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!