Installation of ball valves
1. A ball valve must be cleaned before operation.
2. The actuator of ball valve drives the valve stem to rotate according to the size of the input signal. When the forward rotation is 1/4 circle (900), the ball valve is closed. When the reverse rotation is 1/4 circle (900), the ball valve is opens.
3. When the direction indicator arrow of the actuator is parallel to the pipeline, the ball valve opens. When the arrow is vertical to the pipeline, the ball valve is closed.
Maintenance of ball valves
Longer service life and maintenance free time will depend on several factors such as maintaining a harmonious temperature or pressure ratio under normal operating conditions and reasonable corrosion data.
Note: when the ball valve is closed, the fluid pressure in the valve body still exists.
Remove line pressure and leave valve in open position before servicing.
Before maintenance, disconnect the power or air source.
Before maintenance, separate the actuator from the bracket.
1. Packing locking
If the packing culvert is in the micro leakage filling, the valve stem nut must be locked.
Note: do not lock; usually lock 1/4 ring to 1 ring; leakage will stop.
2. Replace seats and seals
A. Disassembly
Leave the ball valve in the half open position and flush the possible hazardous substances inside and outside the valve.
Close the ball valve; remove the bolts and nuts from the flanges on both sides and completely remove the valve from the pipe.
Remove the drive actuator, connecting bracket, lock washer, stem nut, butterfly spring piece, gland, wear plate and valve stem packing in sequence.
Remove the connecting bolts and nuts of the body cover; separate the valve bonnet from the valve body, and remove the valve bonnet gasket.
Make sure the ball is in the off position, and it can be easily taken out of the valve body. Then, remove the seat. Push down the valve stem from the hole in the valve body until it is completely taken out, and then take out the O-ring and packing ring.
Note: Please operate carefully to avoid scratching the surface of the valve stem and the packing seal of the valve.
B. Reassemble
Clean and inspect parts of inspected parts, and replacement of seat and bonnet gasket and seal with spare parts package is highly recommended.
Assemble in reverse order.
Cross lock the flange bolts with the specified torque.
Lock the nut with the specified torque.
After the actuator is installed, the valve core is driven to rotate the corresponding input signal by rotating the valve stem to make the valve open and close.
If possible, seal pressure test and performance test of valve according to standard after piping installation.
Daily maintenance of ball valves
1. For API 6D pipeline ball valve, the sealing performance of the valve shall be inspected periodically, and the blowdown valve shall be used for inspection. If there is internal leakage, it shall be treated according to the procedure.
2. According to ball valve activity frequency, inject a certain amount of grease into the valve seat. Generally, proper amount of grease should be injected after the valve moves once, and the amount of each injection is 1/8 of the sealing system. In this way, the impurities in the pipeline can be avoided to enter the back cavity of the valve seat and affect the movement of the valve seat, resulting in sealing failure. Meanwhile, the sealing surface is always in the lubrication state and the service life is prolonged.
3. For the ball valve with little activity, it should be opened and closed once a year, and a certain amount of grease and cleaning fluid should be injected to avoid the combination of ball and seat glue.
4. Before winter, the ball valve should be maintained. And the water in the valve chamber and the actuator should be drained to avoid freezing in winter and affecting the use function.
5. Add wear-resistant grease to the valve worm head actuator every year; regularly check the valve stem seal and remove rust; have external protection.
In order to improve the reliability of the valve and prolong the service life of the valve, it is very important to do well in the early maintenance and supervision work, and many problems can be avoided by early detection and timely treatment.
Therefore, in the management and maintenance of ball valves, we should not only strengthen professional training to achieve scientific, standardized and safe maintenance, but also change the concept, carry out preventive maintenance management, and do a good job in the operation safety of heating systems to ensure the heating quality.
1. A ball valve must be cleaned before operation.
2. The actuator of ball valve drives the valve stem to rotate according to the size of the input signal. When the forward rotation is 1/4 circle (900), the ball valve is closed. When the reverse rotation is 1/4 circle (900), the ball valve is opens.
3. When the direction indicator arrow of the actuator is parallel to the pipeline, the ball valve opens. When the arrow is vertical to the pipeline, the ball valve is closed.
Maintenance of ball valves
Longer service life and maintenance free time will depend on several factors such as maintaining a harmonious temperature or pressure ratio under normal operating conditions and reasonable corrosion data.
Note: when the ball valve is closed, the fluid pressure in the valve body still exists.
Remove line pressure and leave valve in open position before servicing.
Before maintenance, disconnect the power or air source.
Before maintenance, separate the actuator from the bracket.
1. Packing locking
If the packing culvert is in the micro leakage filling, the valve stem nut must be locked.
Note: do not lock; usually lock 1/4 ring to 1 ring; leakage will stop.
2. Replace seats and seals
A. Disassembly
Leave the ball valve in the half open position and flush the possible hazardous substances inside and outside the valve.
Close the ball valve; remove the bolts and nuts from the flanges on both sides and completely remove the valve from the pipe.
Remove the drive actuator, connecting bracket, lock washer, stem nut, butterfly spring piece, gland, wear plate and valve stem packing in sequence.
Remove the connecting bolts and nuts of the body cover; separate the valve bonnet from the valve body, and remove the valve bonnet gasket.
Make sure the ball is in the off position, and it can be easily taken out of the valve body. Then, remove the seat. Push down the valve stem from the hole in the valve body until it is completely taken out, and then take out the O-ring and packing ring.
Note: Please operate carefully to avoid scratching the surface of the valve stem and the packing seal of the valve.
B. Reassemble
Clean and inspect parts of inspected parts, and replacement of seat and bonnet gasket and seal with spare parts package is highly recommended.
Assemble in reverse order.
Cross lock the flange bolts with the specified torque.
Lock the nut with the specified torque.
After the actuator is installed, the valve core is driven to rotate the corresponding input signal by rotating the valve stem to make the valve open and close.
If possible, seal pressure test and performance test of valve according to standard after piping installation.
Daily maintenance of ball valves
1. For API 6D pipeline ball valve, the sealing performance of the valve shall be inspected periodically, and the blowdown valve shall be used for inspection. If there is internal leakage, it shall be treated according to the procedure.
2. According to ball valve activity frequency, inject a certain amount of grease into the valve seat. Generally, proper amount of grease should be injected after the valve moves once, and the amount of each injection is 1/8 of the sealing system. In this way, the impurities in the pipeline can be avoided to enter the back cavity of the valve seat and affect the movement of the valve seat, resulting in sealing failure. Meanwhile, the sealing surface is always in the lubrication state and the service life is prolonged.
3. For the ball valve with little activity, it should be opened and closed once a year, and a certain amount of grease and cleaning fluid should be injected to avoid the combination of ball and seat glue.
4. Before winter, the ball valve should be maintained. And the water in the valve chamber and the actuator should be drained to avoid freezing in winter and affecting the use function.
5. Add wear-resistant grease to the valve worm head actuator every year; regularly check the valve stem seal and remove rust; have external protection.
In order to improve the reliability of the valve and prolong the service life of the valve, it is very important to do well in the early maintenance and supervision work, and many problems can be avoided by early detection and timely treatment.
Therefore, in the management and maintenance of ball valves, we should not only strengthen professional training to achieve scientific, standardized and safe maintenance, but also change the concept, carry out preventive maintenance management, and do a good job in the operation safety of heating systems to ensure the heating quality.
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Previous: Notes for Quick Installation of Ball Valves
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