When it’s critically important to keep a gas or liquid inside a system, consider a bellows seal valve. Bellows seal valves incorporate a cylindrical metal tube that expands and contracts like an accordion to create a hermetically sealed closure in a valve stem. The bellows get compressed when the valve is in the open position and expands when the valve is closed. Because the bellows expand and contract as the valve is operated, and because it is welded to the stem and bonnet, there is no leak path for the gas or liquid to escape.
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When transferring hazardous materials, bellows seal valves outperform standard or packed valves, which leave a space between the stem and the rest of the valve in order to allow the valve to open and close. That space leaves a chance for fugitive emissions (more on that later!) to leak.
Another reason to use a valve with a bellows seal rather than a standard packed valve is when transferring liquids or gas subject to changes in temperature. As Dan Fisher, a business development manager with Dixon explains, “If you have a piping system that runs hot and cold, traditional packed valves tend to loosen up with the temperature changes,” he says. “A bellows seal valve does not because it’s hermetically sealed. That’s why bellows seal valves are the valve of choice in heating and steam services applications.”
Dixon Eagle® bellows seal valves are the industry standard in steam, oil, gas, and chemical plants or wherever keeping a hazardous gas or liquid contained is required.
Hydraulically Formed vs. Welded Bellows
Traditionally, there are two primary ways to manufacture a bellows seal valve. One method involves welding a series of thin washer-like plates at both their inner and outer circumference to form the accordion bellows shape. A hydraulically formed bellows, on the other hand, is manufactured by pressurizing a single metal tube into wide-spaced metal folds to form the proper shape.
Hydraulically Formed Bellows
Formed bellows are more economical but require more vertical space
Welded BellowsWelded piles 'nest' together to create a shorter height; convenient for small spaces
There are advantages and disadvantages to both. Welded bellows generally take up less space than hydraulically formed bellows. A welded bellows has more folds per unit length as compared to formed bellows. Thus, for the same stroke length, formed bellows are two to three times longer than their welded counterparts.
Hydraulically formed bellows are typically larger, but they incorporate fewer welds, so there is a perception that they are stronger and will last longer. Fisher says that’s not necessarily the case. “If an edge-welded bellows is designed and welded correctly, they can have just as long a life cycle as a hydro-formed valve,” he says. “Form factor is really the major reason to choose one over the other.”
Gate or Globe?
Like standard valves, bellows seal valves employ a gate or globe to form a seal over an opening. A globe valve gets its name from its shape — a cone-shaped plug moves in and out of the flow of fluid or gas. A gate valve operates just like a gate, sliding in between the seats of the valve at a right angle to fluid flow. Why would you choose one over the other?
As a general rule of thumb, bellows valves with a globe closure have a lower flow coefficient than a gate valve—it puts more restrictions on the line, so your liquid or gas will flow at a slower rate for a given pressure. But a globe valve offers a tighter seal than a gate valve. Deciding which type to use depends upon your application.
Safety and Cost Considerations
The primary reason to use a valve with a bellows seal is to contain fugitive emissions — accidental leaks of gas or vapors that escape the system. Fugitive emissions can pose a danger to workers in the area and the greater environment. Since the passage of the U.S. Clean Air Act of 1963, the federal government has issued testing requirements for measuring fugitive emissions on valves. These standards have been updated and strengthened over the years, and if end users do not comply with EPA guidance, they can face both monetary and safety repercussions.
Fugitive emissions also affect revenue as it pertains to product loss. In a large plant, continuously leaking valves can cost millions of dollars. “With a standard packed refinery valve, you can lose on order of $250,000 in product loss per ton of fugitive emissions,” says Fisher. “If you’ve got a 300-million-barrel-per-day refinery, on average, these are going to lose maybe 12 to 15 tons a year. If you do the math, that’s $3 million to $3.75 million that goes into the air in a year. So, a leak-free valve can save that product and put it into your bottom line.”
When it comes to a typical steam plant, valve stem seal leaks are common in steam lines because thermal cycling tends to loosen the valve packing. This can also lead to hazardous conditions for workers as well as lost revenue.
For example, consider a typical natural gas-fired boiler supplied with 230°F (110°C) feedwater, producing 450 PSIG saturated steam and a natural gas cost of $1.54/MMBtu. Using the estimated cost of steam, the cost of leakage of a valve in a 115 PSI line that is throwing a plume of steam 3 feet at 90°F ambient temperature would yield a cost of $792.78 per year. (If you’d like to do the math, that’s (50 lb./hr.) x ($1.81/1,000 lb.) x (8,760hrs./year)
A valve in a 115 PSI line that has a packing leak approximated by a 1/16-inch hole would yield a cost of $237.83 per year. (15 lb./hr.) x ($1.81/1,000 lb.) x (8,760hrs./year)
Considering all the valves in a typical plant, the total savings would be significant. Based on eliminating the cost of steam leakage as estimated, a Dixon Eagle bellows seal valve can pay for itself in a period of one to two years.
These bellows seal valves can also save money in other ways as well. Many refiners operate under consent decrees with the EPA, guaranteeing they will not put a certain amount of emissions into the air. Incorporating Dixon Eagle bellows valves will help prevent “chronic leakers,” reducing potential fines and the cost of repairs to the line.
Why Else Should You Choose Dixon Eagle Brand Bellows Valves?
Dixon Eagle is one of the oldest bellows seal brands in the United States, and many seals have been in the field for more than 20 years. All Dixon Eagle valves are manufactured in the U.S., under ISO 9001:2015 Certification. Valves used for chlorine transport by rail cars also meet the standards established by the Association of American Railroads.
Dixon offers dozens of different bellows seal options off the shelf. If your application requires a custom design, we can help with that, too. “Engineering for special high-hazard or critical applications that aren’t necessarily run-of-the-mill, those are the types of projects we specialize in,” says Fisher. “We want to be more of a partner with our customers, making sure that the product is tailored to their applications.”
Plus, with Dixon’s extensive distribution network and fast lead times, you can get your product quickly and save money on shipping.
So, if you’re looking for the best products for your hazardous or toxic materials application, Dixon would love to help. Contact one of our specialists at 713.678.4291 or visit dixonvalve.com.
A bellows seal globe valve is an essential component in many industries, such as chemical, oil and gas, and petrochemical industries. It is a type of industrial valve used to regulate and control the flow of fluids, gases, and other media through a pipeline or system. These bellows valves are widely used because of their unique design, which includes a bellows seal that protects the stem from corrosion and prevents fluid from eroding the stem. So it’s very common to see the condition for corrosive or toxic media.
globe valvesThe bellows seal globe valve consists of body, disc, stem, bonnet, bellows seal, and packing. The valve body is the primary component that houses the valve disc, which controls the flow of media. The valve stem connects the valve disc to the actuator or handwheel, which opens or closes the valve. The bonnet covers the stem and packing and the bellows valve provides a seal to prevent leakage. The following is the photo of bellow seal globe valve.
din globe valve with bellowsNo.Parts Name Materials1BodyGS-C25/1.0619CF8/1.4301CF8M/1.44082SeatOverlay 13CrSS304SS3163Disc surfaceOverlay 13CrSS304SS3164StemX20Cr13SS304SS3165BellowsSS304/SS316/SS321/SS316T1SS304/SS316/SS321/SS316HSS316/SS321/SS3167I6GasketGraphite+SSGraphrte+SSGraphite+SS7Bellows coverSS304ZSS316SS304/SS316SS3168BonnetGS-C25/1.0619CF8/1.4301CF8M/1.44089NutA194 2HA194 8A194 8M10BoltA193 B7A193 B8A193 B8M11 PackingGraphiteGraphiteGraphite12Glandc.sCF8CF8M13PinSteelSteelSteel14Guide pieceSteelSteelSteel15Stem nutDuctile ironCopper alloyCopper alloy16Grease NippleH2H2H217Hand wheelSteelSteelSteel18Lock nutA105A105A105There are several types of bellows seal valves and globe valves available in the market, each with unique design features and applications. Here are some of the most common types of bellows seal globe valves:
This type of valve has welded metal bellows that provides a flexible, leak-proof seal and protects the stem from corrosion. Welded ends bellows seal globe valves are ideal for high-temperature and high-pressure applications.
This type of valve has a flanged connection that makes it easy to install and remove. Flanged bellows seal globe valves are suitable for applications that require frequent maintenance and inspection.
din globe valve with bellowsThis type of valve has socket-welded connection ends which are suitable for high-pressure applications.
This type of valve has a threaded connection that makes it easy to install and remove. Threaded bellows seal globe valves are commonly used for small pipeline.
This type of valve has extended bellows that provide additional protection against corrosion and allows the valve to operate at extreme temperatures and pressures.
api globe valve with bellowsThe Y-Type Bellows Seal Globe Valve is an exceptionally secure and reliable component, featuring a double sealing structure of bellows and packing. This ensures complete protection from any potential leakage at the stem, making it ideal for use in pipelines carrying dangerous, flammable, explosive, toxic or valuable substances. Additionally, its construction ensures tight seals are maintained under high temperatures and pressures, while also minimizing any risk of leaks.
din y type globe valve with bellowsTHINKTANK is a reliable globe valve manufacturer that has been producing high-quality industrial valves for over three decades. Our valves are made from high-quality materials and are designed to meet the specific needs of each application, just feel free to contact us for a free consultation.
A globe valve and a bellows seal globe valve both belong to the family of globe valves, which are used to control the flow of fluids through a pipeline or system. However, the primary difference between them is the presence of a bellows seal in a bellows seal globe valve. A bellows seal is a flexible metal component that provides a leak-proof seal and protects the stem from corrosion, which makes the bellows seal globe valve more suitable for applications that require high performance and reliability.
din globe valve with bellowsdin globe valveThe primary purpose of bellows in valves is to provide a flexible, leak-proof seal that protects the stem from corrosion and prevents fluid from eroding the stem. Bellows are also used to compensate for changes in temperature and pressure in the system, which allows the valve to operate smoothly and efficiently.
The primary difference between a bellows seal valve and a common valve is the presence of a bellows seal. A bellows seal valve has flexible metal bellows that provide a leak-proof seal and protect the stem from corrosion, while a normal valve does not have this feature.
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A bellows seal is a flexible metal component that is used in valves to provide a leak-proof seal and protect the stem from corrosion. The bellows seal consists of metal bellows that is welded to the stem and a packing gland that secures the bellows in place.
The primary reason for using bellows in a valve is to provide a flexible, leak-proof seal that protects the stem from corrosion and prevents fluid from eroding the stem. Bellows are also used to compensate for changes in temperature and pressure in the system, which allows the valve to operate smoothly and efficiently.
Bellows work by expanding and contracting to compensate for changes in temperature and pressure in the system. When the temperature or pressure in the system changes, the bellows expand or contracts to allow the valve stem to move freely, which prevents damage to the valve and ensures smooth operation.
There are three types of valve seals: packing, mechanical, and bellows.
Packing seals use a flexible material, such as graphite, to provide a seal around the stem. Mechanical seals use a rotating component to provide a seal, while bellows seals use a flexible metal component to provide a leak-proof seal and protect the stem from corrosion.
The two basic types of valve seals are static and dynamic. Static seals provide a seal between two stationary components, while dynamic seals provide a seal between two moving components.
One of the primary disadvantages of bellows is that they can fail over time, which can lead to leakage and other issues. Bellows can also be more expensive than other types of valve seals, which can make them less suitable for certain applications.
Bellows failure can occur due to a variety of factors, such as fatigue, corrosion, or mechanical damage. When a bellows fails, it can lead to leakage, reduced valve performance, and other issues. Regular inspection and maintenance can help prevent bellows failure and ensure the continued performance of the valve.
The operational principle of a bellows seal globe valve is based on its unique design, which includes a bellows seal that protects the stem from corrosion and prevents fluid from eroding the stem. The valve consists of a valve body, a valve disc, a valve stem, a bonnet, a bellows seal, and packing.
When the valve is in the open position, the valve disc is lifted away from the valve seat, allowing media to flow through the valve. The stem and the disc move together as the stem is rotated by the actuator. When the valve is in the closed position, the valve disc is pressed against the valve seat, preventing media from flowing through the valve.
The bellows seal globe valve is widely used in industries where leak-proof and corrosion-resistant valves are required. Some common applications of the bellows seal globe valve are:
Here are some reliable bellow seal globe valves manufacturer in China for your reference.
The primary difference between a bellows seal valve and a traditional valve is the presence of a bellows seal. A bellows seal valve has flexible metal bellows that provide a leak-proof seal and protect the stem from corrosion, while a traditional valve does not have this feature.
20k 80 globe valve and check valveSelecting the right bellows seal globe valve for your application is crucial to ensure optimal performance, reliability, and safety. Here are some factors to consider when selecting the right bellows seal globe valve for your application:
Bellows seal globe valves offer several advantages in high-pressure and high-temperature applications, making them a popular choice for such applications. Here are some of the advantages of using bellows seal globe valves in high-pressure and high-temperature applications:
The frequency of bellows seal replacement in bellows seal globe valves depends on several factors, such as the type of fluid being transported, operating conditions, and the quality of the bellows seal.
In general, bellows seal replacement is typically required when there is evidence of seal failures, such as leakage or reduced performance. Regular inspection and maintenance can help detect signs of bellows seal failure and prevent unexpected downtime or safety hazards.
The recommended replacement interval for bellows seals can vary depending on the application and the manufacturer’s guidelines. However, a general rule of thumb is to replace the bellows seal every 2-3 years or when there is evidence of seal failure, such as leakage or reduced performance.
It is important to note that regular inspection and maintenance are crucial to ensuring the proper functioning of the bellows seal globe valve. This includes checking the bellows seal for signs of wear and damage, inspecting the stem and disc for proper alignment, and ensuring that the valve is properly lubricated.
By following the manufacturer’s guidelines and performing regular inspection and maintenance, you can ensure that the bellows seal globe valve operates safely and efficiently and that the bellows seal is replaced as needed to prevent leakage and other issues.
globe valve with bellowsHere is a table outlining some common issues that can arise with bellows seal globe valves and possible troubleshooting steps:
IssuePossible CausesTroubleshooting StepsLeakageDamaged or worn bellows seal, improperly installed valve, damaged valve body or disc, excessive fluid pressure or temperatureInspect bellows seal for signs of wear or damage, check valve installation for proper alignment and torque, inspect valve body and disc for signs of damage, check fluid pressure and temperature to ensure they are within valve limitsValve does not close completelyImproperly adjusted actuator, damaged valve disc or seat, obstruction in valve bodyCheck actuator settings and adjust if necessary, inspect valve disc and seat for signs of damage or wear, inspect valve body for obstructions and remove if necessaryExcessive noise or vibrationMisaligned valve components, excessive fluid pressure or flow rate, worn valve componentsInspect valve components for proper alignment, check fluid pressure and flow rate to ensure they are within valve limits, inspect valve components for signs of wear and replace as neededDifficult to operateDamaged or worn stem or packing, improper lubrication, misaligned valve componentsInspect stem and packing for signs of damage or wear, lubricate valve components according to manufacturer’s recommendations, inspect valve components for proper alignmentCorrosionExposure to corrosive fluids or environments, low-quality materialsSelect valve materials that are resistant to corrosion, ensure proper maintenance and cleaning to prevent corrosion buildupIn conclusion, the bellows seal globe valve is an essential component in many industries due to its unique design and functionality. Its ability to provide a leak-proof and corrosion-resistant seal makes it an excellent choice for applications that require high performance and reliability. We hope that this article provides you with valuable insights into the design, functionality, and applications of the bellows seal globe valve. Please do not hesitate to contact us if you have any questions or comments. THINKTANK is your reliable industrial valve partner here.
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