In high-tech fields such as semiconductor manufacturing and vacuum coating, vacuum valves serve as the first line of defense for maintaining a vacuum environment. However, poor installation can cause top-notch equipment to malfunction instantly. From sealing surface treatment to torque control, any oversight in details could lead to a sharp increase in leakage rates and system crashes. This article, based on the practical experience of ZhenChao vacuum valves, dissects six fatal installation errors and teaches you how to avoid these pitfalls at the source, ensuring the stable operation of the vacuum system without any accidents.
Vacuum valves are specialized control valves designed for vacuum systems.They are the core components that maintain the vacuum environment of the system.Their main functions include on-off control, pressure regulation, and isolation protection.Additionally,in extremely demanding scenarios such as high vacuum and ultra-high vacuum,vacuum valves can reduce leakage rates,ensuring that the system remains in a stable vacuum state for a long time,meeting the special process requirements of fields like semiconductor manufacturing, vacuum coating,and aerospace simulation.
The vacuum valve operates by the interaction between the closure element and the valve seat. When an opening signal is received, the driving device moves the valve stem. The closure element rises or rotates, opening the passage and allowing the medium to flow. Upon receiving a closing signal, the closure element immediately seals against the valve seat. The sealing surfaces are tightly fitted, blocking the passage. Due to the special nature of vacuum conditions, metal or high vacuum rubber is used for sealing, with the leakage rate minimized. Some models come with a feedback device, which provides real-time monitoring and automatic adjustment, ensuring stable vacuum levels.
Mistake:Ignoring the cleaning and grinding of the valve seat and flange contact surfaces before installation is a frequent hazard.Oil stains adhering to them will directly damage the integrity of the sealing surface.Even if subsequent sealing measures are in place,there is a high likelihood of micro-leaks.What is even more overlooked is the failure to meet the surface roughness requirements.If it is too rough,it can cause impurities to get stuck,and if it is too fine,it will affect the fit of the sealing parts.
Solution:First,thoroughly wipe the contact surfaces with anhydrous ethanol to remove oil stains and floating dust.Then,lightly sand the oxide layer with fine sandpaper to ensure there are no scratches or protrusions on the surface.Finally,check that the surface roughness meets the requirements specified in the valve manual.If necessary,apply a special sealing aid to prevent the residue of impurities from causing sealing failure and avoid leakage risks at the source.
Mistake:The tightening of bolts is entirely based on experience. Either they are tightened too tightly or too loosely, both of which carry risks. When the torque is insufficient, the force on the flange joint surface is uneven, and in a vacuum environment, it is prone to produce gaps, leading to leakage.If the torque is too large, it is even more fatal. It will squeeze and deform the sealing parts,and even damage the valve flange,causing irreversible damage.
Solution: A torque wrench must be used. Operate strictly according to the torque values marked in the valve manual.Follow the diagonal alternate tightening principle,add force gradually in multiple steps instead of tightening all at once.After tightening, check again to ensure that each bolt is evenly stressed. This not only ensures the required pressure for sealing but also does not exceed the limit of the components, avoiding chain reactions caused by brute force operation.
Mistake:During installation, forcefully aligning the valve with the pipeline while ignoring the coaxiality deviation is a hidden error. The deviation of the center axes of the pipeline and the valve will cause uneven force on the internal components of the valve, resulting in jamming.In severe cases, it may even cause local excessive force on the flange sealing surface, leading to cracks or sealing failure. Some installers, in an attempt to save time, use brute force to correct the alignment, which instead exacerbates the deformation of the components.
Solution: Before installation, calibrate the coaxiality between the pipeline and the valve, and use a level gauge and a micrometer to assist in positioning. If there is a deviation, correct it by adjusting the position of the pipeline support instead of forcefully aligning. After alignment, manually rotate the valve to confirm that there is no jamming or offset, and then proceed with the subsequent fixation to avoid operational failures caused by the axis deviation.
Mistake:The vacuum valve itself has a certain weight. Without proper support, the pipeline will bear additional load, causing the pipeline to deform, the interface to loosen, and subsequently leading to leakage.Especially for large vacuum valves, the weight is concentrated at the interface, which will also affect the accuracy of the valve core inside the valve, resulting in poor operation.
Solution: According to the valve specifications and weight, install corresponding supports or hangers to ensure that the valve’s weight is evenly distributed and does not transfer to the pipeline interface. The installation of the supports must be firm, and buffer pads should be added at the contact area with the valve to reduce the impact of vibration on the valve. Regularly check the status of the supports during operation to prevent loosening or deformation, and ensure that the valve is always in a stable force-bearing state.
Mistake:Some installers use ordinary washers in combination with vacuum-specific washers. Ordinary washers tend to age and deform in a vacuum environment, losing their sealing performance. What’s more serious is that the material of the washer reacts with the medium, polluting the medium and corroding the washer, leading to sealing failure and even damaging the valve components.
Solution: Select washers strictly based on the medium type, working pressure, and temperature range of the vacuum system. Preferentially use vacuum-specific washers to ensure material compatibility and meet sealing performance standards. Before installation, inspect the appearance of the washers for no damage, no aging, precise matching of size with the flange interface, and avoid potential sealing problems caused by washer issues.
Mistake:Many micro-leaks are difficult to detect initially. After being put into operation, as the working conditions change, the leakage volume will gradually increase, affecting the system’s vacuum degree and reducing the equipment’s operational efficiency. In severe cases, it may also cause medium loss, pollution, and even trigger safety accidents. The difficulty of locating the leakage points in the subsequent investigation is much greater than the testing during installation.
Solution: After installation, a special leakage test must be conducted. The helium mass spectrometry leak detection method or the pressure holding method is commonly used. Gradually increase the system pressure and conduct segmented detection of key parts such as valve interfaces and sealing surfaces. Immediately stop the machine and handle the leakage point upon discovery. After rectification, conduct another test until there is no leakage at all. Only after confirmation of qualification can it be put into operation, and prevent starting with hidden dangers.
Pre-installation inspection is the key to preventing faults before they occur. First, check the valve model and specification to ensure they match the system conditions and pipe dimensions, and avoid mismatched rework. Then, check that the valve body has no cracks, the sealing surface has no scratches, and the valve core operates smoothly. The accessories must be complete and undamaged, and the torque wrench and leak detection equipment should be ready. Clean the installation environment, removing dust and oil stains, and reserve maintenance space. Check each point carefully, not neglecting details, to avoid subsequent troubles caused by previous oversights.
Step-by-step installation is the core of quality. First, pre-process the contact surfaces, clean, sand, and calibrate the roughness. Then, precisely align the valve with the pipeline, calibrate the coaxiality, and strictly prohibit forceful connection. Test the valve core to confirm there is no jamming. According to the torque standard, alternately tighten the bolts diagonally in turns, and apply force incrementally. Install special supports to distribute the weight. Finally, conduct sectional leak testing. Do not skip steps or simplify procedures. Each step must be well executed to ensure the stability of the valve operation.
Zhengchao vacuum valves are designed with ease of installation as the core principle. They adopt a quick-connect clamp structure, requiring no complex tools and allowing for quick disassembly and assembly, saving time. The valve body is compact, suitable for narrow spaces, and the coaxiality is preset precisely, reducing the hassle of alignment and calibration. An anti-loosening device is built-in, along with a dedicated sealing component, preventing leakage caused by installation errors. The stainless steel material is corrosion-resistant, and the sealing surface is precisely processed, significantly reducing the failure rate after installation and meeting the needs of various working conditions.
Zhenchao offers full-cycle technical support and breaks through the barriers of after-sales service. It comes with detailed installation manuals, precisely marking torque and compatible parameters, making it easy for beginners to operate. Exclusive engineers provide online answers to questions, promptly solving installation problems. It offers customized solutions to meet special working conditions. It also comes with maintenance tutorials and a parts list, providing a basis for later maintenance. From selection to operation and maintenance, all resources are fully equipped, making installation and maintenance more worry-free.
Every step of the installation of a vacuum valve determines the life and death of the system. The six pitfalls summarized in this article are the deep practical experience accumulated by ZhenChao in serving customers worldwide. ZhenChao’s vacuum valves offer a user-friendly design and professional technical support, making complex installations simple. Choosing ZhenChao not only allows you to avoid 90% of installation risks, but also ensures that your vacuum system is worry-free from installation to operation and maintenance. Want your production line to be stable and efficient? Start by choosing ZhenChao’s vacuum valves.
A: The sealing surface is not properly treated. Residual oil stains and substandard roughness directly cause micro-leaks.
Q2: Is it better to tighten the torque as much as possible?
A: No. Excessive torque can easily damage the sealing parts, while too little torque will result in poor sealing. The torque must be tightened diagonally alternately according to the manual values.
Q3: What should be done if the valve and the pipeline are not aligned?
A: It is strictly forbidden to forcibly align them. The pipeline position needs to be adjusted, and the coaxiality must be calibrated using a level gauge to prevent the valve parts from getting stuck or the sealing surface from being damaged.
Q4: Does a vacuum valve require additional support?
A: Yes. Especially for large-diameter valves, their own weight can pull the pipeline and cause deformation, so a special support must be installed to disperse the stress.
Q5: Can ordinary gaskets be used for vacuum valves?
A: No. Ordinary gaskets tend to age and deform in a vacuum environment. Only vacuum-specific gaskets must be used to ensure material compatibility.
Q6: Must a leak test be conducted after installation?
A: Yes. Helium mass spectrometry leak testing or pressure retention testing are crucial. They can detect micro-leaks in advance and prevent potential hazards after system operation.
Q7: What are the installation advantages of ZhenChao vacuum valves?
A: They adopt a quick-fit clamp structure, requiring no complex tools. They come with anti-loosening design and precise coaxiality, significantly reducing the error rate during installation.
Q8: What checks should be done before installation?
A: Verify the valve model, check for no scratches on the sealing surface, prepare torque wrenches and leak detection equipment, and clean the installation environment.
Q9: How often should a vacuum valve be rechecked after installation?
A: It should be rechecked once or twice after the first operation. During regular maintenance, focus on checking the torque and sealing condition.
Q10: What pitfalls are prone to be overlooked when installing a vacuum valve by beginners?
A: Ignore surface cleaning, rely on experience to tighten the torque, and skip the leak test. Choosing the right ZhenChao valve can avoid most risks.
