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Design and Analysis of Industrial Ball Valve using Computational Fluid

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P. Ebenezer Sathish Paul, G. Uthaya Kumar, S. Durairaj, D. Sundarrajan 1

Design and Analysis of Industrial Ball Valve

using Computational Fluid Dynamics
P. Ebenezer Sathish Paul, G. Uthaya Kumar, S. Durairaj, D. Sundarrajan

Abstract: Computational Fluid Dynamic analysis is carried out P.Ebenezer Sathish Paul, Assistant Professor, Department of Mechanical
to establish a robust affiliation between the design variables of Engineering, P.S.R. Engineering College, Sivakasi, Tamil Nadu, India.
([email protected])
material design domain and product design domain. The CFD
analyses performed for both ball valve and gate valve is It is quite disturbing that detailed investigation was not done
necessitated with input parameters that outfits the application over the integration of material design and valve design to suit
such as pressure, density, viscosity and temperature. The a specific functionality. This research work is focussed on
maximum pressure acting over diverse regions of the valve establishment of relationships between the design variable of
system that crop up due to fluid flow was examined by the both material and product design domains. Computational
extension of pressure concentration for different fluids viz. fluid dynamics a powerful analysis tool is utilized to compute
water, lubricant and diesel. The analysis is presumed to be
flow restrictions in the form of resistance co-efficient and flow
conversant with material selection strategies that satisfy the
criterions for the new product development and therefore well volume co-efficient.
defined inputs inclusive of virtual solid model, boundary
conditions are promoted with higher grade mesh resolutions. In
these cases, approximate selections are exercised and numerical
scheme of properties has been adhered to embrace perfection in
simulation analysis. The CFD study exemplifies accurate regions
wherein maximum pressure assaults the valve body and so the
observations originate to ascend product development without
the expense of physical testing. The verification studies put forth
for the pressure distribution generated due to fluid flow through
the valve system is in stripe with end results. Furthermore valve
deformation and valve performance is obligatory for material
and product design integration and hence customary predictions
is done by coupling the CFD results with finite element analysis.

Keywords: CFD, Ball Valve, FEA Fig. 1 WAY BALL VALVE L-SHAPED BALL RIGHT, T-SHAPED LEFT

I. INTRODUCTION In CFD analysis the pressure distribution across the required

area is analyzed by gratifying the boundary condition applied.
Valves are components which controls the fluid flow and In order to perform the design, optimization and the analysis
pressure of a system. Types of applications for valves differ on of the valve performance, for a particular application dynamic
their own and are normally used on safety and flow control fluid analysis is performed on two types of valve viz. stem
grounds. While these valves are used for flow control, it is valve and ball valve. Valve body is chosen for generating
obvious that the dynamics of the valve and its control loop has relation between type of fluid flow, geometry and pressure
to match strictly with dynamics of the control system. In the loses using CFD, since they have a simple mechanical
course of study on these facets it is over and done with construction, utmost exposure during fluid flow, attains
establishment of relationship between valve positions, critical deformation, and more importantly, give a low head
pressure drop and flow which is commendable as highly loss. CFD analysis is capable to reveal the complex flow
non-linear. The able-bodied documentation of valves is not structure and the sonic characteristics around the valve, which
admirable for the reason; these facts features technical hitch to the experiments hardly ever provide. Even otherwise,
predict the properties down or up-sized. In any flow system experimentation needs to be supplemented with CFD analysis
the familiar flow restrictors are the valves and hence its design because of intricate geometry as well as complexities like
and performance analysis will be a significant task. The turbulence during the sonic flow through a valve.
selection of the valve types, design and material plays a vital
role in its performance and reliability. A number of researches II. LITERATURE SURVEY
have been experimented in valves for its shape, size, fluid Industrial ball valve is designed by integral formulations,
types, operating parameters, discharge coefficient, and differential formulations and also computer simulation is
eroding characteristics for the improvement of valve needed for validating every result computational fluid dynamic
technology. has been used as research and design tool in the modeling of
ball valve. A search on the different simulation models from
literature are given as follows:
Ying Sun et al [1] have predicted that the fundamental

International Journal of Recent Trends in Mechanical Engineering (IJRTME- ISSN: 2347-7326)

P. Ebenezer Sathish Paul, G. Uthaya Kumar, S. Durairaj, D. Sundarrajan 2

equations of thermodynamics, a new method proposed in this electromagnetic circuit. By finite element calculations, we
paper gives comprehensive consideration of the various have optimized the structure of the electromagnet that
factors, such as heat transfer, leakage, gas pulsation and valve actuates a rare-earth permanent magnet embedded in a poly
motion, that influence the working process of the compressor (dimethylsiloxane) (PDMS) pumping membrane. Powder
and establish all the mathematical simulation equations. By blasting and conventional micromachining techniques are used
using numerical computation, the thermodynamic parameters for micropatterning the PMMA layers forming the
which govern the working process of the compressor and the microfluidic circuit. The self-priming ball-valve micropump
macroscopic thermodynamic performances, such as capacity, exhibits a backpressure up to 35 kPa; water is pumped at a
power and specific power in the compressor can be found. The flow rate as high as 6.0 mL/min for a 2 W electromagnetic
results of the computation are in good agreement with actuation power at the resonant frequency of 20 Hz. The
practical measurements and the correctness and applicability actuation frequency-dependent flow rate is in excellent
of the proposed method are demonstrated. agreement with a damped oscillator model.
A.S.Tabrizi et al [2] have predicted that the ball valve S. Bagherifard et al [5] have predicted that the failure of a
performance is numerically simulated using an unstructured sub-sea ball valve, used in an oil-piping line, is analysed. The
CFD (Computational Fluid Dynamics) code based on the finite valve was of the same type and material already used for the
volume method. Navier-Stokes equations in addition to a construction of valves that were worked in service without
transport equation for the vapor volume fraction were coupled any problem. The valve failed in the first pressure cycles
in the RANS solver. Separation is modeled very well with a during the preliminary laboratory tests, although the applied
modification of turbulent viscosity. The results of CFD pressure was less than the design value. Metallographic and
calculations of flow through a ball valve, based on the concept microstructural analysis of the fracture surfaces performed by
of experimental data, are described and analyzed. Comparison means of optical and scanning electron microscope (SEM),
of the flow pattern at several opening angles is investigated. residual stress and hardness measurement, tensile, toughness
Pressure drop behind the ball valve and formation of the and Charpy tests, were executed in order to identify the causes
vortex flow downstream the valve section are also discussed. of the failure. The results allowed assessing that the failure
As the opening of the valve decreases, the vortices grow and was due to two concomitant factors: a severe notch effect and
cause higher pressure drop. In other words, more energy is an incorrect thermal treatment.
lost due to these growing vortices. In general, the valve G. Gokilakrishnan et al [6] have forecast the ball valve is a one
opening plays very important roles in the performance of a ball way valve with a spherical disc, which controls the flow
valve. through it. Torque is the main factor for operating ball valves.
Zhi-gang Su et al [3] have predicted that to achieve Most of the ball valves require high operating torque for its
improvements in the production capacity and energy operation, some external devices are required to overcome
efficiency of an industrial tubular ball mill, a novel method, this torque. Hence more research is necessary to reduce the
monitoring an unmeasured parameter (level of coal powder) operating torque; thereby one can reduce manual effort. This
and diagnosis of the operating modes of the mill, was paper deals with basics, advantages and disadvantages of ball
proposed. Two accelerometers were installed on bearing valve, torque and its importance in ball valves, torque
housing to pick up the vibration transferred from the mill measuring and applying instruments used for ball valves.
shaft. A system was designed to record the vibration signals Mahesh Kamkar A et al [7] have predicted that the valve is a
and transfer them into energy amplitudes, by using a wavelet mechanical device which regulates either the flow or pressure
packet approach, based on the KINGVIEW program, as well of the fluid. Among the different types of valves, high pressure
as Visual C++ environment. Based on these, a series of ball valve finds use in certain application like industrial
experiments was conducted in a 250 MW power plant to hydraulics and marine hydraulics. The present study involves
investigate the vibration characteristics corresponding to the designing the high pressure valve of nominal diameter 25mm
effects of different levels without air particle removal, milling (DN 25 and PN 350). When the flow line exceeds 150bar, the
times, and varying levels in practical working conditions. valves are known as high pressure valves. With the increasing
The experimental results show that the operating modes of the the pressure, the design of various components of the valve
mill, such as mill over-load, stable case, etc., can be diagnosed become critical. The designing of high pressure ball valve
by proper interpretation of these vibration characteristics; and components depends on pressure, temperature ratings and
also the unmeasured parameters, i.e., level of coal powder also other factors. The design calculation is done for sealing
filling the mill, can be monitored on line. Finally, methods for cup, ball, connection adaptor, valve housing and operating
diagnosing operating modes and a model for on line lever. The maximum stress and deflection is calculated for
monitoring of varying level by using a non-linear partial least different sealing cup materials under high pressure. The torque
square (NPLS) algorithm were presented. Combining the required to operate the valve, which includes breaking torque,
method and the model, we believe that the performance of ball running torque and ending torque are calculated and
mill can be improved. compared with technical information from research case
Meng Shen et al [4] have fabricated and characterized a study.
reciprocating polymethylmetacrylate (PMMA) ball-valve Dong-Soo KIM et al [8] have predicted that the natural gas is
micropump actuated with a miniaturized cylindrical being hailed as alternative energy sources for a petroleum,

International Journal of Recent Trends in Mechanical Engineering (IJRTME- ISSN: 2347-7326)

P. Ebenezer Sathish Paul, G. Uthaya Kumar, S. Durairaj, D. Sundarrajan 3

because it is almost no emissions of pollutants in the

environment. Use of equipment for liquefied natural gas, along
with increased demand for natural gas is also growing.
Cryogenic ball valve is used to control the liquified natural gas
which temperature is - 1960C, supplied pressure is 168kg/cm2.
To acquire the safety along with durability of cryogenic ball
valve, we should consider the structural mechanics such as
stress, deformation and dynamic vibration characteristics and
identify those important aspects in the stage of preliminary
design engineering. For the cryogenic ball valve, the assurance
of structural integrity and operability are essential to meet not
only normal, abnormal loading conditions but also
functionality during a seismic event. In this study, analytical
approach and results using finite element analysis and
computational method are herein presented to evaluate the Fig.2 Four view of Ball
aspects of structural integrity along with operability of
cryogenic ball valve. Janusz Rogula [9] has predicted that the
ball valves are used in places of pipelines where turn on/off of
steam flow is needed. The leakage has influence on the system
efficiency. Paper presents the results of investigations of the
ball valve tightness. The basic assumption needed to be
verified was, whether the leakage through a seal after fatigue
load will increase. The helium detector was used to determine
the leakage volume in given time intervals. Very important
assignment was to build a measuring facility which would
enable leakage detection from the ball valve at helium
overpressure range 0, 1 – 4, 5 MPa. Impact of the pressurized
air on the closed ball was used as a fatigue factor. Impact
could be used as a diagnostic procedure simulating Fig. 3 50% Opened Valve
exploitation conditions. Gas escaping around the ball was
measured when element was new, then after 5,000 and finally
after 10,000 pressure impacts. Experiment included also
similar leakage measurement through a stuffing box.

III. MODELING OF A 4”600# BALL VALVE

For designing the ball valve in ANSA software, the following
parts are needed. They are inlet extension, inlet pipe, ball
portion, outlet extension, outlet pipe etc. Modeling these parts
should be enough for to get good result. The parts are drawn
by using ANSA. Starting from Vertex, Edge, Face and
Volume should be created. If more than one volume is there,
then it should be named as Group are shown in Fig.2 & 4 and
Fig.4 Body
the assembled view of ball valve is shown in Fig.5.
Specification for the 4” 600# Ball valve is given below:
Ød = 101.6
ØD = 273.05
T = 38.1
F = 6.35
Øg = 157.23
Øc = 215.9
Øh = 25.4
L = 431.8
H = 209.8
W = 462.28
ØA = 127
B = 114.3
Fig.5 Top view, Front view, Right side view & Trimetric view of 4” 600# Ball
N = 8 Valve

International Journal of Recent Trends in Mechanical Engineering (IJRTME- ISSN: 2347-7326)

P. Ebenezer Sathish Paul, G. Uthaya Kumar, S. Durairaj, D. Sundarrajan 4

Finite element model was created with tetrahedron elements

TABLE 1 MATERIAL PROPERTIES OF 4”600# BALL VALVE by using hypermesh software as shown in Fig.6. Both flanges
Young’s are constrained in all degrees of freedom and the inlet pressure
Name of Density Poisson’s
Material Modulus given in the domain as 15MPa as per API standards. The
Part (Kg/m3) ratio
(MPa)
Body Cast iron 7850 2.06e5 0.28
extraction of the domain with meshing is given in Fig.7 & its
(A216 WCB) restrictions is given in Fig.8
Cap Cast iron 7850 2.06e5 0.28
(A216 WCB)
Stem Stainless Steel 7850 2.1e5 0.3
(A275-316)
Ball Stainless Steel 7850 2.16e5 0.3
(A351 CF8M)
Packing Poly tryfluoro tetra 1900 -- 0.33
Ring ethylene
Handle Cast Iron 7850 2.06e5 0.28
(A216 WCB)
Gland Cast Iron 7850 2.1e5 0.3
(A216 WCB)
Gasket Graphite 1900 -- 0.33
Fig.7 Domain meshing by using TGRID
IV. COMPUTATIONAL FLUID DYNAMICS
Computational fluid dynamics (CFD) is the science of
determining a numerical solution to the governing equations
of fluid flow whilst advancing the solution through space or
time to obtain a numerical description of the complete flow
field of interest. The various steps involved in solving a flow
problem in CFD approach involve the following basic steps
• Defining the geometry of the problem (i.e. the physical
boundary)
• Meshing the volume occupied by the fluid into discrete
cells.
• Physical modeling of the problem (i.e. the governing
Fig.8 Volume mesh by using TGRID
equations)
• Defining the boundary conditions TABLE 2 MATERIALS USED
• Solving the governing equations iteratively either as a
steady state or as a unsteady state Name WATER
• Post processing (i.e. analysis and visualization of the Material type FLUID
results) Density 1000 Kg/m3
Specific Heat 4185.5 J/Kg-K
V. SOFTWARE SIMULATION Thermal Conductivity 0.0014 W/m-K
Meshing is important for every parts, size interval is given as Viscosity 1.79*10-05 Kg/m-s
0.05. If mesh size is minimized the accuracy is more. Ease of
use was a major goal in Fluent's development of ANSA 2.2. It CFD has helped engineers improve a wide range of products
is a preprocessing software. Its role is to build the computer involving fluid flow by allowing them to evaluate alternative
model, which is then processed by the solver portion of the designs on the computer without having to build costly
prototypes. CFD involves the solution of the governing
software. The model structure, or geometry, is built. Then, a
equations for fluid flow, heat transfer, and chemistry in tens or
mesh of numerical coordinates is overlaid onto it, so that the
hundreds of thousands of computational cells in the defined
analysis can take place.
flow domain. A CFD analysis yields values for pressure,
velocity, temperature, and other flow variables throughout the
solution domain. A key advantage of CFD is that it provides
the flexibility to readily change design parameters and
determine the impact of those changes on performance.

Fig.6 Meshing by HyperMesh

International Journal of Recent Trends in Mechanical Engineering (IJRTME- ISSN: 2347-7326)

P. Ebenezer Sathish Paul, G. Uthaya Kumar, S. Durairaj, D. Sundarrajan 5

at 50% opening condition and is below the yield stress 270

Mpa. So, the boundary condition applied in the ball valve is
within the limit, the component is safe. The deformation of
the body is around 0.087178mm. The stress developed in the
stem is maximum at 50% opening position is 69.869 MPa. The
deformation of the stem is around 0.030869 mm. The stress
developed in Body and Cap is also maximum at 50% opening
position is 108.3 MPa and 110.8 MPa respectively, and is
Fig.9 Deformation of the body Fig.10 Stress induced in the body
below the yield or ultimate stress of the material 450 Mpa.
From the analysis it is confirmed that the valve design is safe.
The maximum stress developed in the shaft when a torque 50
N-m is applied is 69.8 Mpa and is below the yield stress of the
material 270 Mpa and the component is safe.

REFERENCES

Fig.11 Deformation in stem Fig.12 stress induced in the stem [1] Ying Sun and Ting-Rong Ren, “NEW METHOD OF
THERMODYNAMIC COMPUTATION FOR A BALL VALVE:
COMPUTER SIMULATION OF WORKING PROCESS” Department
of power machinery, Xian Jiao-tong university, Xian, Shaanxi province,
pp 343–353, (1995).
[2] A.S.Tabrizi, M.Asadi, G.Xie, G.Lorenzini, C.Biserni,
“COMPUTATIONAL FLUID DYNAMICS BASED ANALYSIS OF
A BALL VALVE PERFORMANCE IN THE PRESENCE OF
CAVITATION”, Journal of Engineering Thermophysics, Volume 23,
Issue 1, pp 27–38, (2014)
[3] Zhi-gang Su, Pei-hong Wang, Xiang-jun Yu, Zhen-zhong Lv,
“EXPERIMENTAL INVESTIGATION OF VIBRATION SIGNAL
OF AN INDUSTRIAL TUBULAR BALL MILL: MONITORING
Fig.13 Static Pressure of Path Line Fig.14 Velocity magnitude AND DIAGNOSING”, Minerals Engineering, Volume 21, Issue 10, pp
699–710, (2008)
[4] Meng Shen, Christophe Yamahata, Martin A.M. Gijs,
“MINIATURIZED PMMA BALL-VALVE MICROPUMP WITH
CYLINDRICAL ELECTROMAGNETIC ACTUATOR”,
Microelectronic Engineering, Volume 85, Issues 5–6, pp 1104–1107,
(2008)
[5] S. Bagherifard, I. Fernández Pariente, M. Guagliano, “FAILURE
ANALYSIS OF A LARGE BALL VALVE FOR PIPE-LINES”,
Engineering Failure Analysis”, Volume 32, pp 167–177, (2013)
[6] G. Gokilakrishnan, S. Divya, R. Rajesh, V. Selvakumar,
“OPERATING TORQUE IN BALL VALVES-A REVIEW”,
Fig.15 Static Pressure of the ball Fig.16 Total Pressure of the ball International Journal for Technological Research in Engineering,
Volume 2, Issue 4, pp 311–315, (2014)
[7] Mahesh Kamkar, S.R.Basavaraddi, “CONCEPTUAL DESIGN AND
ANALYSIS OF HIGH PRESSURE BALL VALVE”, International
Research Journal of Engineering and Technology (IRJET), Volume 02,
Issue 03, pp 1185–1189, (2015)
[8] Dong-Soo KIM, Myoung-Sub KIM, “ANALYSIS AND DESIGN OF
CRYOGENIC BALL VALVE”, Proceedings of the 7th JFPS
International Symposium on Fluid Power, pp 397–402, (2008)
[9] Janusz Rogula, “THE INFLUENCE OF SEAT FATIGUE TEST ON
THE LEAKAGE IN BALL VALVE” XIIIth International Scientific and
Engineering Conference "Hermetic Sealing, Vibration Reliability and
Ecological Safety of Pump and Compressor Machinery" Volume 39, pp
Fig.17 Turbulent intensity 91–97 (2012)
[10] GAMBIT software-V2.2.30 user’s manual.
[11] FLUENT software-V6.2.16 user’s manual.
VI. CONCLUSION

FEA has become a solution to the task of predicting failure

due to unknown stresses by showing problem areas in a
material and allowing designers to see all of the theoretical
stresses within. This method of product design and testing is
for superior to the manufacturing costs which would accrue if
each sample was actually built and tested. From the above
structural analysis on valve assembly at different Ball opening
position the maximum stress found is 142.65 Mpa in the Ball

International Journal of Recent Trends in Mechanical Engineering (IJRTME- ISSN: 2347-7326)

P. Ebenezer Sathish Paul, G. Uthaya Kumar, S. Durairaj, D. Sundarrajan 6

P. Ebenezer Sathish Paul, Assistant Professor,

P.S.R. Engineering College, Sivakasi. Completed
my undergraduate in Karunya Institute of
Technology, Coimbatore. Post graduate in Mepco
Schlenk Engineering College, Sivakasi. Working
as Assistant Professor in P.S.R. Engineering
College, Sivakasi with 7 years experience. Life member in Indian
Society for Technical Education. Published six papers in
international Journals. Organized two National conferences titled
“RAME”.

G. Uthayakumar, Assistant Professor, P.S.R.

Engineering College, Sivakasi. Completed B.E
in College of Engineering, Guindy, Chennai and
M.S. (Engineering Sciences) in Louisiana A&M
College, LSU, Baton Rouge, USA. Currently
working as an Assistant Professor in Dept. of
Mechanical Engineering in P.S.R. Engineering
College, Sivakasi with 7 years experience. Life member in Indian
Society for Technical Education. Published 4 papers in international
Journals.

S.Durairaj, Assistant Professor, P.S.R.

Engineering College, Sivakasi. Completed my
undergraduate in P.S.R.Engineering college,
Sivakasi. Post graduate in Regional Centre of
Anna University,Tirunelveli. Working as
Assistant Professor in P.S.R. Engineering College,
Sivakasi with 1 year experience.

D.Sundarrajan, Assistant Professor, P.S.R.

Engineering College, Sivakasi. Completed my
undergraduate in Theni kammavar sangam
college of Technology,Theni. Post graduate in
P.S.R.Engineering College, Sivakasi. Working as
Assistant Professor in P.S.R. Engineering
College, Sivakasi with 1 year experience. Published 1 paper in
international Journal.

International Journal of Recent Trends in Mechanical Engineering (IJRTME- ISSN: 2347-7326)

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