1Cast steel globe valveInstallation phase: Standardized operation, laying a foundation for safety

Position selection and direction confirmation

Valves should be installed in locations that are easy to operate and maintain, avoiding obstruction or high temperature, humid environments.

The flow direction of the medium should be consistent with the direction of the arrow on the valve body to prevent sealing failure caused by reverse pressure.

Case: A chemical plant caused a leakage accident due to the reverse installation of valves, resulting in the erosion of the sealing surface by the medium.

Connection and fixing requirements

When connecting flanges, ensure that the gaskets are intact and the bolts are symmetrically tightened to avoid leakage.

The connection between the valve stem and the valve cover needs to be coated with sealing grease to prevent medium leakage.

Data: Statistics show that 30% of valve failures are caused by loose connections.

Pre-installation check

Confirm that the valve model, pressure rating, and pipeline match.

Check the valve stem and disc for cracks or damage, and ensure that the operating mechanism is flexible.

Tool: Use a pressure tester to verify valve sealing.

2、 Operation stage: Standardize actions to avoid human damage

Opening and closing specifications

Manual valve: Slowly rotate the handwheel to avoid excessive force causing the valve stem to bend or the sealing surface to be damaged.

Electric/pneumatic valves: By adjusting the opening and closing speed through the control system, water hammer effects can be prevented.

Taboo: It is strictly prohibited to use force rods for forced operation, otherwise it may cause valve body rupture.

Operating environment and protection

Operators need to wear protective gloves and glasses to prevent medium splashing.

In rainy or snowy weather or extreme temperatures, anti slip and anti freezing measures should be taken.

Case: A certain power plant suffered burns due to the spraying of high-temperature steam during operation without wearing protective equipment.

exception handling

When encountering blockages, leaks, or abnormal noise, immediately stop operation and investigate the cause.

Step: Close the upstream and downstream valves → Release pressure → Check the sealing surface/valve stem → Replace damaged parts.

3、 Maintenance phase: Regular maintenance to extend service life

Daily inspection content

Appearance: The valve body is free of rust and leakage, and the handwheel/drive device is intact.

Sealing: After closing the valve, check the downstream pressure gauge or observe for any dripping at the valve stem packing box.

Operation check: Manually open and close 1/4 stroke, feel if there is any jamming.

Regular maintenance plan

Lubrication: Add lithium based grease to the valve stem threads and packing box every 2-3 weeks.

Cleaning: Clean the surface dust of the valve body every month and check if the handwheel bolts are loose.

Seal inspection: Replace aging sealing gaskets every 3-6 months.

Data: Regular maintenance can extend the lifespan of valves by over 40%.

Maintenance under special working conditions

High temperature/high pressure environment: Shorten the inspection cycle of seals and select high temperature resistant materials (such as Stellite alloy).

Containing particulate media: Add a filter screen and regularly clean impurities from the valve disc and seat.

Corrosive medium: The sealing surface is made of welded hard alloy and coated with anti rust paint on the outside.

4、 Troubleshooting and Emergency Response

Common faults and solutions

Internal leakage: impurity blockage → clean the pipeline and install a filter; Seal surface erosion → Replace erosion resistant valve disc.

Leakage: Worn packing → Replace packing; Ripple tube rupture - choose double-layer 316L stainless steel corrugated tube.

Difficulty in operation: rusting of valve stem → application of anti rust oil; Drive device malfunction → Check power/air source.

Emergency Response Plan

When there is a leak, immediately close the upstream and downstream valves and set up a warning area.

Activate the emergency shutdown system under fire or explosion risk conditions.

Tools: Equipped with explosion-proof tools, fire-fighting equipment, and emergency lighting.

5Cast steel globe valvePersonnel training and safety awareness

Qualification Requirements

Operators need to receive professional training and be familiar with valve performance, structure, and operating procedures.

Case: An enterprise caused an overpressure explosion accident due to failure to train employees to operate valves.

Safety records and improvements

Record data such as operation time, valve opening, flow rate, etc.

Regularly analyze the causes of faults, optimize maintenance cycles and operational processes.

Tool: Use a digital management system to track the entire lifecycle of valves.