When using valve balls, it is necessary to pay comprehensive attention to aspects such as installation, operation, maintenance, medium compatibility and environmental control to ensure their performance and lifespan. The details are as follows:
I. Installation Stage: Ensure the foundation is stable
1. Flow matching
Adjust the installation direction according to the design characteristics of the sphere. For example, for high-pressure ball valves, ensure that the medium flow direction is consistent with the valve design direction, and use pressure to assist in sealing; for floating ball valves, it is recommended to install them horizontally, using the weight of the ball to enhance the sealing performance during closure.
2. Pipeline cleaning
Before installation, thoroughly remove all welding slag, iron filings and other impurities from the pipeline to prevent foreign objects from getting stuck between the sphere and the valve seat, which could cause damage to the sealing surface or result in the valve getting stuck.
3. Standard connection method
Flange connection: Check the flatness of the sealing surface, and ensure that the tightening torque of the bolts complies with the standards to prevent leakage.
Threaded connection: Ensure the correct rotation direction is maintained and avoid over-tightening which may cause damage to the threads.
Welding connection: Control the welding temperature to prevent damage to internal components due to high heat, and also prevent welding slag from entering the valve body.
II. Operation Phase: Standardize the usage process
1. Torque control
During manual operation, stop immediately when you feel the resistance increasing. It is strictly prohibited to forcibly rotate using an extension rod to prevent deformation of the valve stem or ball. For electric/ pneumatic ball valves, ensure that the output torque of the drive device is within the range that the valve can withstand.
2. Speed Management
Slowly open/close the valve, especially in high-pressure and high-flow systems. Avoid rapid operation as it may cause water hammer effect or pressure shock, which could lead to pipeline rupture or valve damage.
3. Status Confirmation
After the operation, confirm through the opening indicator or the position of the handle that the sphere is in the fully open or fully closed state to prevent the semi-open state from affecting the fluid flow or causing a loose seal.
III. Maintenance Phase: Extension of Service Life
1. Regular inspection
Visual inspection: Monthly check for any wear, corrosion or deformation of the sphere, valve seat and valve stem.
Sealing test: Conduct a pressure test to detect leakage conditions and replace aging sealing components (such as O-rings, packing) in a timely manner.
Connection and fastening: Check if the bolts and nuts are loose, especially in situations with frequent vibrations.
2. Cleaning and Lubrication
Surface cleaning: Regularly remove dirt from the valve body surface to prevent residual corrosive media.
Lubrication of moving parts: Apply lubricating grease to the valve stem, gears, and other areas (such as food-grade lubricants used in the food industry) to reduce friction and wear.
3. Fault Handling
Malfunction: Check if it is blocked by foreign objects, or caused by the valve stem being skewed or the sealing surface being worn. In such cases, cleaning or replacement of parts is necessary.
Leakage: Replace the sealing surface, sealing gasket or fasteners as per the cause. If necessary, reinstall them.
Leakage: Replace the aged sealing gasket, damaged sealing components (such as O-rings), or correct the deformed ball.
IV. Medium Adaptation: Select Appropriate Materials
1, corrosive medium
Select corrosion-resistant materials based on the chemical properties of the medium, such as:
Strong acids/strong bases: Use PTFE (polytetrafluoroethylene) lined ball valves.
Chlorinated media (such as seawater): Use 316 stainless steel ball valves, whose molybdenum content can enhance the resistance to chloride ion corrosion.
2. High-temperature medium
Select materials with high temperature resistance (such as ceramic ball valves) or use dedicated temperature-resistant ball valves to prevent the sealing materials from aging or deforming due to high temperatures.
3. Thick/Particulate Media
Choose V-shaped cut ball valves or wear-resistant ball valves to prevent the medium from blocking or wearing out the sealing surface.
V. Environmental Control: Minimizing External Influences
1, corrosive environmental protection
In outdoor or harsh industrial environments (such as near the sea, in acid mist workshops), apply paint to the ball valve or install protective covers to slow down external corrosion.
2. Pressure and Temperature Monitoring
Ensure that the pressure and temperature inside the pipeline are within the rated range of the ball valve, and avoid operating beyond the pressure or temperature limits to prevent seal failure or valve damage.
3. Anti-static Measures
When transporting flammable and explosive media, ensure that the ball valve has anti-static properties and strictly prohibit the generation of sparks during operation.
