Ball Valve with Saddle Seals

An improved ball valve has a valve housing having a first end and a second end, a main bore and a valve chamber between the first end and the second end, the valve chamber has a first and second end, the valve housing also has a first portion of the main bore extending between the first end of the valve housing and the first end of the valve chamber, the second end of the valve chamber is adjacent to the second end of the valve housing, the valve housing also has a valve stem port between the first end and the second end, the valve stem port extending through the valve housing into the valve chamber perpendicular to the main bore, a first seat ring in the valve chamber adjacent the first end of the valve chamber and a second seat ring adjacent to the second end of the valve chamber, a valve stem having a first end and a second end and a long axis extending between the first end and the second end, the valve stem extending through the valve housing within the valve stem port with the long axis of the valve stem perpendicular to the main bore, the valve stem having a handle removable secured to the first end of the valve stem and operable to rotate the valve stem about the long axis of the valve stem, a valve ball frictionally engaged between the first and second seat rings within the valve chamber, the valve ball removably secured to the second end of the valve stem and rotatable about the long axis of the valve stem, the valve ball having a central bore perpendicular to the long axis of the valve stem and operable to conduct fluid from the first end of the valve housing to the second end of the valve housing through the first portion of the main bore and the central bore of the valve ball when the valve ball is oriented between the first and second seat rings with the central bore of the valve ball colinear with the main bore, the improvement comprising:

• a first and second saddle seal configured to frictionally engage and surround the valve ball central bore between the first and second seat rings and operable to seal to each other and to the first and second seat rings.

A method of sealing a ball valve having a valve housing, a second end fitting and a valve stem operably connected to the valve ball at a valve stem connection and first and second ring seats frictionally engaging the valve ball, the valve ball and the first and second ring seats collocated in a valve chamber comprising the steps:

• Removing the second end fitting;
• removing the valve stem from the valve housing;
• removing the second ring seat and the valve ball from the valve chamber;
• installing a first and second saddle seal around the valve ball with the valve stem connection oriented within a valve stem opening in the first saddle seal;
• installing the first and second saddle seals and the valve ball into the valve chamber;
• installing the second ring seat in the valve chamber;
• and
• operably connecting the valve stem through the valve housing and the first saddle seal to the valve stem connection on the valve ball.