Ball valves use a simple design based on a ball or sphere that is ported or drilled out to provide a flow path for gases and liquids moving through the valve. These ported valve balls are attached to handles that require only a quarter turn to allow full flow or shut off the flow, but they are unsuitable for throttling flow. The ball valve design creates a relatively low pressure drop across the valve.
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Miniature ball valves come in a wide selection of specifications and options. These choices provide the flexibility to choose the best ball valve for any fluid or gas handling application. Decisions to make include:
One-way or unidirectional vs. two-way ball valves
The most common miniature ball valve is the two-port ball valve with two ports or connections. The option of choosing between a one-way or two-way ball valve sometimes shows up with metal ball valves designed to handle relatively high pressures, usually about 200 psi and higher. The difference between a one-way and a two-way ball valve is that flow direction matters.
One-way ball valves have a flow direction. This orientation is because one-way ball valve designs only seal and handle pressure flowing in one direction. A one-way valve ball has only one seat for sealing against the ball. Besides providing the sealing surface, valve seats also provide a surface that uniformly distributes force pressing against the ball.
Not only do one-way ball valves not seal against upstream pressure, but they also do not hold up well to the wear caused by this upstream pressure. Despite these limitations, unidirectional ball valves are a practical option because of their lower cost.
Two-way ball valves can adequately handle the pressurized flow from either port without leaking or premature wear to the valve components.
Miniature three-way ball valves usually come as one of two types based on the design of the balls inside the valve: L-port and T-port. The two ball port types also come in either an upright (vertical) or horizontal orientation.
L-port three-way ball valves (vertical and horizontal) have “L” shaped holes bored through the valve balls. T-port three-way ball valves have a “T” shaped passage running through the ball. L-port valves, sometimes called diverter valves, divert flow between different destinations.
T-port and L-port horizontal ball valve flow patterns schematic.
L-port ball valves may or may not have an “off” or closed position depending on whether the valve body includes stops that limit the rotation of the handle. Horizontal T-port valves do not have an “off” or closed position. Vertical or upright T-port three-way valves do have an off or closed position.
Get a more detailed look at three-way ball valve flow patterns >>
Ball valves also come in four-way and five-way designs with either four or five possible flow connections. The most common ball porting for these multi-port valves makes them suitable for diverting or mixing flow. There is usually an option for blocking one of the ports to add shutoff positions.
Four-way ball valves have more complex valve ball porting than three-way valves. The most common four-way ball porting is based on a five-way ball valve with the common port plugged. This option leaves the valve with two separate right-angle flow paths in the same plane running through the ball. Manufacturers usually list them as X-port valves. Turning the handle of these four-way ball valves diverts two different flow paths coming into the valve flow simultaneously to two alternate destinations.
The simplest five-way ball valves are diverter valves with an “L” or 90-degree hole that allows flow between the bottom or common port and one side port, but none of the other side ports. Five-way ball valves can have one port plugged to add an off or closed flow position.
Because of the customization flexibility of five-way ball valve bodies, valve balls for four-way and five-way valves come with more ball flow patterns than just L, T or X.
Four-way and five-way ball valves can be customized for various mixing options. Flow pattern options include:
Customized multi-port valve ball porting applications:
Ball valve types and designs takeaways:
What is flow efficiency?
Flow efficiency measures how little or how much flow resistance there is as a fluid or gas passes through a valve, fitting or piping.
Right-angle ball valves create some flow turbulence and thus more resistance to flow than straight valves. Straight ball valves also have a relatively lower pressure drop across the valve than other types of valves. Full port or full flow ball valve designs provide even greater flow efficiency.
Full port ball valves have valve balls with holes ported through them with the same inner diameter as the pipe or tubing connected to the valve. Standard port ball valves use balls with smaller diameter ports than the flow coming into and leaving the valve. This constricted flow decreases flow efficiency and creates a higher pressure drop across the valves.
Full port versus standard port ball valves:
Find out more about Full Port Ball Valves vs. Standard Port ball valves >>
Flow efficiency takeaways:
Miniature ball valves come in many connection types. These connection options provide easy installation and replacement:
Valves with one or more hose barb connections are popular because they are considered tool-free and are quick to install. Hose barbs are designed for use with flexible plastic tubing.
Hose barb connection takeaways
Hose barb connections are known for being particularly leak resistant. Be aware that trouble-free connections require:
Find out more about the design and function of hose barb connections >>
Find out more about flexible tubing durometer and why it matters >>
Fluid and gas handling valves and fittings commonly use threaded pipe connections because they are solid and leak-tight when properly installed. Most miniature ball valves available in North America come with NPT pipe thread. NPT (American National Standard Taper Pipe Thread) are tapered pipe threads and rely on a combination of thread sealant and a thread design that creates an interference fit to help make a tighter, stronger connection.
Threaded connection takeaways:
Compression connections connect rigid and semi-rigid plastic or thin-walled metal tubing to fittings such as valves or tubing unions. This type of connection is useful because it can effectively connect two tubing sections not made of the same material. It can also connect a tubing made of a different material than the fitting. As a bonus, it creates no flow restriction.
Compression fittings have an outer compression nut with a tapered seat, a barrel-shaped compression ring (ferrule) with tapered ends and a tapered seat on the receiving end of the fitting.
Properly tightening the compression nut presses the ferrule ends evenly into the seats inside of the compression nut and the fitting. Additional tightening deforms the ferrule, compresses it around the tubing, fills the space between the tubing, nut, and receiving end of the connection and seals the connection. Generally, do not reuse ferrules because they deform during the installation process.
Compression connections require proper installation for leak-free seals. Overtightening can cause leaks. A good rule of thumb for assembling compression connections is:
Always follow manufacturers’ durometer specifications when using plastic tubing with compression connections. Plastic tubing walls must be stiff enough (higher durometer) to not collapse or move away from the ferrule when compressed. If softer tubing (lower durometer), use a tubing insert to reinforce the tubing wall.
Tubing minimum acceptable wall thickness is also necessary for metal tubing and rigid plastic tubing. With softer plastic tubing, the tubing inner diameter should match the tubing insert.
Compression connection takeaways:
Push-in or push-to-connect connections are a type for connecting metal or rigid and semi-rigid plastic tubing to unions and fittings such as ball valves without the use of tools, soldering or adhesives.
The working parts of push-in connectors are:
Installation requirements for leak-free, reliable push-in connections:
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Push-in connection takeaways:
Even though ball valves have a simple design, they all contain internal components. These components may be of different materials than the valve body. Material differences affect the valve’s compatibility with various chemicals, chemical mixtures and gases passing through it.
Be aware of which valve components will contact the fluids passing through the valve. These are sometimes called wetted parts.
Typical ball valve components:
Materials that come into contact with foods and potable liquids are subject to regulatory control.
Manufacturers of commercial food equipment and food processing equipment used in the United States are responsible for using materials that comply with FDA regulations. Rules cover both raw materials and the appropriate end-use or real-world application of components made from these materials. Appropriate end-use rules consider factors such as exposure time, temperature, and acidity.
The NSF sets standards for materials that come into contact with drinkable water in the United States. They base these standards on testing for substances that can leach into drinking water from a valve's interior or wetted surfaces.
US materials and components standards for foods and potable water:
When using valves for food and potable water applications, be sure the manufacturer clearly states that they make their valve from compliant materials or materials approved for food or potable water contact.
A particular application may require an NSF certified valve. If so, the manufacturer may provide this NSF certification information, so ask. NSF approved food contact materials are also FDA compliant.
Find out more about materials that are safe for direct food contact >>
Ball valves often use soft seat designs where an elastomer or plastic is the seat material. Using these softer materials provides a better seal that is more resilient, lighter and less expensive than a hard metal seat. Because of that polymer seat, a metal ball valve with a polymer seat will have an upper working temperature limit.
Ball valve materials takeaways:
CWP, Cold Working Pressure
CWP is the maximum working pressure a valve can handle at temperatures between -20°F to 100°F (about -29°C to 38°C).
Operating temperature range
A valve used within its operating or material temperature range will not suffer damage or failure to any of its components or have a shortened working life.
Maximum operating pressure and temperature
The maximum safe operating pressure or PSI rating of a valve is provided based on its maximum safe operating temperature.
Blow out proof stems
Miniature ball valves with blow-out proof stems have mechanical design elements that prevent high-pressure surges from blowing the valve stem out of the valve body.
Cv (flow coefficient) and flow efficiency
Cv stands for flow coefficient. It represents how efficiently a gas or liquid can flow through piping, a fitting or a valve. Many manufacturers provide ball valve specifications, including their flow coefficient. If the Cv number of two valves is known, a higher Cv number means a valve provides a higher flow under the same operating conditions.
WOG, Water, Oil or Gas
WOG is an older term that is no longer widely used. In general, it simply indicates that a ball valve is suitable for general use and can handle water, oil or gas but not steam or combustible gases. Ball valves for use with combustible gases have specialized additional design elements and certifications that approve the valves for this use.
WSP, Working Steam Pressure
WSP is the maximum steam pressure a ball valve can handle. Generally, no miniature ball valve will be suitable for use with steam unless the manufacturer clearly says it is and provides the Working Steam Pressure. SWP, Steam Working Pressure has the same meaning.
Technical specifications takeaways:
Ball valves are simple, sturdy shutoff valves that can be closed with a quick quarter-turn of the valve handle. They are reliable and work even after long periods of idleness. In contrast to industrial ball valves, miniature ball valves come with a broader range of material and design options. Look for and ask about our miniature ball valve options to find the best choice for an application.
A ball valve is a type of valve that uses a hollow, pivoting ball to control the flow of a medium through itself. If the hole of the ball is in line with the flow, the valve is open, and it is closed when the valve handle has been used to pivot the ball ninety degrees.
The main function of a ball valve is to isolate parts of a plumbed system by starting, stopping, or adjusting the flow of a medium (usually water, air, or gas) between separate chambers, ducts, and pipes. This is achieved by either allowing the medium to pass freely through the ball valve, partially admitting the medium through a narrowed opening, or blocking the flow completely. Ball valves can also be used to divert flow into different directions, depending on the valve type and handle position.
Ball valves offer operational simplicity, quick repair, and a high level of versatility. This means that they are extensively used in industrial applications and able to support pressures up to 1,000 bar (100 MPa, or 15,000 psi) and temperatures up to 400°C (752°F), depending on the material, medium, and design used.
These components are typically chosen for applications where on or off are the key positions required. The design of ball valves means that they inherently provide a reliable shut-off function, provided all components are in good working order. However, they are often less effective at accurately controlling flow rates at graduated positions in between fully open and fully closed.
Ball valves are most commonly found in plumbing systems and related applications such as industrial cooling. Their role is generally to help manage the flow rate of liquid or gas passing through a specific port or opening, influencing the balance of pressure in other key parts of the system.
They are also familiar features in various types of tap, faucet, and spigot, as well as being widely used on gas lines, domestic appliances, and additional industrial applications. In most cases, ball valves for industrial use tend to be more heavy-duty and robust in construction than their domestic counterparts. They are typically found in applications where machines or systems operate under significantly higher pressures and temperatures, within industries as diverse as manufacturing, assembly and production, plastics and metals, chemical, medical, industrial power, food and beverages, printing and textiles, electronics, automotive, and logistics.
Several different types of ball valves exist, each suited to varying applications. The types available include manual ball valves, process ball valves, and pneumatic ball valves.
Understanding how a ball valve works is fairly straightforward. It is usually designed with a large borehole running through the centre, from one side to the other. The ball sits snugly on its seating within a duct opening (port). It is attached directly to the operating handle of the valve, which is usually located above or to the side of the device, often on the outside of a pipe assembly. By rotating the handle, typically one-quarter turn through 90 degrees, the ball is physically turned on its axis within the port.
This action aligns the hole in the ball with the flow direction of the medium inside the duct, allowing it to pass freely through the ball valve. This is known as the on or open position. Turning the handle back 90 degrees in the other direction, to off or closed, causes the ball to rotate so that the hole running through it is perpendicular to the flow direction. At this point, the medium can no longer pass through the ball valve, and the flow is completely blocked off.
Regardless of which ball valve types you are dealing with, most will consist of four main parts. These are the valve housing, the central metal ball, the seating that holds the ball in place within the valve, and the lever used to move the ball valve between on/open and off/shut positions. The main body of a ball valve is most often made from stainless steel, brass or nickel-plated brass, PVC, or a similarly tough, plastic polymer. The balls themselves are usually manufactured from stainless steel or brass (again, often nickel-plated or chrome-plated brass).
Different models and configurations of ball valves are further distinguished from one another by their various attachment or fitting types. These might include manual ball valves with either compression fittings or threaded fittings.
More complex ball valve designs can offer additional flow control options, besides simply on or off. Both flanged and vented ball valves are available, which can give multiple other flow outcomes depending on the position of the lever. For instance, a common requirement is for a vented ball valve to divert or block flow on only the upstream or downstream side of a valve, allowing continued flow in the opposite direction.
Vented models achieve this by having a secondary, smaller hole in the ball, which can be aligned with a particular direction of ducting when the handle is moved to the correct position. This creates a T-shaped or L-shaped junction in a multi-port arrangement, such as at the joining of 3 or 4 different ducts. You will often see devices with this built-in capability sold as 3-way ball valves or 4-way ball valves.
Ball valves are generally very hard-wearing, and for the most part, they require little maintenance to keep running smoothly for a long time. This is partly to do with the simplicity of their design and operation.
However, over an extended period of service, the components of a ball valve can wear down. When this happens, they may become stiff or loose, or gradually lose their effectiveness in providing a perfect shut-off function. If you suspect that a worn ball valve may be causing issues in a plumbing system, there are some basic steps that you should take to investigate and solve the problem.
The tools that you will need to repair or replace a ball valve will vary, depending on both the type of ball valve in question as well as the damage which needs to be fixed. A spanner or pipe wrench is usually all you will need to check a domestic plumbing ball valve, but you should also keep a cloth to hand to catch any excess liquid as you disassemble the pipe fittings around the valve.
One key advantage of ball valves in most industrial applications is that they are generally seen as rugged, low maintenance fixtures. They offer excellent all-around durability over many years of service and require minimal servicing and repairs.
A second important advantage of ball valves is their simple, effective design. This means that they tend to offer reliable perfect shut-off capabilities. Provided that the seating, ball, and other main components of the ball valve, duct, and port are in good working order, flow is completely blocked off when the valve is closed. A properly functioning ball valve is not prone to leaking by allowing small quantities of liquid or gas to pass through, because there is physically no opening available when the ball faces perpendicular to the flow direction.
The main disadvantage of ball valves in certain applications is that they are less good at accurately controlling specific flow rates. For achieving a precise flow anywhere between fully open and fully closed, various other valve types might be a better option. If a system requires very precise control over a partial flow rate, then solenoid valves, needle valves, or gate valves will be far more accurate and effective than most ball valves.
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