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A Guide to Ball Float Valve Installation: Potential Issues and How to Fix Them

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Though plumbers, mechanics, or other contractors tend to install ball float valves, it is possible for those not technically trained to do so, too. Sometimes, it’s best to consult an expert to ensure the suitable ball float valve is selected for the application. Prior to ball valve installation, however, a few preparations come first. 

Installing Ball Float Valves

Preparations for installing a ball float valve should include the following steps: 

  • The position at which the ball float ball is installed should be on the same axis as the pipeline, while the two flanges should remain parallel on the pipeline. This helps confirm that the pipeline bears the ball float valve’s weight. Additional support must be added if the pipeline cannot support this weight on its own.
  • The pipeline should be cleaned of welding slag or other impurities within the pipeline.
  • The ball float valve should be tested by fully opening and fully closing it numerous times to confirm normal operation and then meticulously inspected to certify it remains intact.
  • The cover that protects both valve ends should be removed, and the valve body should be checked to ensure it’s clean. The cavity of the ball float valve should also be cleaned thoroughly, as even the smallest contaminants can cause surface damage.

Installing a ball float valve entails the following steps: 

  • At the upstream end, any segment of a ball float valve can be installed, while the valve’s handle can be installed at any point along the pipeline. For ball float valves with actuators, installation must be vertical, while the valve’s outlet and inlet should be horizontal.
  •  In accordance with the pipeline’s design requirements, a gasket is installed between the pipeline’s flange and the ball float valve’s flange.
  • Bolts should be tightened evenly, symmetrically, and in sequence.
  • For ball float valves that need to adapt to electric, pneumatic, or other actuators, the power supply or air source should be installed according to instructions.

While there should be no issues if installed correctly, it’s important to note when potential problems with ball float valves have issues and how to correct them.

Potential Issues with Ball Float Valves & How to Handle Them 

Numerous issues can develop with ball float valves in tanks. For example, waves within a tank affect the amount of liquid that flows from or to a tank through the float valve to fluctuate. This fluctuation can then exacerbate this problem, as waves naturally cause additional fluid movement within the tank. Should this happen near the valve’s closure, this can also lead to a water hammer developing, which can then damage both the seat and disk. This surge can also interrupt the inlet process system. 

This may cause pressure gauges to vibrate and needles to fall off, while flowmeters and pressure transducers produce inconsistent or erroneous readings. In situations like these, fixing the problem requires stabilizing the liquid’s surface. This problem can be resolved by diffusing the flow and introducing an outlet under the surface. Placing baffles across the tank also reduces surface movement. In water tanks, this results in a reliable water supply that prevents the tank from overflowing.

There are a few common issues with ball float valves in tanks. These include the valve not closing under both no-flow and flow conditions or once it reaches the desired thermal work limit, chattering, and unusually high noise levels when discharging or surging liquids within the tank. Often, these issues develop due to simply choosing the wrong ball float valve for the job, though poor maintenance or installation can also be the primary cause.

Valve Not Closing Under No-Flow & Flow Conditions

This type of problem with ball float valves is usually caused by one of three things. These include a dirty valve seat or worn valve face, which obviously require cleaning or replacing, respectively. However, this issue could instead result from the lever mechanism producing too little force to close when shut-off pressure is reached, which requires a more complicated fix if the wrong type of valve was chosen for the job.

If a ball float valve that isn’t able to handle the pressure is involved, it’s important to first determine the maximum pressure for the mains water supply. From this data, the correct float valve can be sourced and fitted. If feasible, a larger ball float could be used with the existing valve, or else the lever could simply be extended. If this doesn’t completely resolve the problem, the float might be unable to provide the necessary upward force due to damage, which requires replacement.

Valve Not Closing Once Desired Thermal Work Limit is Reached

This specific difficulty indicates that the float arm may need to be tweaked. On certain valves, the float arm may require adjusting, which won’t compromise the ball float valve’s normal functions. This could involve simply reducing the designated lever ratio, resulting in a comparable decrease in the valve’s closing force. Likely, this won’t compromise the valve’s operation, as the closing force should meet the pressure conditions needed for shutting off.

When this fix is unlikely to resolve the problem, alternatives include: 

  • Fitting a float with a larger diameter to improve buoyancy and increase the length of the valve’s lever.
  • An extended lever arm, known as a “drop rod,” is fitted to lengthen the adjustable lever to reach the desired thermal work limit.

Valve Chattering Within Tank

Sometimes, a ball float valve chatters when the float and lever assembly lose control of the valve’s internal components. This is due to hydraulic forces that change constantly as the valve finally closes. When small draw offs from the tank occur, this issue becomes even more evident. In almost every case, this results from installing a float valve unable to handle the closing-off pressure.

Solutions include: 

  • Equipping the tank with an oversized ball float valve to augment closing forces.  
  • Fitting with a smaller orifice may work for certain valve types, for which a conversion kit from the manufacturer or distributor can be used.
  • Increasing lever length to increase the closing forces.
  • Installing a ball float valve with a higher pressure rating.

If this problem isn’t addressed appropriately, the valve seating will deteriorate rapidly. It can also damage pipeline joints since the chatter often indicates the generation of high-frequency shocks from water hammers.

Noisy Discharges

Ball float valves and pipework surrounding them often become noisy with too high flow rates. Noise levels increase with flow velocity, causing greater wear and tear on internal components in the controls. When float valves make too much noise in this situation, it’s important to frequently inspect and maintain them to ensure their continuing viability. Using specially ported float valves or decreasing their orifice will help resolve this issue.

Surging Liquids

When the frequency of wave and valve action within the tank synchronizes, this can cause surges. This issue tends to build up over time until it slowly becomes a real problem, though it may also cause more movement of the float valve. This can then increase velocity in the pipeline rapidly, causing pressure surges. If left unchecked, piping malfunctions will likely follow. It’s necessary to disrupt the reverberating frequency that occurs between the wave and valve action.

Some possible solutions include: 

  • Mounting a stilling chamber to stop the wave action from returning to affect the float action.
  • A baffle is placed between the valve float and the exiting water to lessen turbulence on the surface surrounding the float.

Fixing surges often involves trial and error, and care must also be taken when selecting the most suitable materials for constructing a baffle.

Arthur Harris: Specialists in Ball Float Valves

Ball float valves are crucial in liquid-level control systems. Our top-notch valves are renowned for corrosion resistance and reliability in tough industrial settings. We offer various fluid-level control solutions to meet your needs. Contact us at Arthur Harris to learn more! 

How to Enhance Tank Performance with Ball Float Valves

Posted by & filed under Float Valve.

Regardless of the tank type or its exact purpose, ensuring a reliable water supply is crucial for many residential, industrial, or commercial applications. Yet the means to efficiently regulate levels within water tanks comes from a relatively simple device, the ball float valve.  First developed in the late 1700s, ball float valves are widely used in HVAC systems, plumbing, water treatment, and other applications to regulate water levels. Commonly known as a ballcock, balltap, or simply a float valve, this device remains one of the most efficient solutions for controlling water levels in tanks of all sizes.

Ball float valves float on the water’s surface, rising and falling as water levels increase. When water levels are too low, the valve opens to allow water to flow into the tank and closes when a certain predetermined level is reached. However, sometimes ball float valves don’t operate as expected, often due to the wrong type or size of ball float valve being selected. Issues can also occur because of poor installation or upkeep. For this reason, it’s essential for those who depend on their performance to understand the different types and sizes of ball float valves, how to install them, and resolve issues that sometimes affect their operation.

Maintaining Tank Liquid Levels with Ball Float Valves

Ball float valves work by mechanically controlling liquid levels and detecting changes in tank water levels by opening or closing the valve to allow water to enter or exit the tank. Domestic water systems use smaller ball float valves, such as those used in toilets, that manage the water used to flush waste away. In a hot water heater, a ball float valve maintains the level in the cold-water header tank that regulates the pressure of the hot water within it. Other ball float valves are fitted into copper piping and designed to regulate water pressure coming into a building.

Choosing the best ball float valve for an application depends on the following:

  • Material: Ball float valves can be made from stainless steel, plastic, or brass, with certain materials more suitable depending on their durability and the water’s composition.
  • Specifications: Sometimes, the type of ball float valve requires certain specifications dependent on the application, including whether it’s for agricultural, industrial, or residential purposes.
  • Tank size: Larger tanks have higher water pressure, so they need more robust ball float valves.

Depending on the material, ball float valves can be used for different types of liquids, but all help prevent the tanks from overfilling by diverting the liquid rather than allowing it to overflow. Some floats are mounted on the tank’s base, with an outlet that pipes fluid through the tank’s wall. The valve portion of the mechanism is linked to the float arrangement within the tank to control fluid levels.

Comparing Ball Float Valves

Though most ball float valves close when liquid levels rise, certain industrial types reverse this action. The most common setup involves the float valve mounted on the side of the tank and above the fluid level to enable maintenance without draining fluid from the tank. More economical varieties allow adjustment of liquid levels through the bending of the ball arm, while more pricey versions feature a bolted connection that facilitates adjustment of the ball arm.

Some of the more commonly used ball float valves include: 

  • Floating ball valve: In this kind of ball float valve, the ball remains unfixed from the valve’s stem, instead relying on fluid pressure to create a seal.
  • Full bore ball valve: Also referred to as a full port ball valve, this float valve has a large ball with a diameter that matches a pipeline’s inner diameter; this type of ball float valve reduces pressure drops throughout the valve with a design that doesn’t restrict flow.
  • Multi-port ball valve: This variety of ball float valves has several ball configurations and ports, diverting fluid in different directions and allowing a more versatile pattern of flow.
  • Reduced bore ball valve: Also known as a reduced port ball valve, this version of a ball float valve features a smaller diameter than the inner diameter of a pipeline; these types of ball float valves offer somewhat more excellent resistance to the flow of fluid, though they’re also inexpensive and more compact.
  • Trunnion-mounted ball valve: The trunnion tends to be used for higher pressures and offers this ball float valve additional support, which reduces the ball’s load.
  • V-port ball valve: This version of a ball float valve features a V-shaped ball, enabling greater accuracy and control over the flow and is used for processes that require more precise regulation of fluid flow.

Considering these general designs allows those tasked with determining the best ball float valve for an application to select the style that’s most suitable.

Advantages of Ball Float Valves 

Ball float valves provide certain advantages for numerous applications, which is why they’re often used in industrial settings.

Key benefits of ball float valves in tank systems include: 

  • Averting wastage of water through control of the fluid level to minimize the chance of overflow. 
  • Longer lifespan of the system due to the float valve’s robust structure, which can also resist corrosion and wear if made from the right materials. 
  • Controlling flow in both directions to augment their usefulness.
  • Handling wider ranges of pressures and temperatures that make them appropriate for an assortment of applications.
  • Minimizing loss of pressure due to their streamlined design, which also makes them more energy efficient.
  • Protecting areas against damage from water (or other fluids) by mitigating the risk of overflows.
  • Providing a consistent and reliable water supply by ensuring a stable level of water.
  • Reliably and immediately shut off during emergencies.

While ball float valves have these many advantages, they’re also prone to flow obstruction, so they shouldn’t be used with slurries and other thick liquids. Additionally, float valves can cause issues with surging, as they can cause waves on the surface of fluids in tanks.

Arthur Harris: The Ball Float Valve Experts 

Ball float valves are central to many control systems that require liquid-level control. Arthur Harris & Company specializes in stainless steel floats, for which our company has been a market leader for over a century. Our high-quality stainless steel ball float valves are used in many industries for their corrosion resistance, durability, and reliability, allowing them to withstand harsh industrial conditions. Arthur Harris also provides numerous other fluid-level control solutions that can be customized to suit the needs of our customers. Contact Arthur Harris directly to learn more about our stainless steel ball float valves and other products and services.

The Versatility of Stainless Steel Hemispheres and Shells in Industrial Applications

Posted by & filed under Stainless Steel Floats.

Many facilities use stainless steel float balls for liquid level control for numerous industrial processes. These float balls ensure continuous measurement and control of liquid levels in tanks and other industrial containers that hold fluids. Sometimes, customers purchase stainless steel hemispheres or shells instead of fully assembled float balls as they’re more versatile and cost-effective for many applications.

Applications for Stainless Steel Hemispheres & Shells

Stainless steel is generally preferred because of its strength, corrosion resistance and buoyancy when compared to other materials used for managing liquid levels in industrial processes. For example, metals like copper also have excellent corrosion-resistant properties but cost about double that of most grades of stainless steel, while also being denser and less buoyant. Though engineered plastics are sometimes used for float balls, stainless steel has unique properties that make it useful under high-pressure and high-temperature conditions involving corrosive liquids.

For industrial facilities that require liquid level control, using stainless steel hemispheres or floats is often less costly than producing or purchasing fully assembled float balls. The reasons for this are straightforward, primarily due to the cost savings both float manufacturers and customers can glean from purchasing unassembled float balls. By removing this step in the assembly process, manufacturers save time and money, which they can then pass along to their customers. 

Because of their geometries, far more stainless steel hemispheres and shells can be packaged in the same space as that used for already fabricated floats. Besides the lower shipping costs from more compact packaging of float balls made from stainless steel, hemispheres, and shells are less prone to damage than those that come preassembled. Not only does this lower shipping expenses, but it also saves storage space for manufacturers and distributors.

Selling stainless steel hemispheres or shells separately also allows manufacturers to simplify production, as float assembly often involves specialized machinery and familiarity with the application. It’s for this reason that many customers who require float balls for liquid-level management prefer to assemble stainless steel hemispheres or shells into floats, though sometimes a service provider will be hired to do so. Various applications and industries may require customized attachments or features, so it makes sense for them to purchase these as unassembled stainless steel hemispheres or floats.

Industries that use stainless steel hemispheres and shells to make floats include: 

  • Chemical processing: Used in assorted processes to calculate levels of corrosive fluids.
  • Food processing: Measures fluids used in the production and storing of food and beverages.
  • Oil and gas: Monitors liquid levels in pipelines and storage tanks.
  • Transportation: Acts to shut off the flow of liquids when tanker trucks reach capacity.
  • Water treatment: Employed for sewage systems and in water treatment facilities to gauge water levels.

Stainless steel hemispheres and shells thus provide a practical way to save time and money for both manufacturers and customers. These floats are useful for an array of control systems that manage liquid levels for various industrial processes. They’re used for managing levels of liquids like water, petroleum, natural gas, liquified chemicals, gasoline, or diesel fuel, controlling the timing of when pumps transport fluids while monitoring for safety.  

Chemical Processing 

Facilities that process and store chemicals often use chemical-resistant materials like stainless steel. Hemispheres and shells are often used to make stainless steel float balls to control liquid levels in storage tanks to make work environments safer. These float balls interact with valves, switches, sensors, and other devices to track liquid levels in chemical processing facilities.

Chemical processing applications for stainless steel floats include: 

  • Controlling the flow of chemical fluids between processes via pumps, valves, and other apparatus throughout a plant’s pumping system.
  • Distillation processes in which chemical compounds are purified and separated to help maintain proper levels in columns used for this purpose.
  • Handling corrosive substances like acids and alkalis while controlling and monitoring their levels during processing.
  • Measuring and controlling liquid levels accurately in reactors, storage tanks, and other receptacles containing various chemical solutions.
  • Regulating levels of reactants and other chemicals in process vessels during chemical reactions.
  • Storage tanks often include floats made from stainless steel hemispheres or shells to prevent overfilling or underfilling, as well as to minimize risks from leaks or spills.

Chemical processing often involves mixing, heating, and cooling chemicals, so using materials that can handle these harsh conditions is necessary. Stainless steel hemispheres for floats are thus often used in chemical processing applications due to their buoyancy and durability, while also resisting corrosion and extreme temperatures.

Food Processing

In food processing applications, switches attached to float balls within tanks containing liquid ingredients detect changes in liquid levels, which in turn set off alarms or cause pumps to begin operating. Here, float balls made from stainless steel hemispheres or shells can play an integral role in measuring liquid ingredients during the production of foods and beverages. Acidic liquids like citrus juices or vinegar, as well as alkaline fluids such as those containing dairy, can corrode these floats. For this reason, many are made from materials that can withstand these corrosive liquids, such as stainless steel. Hemispheres and shells require thinner walls when made from corrosion-resistant steels, making them preferred for many food processing applications.

Food processing applications for stainless steel floats include: 

  • Blending food products together to ensure correct ingredient proportions through managing liquid levels in mixing vats.
  • Controlling temperatures in tanks or other containers by managing the flow of media used to cool or heat liquid ingredients or products, with the help of switches or valves connected to the float ball.
  • Conveying liquid products like gravies, sauces, or syrups in conjunction with various processes with switches or valves to prevent product spillage or overflow.
  • Filtering solids from liquid ingredients or mixtures by integrating floats made from stainless steel hemispheres into filtration systems.
  • Monitoring and measuring beverages, oils, sauces, water, and other fluids in real-time during food processing operations.
  • Sanitation of processing equipment with clean-in-place systems, where they monitor the flow of liquid cleaning agents.  

Stainless steel hemispheres and shells used for float balls help ensure safety, efficiency, and cleanliness for a variety of food processing applications.  

Oil & Gas

Oil, gas and other liquid fuels depend on floats to track levels of these fluids when combined with other mechanisms, such as switches or valves. As a tank is filled or drained, once a float matches a certain level it activates a switch that in turn stops or starts the flow of fluid. Stainless steel hemispheres or shells made into float balls are often used for this purpose.

Oil and gas industry applications for stainless steel floats include:

  • Acting as “pigs” in pipeline pigging operations for inspection and maintenance of pipeline interiors.
  • Measuring and controlling levels of both refined and unrefined fluids, along with chemical ingredients contained within storage tanks and other containers.
  • Use in systems that help separate water and other contaminants out of oil, gas and other fuels.
  • Working in tandem with pressure relief valves to ensure safe operating conditions during processing and transport.

In the oil and gas industry, these stainless steel hemispheres or shells contribute to making operations within the oil and gas sector safer and more efficient by controlling and monitoring liquid levels.

Transporting Liquids 

Tanker trucks that transport liquids also require float balls that can be made with stainless steel hemispheres and shells. These floats are often used when transporting chemicals, fuel, sewage, water, and other liquids. Stainless steel float balls are widely used for suction lines. Once float balls reach the top of the truck’s tank, they trigger a switch that stops the vacuum hose from continuing to draw in more liquid. While durability and strength make stainless steel a good choice for these applications, these alloys also withstand higher pressure conditions well.

Water Treatment 

The treatment of water and wastewater requires considerable care. Water treatment facilities feature a series of holding tanks and other means of containment for water, along with chemicals used in water purification. Liquid level control is particularly crucial for water treatment processes that include cooling, filtering, and heating of fluids. It’s in the containers used for these purposes where stainless steel float balls are mostly used.  Additionally, these float balls can be used for managing liquid levels in sludge tanks, process basins, chemical storage tanks, aerobic digesters and other containers used in water treatment.

Water treatment applications for stainless steel floats include:

  • Controlling levels of air and water within tanks used for aeration so that dissolved compounds and gases can be removed from wastewater.
  • Ensuring a stable supply of treated water to municipal customers by monitoring water levels precisely in basins, reservoirs, and storage tanks.
  • Expediting and enhancing the sludge digestion process by controlling levels of sludge in digestion tanks.
  • Incorporating floats into filtration systems to remove microbes, particulate matter, and other contaminants.
  • Monitoring and maintaining water levels in sumps or wet wells at pump stations through the use of sensors or switches attached to float balls to ensure greater efficiency.  
  • Regulating chemicals include agents that manage pH, coagulants, disinfectants and flocculants used to precisely dose water to ensure optimal water quality.

Float balls made from stainless steel hemispheres or shells also help prevent cavitation and overflows that can result in equipment or system failure. Similar to other industries that require liquid level control, floats play an important role in the water treatment process.

Stainless Steel Hemispheres & Shells by Arthur Harris

Arthur Harris & Co. can supply a wide array of stainless steel hemispheres and shells for fabricating float balls. We make these hemispheres and shells with walls as thin as 28 gauge and diameters up to 14 inches (35.56 cm). Arthur Harris also has numerous other capabilities, which extend to CAD (computer-aided design), CAM (computer-aided manufacturing), heat treatments, metal finishing, powder coating, soldering, stamping, and welding, along with other processes and products. Contact Arthur Harris today to learn more about our stainless steel hemispheres and shells for floats and our other products or services.

 

Precision Metal Forming: Ensuring Quality in Manufacturing

Posted by & filed under Metal Forming.

The precision fabrication of metal sheeting is a process often referred to as metal forming. Metal forming machines make parts and products for aerospace, communications, defense, medical, renewable energy, and other industries. These processes produce an array of different geometries by applying force to metal sheets. Forming machines fabricate precision components from sheet metal to make them more durable and reliable. Understanding how some standard techniques for custom metal forming work to create metal parts and products enables manufacturers to choose methods that best suit their applications. (more…)

Stainless Steel Ball Valve Maintenance: A Comprehensive Guide

Posted by & filed under Float Valve.

Regularly scheduled ball valve maintenance can help ensure that industrial process systems function smoothly with limited interruption or significant downtime. Proper maintenance can identify any potential issues with the ball valves before they become major problems and, in doing so, extend their service life as well. Ball valve maintenance can also help prevent equipment failures, and damage to the system, and reduce safety hazards for workers. (more…)

The Limitless Uses of Stainless Steel Float Valves

Posted by & filed under Float Valve.

Stainless steel float valves are remarkable yet simple mechanical devices that offer limitless uses for liquid-level control systems applications. Float valves are, in their basic form, liquid-level controllers. They measure, monitor, or activate a particular mechanical level control system to regulate fluid levels in various open and closed storage tanks, vessels, basins, condensate tanks, remote tanks, reservoirs, and piping. (more…)

9 Top Styles of Cabinet Hardware for Your Home

Posted by & filed under Stainless Steel Hardware.

When designing cabinets for a kitchen or any other room in the home, the cabinetry isn’t quite complete until the hardware is attached. Not only is such hardware functional, but these pulls, knobs, backplates, or other cabinet accessories are also decorative. Such hardware can come in various sizes, styles, and types, made from various materials with differing finishes. Whether it’s chic stainless steel pulls or minimalistic designs requiring no hardware, styles for cabinetry within the home depend on the homeowner’s desired look. (more…)

9 Heat Treatment Methods for Stainless Steel

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When it comes to stainless steel heat treatment, methods will vary according to the metal’s end use and the properties necessary for the application. Sometimes this involves the metal undergoing several types of heat treatment, with methods for certain superalloys going through as many as six steps to optimize their properties. (more…)

What is a Liquid Level Control System?

Posted by & filed under Stainless Steel Floats.

Many industries use various equipment to maintain fluids, or even fluid-like substances, at a certain level. A liquid level control system utilizes various floats, probes, and other simple or complex technologies to moderate fluid levels. Some of these systems, processes, and implements can also be used with dry powders, chemicals, or any material that flows. Though some of these systems are versatile and have multiple applications, it’s important to understand the purpose for which it is used to ascertain the best type and method for liquid level control for a specific application. (more…)