1 Valve Installation 1.1 Preparation before installation (1) Ball valve before and after the pipeline is ready. Before and after the pipeline should be coaxial, two flange sealing surface should be parallel. The pipe should be able to withstand the weight of the ball valve, otherwise the pipe must be equipped with appropriate support. (2) purge the pipeline before and after the pipeline clean, clear the pipeline of oil, welding slag and all other impurities. (3) check the ball valve logo to find the ball valve intact. Open the valve fully closed several times to confirm its normal operation. (4) Remove the protective parts on the connecting flanges on both ends of the ball valve. (5) Check the valve hole to remove possible dirt, and then clean the valve hole. Even small particles of foreign matter between seat and ball may damage seat sealing surface. 1.2 Installation (1) install the valve on the pipeline. Either end of the valve can be installed on the upstream side. The handle-actuated valve can be mounted anywhere on the pipe. However, ball valves with gearboxes or pneumatic drives should be erected, mounted on a horizontal pipe with the drive above the pipe. (2) between the valve flange and pipeline flange installed according to the pipeline design requirements gasket. (3) The bolts on the flange should be symmetrical, one after another, evenly tightened. (4) Connect the pneumatic line (with pneumatic actuator). 1.3 After the installation of inspection (1) Operate the drive Kai, close the ball valve several times, should be flexible without astringent, confirmed its normal operation. (2) According to the pipeline design requirements of pipe and ball valve flange sealing surface between the performance check. 2 valve maintenance 2.1 General (1) must first identify the ball valve, the downstream pipe has been removed after the pressure, to disassembly and disassembly. (2) Disassembly and reassembly must be performed with care to prevent damage to the sealing surfaces of parts, especially non-metallic parts. Special tools should be used when removing o-rings. (3) The flange bolts must be symmetrical, tighten gradually and evenly. (4) The cleaning agent should be compatible with the rubber parts, plastic parts, metal parts and working medium (such as gas) in the ball valve. Working medium for gas, gasoline (GB484-89) can be used to clean metal parts. Non-metallic parts with pure water or alcohol cleaning. (5) Disassembled individual parts can be cleaned by dipping. Non-metallic parts that remain undistracted may be cleaned with a clean, fine, silk-dipped detergent cloth (to prevent the fibers from sticking to the parts). Cleaning to remove all adhesion on the wall of grease, dirt, glue, dust and so on. (6) Non-metallic parts should be removed from the cleaning agent immediately after cleaning, not for a long time immersion. (7) After cleaning, it needs to be assembled after the wall surface cleaning agent is volatilized (it can be rubbed with silk cloth without cleaning agent), but it should not be shelved for a long time; otherwise, it will rust and be polluted by dust. (8) New parts also need to be cleaned before assembly. (9) Lubricate with grease. Grease should be ball valve metal materials, rubber parts, plastic parts and working medium are compatible. When the working medium is gas, for example, special 221 grease. Apply a thin layer of grease to the surface of the seal mounting groove and a thin layer of grease on the rubber seal. Apply a thin layer of grease to the sealing and friction surfaces of the valve stem. (10) The assembly should not allow metal debris, fiber, grease (except for the provisions of the use of) dust and other impurities, foreign body pollution, adhesion or stay on the surface of the parts or into the cavity. 2.2 Replacing Stem Packing 40 or 45 Online, Replacing O-rings 56, 112 and External Parts, etc. can be done on the pipeline without removing the valve from the pipeline. Decomposition order according to the different drive device are described below: 2.2.1 Ball valve with handle ─ ─ filler 45 replacement (1) Close the ball valve on the downstream cut-off valve. Deflate the pressure in the pipe before and after the ball valve is deflated. (2) Make the ball valve fully closed. (3) Unscrew the nut 52, remove the washer 75, the wrench head 74 and the handle 47. (4) Unscrew nut 48, remove spring washer 49, stem stopper 66, and packing gland 50. (5) Remove the packing 45. (6) Check the removed parts, if damaged, repair or replacement, the parts clean. (7) Scrub and lubricate stuffing box sealing surface. (8) Load new packing 45. (9) The packing gland 50, the stem stopper 66, the spring washer 49, and the washer 48 are sequentially fastened in the reverse order of disassembly to fasten the above components. (10) Reinstall the wrench head 74 and the handle 47, install the washer 75, and fasten it with the nut 52. (11) Operating handle check ball valve opening and closing flexibility. (12) Air tightness test. 2.2.2 Ball Valve with Gear Box ───────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────────── To deflate the pressure in the pipe before and after the ball valve. (2) Make the ball valve fully closed. (3) Remove the screw 10 and remove the gear box. (4) Unscrew the screw 15 and remove the driver flange 34. (5) Unscrew the nut 48, remove the spring washer 49 and the packing gland 50, and take out the packing 45. (6) Check the removed parts, if damaged, to be repaired or replaced, the parts clean. (7) Clean and lubricate stuffing box sealing surface. (8) Load new packing 45. (9) in accordance with the decomposition of the order of reverse loading packing gland 50, spring washer 49, nut 48 with the above components. Reinstall driver flange 34 and tighten with screws 15. (10) Install the gear box and fasten it with the screw 10. (11) Operate the gearbox to check the opening and closing flexibility of the ball valve. (12) Air tightness test. 2.2.3 Ball Valve with Pneumatic Actuator ── Replacement of Packing 40 and O-rings 56, 112 (1) Close the shut-off valve upstream and downstream of the ball valve. To deflate the pressure in the pipe before and after the ball valve. (2) Make the ball valve fully closed. Remove the pneumatic line. (3) Unscrew the screw 35 and remove the drive and drive flange together. (4) Remove the key 11 on the stem, unscrew the screw 15, remove the packing gland 33 and remove the packing 40. (5) Remove O-rings 56 and 112 from the packing gland. (6) Check the removed parts, if damaged, repair or replacement, the parts clean. (7) Clean and lubricate stuffing box sealing surface and O-ring mounting groove. (8) Insert new packing 40 and install new o-rings 56 and 112. (9) Install the packing gland 33, fasten with the screw 15, install the key 11. (10) Install the driver flange and driver together and secure with the screw 35. (11) Connect the pneumatic line, operate the drive to check the valve opening and closing flexibility. (12) Air tightness test. 2.3 offline maintenance ─ ─ seat 2 replacement, O-ring 6, gasket 39 replacement. Valve seat, ball, stem, valve internal seal replacement and repair of the ball valve must be removed from the pipeline in order to proceed. 2.3.1 Two pairs of fractional ball valve (1) Close the ball valve upstream and downstream of the cut-off valve, deflate the ball valve before and after the pressure in the pipeline. (2) Close the ball valve so that it is fully closed. If the pneumatic device-driven, remove the pneumatic line. (3) The valve removed from the pipeline, flip placed so that the valve body 26 up. (4) Unscrew the nut 8, remove the valve body 26. (5) Remove the valve seat 2 and the O-ring 63. (6) Remove the O-ring 6 and the gasket 39 from the valve body 26. (7) Remove the ball 3. (8) Remove the seat 2 and the O-ring 63 at the other end. (9) Check the valve body (1), ball 3 and valve body 26, if damaged to be repaired, the parts clean. (10) Lubricate the valve seat installation surface and each seal installation groove. (11) Install the new O-ring 6 and gasket 39 into the mounting groove of the valve body. (12) Install the O-ring 63 into the valve seat 2 in advance and insert the valve seat 2 into the valve body 1 and the valve body connector body 26. (13) Insert the ball 3 into the body 1 and fit the stem 4 into the groove on the ball. (14) Install the valve body 26 on the valve body 1 and fasten it with the nut 8. (15) Install the pneumatic line (pneumatic actuator driven ball valve) and operate the drive to check valve opening and closing flexibility. (16) Air tightness test. (17) installed on the pipeline, according to pipeline requirements for gas tightness test. 2.3.2 Three-piece ball valve (1) Close the ball valve upstream and downstream of the cut-off valve, deflate the ball valve before and after the pressure in the pipeline. (2) close the ball valve to be in the fully closed state. (3) The valve removed from the pipeline, flip placed so that one end of the valve body 26 up. (4) Unscrew the nut 8, remove the valve body 26. (5) Remove the valve seat 2, spring 20, O-ring 17. (6) Remove the O-ring 6 and the gasket 39 from the valve body 26. (7) Remove the ball 3. (8) Turn the other end of the valve body connector body 26 upwards, and then remove the other parts according to the order of (4) ~ (6). (9) Check the valve body 1, ball 3, valve body 26, if damaged to be repaired. Clean the parts. (10) Lubricate the valve seat mounting surface and the seal mounting groove, install the new O-ring 6 and gasket 39 into the mounting groove of the valve body 26. (11) Install the new o-ring 17 in the new seat 2 and place the spring 20 in the relevant position. (12) First ball 3 into the body 1, the stem 4 must be fitted ball 3 of the groove. Turn valve stem 4 90 ° to open the valve. Place the valve seat 2 on the ball and then insert the valve body 26 onto the stud 7 and insert the valve body 26 into the valve body 1 with the valve seat 2 inserted exactly into the valve body 26. (13) into the other end of the valve seat 2 and valve body 26 by the method (12). (14) Tighten the nut 8. (15) Operate the drive to check valve opening and closing flexibility. (16) Air tightness test. (17) installed on the pipeline, according to pipeline requirements for gas tightness test. 2.4 offline maintenance ─ ─ a comprehensive breakdown of the ball valve, O-ring 21 and the thrust washer 31 replacement. (1) Remove the ball valve according to section 2.3 for decomposition. (2) Disassemble according to Section 2.2. (3) Remove the stem 4 and remove the thrust washer 31 and O-ring 21. (4) Check the parts, if damaged to be repaired, the parts clean. (5) Lubrication of the sealing surface, the valve stem coated with a thin layer of grease. (6) Install a new O-ring 21 and thrust washer 31, install the valve stem. (7) Assemble according to Section 2.2. (8) Assemble according to section 2.3. (9) Operate the drive to check valve opening and closing flexibility. (10) air tightness test. (11) Install the pipeline, according to the pipeline requirements for gas tightness test. 2.5 Air tightness test 2.5.1 The air tightness test on the removed ball valve. (1) The valve is half open. Seal both ends of the ball with a flanged cover with a pipe fitting. (2) Introduce the test medium to one end with clean nitrogen or air. The other end of the pipe fittings blocked. Gradually pressurized to 5.6bar after closing the intake valve to stop the intake. (3) Close the ball valve by turning the ball a few times (operating the drive). (4) Open the pipe plug of the other end (without introducing the test gas end) to reduce the pressure in the chamber to atmospheric pressure. (5) Under the test pressure (5.6bar), the pressure in the air inlet chamber shall not decrease within more than 5min. The pressure gauge used should be 0.4 level, range 10bar. (6) At the same time with soapy water to check the connection flange parts and packing parts of the external leakage, may not have an ever-increasing bubble. (7) Then introduce the test medium from the other end and repeat the above test. (8) After passing the test, purge the soapy water residue with compressed air. Remove both ends of the flange cover, clear the sealing surface of both ends of the ball valve seal residual, if any residual into the valve hole should be cleaned and scrubbed. 2.5.2 online seal test (1) to identify the test ball valve, the downstream cut-off valve is closed. (2) The ball valve to be tested in a semi-open state. (3) Introduce the test medium to the pipe in front of the ball valve under test, and gradually purge the test medium with clean nitrogen to 5.6 bar and close the inlet valve to stop the intake air. (4) Turn the ball several times after turning the ball (operate the drive). (5) Open the deflation valve on the pipe downstream of the tested ball valve to make the ball valve outlet cavity pressure be the atmospheric pressure. (6) Under the test pressure (5.6bar), the pressure of the air inlet chamber shall not decrease during the period of more than 15min. The pressure gauge used shall be 0.4 level with the measuring range of 10bar. (7) At the same time with soapy water to check the external leakage of the connection flange parts and packing parts, there must be no growing bubbles. (8) Then introduce the test medium into the pipe of the tested ball valve and repeat the above test. (9) After passing the test, purge the soapy water residue with compressed air.