Valves play a huge role in controlling the flow of liquids and gases in fluid control systems. Among the many valve types to choose from ball valves and plug valves are two common options. While they both perform similar functions, their design, functionality, and applications are different. Let us look at the differences between ball valves and plug valves.
It is important to understand the basic differences between plug and ball valves before installing or repairing a business valve.
The two types of valves need regular service to ensure maximum efficiency, while plug valves demand less care because of fewer moving elements and a simpler design.
What is the structure of a plug valve?
Plug valves are primarily used to stop, distribute, and modify the flow direction of a material. The plug valves are the key portion of the closing mechanism. Plug valves are rotating conical plugs (plugs) with a medium channel in the shape of a cone-shaped frustum, a rectangle-like cross-sectional area and an opening in the center of the channel perpendicular to the plug’s axis. The fluid channel is totally closed once the cock rotates around 90°. Plug valves are valves which open and close by using a conical plug with a hole. Plug valves are primarily used to stop, distribute, and modify the flow direction of a material. The plug valves are the key portion of the closing mechanism. Plug valves are rotating conical plugs (plugs) with a medium channel in the form of a cone-shaped frustum, a rectangle-like cross-sectional area and an opening in the center of the channel perpendicular to the plug’s axis. The fluid channel is totally closed once the cock rotates around 90°. Plug valves are valves which open and close by using a conical plug with a hole. To close the space between the cock and the valve body, the conical cock is aligned with the conical compressing surface created on the inside of the valve body, and the upper half of the valve body is secured with packing. The top of the cock has a square tenon, and the plug is turned with a unique square-hole wrench while in use.
What is the structure of a ball valve?
The valve stem drives the opening and closing component (ball) of the ball valve, which revolves around the ball valve’s axis. It can also be used for fluid regulation and control, as there is a significant force of shear generated by the V-shaped ball core of the hard-sealed V-shaped ball valve and the metal valve seat of hard alloy surfacing, which is particularly ideal for fibers and microscopic solid particles. The pipeline’s multi-port ball valve can not only manage the intersection, distraction, and changing of the medium’s flow direction, but it can also close any channel and link the other channels together. In most cases, this sort of valve should be positioned horizontally in the pipeline. According to the operating method, ball valves are classified as pneumatic ball valves, electric ball valves, and manual ball valves. The ball valve has a slightly poorer sealing function, but it is capable of a big diameter. The ball valve’s sealing action is becoming increasingly effective as technology advances.
What is the difference between a ball valve and a plug valve?
Plug valves have stronger sealing areas than ball valves and hence offer tighter seals. Their higher surface area, however, makes them more prone to damage from use and tear. On the contrary, a ball valve is designed to avoid continually contacting its disk. This decreases pressure and friction on the valve, extending its lifespan. Ball valves come in a variety of shapes and sizes, including reduced bore valves. These valves are ideal for circulation of gases applications since they have fewer dimensions than other ball kinds. Plug valves are used in a wide range of piping systems, ranging from liquid operations to manufacturing processes. Plug valves are reliable shutdown options in difficult settings because to their simple working mechanism and anti-corrosion qualities.
Plug valves are considered easier to operate compared to ball valves because they require a smaller force to open and close. As a result, they can be used in applications that need less force. Furthermore, they have higher application diversity and are capable of handling more fluids. Gas, and liquid fuels, and throttling activities are common applications. Even in mild vacuum settings, these are more effective in directional flow management. Because of their smaller port size, ball valves come with greater pressure ratings and are a preferable alternative for high-pressure applications, albeit this may cause a pressure drop. Furthermore, due to their smaller port size, ball valves are more expensive compared to their ball valve alternatives.
Plug valves are less expensive compared to ball valves but they have more surface area that is in contact with the flowing medium, which means they wear out faster and may rust over time. Plug valves are available in both lubricated and non-lubricated types. Lubricant minimizes resistance among the plug and the valve body, acts as a barrier to moisture, and prevents corrosion. Plug valves are available in a variety of configurations, including full port and limited port. They can be used in alongside air, process, or gas lines.
Plug valves have a wide range of uses, making them appropriate for a variety of operations. They can be used to control gas or liquid fuels, direct flow, and manage fluids with suspended particulates. Because of their simple mechanism, valves are extremely user-friendly. They can be controlled manually, electrically, pneumatically, or by hydraulic actuators. These things can also be greased to make them simpler to carry around and less prone to damage. The lubricant also decreases friction and corrosion. Lubricated plug valves are ideal for bigger systems and high-temperature services because they are more lasting, although they may require relubrication over time.
We at Valvesonly Europe manufacture and export high quality plug valves and ball valves for various industries like Oil and Gas, Chemical Processing, Water Treatment, Pulp and Paper, Power Generation, Petrochemical, Marine and Shipbuilding, Wastewater Treatment Mining, Textiles and many more. Some of the materials that we manufacture our ball and plug valves are- Cast steel, Cast iron, WCB, WCC, WC6, LCC, LCB, Titanium, SS304, SS316, CF8, CF8M, F55, F51, F53, Monel, Ductile Iron.
Our experts can assist you in selecting the best kind of ball valves or plug valves for your needs, including unique solutions depending on your specific project requirements.

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