Unlike the standard ball valves, most gas ball valves are tested and approved by CSA. These valves are vital for combustible gas service in different industrial applications. They are used in natural gas, manufactured gas, and liquefied petroleum gas pipelines.
A gas ball valve is a quarter-turn flow control device that is designed to offer better performance, shut off and sealing characteristics than the conventional ball valves. Unlike high pressure, high temperature, water service ball valves, gas ball valves adopt a compact and lightweight valve body design that increases their versatility, making them suitable for different applications.
Gas ball valves are predominant in applications and piping systems conveying combustible fluids like hydrocarbons, liquefied petroleum gas (LPG), natural gases, and chemical vapors. These valves are also ideal for boilers, furnaces, gas stoves, residential and commercial water heaters.
Flow control applications relying on gas ball valves operate under high pressure and temperature. Given the combustible nature of most of the working fluids, it is vital to prevent leakage at the valves. Sealing and protection against fugitive emissions rely on the metal-seated gas ball valves or PTFE seats.
The benefits of using gas ball valves for different industrial applications are:
Excellent shut-off characteristics — The valves open and close quickly in response to pressure conditions of the pipeline. It is vital for preventing backflows and contamination.
Versatility and efficiency — Gas ball valves have a compact design that fits into different industrial applications. They operate at low torque and require simple actuation mechanisms.
Durability and easy maintenance — These valves provide excellent flow control throughout their service life and demand minimal maintenance interventions.
Before using gas ball valves for combustible fluid service, they require approval from Canadian Standards Association (CSA). The association rates the valves based on application areas and country-specific requirements. CSA is accredited by several US regulatory authorities including the Occupational Safety and Health Administration (OSHA) and the American National Standards Institute (ANSI).
Valves bearing CSA ratings can be used in different industries across the US. According to the CSA ratings, gas ball valves designed for outdoor fluid applications in the USA bear the BRS125G-rating and CAN 3.16 in Canada.
For indoor applications, the CSA ratings are the same for the USA and Canada. Any ball valve bearing the ½ PSI and 5G- ratings are strictly used for indoor gas applications. The ½ PSI rating indicates that the installation location of the valve is on the appliance. Household piping systems use valves bearing the 5G rating. Indoor gas systems operate at a lower pressure when compared with outdoor piping systems.
CSA 3.16-15 standards apply to all lever-operated gas shut-off valves. These are metallic gas ball valves that are manually operated and contain flanged, threaded, or welded ends. Their service temperatures range between -1048°F (-600°C) and 3272°F (1800°C), while their maximum pressure limit is 125PSI. These valves are suitable for natural gas, liquified petroleum gas, and manufactured gas service.
Valves under the CSA 3.16-15 ratings can be used for methane gas service in sewage treatment plants. However, they are likely to suffer from the negative impacts of contaminant accumulation around the valve body. Gas ball valves are unsuitable for use in piping systems with traces of hydrogen sulfide (sour gas).
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For the efficiency of fluid flow applications, it is necessary to control and monitor fluid pressure. Gas ball valves are equipped with pilot taps for fixing pressure gauges. With these gauges, operators can monitor the pressure of the piping system and perform pressure tests. Fixing the pressure gauges at the valves guarantees accurate pressure control in the system to facilitate the safety and consistency of gas applications.
Gas ball valves have standard pilot taps in the form of ⅛" female pipe thread or female pipe taper (FPT). The pilot taps come with a ⅛" tapering male pipe thread plug that is tightened to prevent leakages.
Several manufacturers use yellow handles on the valves for identification purposes. Though this is not a standard visual indicator, it is a quick way for buyers to identify ball valves that are approved for combustible gas service. When selecting gas ball valves, do not just rely on visual indicators. Confirm that the intended piping requirements match the CSA approvals and ratings.
Gas ball valves are used in applications with varying temperature and pressure ranges. For the safety of operations, the valves are subjected to rigorous air tests to establish their efficiencies at different operating conditions. According to CSA standards, gas ball valves are tested to withstand 1.5 times their rated valve pressure. Gas ball valves with the CAN 3.16 approval are designed for higher pressure ratings. In some cases, they may be exempt from pressure tests.
The following are gas ball valve ratings and the accompanying test pressures in PSIG (Pounds per square inch gauge)
CAN 3.16 rating — test pressure is 125PSIG
BRS125G — test pressure is 188PSIG
½ PSI — test pressure is 3PSIG
5G — test pressure is 7.5 G
Each gas ball valve has a specific CSA approval rating. However, it is common to find valves with the same CSA ratings having different pressure and temperature ratings. Valves meant for industrial processes with extreme temperatures/pressure may require modifications and additional tests to meet the minimum CSA approval requirements.
Gas ball valves have different constructions to suit their application areas. Piping systems for natural gas service, supply of clean gases or compressed air use fully welded ball valves. These valves have a compact design, are easy to insulate, provide bi-directional tightness, and are designed to be maintenance-free. Such ball valves are fabricated using high-strength materials, have spring-loaded PTFE seals and O-rings for maximum sealing.
Processes in which the working media should be fully open or fully closed use gas ball valves with flanged and welded ends. They are in sections like heating pipeline crossings or heat exchanger stations.
When selecting gas ball valves, consider the installation areas. Are the valves intended for indoor or outdoor usage? After that, select the appropriate size that will meet the desired process parameters.
When selecting a gas ball valve for any industrial application, identify the performance requirements of the system. It will include factors like flow rates, pressure, and temperature ranges. Identify the chemical characteristics of the service medium. Piping systems with traces of sour gas will use gas ball valves with PTFE seats due to their inert nature against chemicals, unlike metal-seated valves that are likely to corrode under similar conditions.
Gas ball valves selected for critical gas pipelines should be easy to maintain or demand minimal maintenance interventions. The quantity of abrasive media and contaminants in the piping system should be minimal to prevent premature valve damage.
Gas ball valves provide an affordable and often ideal solution for combustible gas service in different industrial applications. Their application is guided by CSA ratings and approvals that guarantee safe usage under varying process conditions.
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Your furnace is a controlled fire burning in your home.
Before you let that scare you, let’s talk about the amazing safety features your furnace has to keep you safe while it keeps you warm!
There are five safety features some furnaces have that are important to learn about:
Flame Rollout Sensor
Flame Proving Sensor
High Temperature Limit Control
Flue Exhaust Pressure Sensor
Fan Limit Sensor
Do you know the three ingredients of fire?
Your furnace is a controlled fire burning in your home. Fortunately, there are safety features that keep things safe for your family.Oxygen, heat, and fuel! In order to make your home warm and cozy, your furnace starts a fire in a fire box by using these three ingredients. The gas valve releases raw gas to serve as the fuel. This gas in the fire box comes in contact with the heat source. Depending on your unit, this would either be a pilot light, a hot surface ignitor, or a spark ignitor. When the gas and heat source meet, they use any available oxygen while in the fire box to ignite a fire. This fire is supposed to stay in the fire box, where it’s safely contained and can provide your furnace with warmth. If there’s not enough oxygen for combustion, however, the flame will “roll” out of the furnace in search of the oxygen it needs! Your Flame Rollout Sensor senses when the flame leaves the furnace, and it tells your heating system to shut off the furnace.
What happens when the Flame Rollout Sensor isn’t working right? If this sensor malfunctions, the flame might catch the floor joists, nearby walls, or attic trusses on fire!
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Remember when we talked about how the gas valve releases raw gas into the fire box? Your furnace may also be equipped with a Flame Proving Sensor, which detects when there’s a flame in the fire box. If it detects a flame, it allows the gas valve to stay open and continue releasing gas to keep the fire alive. When it doesn’t detect a flame, it shuts off the gas valve.
What happens when your Flame Proving Sensor isn’t working right? If this sensor malfunctions, it continues to allow raw gas into the combustion chamber without a flame actively using it up. If this happens, even a small spark on that much gas can cause a huge explosion.
In order to heat your home, your furnace has got to get really hot. Of course, there’s a limit to how hot your furnace should get though! Your furnace comes equipped with a High Temperature Limit Control, which has a set limit of how high the temperature of the furnace is allowed to get. If your furnace exceeds this limit, the High Temperature Limit Control shuts off your system.
What happens when the High Temperature Limit Control isn’t working right?
If this control malfunctions, it could burn out your heating system. This can cause one of two problems: either there will be too much heat and you’ll end up with damage to your fire box, or you won’t have enough heat in your home because your unit keeps shutting off. When this happens, you’ll need to call a professional to fix your unit.
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In order for your furnace to safely ignite, it has to do a couple things. It’s gotta provide the proper amount of combustion air to the gas and flame, and it has to make sure there are no blockages in this process. Basically, it makes sure the inducer motor (it’s like a fan) is pulling smoke through the heat exchanger and pushing it through the flue so it can escape your home. If there are no blockages, the sensor will let your unit know it’s ok to turn on the gas and ignitor. If there’s a blockage, your furnace won’t turn on.
Did you know? Your inducer motor has a short lifespan. They usually only last between 8-10 years, so it’s important to get it checked every year!
What happens if the Flue Exhaust Pressure Sensor isn’t working right? If this sensor malfunctions, your unit won’t be able to turn on and you’ll need to call out a professional to fix it.
In order to bring heat into your home, your furnace uses a type of fan called a blower to blow air over the heat exchanger. If the blower stops working or isn’t providing enough airflow over the heat exchanger, your Fan Limit Sensor will shut off the furnace.
What happens if the Fan Limit Sensor isn’t working right? If this sensor malfunctions, your heat exchanger will continue to get really hot and won’t have the air from a fan to push heat away from it. This means your heat exchanger would get red hot, which could allow cracks and splits in the steel. A crack in your heat exchanger is dangerous because it can allow carbon monoxide into your home!
Related: “Do You Have a Crack in Your Heat Exchanger?”
When things start getting cold in the Carolinas, a furnace is a fantastic way to keep your family warm and cozy! We know all of this can make them sound a little scary, but don’t worry! These sensors and controls are meant to keep your family safe. The best thing you can do for your furnace is schedule a Safety Check to make sure all your furnace’s safety features are in great shape to last the winter ahead! They will also check to make sure your furnace isn’t blowing cold air. Each of our technicians is a certified safety expert, and when you schedule service, your tech will check out everything super thoroughly. We don’t take shortcuts, especially when it comes to your family’s safety. You deserve to stay safe and warm this winter!
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