Learn about pneumatic ball valve information
1.Matters needing attention
This operation manual is used to help users install and maintain correctly, and ensure the safe and trouble-free operation of the valve.
Before installation, please do not remove the valve from the package.
The valve must be stored in a dry and dust-free environment and protected from light.
If the valve can be stored correctly, no additional preservation measures are required.
The installation, disassembly and maintenance of the valve must be performed by trained professionals.
Before disassembling the valve, you must first stop the valve from running and isolate it from the system, and make sure that there is no pressure in the valve.
Valves designed according to the special requirements of users can only be used under the conditions specified in the design.
The ball valve can serve as the isolation and adjustment function of the key parts of the system. It is widely used in pipelines in almost all industrial fields. The applicable media include liquids, gases and granular materials.The main application areas are:
-chemical and petrochemical industry
– Marine Engineering
– gas supply system
– food industry
– Wastewater treatment and water supply and drainage engineering
– Cold storage and HVAC system
– power plants and heating plants
The pipeline before and after the ball valve is ready. The front and rear pipes should be coaxial, and the sealing surfaces of the two flanges should be parallel. The pipe should be able to bear the weight of the ball valve, otherwise the pipe must be equipped with proper support. Clean the pipelines before and after the valve to remove the oil, welding slag and all other impurities in the pipeline. Check the mark of the ball valve to find out that the ball valve is intact. Fully open and close the valve several times to verify that it is working properly. Remove the protective parts on the connecting flanges at both ends of the ball valve. Check the valve hole to remove possible dirt, and then clean the valve hole. Even small foreign matter between the valve seat and the ball may damage the seat sealing surface. Install the valve in the pipeline. Either end of the valve can be installed at the upstream end. The valve driven by the handle can be installed at any position on the pipeline. But the ball valve with gear box or pneumatic driver should be installed upright,that is, installed on the horizontal pipeline, and the driving device is above the pipeline. Install a gasket between the valve flange and the pipeline flange according to the pipeline design requirements. The bolts on the flange need to be tightened symmetrically, successively and evenly. Connect the pneumatic line (when using a pneumatic drive). Operate the driver to open and close the ball valve several times. It should be flexible and free of stagnation to confirm its normal operation. Check the sealing performance of the flange joint surface between the pipeline and the ball valve according to the pipeline design requirements.
Before starting, check whether the valve is installed correctly (installation position, flange hole), and check whether the valve core and valve seat sealing ring are suitable for the medium used. POV valve can adjust the control medium arbitrarily between 15° and 70°. Please be careful not to operate the valve in cavitation conditions.
The valve must be disassembled under specified conditions (the pipeline is out of service and there is no pressure).
When removing the valve, place the spool in the closed position.
Loosen the flange bolts slowly and carefully (because there may still be pressure at the pipeline connection).
Remove the valve and place it in a suitable place (such as a wooden trough).
The ball valve is maintenance-free. Please install and use correctly, no daily maintenance is required.
During maintenance, the valve must be disassembled correctly (please refer to the “five” disassembly section).
Please be careful not to damage the valve sealing ring.
Remove the valve drive device.
Removal and replacement parts
It is necessary to find out that the upstream and downstream pipelines of the ball valve have indeed relieved the pressure before disassembling.
When disassembling and reassembling, care must be taken to prevent damage to the sealing surface of parts, especially non-metal parts. Special tools should be used when removing O-rings.
During assembly, the bolts on the flange must be tightened symmetrically, gradually and evenly.
The cleaning agent should be compatible with the rubber parts, plastic parts, metal parts and working medium in the ball valve. When the working medium is gas, gasoline can used to clean the metal parts. Clean non-metal parts with pure water or alcohol.
The disassembled individual parts can be cleaned by dipping. Metal parts with undecomposed non-metal parts can be scrubbed with a clean, fine silk cloth impregnated with detergent. When cleaning, remove all grease, dirt, glue, dust, etc. adhering to the wall surface.
Non-metal parts should be taken out of the cleaning agent immediately after cleaning, and should not be soaked for a long time.
After cleaning, it needs to be assembled after the cleaning agent of the wall surface to be washed evaporates, but it should not be left for a long time, otherwise it will rust and be contaminated by dust.
New parts must also be cleaned before assembly.
Use grease for lubrication. Grease should be compatible with ball valve metal materials, rubber parts, plastic parts and working medium. When the working medium is gas, special 221 grease can be used. Apply a thin layer of grease on the surface of the seal installation groove, apply a thin layer of grease on the rubber seal, and apply a thin layer of grease on the sealing surface and friction surface of the valve stem.When assembling, it should not be allowed to pollute, adhere or stay on the surface of the parts or enter the cavity with metal chips, fibers, grease (except those specified for use), dust, other impurities, and foreign objects.
Close the shutoff valves upstream and downstream of the ball valve. Bleed to relieve the pressure in the pipes before and after the ball valve.
Make the ball valve in a fully closed state.
Unscrew the nut, remove the washer, wrench head and handle.
Unscrew the nut, remove the spring washer, stem stopper and packing gland.
Remove the packing.
Check the removed parts, repair or replace if damaged, and clean all parts.
Scrub and lubricate the stuffing box sealing surface.
Load new packing.
Install the packing gland, valve stem stopper, and spring washer in the reverse order of decomposition, and fasten the above parts with nuts.
Then install the wrench head and handle, install the washer, and fasten it with a nut.
Operate the handle to check the opening and closing flexibility of the ball valve.
Air tightness test.