Sanitary clamp ball valves are widely used in industries with high hygiene requirements such as food, pharmaceuticals, and cosmetics. The following is its installation and use guide:
I. Installation guide
1. Preparation before installation
Check the valve: Confirm that the specifications and models of the ball valve are consistent with the design requirements, check whether the valve appearance is damaged, whether the parts are complete, and the ball should rotate flexibly without jamming.
Clean the pipeline: Use compressed air or other appropriate methods to remove debris, dust, oil, etc. in the pipeline to prevent impurities from entering the valve and affecting the sealing performance and normal operation.
2. Installation location selection
Easy to operate and maintain: Choose a location with open space and easy access to install, so that operators can perform switch operations and daily maintenance. At the same time, reserve enough space for disassembly and replacement of valves.
Avoid vibration and shock: Try to avoid places with strong vibration and shock, such as near large mechanical equipment, compressors, etc., so as not to affect the sealing performance and service life of the valve.
Consider the flow direction of the medium: Install according to the flow direction of the medium marked on the valve. Generally, the fluid should flow in from the inlet end of the ball valve and out from the outlet end to ensure the normal operation of the valve.
3. Connection method installation
Quick connection: Quick-install sanitary ball valves are usually connected by clamps or quick-install connectors. During installation, first process the pipe end to meet the required size and surface roughness, then align the quick-install interface of the valve with the pipe, insert the clamp or quick-install connector, evenly tighten the clamp bolts or operate the locking device of the quick-install connector to ensure a firm connection and reliable sealing. Be careful not to damage the sealing surface of the valve and the pipe during installation.
4. Post-installation inspection
Sealing inspection: After installation, before the pressure test of the pipeline system, a separate sealing test should be conducted on the ball valve. Air pressure or water pressure test can be used. The test pressure is usually 1.1 times the nominal pressure of the valve. Keep the pressure for a period of time (such as 5-15 minutes) to check whether there is leakage in the sealing parts of the valve.
Valve debugging: Manually operate the ball valve to check whether the ball is flexible to open and close, and whether the limit device is accurate and reliable. For pneumatic or electric ball valves, it is also necessary to check whether the action of the drive device is normal, whether the connection with the valve is firm, and whether the control signal is accurately transmitted to ensure that the valve can be switched as required.
2. Usage Guide
1. Operation precautions
Manual operation: When operating a manual ball valve, a dedicated operating handle or wrench should be used to avoid using excessive force to force the valve to open or close, so as not to damage the valve drive device or ball. When opening or closing the valve, it should be operated slowly. Do not force it when you feel resistance. Find out the cause and eliminate the fault before continuing to operate.
Pneumatic or electric operation: For pneumatic or electric ball valves, ensure a stable supply of air source or power supply, and the air source pressure should meet the requirements of the valve drive device. During operation, if the valve is found to be abnormal or there is an abnormal sound, stop the operation immediately, cut off the air source or power supply, and conduct inspection and maintenance. At the same time, regularly check whether the sealing performance, lubrication and electrical connection of the drive device are good.
Avoid frequent switching: In normal production, frequent opening and closing of ball valves should be avoided as much as possible to avoid wear and fatigue of the sealing surface, which will affect the sealing performance and service life of the valve. Necessary switching operations are performed only when the flow needs to be adjusted or the process needs to be switched.
2. Maintenance
Regular cleaning: Clean the valve surface regularly to remove dust, oil and other contaminants and keep the valve appearance clean. For the inside of the valve, online cleaning or offline cleaning can be performed regularly according to the requirements of the production process and the characteristics of the medium. When cleaning online, a suitable cleaning fluid can be used for circulation cleaning through the pipeline system; for offline cleaning, the valve needs to be disassembled and placed in a special cleaning equipment for cleaning. After cleaning, ensure that the inside of the valve is dry and there is no cleaning fluid residue.
Check the sealing performance: Check the sealing performance of the valve regularly. You can observe whether there is any medium leakage when the valve is closed, or use professional leakage detection instruments for detection. If the sealing performance is found to be reduced, the cause should be analyzed in time. It may be caused by wear, aging, impurity particles, etc. of the sealing surface. Take corresponding repair measures for different causes, such as replacing seals, grinding the sealing surface, etc.
Lubrication and maintenance: For the rotating parts of the valve, such as the valve stem and ball, regular lubrication and maintenance are required to reduce friction resistance and ensure the flexible rotation of the valve. According to the use environment and medium characteristics of the valve, suitable lubricants, such as food-grade lubricants or greases, can be selected and applied or injected according to the prescribed cycle. At the same time, check whether the various connection parts of the valve are loose. If there is any looseness, tighten it in time.
3. Troubleshooting
The valve cannot be opened or closed: Possible reasons include drive failure, valve stem jamming, ball and valve seat jamming, foreign matter blockage, etc. First, check whether the power supply and air source of the drive device are normal, and whether the parts of the drive device are damaged. If there are any problems, repair or replace them in time. If the drive device is normal, check whether the valve stem is deformed, bent or rusted. If so, repair or replace the valve stem. If the valve stem is normal, there may be foreign matter stuck between the ball and the valve seat or the sealing surface is damaged. The valve needs to be disassembled for inspection, cleaning or repair of the sealing surface.
Valve leakage: If the connection at both ends of the valve leaks, it may be that the connecting bolts are loose or the sealing gasket is damaged. The bolts should be tightened or the gasket should be replaced. If the sealing surface inside the valve leaks, it may be that the sealing surface is worn, scratched, aged, or there are impurities and particles that affect the sealing performance. For minor wear or scratches, it can be repaired by grinding the sealing surface; if the sealing surface is severely damaged, the seal or the entire valve needs to be replaced.
Correct installation and use of sanitary quick-install ball valves can not only ensure their normal operation, but also extend the service life of the valve and ensure the safety and stability of the production process. During the installation and use process, if you encounter complex problems, you should consult professional technicians or manufacturer after-sales service personnel in a timely manner.