Introduction to the installation and maintenance of ball valves

Before installing a ball valve, it's essential to ensure all preparations are properly completed.

First, verify that the ball valve is positioned correctly. It should be aligned with the pipeline so that both flanges are parallel. Make sure the pipeline can support the weight of the valve. If not, provide additional supports before installation to prevent damage or misalignment.

Next, inspect the pipeline for any debris, weld slag, or other contaminants. A thorough purge of the pipeline is necessary to avoid blockages or damage to the valve’s internal components during operation.

Check the valve’s nameplate and test its operation by opening and closing it several times. This helps confirm that the valve functions smoothly and without issues. Additionally, conduct a detailed inspection to ensure the valve is undamaged and ready for installation.

Remove the protective covers on both ends of the valve and clean the body thoroughly. Pay special attention to the sealing surface of the ball, as even small particles can cause wear or leaks over time.

When installing the ball valve, make sure it is placed at the upstream end. The handle type can be installed in any position, but if an actuator (like a gear box or electric actuator) is used, it must be mounted vertically and horizontally to ensure proper operation.

Install a gasket between the valve flange and the pipeline flange according to the design specifications. This ensures a tight seal and prevents leakage.

Tighten the flange bolts in a symmetrical and even manner. This helps distribute the load evenly and prevents uneven stress on the valve or pipeline.

If the ball valve is equipped with a pneumatic or electric actuator, follow the manufacturer’s instructions to connect the air source and power supply properly.

After installation, perform a few test cycles by opening and closing the valve. It should move smoothly and evenly, with no resistance or irregularities. This confirms the valve is functioning correctly.

Apply pressure according to the pipeline design requirements and check the sealing performance at the joint between the valve and the pipe flange. Ensure there are no leaks or signs of failure.

For maintenance, only disassemble the ball valve when the pressure has been fully released. This prevents accidents and protects the integrity of the system.

During disassembly and reassembly, take care to protect all sealed areas, especially non-metallic parts like O-rings. These components are sensitive and can be easily damaged if mishandled.

When reassembling the valve body, tighten the bolts gradually and symmetrically to ensure even pressure distribution and a secure fit.

Use cleaning agents that are compatible with all materials in the ball valve, including rubber, plastic, and metal parts. For gas applications, gasoline (GB484-89) can be used for metal parts, while non-metallic components should be cleaned with purified water or alcohol.

Clean individual parts by dipping them into the solution. For metal parts that remain intact, use a soft cloth soaked in the cleaning agent to wipe away dirt and residue. Be careful not to leave any foreign material behind.

Non-metallic parts should be removed from the cleaning agent immediately after washing. Prolonged soaking may degrade the material and reduce its effectiveness.

After cleaning, allow the parts to dry completely before reassembling. Wipe off any remaining cleaning agent with a clean silk cloth. Do not leave the parts exposed for too long, as this may lead to rust or contamination from dust.

All new parts should also be cleaned before assembly to ensure they are free from any manufacturing residues or contaminants.

Lubricate the valve using a grease that is compatible with all materials and the working medium. For gas applications, a specialized grease like 221 can be used. Apply a thin layer to the seal grooves, rubber seals, and the stem’s sealing and friction surfaces to ensure smooth operation.

Avoid leaving any metal shavings, fibers, or excess grease on the parts. These can cause damage, clogging, or malfunction of the valve over time.