I. Pneumatic Butterfly Valve Installation Manual
1. Pre-installation Inspection and Preparation
Before installation, ensure that the pneumatic butterfly valve has passed strict factory testing and quality checks. Whether it is a manual, pneumatic, hydraulic, or electric valve, the valve undergoes rigorous testing for sealing performance and operational reliability before shipment.
Steps:
● Sealing Performance Check: Before installation, the user should recheck the sealing performance of the pneumatic butterfly valve. To do this, both the inlet and outlet should be securely fixed, and the valve should be closed. Then, apply pressure to the inlet side and observe the outlet side for any leakage. At this stage, the valve should be fully closed.
● Operation Before Strength Testing: Prior to performing strength tests on the pipeline, ensure that the valve disc is fully opened to prevent any damage to the sealing surfaces.
2. Adjustment of Equipment During Installation
Although the pneumatic butterfly valve’s drive unit is factory-tested, vibrations or improper handling during transportation may cause some screws to loosen or misalign. Therefore, before installation, the user should check the drive unit and adjust the pneumatic, hydraulic, or electric components as necessary, according to the instructions provided with the drive unit.
●Drive Unit Adjustment: If the valve uses pneumatic or hydraulic actuation, verify that the actuator’s air or fluid supply pressure matches the system requirements and ensure all connections are correct
●Re-adjustment: If any deviations in the adjustment are found due to transport or handling, perform re-adjustment to ensure the valve opens and closes smoothly.
3. Electric Valve Wiring and Commissioning
Electric actuated butterfly valves are usually calibrated for their opening and closing strokes before shipment. However, when first powering the valve, the user must ensure that the electrical wiring is correctly connected. To avoid wiring errors, follow these steps during the initial power-up:
●Manual Adjustment: Upon first powering up, manually open the valve to the half-open position.
●Check Electric Actuator: Then, press the electric switch and observe whether the valve’s opening and closing direction aligns with the direction indicated on the actuator. If there is any misalignment, adjust the actuator control to match the valve’s opening and closing direction.
4. Installation Position
The installation position of the pneumatic butterfly valve directly affects its lifespan and performance. For optimal performance, it is recommended to install the pneumatic butterfly valve in the middle section of the pipeline, with the valve positioned vertically. Do not install it upside down, as this could cause operational issues.
●Optimal Installation Position: The best installation position is vertical(standing up).
●Avoid Inverted Installation: Installing the valve upside down may reduce sealing performance and cause other operational failures.
II. Common Faults and Troubleshooting for Pneumatic Butterfly Valves
While pneumatic butterfly valves undergo strict factory testing, various issues can still arise during operation due to environmental factors or differing media. Below are common problems and troubleshooting methods for pneumatic butterfly valves.
1. Incorrect Flow Direction
Pneumatic butterfly valves are usually marked with a flow direction arrow. If the valve is installed with the flow direction arrow facing the wrong way, the valve will not operate as expected. Therefore, it is important to confirm that the valve’s flow direction arrow matches the actual flow direction of the media.
●Solution: Carefully check that the flow direction arrow on the valve matches the flow direction of the media in the pipeline. If there is a mismatch, adjust the valve’s installation to ensure the flow direction aligns.
2. Contamination of Disc and Seals
While the valve’s sealing surfaces are cleaned at the factory, debris or foreign objects may enter the valve during transportation or installation. If dirt or debris accumulates on the sealing surfaces or disc, it can cause sealing failure or prevent the valve from closing properly.
●Solution: Prior to installation, thoroughly clean the internal cavity of the valve, paying special attention to the sealing surfaces and disc. Only close the valve after it is fully cleaned to avoid damaging the seals.
3. Improper Valve Installation Position
The installation position of the pneumatic butterfly valve significantly affects its opening and closing function. If installed incorrectly, the valve may not open or close properly, which can negatively impact fluid control and flow regulation.
●Solution: Ensure the pneumatic butterfly valve is installed in the vertical Avoid installing the valve at the end of the pipeline. If installation at the pipeline’s end is necessary, install an outlet flange to prevent over-compression of the sealing ring.
4. Poor Lubrication of the Valve
For butterfly valves that frequently open and close, the internal lubrication system (such as the worm gear box) requires regular maintenance. If the lubrication oil is insufficient or of poor quality, the valve may not operate smoothly, leading to malfunctions or even damage.
●Solution: Periodically check the lubrication oil level in the worm gear box. If necessary, add appropriate grease to ensure smooth valve operation. For valves that have been idle for an extended period, re-lubricate them before use to ensure optimal performance.
5. Valve Not Closing Properly or Leaking
If the valve does not seal properly when closed, it may be due to worn seals, a damaged stem, or a problem with the sealing surface. This can lead to leakage or the inability to fully shut the valve.
●Solution: Regularly inspect the seal and stem areas to ensure tight seals. Check all connection points to ensure they are properly tightened, and verify that the valve stem can rotate freely. If leakage persists, replace the seals or adjust the packing gland to ensure a proper seal.
6. Issues with Metal-Seated Butterfly Valve Installation
Metal-seated butterfly valves are not recommended for installation at the end of the pipeline, as the sealing ring may be over-compressed, leading to poor sealing performance.
●Solution: If it is necessary to install a metal-seated butterfly valve at the pipeline’s end, ensure that an outlet flange is installed to prevent over-compression of the sealing ring and avoid damage to the seal.
III. Regular Maintenance and Care
Regular maintenance and care are crucial for prolonging the life and ensuring the reliable performance of pneumatic butterfly valves. Below are some common maintenance recommendations:
●Routine Inspections: Inspect all components of the pneumatic butterfly valve, including the actuator, valve body, seals, and stem, at regular intervals.
●Seal Replacement: If seals show signs of wear or aging, replace them promptly.
●Lubrication Maintenance: Ensure sufficient lubrication oil is present to prevent valve sticking during operation.
●Valve Cleaning: Periodically clean the internal cavity of the valve to prevent dust or other debris from accumulating.
By following the detailed installation, commissioning, and troubleshooting guidelines above, you will be able to ensure the proper operation of your pneumatic butterfly valve. Correct installation and regular maintenance not only extend the valve’s service life but also enhance the overall stability of your system. If you have any questions or require further technical assistance, please feel free to contact us. We are always here to help!
