1、 Installation precautions

1. Installation location selection
   • Avoid installation in areas with high temperature radiation, severe vibration, or susceptibility to mechanical damage, and keep away from heat sources (such as boilers and heating furnaces) to reduce the impact of thermal radiation.
   • Ensure that there is sufficient space around the valve for operation, maintenance, and heat dissipation, while reserving space for passage when the valve is fully open.
2. Pipeline connection requirements
   • The inner wall of the pipeline should be clean and free of impurities to prevent welding slag, rust, etc. from entering the valve interior, causing jamming or wear.
   • During welding, argon arc welding is used as a base to ensure a smooth weld and prevent cracking or deformation of the weld at high temperatures.
   • The parallelism error between the pipeline flange and the valve flange is ≤ 0.5mm, and the bolt tightening torque is uniform to avoid stress concentration and leakage.
3. Gas source and signal line configuration
   • The air source needs to be dried and filtered to ensure that the compressed air has an oil content of ≤ 5ppm and a dust particle size of ≤ 5 μ m, in order to prevent internal corrosion or jamming of the pneumatic actuator.
   • The signal line adopts shielded cables and is kept away from strong electromagnetic interference sources (such as frequency converters and high-voltage cables). The signal transmission distance is ≤ 100 meters to avoid signal attenuation or distortion.

2、 Debugging precautions

1. Pneumatic actuator debugging
   • Adjust the air source pressure to the rated pressure of the valve (usually 0.4~0.7MPa) to avoid damage to the actuator caused by high pressure or slow action caused by low pressure.
   • Verify the zero point and range of the locator to ensure that the valve opening corresponds linearly with the input signal (4-20mA), with an error of ≤± 1%.
   • Test the fully open/fully closed time of the valve to ensure that the action time meets the process requirements (such as ≤ 5 seconds), and avoid affecting the system response due to slow action.
2. Adaptive debugging for high temperature working conditions
   • Before starting in a low-temperature environment, the valve needs to be preheated to the process temperature range (such as 100-200 ℃) to prevent seal damage or leakage caused by thermal expansion and contraction.
   • Simulate high temperature conditions (such as 300-500 ℃), test the flexibility and sealing performance of the valve under high temperature, and ensure no jamming or leakage.

3、 Operation precautions

1. Temperature monitoring
   • Install temperature sensors on the valve body and upstream and downstream pipelines to monitor temperature changes in real time, ensuring that the temperature is within the design range of the valve (such as -29 ℃~550 ℃).
   • If the temperature exceeds the limit, immediately activate interlock protection (such as closing the gas source, switching to backup valves) to prevent valve damage or process accidents.
2. pressure control
   • Ensure stable system pressure, avoid pressure fluctuations exceeding ± 10% of the valve's rated pressure, and prevent damage to valve internals due to pressure shock.
   • Install pressure gauges before and after the valve, regularly compare the pressure difference. If the pressure difference increases abnormally, it may indicate valve blockage or internal wear, and timely maintenance is required.
3. Flow direction and velocity of the medium
   • Strictly follow the flow direction indicated on the valve during installation to avoid reverse flow that may cause erosion of the sealing surface or damage to the valve seat.
   • Control the flow rate of the medium to be ≤ 30m/s to prevent valve vibration or noise exceeding the standard (≤ 85dB) due to high flow rate.

4、 Maintenance precautions

1. Regular inspection and cleaning
   • Check the appearance of the valve every quarter to confirm that there are no leaks, deformations, or corrosion, and clean the dust and oil stains on the surface of the valve.
   • Disassemble the valve for internal inspection every year, clean the impurities such as scale and welding slag in the valve chamber, check the wear of the valve seat and valve disc sealing surface, and replace the sealing components if necessary.
2. Lubrication and sealing maintenance
   • Regularly add high-temperature lubricating grease (such as molybdenum disulfide grease) to the moving parts such as pistons and bearings of pneumatic actuators to ensure flexible operation.
   • Check the sealing of the packing box. If any leakage is found, adjust the packing gland or replace the packing (such as graphite packing) to ensure that the leakage rate is ≤ 0.1ml/min.
3. Spare Parts Management
   • Reserve commonly used spare parts (such as seals, packing, positioners, etc.) to ensure that the spare parts model matches the valve and avoid prolonged downtime due to missing spare parts.
   • Regularly check spare parts inventory, replenish consumables in a timely manner, and ensure that maintenance response time is ≤ 4 hours.