Installation and commissioning process and precautions for three-way internal thread ball valve

1、 Installation process

1. Pre-installation preparation
   • Clean the valveRemove the protective covers on both sides of the flange end of the pneumatic three-way internal threaded ball valve, and rinse and clean it with the valve open to remove internal impurities.
   • whole machine testingConduct a complete machine test according to the prescribed signal (electric or pneumatic) to prevent performance from being affected by transportation vibrations. After passing the test, it can be installed online, and the wiring needs to be operated according to the circuit diagram of the electric actuator.
   • pipe cleaningBefore connecting to the pipeline, it is necessary to flush and remove any remaining impurities in the pipeline, such as welding slag, rust, etc., to prevent damage to the valve seat and sphere.
2. Installation operation
   • Avoid lifting the actuatorDuring installation, it is prohibited to use the actuator part of the valve as a lifting point to avoid damaging the actuator and accessories.
   • Installation directionPneumatic three-way internal threaded ball valves should be installed in the horizontal or vertical direction of the pipeline to ensure flexible valve operation.
   • Pipeline supportThe pipeline near the installation point should not have any low hanging or external force bearing phenomenon. Pipeline brackets or supports can be used to eliminate the deviation of the pipeline and prevent valve damage due to pipeline deformation.
   • connecting boltAfter connecting the valve to the pipeline, it is necessary to cross lock the flange connection bolts with the specified torque to ensure a tight and leak free connection.
3. Check after installation
   • Visual inspectionConfirm that the installation position, height, and inlet/outlet direction of the valve meet the design requirements, and that the threaded connection is firm and tight.
   • Sealing gasket inspectionA sealing gasket should be installed between the valve flange and the pipeline flange according to the pipeline design requirements to prevent leakage.
   • Handle directionManual valves installed on insulated pipelines must not have handles facing downwards to avoid inconvenience or damage during operation.

2、 Debugging process

1. Sealing test
   • strength testFor valves with a working pressure greater than 1.0 MPa and a shut-off function on the main pipeline, a strength test must be conducted before installation. The test pressure is 1.5 times the nominal pressure, and the duration is not less than 5 minutes. The valve housing and packing should have no leakage.
   • Sealing TestThe test pressure is 1.1 times the nominal pressure, and the duration of the test pressure should comply with the requirements of JB/T9092 standard. It is qualified if there is no leakage on the sealing surface of the valve disc.
2. Operation inspection
   • Rotational flexibilityGently rotate the handle or drive device of the ball valve to check if it rotates smoothly and without any jamming.
   • flow regulationAdjust the opening of the ball valve as needed, observe changes in fluid flow rate, and ensure that the valve regulation function is normal.
   • Leak checkAfter closing the ball valve, observe for any fluid leakage. If there is a leak, it needs to be reinstalled and sealed with a sealing gasket.
3. record data
   • Record key data during the debugging process, such as test pressure, duration, leakage situation, etc., for future reference and maintenance.

3、 Precautions

1. Installation precautions
   • Valve selectionWhen selecting valves, factors such as valve function, size, fluid temperature, pressure, etc. should be considered to ensure that the valve matches the pipeline system.
   • Valve with transmission mechanismFor ball valves with transmission mechanisms, installation should be carried out according to the product manual to prevent transmission failure caused by improper installation.
   • nameplate inspectionBefore installing the valve, a visual inspection must be carried out, and the valve nameplate should comply with the provisions of the national standard "General Valve Marking" GB12220.
2. Debugging precautions
   • Operation intensityAttention should be paid to the force during operation, and excessive force should not be used to avoid damaging the ball valve.
   • Flow directionAttention should be paid to the flow direction of the valve during operation to avoid unnecessary resistance.
   • Confirmation before operationBefore operation, ensure that the ball valve is in the closed state to avoid accidents.
   • Usage environmentAttention should be paid to the usage environment to avoid corrosion or damage to the ball valve during use.
3. Safety precautions
   • personal protectionOperators are required to wear personal protective equipment such as protective gloves and goggles to prevent injury caused by valve leakage or improper operation.
   • emergency responseDevelop emergency plans and clarify the operating procedures in case of valve failure, such as closing upstream and downstream shut-off valves, starting backup systems, etc.
   • Explosion proof and anti-staticIn flammable and explosive environments, explosion-proof pneumatic control valves and supporting instruments should be selected to ensure that electrical connections comply with explosion-proof standards. Valves and pipelines must be reliably grounded to prevent static electricity accumulation from causing sparks.