media that the valve will operate on. In such application areas as containing abrasive or corrosive fluids, the material of the valve and its construction plays a decisive role. These problems should be avoided and a competent ball valve manufacturer should be consulted in order to ensure that the correct valve is chosen to suit the application.
Cost Analysis and Conclusion
When it comes to expenditure, it will be wise if one takes into consideration both the capital expense and the recurring expense. Plug valves are generally costlier at the initial stage as they have a complex build and the material that is used to make them, is made to withstand the conditions that are likely to be encountered. In such applications where their peculiar advantages are required, the higher initial cost can be justified by the valve performance and durability.
Compared with other types of valves, ball valves are relatively cheap to purchase and the cost of operation and maintenance is much lower and the service life is much longer. Ball valve manufacturers have engineered these valves to give optimum performance and the need for frequent servicing is minimum and this has made these valves to be suitable for many industries especially the ones looking forward to cutting on expenses. Ball valves are also cost effective due to adaptability, where the valve can be adopted for many applications without much modification.
All in all, the plug valve and the ball valve are two different valves with their own characteristics and the users should select the best one according to their own requirements. Plug valves have great performance characteristics when it comes to throttling applications that involve high levels of sealing, minimum pressure drop and high pressure-temperature conditions which are typical of process industries. Ball valves are less complicated to operate and maintain as compared to other valves, it is extensively used in broad fields so that it can be concluded that ball valves can be economical for so many fields of industries. The advice from the independent ball valve manufacturers can help industry experts to make the right choice of the valve which will best meet the requirements of their operation and provide the greatest saving in terms of cost and efficiency.
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