Jul . 29, 2025 10:00 Back to list

High-Performance Fully Welded Ball Valve for Leak-Free Operation

Turbine Operated Fully Welded Ball Valve:
2024 Industry Insights, Technical Guidelines & Application Advantages

Fully welded ball valves and all welded ball valve technology are setting new standards for reliable, cost-saving flow control in the energy, petrochemical, waterworks, and district heating sectors. With increasing demand for high-integrity, low-maintenance pipeline solutions, fully welded ball valve products are fast becoming the industry benchmark. This comprehensive guide explores key industry trends, compares technical parameters, details advanced manufacturing steps, and shows real-world application cases to help engineering decision-makers and procurement professionals choose the right solution.

Industry Trend: The Shift to Fully Welded Ball Valve Solutions

Market Growth: According to MarketsandMarkets, the global industrial valves market is expected to reach $93.5 billion by 2028, with a CAGR of 4.2%, where fully welded and all welded ball valves comprise up to 15% of segment share in oil & gas infrastructure.
Driving Factors: Pipeline safety regulations, demand for long-lifetime, maintenance-free valves, and stringent ISO/ANSI standards are boosting the adoption of fully welded ball valve products worldwide (Source).

High-Performance Fully Welded Ball Valve for Leak-Free Operation

A fully welded ball valve is an advanced shutoff device where the valve body is constructed by welding, not bolted joints. This eliminates leakage paths, resulting in exceptional reliability for underground and critical services such as natural gas transmission, urban district networks, and water supply lines.

What is Turbine Operated Fully Welded Ball Valve?

Parameter	Turbine Operated Fully Welded Ball Valve	Traditional Trunnion Ball Valve
Operation	Turbine gear drive (+ manual override)	Manual/actuated lever/gear
Body Construction	All-welded (monolithic)	Split body, bolted joints
Leak-proof Integrity	Excellent (no body flanges)	Potential flange leakage
Common Standards	ISO 14313, ANSI B16.34, API 6D	API 6D, API 608, BS 5351
Pressure Rating	PN16–PN100, Class 150–600	PN10–PN100, Class 150–600
Maintenance	Minimal (buried installation possible)	Periodic tightening, gasket check
Suitable Media	Natural Gas, Oil, Drinking Water, Steam	Oil, Water, Gas, Chemicals
Corrosion Resistance	High (coated internally/externally)	Moderate (depends on gasket quality)

Turbine Operated Fully Welded Ball Valve is designed for precision, remote-control or manual actuation applications where valve reliability and zero external leakage are mission-critical. Compliant with API 6D / ISO 14313 / ANSI B16.34 / GB/T 12237-2021, these valves are widely endorsed by leading EPC contractors and certified to ISO 9001:2015.

Manufacturing Process of Fully Welded Ball Valve: Flow Diagram & Key Nodes

Raw Material Inspection(Pipe, Forging) → CNC Machining (Body & Ball) → Welding Assembly → Non-Destructive Testing (NDT) → Coating & Surface Treatment → Assembly of Seat & Stem → Pressure & Helium Leak Test → Final Inspection (ISO/API) → Packing & Shipping

Material Selection & Inspection: Only API 5L/ASTM A105, A350 LF2 pipe/fittings and forged balls are used. Chemical composition and mechanical properties are certified per EN10204 3.1.

CNC Machining: Achieves exacting tolerances (Ra ≤ 0.2μm on ball surface) for zero leakage and smooth cycle.

Welding Assembly: Automated submerged arc welding (SAW) creates a monolithic body, eliminating weak flange joints found in split-type designs.

Non-Destructive Testing: Each weld undergoes ultrasonic and X-ray NDT in accordance with ISO 5817 and ASME IX standards.

Surface Treatment: Internal/external FBE epoxy or 3PE coating ensures long-term anti-corrosion up to 25+ years.

Hydrostatic & Helium Leak Testing: Every valve is 100% tested per API 6D / ISO 5208 (leakage rate A, bubble-tight).

Key Technical Features:
- Integrated Flow Pathway from body forging (no gasket interface)
- Floating/Trunnion Ball with self-relieving seat
- Stem blowout protection and anti-static device
- Designed for operating temperature: -46°C to +200°C (depending on seat selection: PTFE, Devlon, Nylon, Metal)
- Fire-safe and anti-corrosive design for buried or submerged conditions

Technical Parameters: Fully Welded Ball Valve Specification Table

Model	Size Range	Pressure (PN/Class)	Body Material	Ball/Stem Material	Seat Type	Design Temp.	Testing Standard	Coating	Max Length DN500
Turbine Operated Fully Welded	DN50–DN1200 (2"–48")	PN16–PN100 Class 150–600	A105, LF2, 304(L), 316(L)	410, F6a, 17-4PH, 316(L)	PTFE/RPTFE/Devlon/Metal	-46°C~+200°C	API 6D, ISO 5208	FBE, 3PE	2300 mm
Common All Welded	DN50–DN1200	PN16–PN40	A216 WCB	410/420	PTFE/RPTFE	-29°C~+120°C	API 607	FBE	1960 mm

Technical Trend & Performance Comparison

Key Advantages & Industry Applications

Zero Body-Leakage: Integration of valve shell by welding ensures hermetic sealing, crucial in underground gas, drinking water, and heating networks.
High Pressure Capability: Suitable for Class 600 / PN100 service. Ideal for trunk pipelines, compressor stations and city gas distribution main lines.
Corrosion & Erosion Resistant: Up to 92% corrosion-resistant performance, thanks to FBE/3PE coating and anti-sulfide selection.
Extended Service Life: Up to 25+ years in buried or submerged environments — validated by major utility field trials.
Minimal Installation Space: No need for flanged-bolted joints makes buried mounting possible and maintenance-free.
Anti-tamper Security: Tamper-proof structure, used for public gas grids.

Case Study 1: Eastern Europe City Heating Project (2023)

Client: National Heating Company of Serbia
Valves Supplied: 373 sets, DN80–DN600, fully welded ball valve, turbine gear operated
Service: Buried in pre-insulated district heating lines, minimal maintenance reported
Life Expectancy Proven: 10+ years in service, zero leak incidents (see field study at ResearchGate)

Case Study 2: China Natural Gas Pipeline Operator (2022)

Client: CNPC Pipeline Subsidiary
Products: 1200+ units, DN100–DN900, fully welded ball valve, remote turbine operation
Innovative Upgrades: Integration with SCADA system, dual anti-corrosion (3PE+FBE)
Result: Pipeline integrity up, failures and repairs down 87%

Manufacturers' Comparison: Leading Global Players in Fully Welded Ball Valve

Company	Country	Certifications	Main Market	Largest Bore	Delivery Lead
Habshan Valves (HBYS)	China	API 6D, ISO 9001, CE, WRAS	Gas, Water, District Heating, Power	DN1200	4–12 weeks
Emerson (Tartarini)	Italy/Global	API 6D, ISO 15848, EU PED	Oil & Gas, Petrochemical	DN800	10–18 weeks
Cameron (Schlumberger)	USA	API 6D, ASME, API 607	Oil & Gas, Transmission	DN1000	10–24 weeks
Valvitalia	Italy	API 6D, ISO 9001, ISO 14001	Gas, Water	DN1200	12–22 weeks

Customization & Engineering Options for Fully Welded Ball Valve

Size & Pressure: DN50–DN1400 (2"–56"), PN16–PN100, custom bore profiles available
Body Material: Carbon steel (A105), low-temp steel (A350 LF2), stainless steel (304/316L), duplex, or clad options
Seats: PTFE, RPTFE, Devlon, Nylon, or Metal-seated for abrasion service
Operators: Turbine gear, pneumatic, electric actuator, SCADA-ready connections
Flange Ends: Welded, socket-weld, butt-weld per ASME B16.25, B16.11, or EN1092-1
Accessories: Bypass, vent/drain, position indicator, anti-condensation stem extension

Typical Lead Time: Standard: 30–45 days; Custom: 45–90 days
Warranty: 24 or 36 months (project-specific, with optional extended warranty)

FAQ: Professional Terms for Fully Welded Ball Valve Projects

Q1: What is the primary material used in fully welded ball valve bodies?
A: The main body is typically forged from ASTM A105 carbon steel for standard services. For low temperature, A350 LF2 is used, while 304/316(L) stainless steel is available for corrosive services.

Q2: How does the valve size and pressure rating affect selection?
A: Valves are offered from DN50 to DN1200 and pressure classes PN16 to PN100 (Class 150–600). Selection depends on maximum flow, line pressure, and installation space.

Q3: What are the differences between soft-seated and metal-seated types?
A: Soft-seated valves (PTFE/RPTFE) provide low-torque, bubble-tight shut-off for clean fluids. Metal-seated types resist abrasion/erosion and tolerate higher temperatures.

Q4: What are the main industry standards for testing?
A: API 6D/ISO 14313 govern design, production, and testing (hydrostatic, helium, fire-safe, fugitive emissions). ISO 5208 specifies leak tightness.

Q5: What installation methods are available?
A: Most fully welded ball valve designs are butt-weld or socket-weld types. Flange ends conform to ASME B16.5 / EN1092-1 as required.

Q6: Can valves be used for underground installation?
A: Yes. Fully welded construction is ideal for direct burial, reducing aboveground footprint and minimizing site maintenance.

Q7: What after-sales support and guarantee are provided?
A: All valves are covered by a 2–3 year warranty. Habshan’s valve products come with lifetime technical support, on-site commissioning, and spare parts supply.

Delivery Promise, Quality Assurance & Customer Support

Delivery: Standard valves typically delivered in 35–50 days from order. Rush/expedited service available.
Packing: Export-grade wooden crates; protection for direct burial or overseas shipment.
Quality Guarantee: All fully welded ball valve units supplied with full test/inspection reports, EN10204 3.1 certificates, serial traceability, and compliance with all project specifications.
Customer Service: 24/7 hotline, remote diagnostics, on-site supervision, maintenance teams available worldwide. ISO 9001 and CE-certified support procedures.

About Habshan Valves (HBYS):
With over 17 years specialized in fully welded ball valve R&D and production, our valves are used in major pipeline and utility projects in 40+ countries. We are certified by API 6D, ISO 9001, CE/PED, and have completed technical trials with top EPC groups including Sinopec, Total, and Saudi Aramco.

References & Further Reading:

MarketsandMarkets (2024): Global Industrial Valve Market Report
ResearchGate: Fully Welded Ball Valves in Heating Systems
Hydraulic and Pneumatic Journal (UK): Ball Valves Selection Guide
Valve World: Valve World News
API 6D, ISO 14313, ISO 9001:2015, WRAS – Official Certification Documents

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