Many ball valve manufacturers will provide an estimate of the expected lifespan of a ball valve, and proper maintenance can certainly extend this range. However, ball valve lifespan can be influenced by a variety of other factors.
Actuation
While some ball valves are powered manually, many are operated via automatic actuator. Depending on your system’s intended cycle speed, you have your choice between pneumatic (air-powered), electric (motorized) or hydraulic (fluid-powered) actuation. By choosing the appropriate power source for your application, you can reduce maintenance expenses, increase uptime and maximize safety. Pneumatic actuated ball valves are the most durable option in high-pressure environments, provided you have access to compressed air. In most cases, actuators will far outlive the ball valves they control.
Two examples of pneumatic actuated ball valves. The actuator sits on top of the valve body and operates the valve via compressed air.
Design
Ball valves come in one-, two- and three-piece designs, the first two of which do not allow for maintenance and must be replaced when components fail. Three-piece ball valves, however, are designed so that the seats and seals can be removed and replaced quickly and easily without removing the entire valve from the system. Provided the valve is made of durable material, the ability to replace components means that three-piece ball valves can long outlive their one- and two-piece counterparts. For this reason, three-piece ball valves are favored for high-cycle and high-pressure applications that subject the seal components to lots of wear and tear.
Left: A manual two-piece ball valve; Right: A manual three-piece ball valve.
Serviceability
Seals are typically the first component to fail in a ball valve, since they are made of much softer material than the valve body. While one-piece and two-piece ball valves must be replaced when their seals expire, three-piece ball valves allow for easy replacement of seals without removing the valve entirely.
Temperature and pressure rating
Ball valves used in high-pressure or high-cycle settings will need to be serviced or replaced more frequently than those in lower-pressure applications. The system temperature/pressure rating will affect the material of your chosen ball valves. Be aware that the closer the media’s temperature/pressure rating is to the ball valve’s rating, the more frequently the valve will need to be replaced.
The good news is that the actuator (which is typically the more expensive component in an actuated valve assembly) will normally outlast the ball valve. This means that in most cases the valve can be replaced without replacing the existing actuator.
Media
Ball valves are generally intended for the on/off control of fluids and gases without solid particulates. Any particles in the media can abrade the valve seals, leading to repairs, valve failure or actuator failure. Conversely, lubricative medias such as oils can reduce seal wear and extend the life of the valve even further.
Valve materials
Media is a major determinant of the materials for ball valve bodies and accessories. Ball valves can be made of stainless steel, brass, bronze, or plastic (PVC). While PVC offers flexibility and cost savings, metal ball valves are more durable and able to withstand higher temperatures and pressures. Overall, metal ball valves have a longer lifespan than those made with PVC or other synthetic materials. When in doubt regarding the appropriate valve material, use the Cole-Parmer Chemical Compatibility Database to ensure valve materials are compatible with your specific media.
Left: A manual two-piece brass ball valve; Right: A manual two-piece stainless steel ball valve.
Source
If your plant contains processing equipment made in the U.S., you’ll want to source ball valves from domestic manufacturers and suppliers. Some valve retailers source their products from all over the world, but products from overseas carry the risk of incompatibility with products made Stateside. Quality aside, it’s best to buy ball valves from domestic sources to ensure longevity and prevent premature replacements.
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