Flow Control Valve: A Comprehensive Guide

Flow control valves are essential parts of most flow systems. They regulate the rate at which fluids pass through a system, providing a practical way to control flow without the need for constant human intervention. From ensuring the smooth operation of equipment to minimizing risks during operation, flow control valves are vital components in various industries. They also enhance the quality of end products, making them indispensable in today&#;s industrial world.

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What is a Flow Control Valve?

A flow control valve is a specific type of valve that manages the flow or pressure of a fluid such as gas or liquid. The main purpose of a flow control valve is to regulate the velocity and volume of the flow in a piping system. This valve can operate automatically, depending on the pressure and temperature changes, or can be manually controlled.

flow control valve 1

Flow control valves are typically responsive to signals from independent devices like flow meters and temperature gauges. They&#;re fitted with actuators and positioners to regulate their function, enhancing the flow control industry&#;s capability to manage fluid pressure in different applications.

How Does a Flow Control Valve Work?

The operation of a flow control valve mainly entails the modulation of the flow or pressure of a fluid, including changes of pressure. In essence, a flow control valve impacts the rate of energy transfer at any given point within a system. It opens, closes, or partially blocks the flow of the fluid to achieve a desired flow rate or maintain a set pressure. By modulating flow rates, these valves ensure the smooth operation of devices downstream and maintain system integrity.
Control valves can also work with hydraulic actuators (also known as hydraulic pilots). For instance, in a hydraulic flow control valve, the valve responds to shifts in pressure or flow, opening, or closing to maintain an optimal flow rate. By doing so, it ensures the hydraulic system operates efficiently and safely. It is the fluid pressure in the system that determines the opening and closing of automatic flow control valves, rather than relying on an external power source. Automatic control valves do not require an external power source and they include pressure reducing valves, flow control valves, back pressure maintenance valves, altitude valves, and relief valves.

What are the Various Types of Flow Control Valves?

There are multiple types of valves designed to meet the diverse needs of different industries for control purposes. Some of these flow control valve types include:

1. Pinch Valves: These valves utilize a flexible element, such as a rubber tube, to interrupt and regulate the flow of fluid. They&#;re particularly useful when working with slurries or liquids with a significant amount of suspended solids.

flow control valve 2

2. Diaphragm Valves: These valves use a flexible diaphragm that comes into contact with a seat at the top of the valve body, forming a seal. Diaphragm valves are great for handling corrosive, erosive, and dirt-laden services.
3. Gate Valves: These valves function primarily for on/off, non-throttling service. They&#;re often used where minimum pressure loss and a free bore is required.
4. Globe Valves: Globe valves are linear motion valves perfect for adjusting, halting, and initiating flow. They can completely close the flow path or remove it from the flow path completely.
5. Needle Valves: These offer precise flow control. They possess a sharp-pointed disc and a matching seat, making them suitable for applications that require precision, such as chemical feed control and continuous blow-off.

flow control valve 3

6. Ball Valves: These are commonly used in commercial and industrial applications due to their durability and excellent shutoff capability. They operate by rotating a ball to open or close the valve.
7. Plug Valves: Plug valves regulate flow by rotating a cylindrical or cone-shaped plug within the valve body.
8. Butterfly Valves: These valves control the flow of fluid by rotating a disc in the flow passage. Although they might lack the high degree of precision attained with other valve types, they are notably cost-effective.

What Are Some Advantages and Disadvantages of Different Types of Flow Control Valves?

Flow Valve TypeAdvantagesDisadvantagesPinch ValveConveniently handling slurries or liquids with many suspended solids; Durable and resistant to abrasion; Simple design means less maintenanceReduced efficiency with larger diameter pipes; Not suitable for high-pressure applicationsDiaphragm ValveSuitable for handling corrosive, erosive, and dirty fluids; Superior hygiene makes it suitable for food and medical applicationsSuited for moderate pressures and temperatures; the elastomeric material may degrade over timeGate ValveIdeal for straight-line flow of fluid with minimal restriction; Suited for a wide range of fluidsNot suited for throttling purposes; Slow to open and closeGlobe ValveProvides better shut-off than gate valves; Excellent throttling capabilitiesCauses a significant pressure drop; Larger and more expensive than other typesNeedle ValveAllows precise regulation; Exceptional performance under extreme conditionsNot suited for high flow rates; More expensive than other valvesBall ValveRapid shut-off; High flow capacity; Minimal pressure dropNot suited for throttling applications; Can potentially trap fluid in the ball&#;s cavityPlug ValveEasy to install and use; Allows rapid opening and closingPossible leakage if the plug wears over timeButterfly ValveLightweight and compact; Affordable; Quick operationNot as effective in controlling flow rate as other valves; Limited ability to provide an airtight shut-off

What Are the Various Applications of Flow Control Valves?

1. Industrial processes and manufacturing operations to regulate fluid flow.
2. Hydraulic and pneumatic systems to control the speed of motors and cylinders.
3. HVAC (Heating, Ventilation, and Air Conditioning) systems to regulate the flow of coolant.
4. Water treatment facilities to manage the flow rate of water.
5. Plumbing systems in buildings to control the flow of water.
6. Automotive and aerospace industries for controlling fuel and hydraulic fluid flow.
7. Power plants to regulate steam for driving turbines.
8. Agricultural equipment for precise delivery of water and fertilizers.
9. The oil and gas sector manages the flow of oil and gas through pipelines.
10. Chemical and pharmaceutical industries control the flow of liquids or gases during the production process.

How to Select Flow Control Valves for Different Industrial Applications?

1. Type of Fluid: Understand what kind of fluid (gas, liquid, etc.) the valve will be controlled. Different valve types handle different fluid types better than others.
2. Operating Pressure and Temperature: Determine the operating differential pressures and temperatures that the valve will be exposed to. Certain valves are better suited to high temperatures or pressures, while others might not perform as well under these conditions.
3. Flow Rate: The desired flow rate will determine the valve size you&#;ll need. Larger valves will allow larger volumes of fluid to pass through at a given time.
4. System Compatibility: Ensure the chosen valve type is compatible with other system elements.
5. Safety Requirements: Some applications may have specific safety requirements that a valve must meet.
6. Maintenance and Durability: Consider the maintenance needs and durability of the valve. Certain valve types, while maybe cheaper upfront, may require more regular maintenance, which can lead to increased costs over time.
7. Cost-Effectiveness: Analyzing the cost versus the expected benefits and lifespan of the flow valve can help to justify the investment.
8. Expert Advice: Consult industry experts or well-reputed suppliers like Dombor for personalized advice on the best flow control valve for your specific application.

What Are the Maintenance Requirements for Different Types of Flow Control Valves?

The maintenance requirements for flow control valves vary based on the type of valve, the system in which it operates, and the kind of fluid it regulates. Regular inspections, cleaning, and lubrication are essential to maintain the performance and extend the life of the valve. Moreover, certain valves such as automatic control valves require special monitoring as their maintenance needs might be more complex. For instance, some require frequent adjustment or replacement of internal parts.

flow control valve 4

Proper training in valve maintenance is essential and should cover all aspects of operation, calibration, troubleshooting, and repair procedures. It&#;s worth noting that ignoring regular maintenance can result in valve failure &#; an issue that could compromise the integrity of the entire system.

Conclusion

Flow control valves play a significant role in various industries and systems, from simply regulating the flow rate of the fluid to maintaining safety and efficiency in operations. While the selection can be extensive, understanding the features, advantages, and applications of each type assists in choosing the best type for your needs.

Choosing a Trusted Partner

As a trusted partner in the flow control industry, Dombor can provide the right flow control valve for your operations. With a comprehensive range of options, top-notch customer service, and industry expertise, Dombor will ensure you get the best value for your investment. Partnering with Dombor guarantees a solution that perfectly meets your requirements and exceeds your expectations.

Instrumentation and control systems take time to design. It&#;s good to know ahead of time which fittings or valves will work best for your chosen fluid, as well as, the best choice for flow management to balance your network.

Mako Products carries an extensive offering of flow control valves to give you the best regulation for your setup. The two most popular valves we offer are ball valves and needle valves, but what&#;s the difference between the two?

They&#;re both considered flow control valves but have separate ways of controlling flow that make them unique. Before you decide on the best one for you, let&#;s discuss their differences and the recommendations for using each one.

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Main Differences in Ball Valves and Needle Valves

What&#;s a Ball Valve?

Simply put, a ball valve is an on-off valve. It can be used to control flow by its main characteristic, the ball, being open or closed. Ordinarily, this only requires a quarter-turn of the ball valve handle.

The ball inside isn&#;t a solid ball, it has a hole through the center. As a result, it permits flow when open and stops flow when closed at 90 degrees. Furthermore, a ball valve can be partially open to regulate the flow of gas/liquid.

An advantage to the ball valve is that it&#;s relatively easy to tell when it is open or closed. Notably, this only requires a quick visual assessment of where the handle is turned. We&#;ll discuss further advantages in a moment.

What's a Needle Valve?

On one hand, a needle valve can be as simplistic as the ball valve with the on-off feature. However, needle valves also have the ability to regulate flow in a variety of other settings.

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These additional settings are possible because the needle valve has a needle-shaped plunger which is adjustable. Specifically, the plunger is capable of moving up and down allowing for half-open, barely open, or fully open positioning. This adjustability enables needle valves to have more precision in controlling flow than the ball valve

Recommendations, Advantages & Disadvantages for Using Each One

It&#;s important to note the function of each of these valves in order to choose the best option for your system. Both valves can be used in a variety of industries including petrochemicals, manufacturing, heating and cooling systems, wastewater treatment, chemical processing, and pharmaceuticals to name a few. We&#;ll showcase more specialized applications for each valve below.

Choose a Needle Valve

As discussed, the core difference in the two valves is the additional regulating opportunities a needle valve provides. The precise control of needle valves makes them &#;an ideal choice for calibration applications because they&#;re capable of being fine-tuned.&#;

When a high degree of accuracy and control are important, it&#;s better to stick with the needle valve. Two prime examples of areas where precise flow regulation is necessary and needle valves are the better option, are vacuum systems and metering systems. A few other regular applications include gas bleeder lines, sampling lines, fluid power systems, and automatic combustion control systems. 

Advantages

• Flexibility, allows for adjustability
• Precision
• Easy to shut-off with finger-tight pressure
• Resistant to both hot and cold temperatures
• Able to endure constant high pressure and vibrations efficiently
• High pressure drop when open

Disadvantages

• Restricted flow: Small passage flow between seat and needle &#; used for low flow rates
• Hard to tell if valve is open or closed

Further information on needle valves can be found on the blog page of our website in this article, &#;How Does a Needle Valve Work?&#;.

Choose a Ball Valve

Because of their generally lower cost and robust durability, ball valves are preferred in applications where a good sealing system is required. They&#;re a notable industrial choice because of their reliable and air-tight sealing when in the closed position.

Common industries where ball valves are used include oil and gas, agriculture, manufacturing, mining, heating and cooling, and construction.

With outstanding corrosion-resistance, stainless steel ball valves are notable for their use in petroleum refining, seawater environments, and brewing systems.

Advantages

• Cost-effective and reliable
• Easy to clean, the seat wipes itself when the ball in the valve rotates and buildup is prevented
• Require little maintenance because of the lack of internal components
• Diverse, able to be used in a wide range of applications
• Low pressure drop when open
• Full port ball valves maintain full, unrestricted flow

Disadvantages

• Not suitable for precision flow control or permanent throttling
• Leakage or abrasion may occur if particles from fluids collide with the surfaces and stick to them

Still curious about ball valves? Read more specific information on our line of ball valves by checking out our article &#;What is a Ball Valve?&#;.

Find the Best Fit with the Mako Products &#; Superlok Selection

We&#;ve laid out the main difference between ball valves and needle valves and have provided common applications, advantages, and disadvantages for each. When you&#;re ready to choose your valve we have several high-quality, affordable options for you at Mako Products!

Mako Products offers Mako threaded end needle valves and Superlok compression end and threaded needle valves, with a variety of sizes and options available. Our Mako threaded ball valve options go up to 4&#; with numerous options. Superlok tube end and threaded ball valves are available in trunnion, floating, flanged, swing out, and many other instrumentation valve types.

Let one of our customer care representatives get you the valve and size you need by contacting our team.

Resources

Best Type of Flow Control Valve for Your Application?

Understanding Valves

Ball Valves

Applications of Needle Valves

Types of Industrial Valves &#; Applications, Advantages, and Disadvantages

What is a Needle Valve and What is the Purpose of Needle Valves

A Guide to Applications for Stainless Steel Ball Valves

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