How to install and repair ball valves

1.Pre-installation

Before the installation of the ball valve should ensure that the valve before and after the pipeline is intact, before and after the pipeline should be coaxial, with two flange sealing surfaces parallel, the pipeline should be able to support the weight of the ball valve, if not, it should be appropriate support. Clean up before and after the pipeline, and remove oil, welding slag, and other impurities.

Check the ball valve markings to ensure that the ball valve is intact. Repeatedly operate the ball valve fully open and fully closed several times to confirm that the ball valve is working properly. This step is very important. Then remove the protective caps on the flanges at both ends of the ball valve, check and clean the valve ports, and remove any debris.

2. Cutting pipes

Use a tube cutter to cut copper tubing in the desired location. Make sure the cut is straight and clean for proper sealing. Rotate the pipe cutter around the pipe and tighten after each revolution until the pipe is cut through.

3.Deburring the Pipe

After cutting the pipe, use a deburring tool to remove any burrs or rough edges on the inside and outside of the pipe. This step is important to prevent damage to the internal parts of the valve and to ensure a smooth installation.

4. Installation of ball valves

Mount the valve on the pipeline, making sure that either end of the valve can be mounted on the upstream side. Valves with handle actuation can be mounted anywhere in the pipeline, while ball valves with gearboxes or pneumatic actuators should be mounted upright on horizontal piping with the actuator located above the pipeline. Install a sealing gasket between the valve flange and the pipe flange as required by the piping desig

If using push-on connectors, simply push the pipe into the fitting until it snaps into place. For threaded connections, wrap thread sealing tape around the male threads of the pipe before screwing the valve onto the pipe to ensure an airtight seal.。

5. Fastening and sealing

If using push-on connectors, simply push the pipe into the fitting until it snaps into place. For threaded connections, wrap thread sealing tape around the male threads of the pipe before screwing the valve onto the pipe to ensure an airtight seal.。

6.Post-installation inspection

After installation, operate the actuator to open and close the ball valve several times (make sure to operate it several times to prevent operation error) to ensure smooth and unobstructed operation. Check the sealing performance of the flange bonding surface between the pipeline and the ball valve according to the pipeline design requirements.

Ensure that the upstream and downstream lines of the ball valve are relieved of pressure before performing any disassembly operations. When disassembling and reassembling, use caution to prevent damage to parts, especially the sealing surfaces of non-metallic parts. Use special tools when disassembling O-rings. Clean valve components with appropriate cleaning agents compatible with rubber parts, plastic parts, metal parts, and the working medium (e.g., gas).

For gas applications, use gasoline (GB484-89) to clean metal parts and water or alcohol to clean non-metallic parts. Clean individual parts by immersion and non-metallic parts with a clean, fine cloth. After cleaning, allow the cleaner to evaporate before assembling the parts.

New parts should be cleaned before assembly. Use grease that is compatible with the ball valve's metal materials, rubber parts, plastic parts, and working medium. Apply a thin layer of grease to the seal grooves, rubber sealing surfaces, and friction surfaces of the valve stem. When reassembling, tighten the bolts on the flange symmetrically, gradually, and evenly. Ensure that no metal fragments, fibers, grease (except for special applications), dust, or other contaminants are contaminated or left on the parts.

A well-maintained ball valve extends its service life and, in a way, saves money for the business or individual.

Assembly and testing after repair:

Stacking the fittings: accurately align and assemble the valve components.

Bolting: secure parts with bolts, ensuring symmetrical and even tightening.

Labeling: Properly record valve repair information for identification and traceability.

Pressure Test: Perform a pressure test to ensure the valve will function properly under operating conditions.

O2 Cleaning (if applicable): Clean valve components with an oxygen-compatible cleaner to remove any contaminants that may react with oxygen. Avoid unnecessary hazards from these residual contaminants

Installing and maintaining ball valves requires careful attention to detail and adherence to proper procedures. By following the steps outlined in this guide, you can ensure a reliable and efficient piping setup and extend the life and performance of your ball valve. Regular inspection and maintenance are also essential to keep your system running optimally.

Bestflow has been designed with absolute customer confidence in mind, from the selection of raw materials to superb engineering. The high quality industrial ball valves produced by Bestflow are also sold to more than 50 countries around the world and have been well received. Trust Bestflow, you will get the best experience!