The vacuum valve is the”throat”of the vacuum system,which controls the flow of the medium and maintains stable pressure.Its lifespan directly affects the efficiency of system operation, whether production can be continuous,and how much maintenance costs.In industrial sites, when vacuum valves fail,it is often not due to poor product quality,but rather a long-term lack of proper maintenance.Failure to lubricate properly or repair a small leak in a timely manner can accelerate valve wear,lead to direct failure,and even cause the entire equipment to shut down. This article breaks down the 6 core maintenance steps for extending the lifespan of vacuum valves,avoiding common pitfalls and guarding the first line of defense in production.
A vacuum valve is a specialized valve used in a vacuum system to regulate flow,cut off pipelines, and connect media.The core task is two-fold:to stabilize the system seal at different vacuum levels,while also controlling the pressure to prevent external air from entering and the medium from leaking out.Compared to ordinary valves,it has extremely high requirements for sealing and materials.
According to structure and purpose,there are four main types of vacuum valves.The gate valve is well sealed and commonly used for cutting media in high vacuum systems,but it opens and closes slowly.Butterfly valves are small in size,have fast response,and are suitable for adjusting flow rates at low to medium vacuum levels.Ball valves have a large diameter,low resistance,and are easy to use in corrosive media environments.Maintenance is also not expensive.Electromagnetic valves rely on electromagnetic force to switch,with a high degree of automation,and are ubiquitous in precision equipment with high-frequency on-off.Valve selection cannot be made blindly,it depends on the vacuum level,the characteristics of the medium,and how frequently it is used under working conditions.Choosing the right one will save effort in subsequent maintenance.
Inspection is the first step in maintenance,and cleaning is fundamental to extending lifespan. Check the appearance at least once a week:whether the valve body is deformed,rusted, scratched,and whether the connecting bolts are loose.Conduct a deep cleaning once a month: thoroughly remove residual media,dust,and impurities from key areas such as valve seats,valve cores,and sealing surfaces.Use the right solvent for cleaning,do not corrode the seals and valve body;When blowing with high-pressure air,the pressure should be controlled well and impurities should not be blown into the gaps of the sealing surface.For workshops with high cleanliness such as semiconductor and pharmaceutical,the cleaning cycle needs to be shortened.When wiping,a dust-free cloth must be used to prevent any secondary pollution.
Lubrication is never better with more.Choose specialized vacuum grease or lubricating oil based on valve type,operating temperature,and medium characteristics.Different brands and models must not be mixed together.Check the lubrication status once a month:if the grease dries, changes color,or clumps,the old oil must be thoroughly wiped off and a new one must be applied. When applying, just apply a thin layer that can cover the moving contact surface.
Sealing is the lifeblood of vacuum valves, and small leaks must be detected and dealt with early. Test the sealing performance once every quarter.Before testing,clean the system thoroughly and stabilize the pressure;After testing,record the data and compare it with the previous values to see if there are any changes.Those frequently used vacuum valves should be tested once a month to prevent small leaks from turning into major malfunctions.
Valve core,valve stem,and actuator are the moving parts that are most prone to wear and tear. Check if the valve stem is flexible every month:whether there is any jamming or abnormal noise. If it gets stuck,first check if there are impurities blocking or if the lubrication is not in place.Never forcefully break or twist it.Disassemble every six months and check if the valve core and seat are tightly attached.If there is wear or scratches,quickly grind and repair them.If they cannot be repaired,replace them directly.The maintenance of actuators should be divided into mechanical and electrical aspects:pneumatic inspection should check whether the air pressure is stable, electric inspection should check whether the circuit is firmly connected,and motor rotation should be normal.Only when the actuator is functioning properly can the valve’s opening and closing commands be transmitted to the position,so that the valve body will not be affected by the actuator’s failure.
The environment in which the vacuum valve is placed directly determines whether it ages quickly or not.Do not install valves in high temperature,humid,dusty,or corrosive gas rich areas.If there’s really nothing we can do,we need to install protective covers,dehumidifiers,and dust collectors. Valves installed outdoors should be well protected from sunlight and freezing;Before use in low-temperature weather,preheat the valve body to prevent it from freezing and cracking.The workshop should be well ventilated to reduce the corrosion of the valve body caused by residual media;It is also necessary to avoid transmitting equipment vibration to the valve,otherwise the bolts are prone to loosening and the seal is prone to failure.
Maintaining records is not just a formality,but a good helper for predicting faults and optimizing processes.Create a dedicated ledger for each valve:record the time,data,who did it,and how it was handled for each inspection,cleaning,lubrication,and testing.Turn over the account every quarter,analyze and analyze the relationship between wear rules,leakage frequency and working conditions,and then adjust the maintenance cycle and methods.
This is the easiest mistake to make,and many people think that ‘applying more oil is always right’. Excessive application of lubricating grease can cause it to overflow,adhere to dust and impurities, and turn into sludge.These oil sludge will dirty the sealing surface,block the valve port,and accelerate the aging of the seals,making the valve core more prone to jamming.What’s even more troublesome is that once the seal is contaminated,it can’t be cleaned thoroughly and can only be replaced,resulting in a sudden increase in maintenance costs.Remember to apply and select the right oil as needed,and strictly follow the dosage instructions in the product manual.
At the beginning,small leaks have little impact on the system and are easily overlooked.But over time,the leakage point will become larger and larger as the medium rushes,the system vacuum will slowly decrease,and energy consumption will also soar.What’s even more dangerous is that leaks may mix different media together,which can easily lead to safety accidents when exposed to flammable and explosive working conditions.In the end,the entire vacuum system will have to be shut down for maintenance.No matter how small the leak is,as long as it is found,we must immediately find the location and fix it quickly. We must never have a lucky mentality.
Improper operation is the human cause of valve body damage.When opening and closing the valve,if the force is too strong or the speed is too fast,the valve core and seat will collide fiercely, the sealing surface will be damaged,and the valve body may also deform;Not preheating or cooling as required,directly opening and closing the valve, the temperature difference will cause the valve body material to crack;Manually breaking the actuator of an automated valve can easily damage the gears and motors inside.Standardized operation is a prerequisite for maintenance, and pre job training must be provided to operators to clearly explain the switch process and taboos that cannot be touched.
In the vacuum coating workshop of a semiconductor wafer factory,several vacuum gate valves always fail to seal,and they break down in less than 6 months on average.The production line often stops,resulting in significant losses.The technicians conducted a thorough investigation and found that the problem lies in cleaning and lubrication:there is a lot of dust in the workshop, which was not cleaned up in a timely manner,and impurities have entered the sealing surface; Also mixed with ordinary lubricating grease,the grease deteriorates at high temperatures,and the valve core wears out quickly.Later,there were two dust-free cleaning sessions per week,and specialized high-temperature vacuum lubricating grease was replaced.A ledger was established and reviewed monthly.
A factory that produces vacuum coating equipment has received feedback from a customer that the accompanying vacuum butterfly valve has been stuck for one year and cannot function properly.The technical team from the factory went to the customer’s site to take a look,and the reason was very obvious:the operator applied too much lubricating grease,and coupled with the high humidity in the workshop,the grease absorbed water vapor and dust,turning into sludge that blocked the valve stem;The place where the valve is installed is not dehumidified,and there is some rust inside the valve body.The final solution provided is to fix the amount of lubricating grease,install a dehumidifier,and change the maintenance cycle to check lubrication once a month and seal once a quarter.
The vibration ultra vacuum valve truly understands the needs of industrial sites.Disassembling and repairing valves does not require complex tools,greatly saving maintenance time and difficulty.Valve cores,seals,and other vulnerable parts are all produced in a standardized manner, making them easy to replace and ensuring compatibility;The surface of the valve body is sprayed with anti-corrosion coating,which is wear-resistant and easy to clean,requiring less effort in daily maintenance.For frequently used working conditions,the structure of moving parts has also been optimized,with better wear resistance and longer maintenance intervals,making it particularly suitable for efficient production in factories.
Reliability is the foundation of vibration ultra vacuum valves.The valve body is made of high-quality materials such as stainless steel and Hastelloy.Before leaving the factory,it undergoes several rounds of vacuum degree,sealing,and temperature resistance tests to ensure that it can be used under various working conditions and can last for a long time.The after-sales team responds quickly,not only providing on-site maintenance but also offering maintenance training to the factory staff.From purchasing valves to using them,there is support throughout the entire process,solving the pain points of the factory’s operation and maintenance,ensuring that the equipment can operate stably all the time.
Extending the lifespan of a vacuum valve does not rely on one step being done well,but on scientific maintenance,standardized operation,and selecting the right product.All three are indispensable.These 6 maintenance steps may seem troublesome,but they are actually the key to saving money.Not valuing maintenance may seem like saving labor and time,but in the end,it requires spending more money on valve replacement,equipment repair,and bearing the losses of production stoppage.Choosing the right valve is the foundation,and maintaining it well is the core.Only by making maintenance a daily habit,avoiding common operational errors,and paying close attention to every detail,can vacuum valves truly play a role and hold the “throat” of industrial production.Ultimately,maintenance is not about spending money, it’s about monitoring production efficiency and costs.
Q1:Can the lubrication cycle of the vacuum valve be adjusted according to the working conditions?
A:Okay.High frequency opening and closing, high temperature conditions need to be shortened to once a month, and medium low frequency and clean environments can be extended to once every three months, with lubrication status as the core judgment basis.
Q2:Can ordinary lubricating grease and vacuum specific lubricating grease be mixed?
A:Absolutely prohibited. Ordinary lubricating grease is prone to volatilization and deterioration in a vacuum environment, which can contaminate the system and damage seals. Therefore, it is necessary to choose the corresponding model of vacuum specific lubricating grease.
Q3:Can the vacuum valve be forcibly opened and closed due to slight jamming?
A:I can’t. Forcefully opening the valve can damage the valve core, valve seat, and actuator. It is necessary to first investigate issues such as impurity blockage and insufficient lubrication before proceeding with the operation.
Q4:Which is more suitable for daily sealing testing, helium mass spectrometry leak detection method or pressure drop method?
A:Daily inspections can be carried out using the pressure drop method, which is convenient to operate and cost-effective; For high-precision scenarios or locating small leaks, helium mass spectrometry leak detection method is more accurate.
Q5:Can the vacuum valve seal be self ground and repaired after wear?
A:Minor scratches can be repaired by self grinding, requiring the use of specialized grinding tools and abrasives; If the wear is severe, it is recommended to replace it to avoid substandard sealing performance after repair.
Q6:How to protect vacuum valves from corrosion in high humidity environments?
A:Install dehumidification equipment to control the environmental humidity below 60%; Regularly clean the valve body and apply anti-corrosion coating, using stainless steel valve components.
Q7:What parts of the actuator of the electric vacuum valve should be inspected in daily life?
A:Focus on checking whether the circuit connection is firm, whether there is any abnormal noise during motor operation, whether the limit switch is accurate, and clean the dust inside the actuator once a month.
Q8:What should be done before reusing a vacuum valve that has been idle for a long time?
A:Clean the valve body and seals, replace aging lubricating grease, conduct sealing performance testing and flexibility inspection, and only put them into use after meeting the standards.
Q9:Is the maintenance focus consistent for vacuum valves corresponding to different media?
A:Inconsistent.Corrosive media require special inspection of the corrosion of seals and valve bodies, high-temperature media focus on lubrication and material aging, and clean media focus on cleaning and pollution prevention.
Q10:Is it necessary to retest after tightening the vacuum valve bolts that have become loose and caused leakage?
A:I need it. After tightening the bolts, a sealing performance test should be conducted to confirm that there is no leakage. At the same time, other connection parts should be checked to avoid multiple looseness caused by vibration.
