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Tips for valve installation

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Update time : 2020-06-11 16:05:25

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The quality of the valve installation directly affects the use, so careful attention must be paid.

First, direction and location
Many valves are directional, such as shut-off valves, throttle valves, pressure reducing valves, check valves, etc., if installed backwards, it will affect the use effect and life (such as throttle valve), or will not work at all (such as Pressure reducing valve), even causing danger (such as check valve). For general valves, there is a direction sign on the valve body; if not, it should be correctly identified according to the working principle of the valve. The valve cavity of the shut-off valve is asymmetrical, and the fluid should be allowed to pass through the valve port from bottom to top, so that the fluid resistance is small (determined by the shape), and the opening is labor-saving (due to the upward pressure of the medium), and the medium does not press the packing after closing, which is convenient for maintenance. This is why the shut-off valve is irreversible. Other valves also have their own characteristics.
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The installation position of the valve must be convenient for operation: even if the installation is temporarily difficult, it is necessary for the operator to work for a long time. It is best to align the valve handwheel with the chest (generally 1.2 meters from the operating floor), so that opening and closing the valve is more labor-saving. The handwheel of the floor valve should be upwards, not tilted, so as to avoid awkward operation. The valve of the wall machine and the equipment should also leave room for the operator to stand. Avoid operating in the sky, especially acid and alkali, toxic media, etc., otherwise it is very unsafe. Do not flip the gate upside down (ie the handwheel is down), otherwise the medium will remain in the bonnet space for a long time, it is easy to corrode the valve stem, and it is taboo for some process requirements. It is extremely inconvenient to replace the packing at the same time. Do not install the open stem gate valve underground, otherwise the exposed stem will be corroded due to moisture. The check valve of the lift type should be installed to ensure that the valve flap is vertical, so that the lift can be flexible. Swing check valve, to ensure that the pin shaft is horizontal during installation, so that the swing is flexible. The pressure reducing valve should be installed upright on the horizontal pipeline, and should not be inclined in all directions.
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Second, construction work
 
Installation and construction must be careful not to hit the valve made of brittle materials.
 
Before installation, the valve should be inspected, the specifications and models should be checked, and any damage should be identified, especially for the valve stem. It has to be turned a few times to see if it is skewed, because the valve stem is most likely to buckle during transportation. Also remove debris from the valve.
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When the valve is lifted, the rope should not be tied to the hand wheel or valve stem, so as not to damage these parts, it should be tied to the flange.
 
The pipeline connected to the valve must be cleaned. Compressed air can be used to blow off iron oxide filings, mud sand, welding slag and other debris. These debris are not only easy to scratch the sealing surface of the valve. Among them, large particles of debris (such as welding slag) can also block the small valve and make it invalid. When installing the screw valve, the sealing packing (wire hemp plus aluminum oil or PTFE raw material tape) should be wrapped on the pipe thread. Do not get into the valve, otherwise the valve will accumulate and affect the medium circulation.
 
When installing flange valves, pay attention to tighten the bolts symmetrically and evenly. The valve flange and the pipe flange must be parallel and the gap is reasonable to avoid excessive pressure or even cracking of the valve. Special attention should be paid to valves with brittle materials and low strength. Valves that must be welded to the pipe should be spot welded, and then the closing part should be fully opened, and then seal in by welding.
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Third, protective measures
 
Some valves must also have external protection, which is insulation and cold insulation. Hot steam lines are sometimes added to the insulation. What kind of valve should be insulated or kept cold depends on the production requirements.
 
In principle, when the temperature of the medium in the valve is reduced too much, it will affect the production efficiency or freeze the valve, so you need to keep warm or even mix the heat; when the valve is exposed, it is bad for production or causes frost and other bad phenomena, you need to keep cold. Insulation materials include asbestos, slag wool, glass wool, perlite, diatomaceous earth, vermiculite, etc.; cold insulation materials include cork, perlite, foam, plastic, etc.
 
Fourth, bypass and gauge
 
In addition to the necessary protection facilities, some valves also have bypasses and meters. The bypass is installed to facilitate the maintenance of the trap. Other valves are also installed with bypass. Whether to install a bypass depends on the valve condition, importance and production requirements.

Fifth, filler replacement
 
In stock valves, some packings are not easy to use, and some are not compatible with the medium used. This requires replacement of packings.
The valve manufacturing plant cannot consider the use of thousands of different media in the unit. The packing box is always filled with ordinary packing, but when used, the packing must be adapted to the medium.
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When replacing the packing, press in one circle after another. The seam of each circle should be 45 degrees, and the circle should be 180 degrees apart. The height of the packing should consider the room for the gland to continue to compact, and now the lower part of the gland should be pressed to the appropriate depth of the packing chamber. This depth can generally be 10-20% of the total depth of the packing chamber. For demanding valves, the seam angle is 30 degrees. The seams between the circles are staggered by 120 degrees. In addition to the above fillers, three pieces of rubber O-rings (natural rubber resistant to weak bases below 60 degrees Celsius, nitrile rubber resistant to oil crystals below 80 degrees Celsius, and fluororubber resistant to various corrosive media below 150 degrees Celsius) can be used according to specific conditions Stacked polytetrafluoroethylene ring (resistant to strong corrosion media below 200 degrees Celsius) nylon bowl-shaped ring (resistant to ammonia and alkali at 120 degrees Celsius) and other forming fillers. Outside the ordinary asbestos packing, covered with a layer of Teflon raw material tape, can improve the sealing effect and reduce the electrochemical corrosion of the valve stem.
When tightening the seasoning, turn the valve stem at the same time to maintain uniformity around and prevent too dead, tighten the gland evenly, not tilt.