注脂維護(hù)保養(yǎng)對(duì)于減少球閥故障、延長(zhǎng)球閥壽命、使球閥方便操作等方面具有重要意義。注脂設(shè)備通過(guò)注脂嘴向閥球密封系統(tǒng)注入潤(rùn)滑脂（清洗液），實(shí)現(xiàn)對(duì)球閥的維護(hù)和保養(yǎng)。由于注脂嘴下端處于閥球內(nèi)流體壓力環(huán)境中，給注脂嘴出現(xiàn)泄漏時(shí)的處置和更換造成了一定困難。
Greasing maintenance is of great significance in reducing ball valve failures, extending the service life of ball valves, and making ball valves easy to operate. The grease injection equipment injects lubricating grease (cleaning fluid) into the valve ball sealing system through the grease injection nozzle to achieve maintenance and upkeep of the ball valve. Due to the fluid pressure environment inside the valve ball at the lower end of the grease injection nozzle, it has caused certain difficulties in handling and replacing the grease injection nozzle in case of leakage.
球閥閥座密封系統(tǒng)
Ball valve seat sealing system
典型球閥的閥座密封系統(tǒng)如圖1所示，嵌在閥座上的密封環(huán)和閥球之間形成密封副，注脂設(shè)備通過(guò)注脂接頭、內(nèi)置止回閥及閥座內(nèi)部注脂通道將潤(rùn)滑脂（清洗液）注入至閥座密封環(huán)位置，從而實(shí)現(xiàn)對(duì)密封副的潤(rùn)滑和密封。注脂嘴的下端通過(guò)螺紋與閥體直接相連，上端暴露于大氣中，注脂嘴上、下端面之間承受的壓力即為管線(xiàn)流體的壓力。如果注脂嘴結(jié)構(gòu)失效，就會(huì)引起流體介質(zhì)泄漏。
The valve seat sealing system of a typical ball valve is shown in Figure 1, where a sealing pair is formed between the sealing ring embedded in the valve seat and the valve ball. The grease injection equipment injects lubricating grease (cleaning fluid) into the valve seat sealing ring position through the grease injection joint, built-in check valve, and the internal grease injection channel of the valve seat, thereby achieving lubrication and sealing of the sealing pair. The lower end of the grease nozzle is directly connected to the valve body through a thread, and the upper end is exposed to the atmosphere. The pressure between the upper and lower end faces of the grease nozzle is the pressure of the pipeline fluid. If the structure of the grease injection nozzle fails, it will cause fluid medium leakage.
多數(shù)球閥在外部注脂嘴之后都設(shè)計(jì)有內(nèi)置止回閥，內(nèi)置止回閥被直接旋進(jìn)閥體，與注脂接頭互不影響，目的是為了實(shí)現(xiàn)在線(xiàn)條件下可以拆卸更換外部注脂嘴。但是由于內(nèi)置止回閥尺寸較小、結(jié)構(gòu)簡(jiǎn)單，因此在實(shí)際工作中這種內(nèi)部止回閥并不完全可靠。
Most ball valves are designed with a built-in check valve after the external grease nozzle. The built-in check valve is directly screwed into the valve body and does not affect the grease joint. The purpose is to achieve the ability to disassemble and replace the external grease nozzle under online conditions. However, due to the small size and simple structure of the built-in check valve, it is not completely reliable in practical work.
注脂嘴一般由蓋帽、鋼珠、彈簧和帶連接螺紋的本體幾部分組成，典型結(jié)構(gòu)，如下頁(yè)圖2所示。從結(jié)構(gòu)可見(jiàn)，注脂接頭一般采用底部壓邊結(jié)構(gòu)將彈簧、鋼珠限制在注脂接頭本體內(nèi)。
The grease nozzle is generally composed of a cap, steel balls, springs, and a body with connecting threads, with a typical structure shown in Figure 2 on the following page. From the structure, it can be seen that the grease injection joint generally adopts a bottom edge pressing structure to restrict the spring and steel balls within the body of the grease injection joint.壓邊失效和彈簧疲勞失效是導(dǎo)致注脂接頭失效的重要原因。如下頁(yè)圖4－1所示是故障前注脂嘴結(jié)構(gòu)；則是注脂接頭內(nèi)的止回球由于被污物（沙粒、金屬碎屑、固化脂等）卡住或彈簧失效而無(wú)法回復(fù)到原位，從而失去止回功能導(dǎo)致泄漏發(fā)生。此外還有止回球鋼珠破損等原因造成注脂嘴產(chǎn)生泄漏。
As shown in Figure 3 on the following page, edge pressing failure and spring fatigue failure are important reasons for the failure of the grease injection joint. The structure of the pre fault grease nozzle is shown in Figure 4-1 on the following page; As shown in Figure 4-2, the check ball inside the grease injection joint cannot return to its original position due to being stuck by dirt (sand particles, metal debris, solidified grease, etc.) or the spring failure, resulting in the loss of check function and leakage. In addition, there are reasons such as damage to the check ball and steel ball, which cause leakage at the grease injection nozzle.
閥座注脂接頭直接和管輸系統(tǒng)相連接。閥腔內(nèi)壓力排空并不意味著帶壓拆卸注脂嘴是安全的。因?yàn)榧词故切掳惭b的止回閥也不是安全、不可靠的。如果此時(shí)從閥體上拆卸外部注脂接頭，管線(xiàn)壓力就可能通過(guò)注脂通道經(jīng)失效的內(nèi)部止回閥將外部注脂接頭打飛，從而帶來(lái)嚴(yán)重后果。如果注脂接頭內(nèi)置止回閥失效，勢(shì)必導(dǎo)致大量泄漏的發(fā)生。如在閥室或建筑物內(nèi)，有可能引發(fā)緊急關(guān)斷、火災(zāi)甚至爆炸。
The valve seat grease fitting is directly connected to the pipeline system. The emptying of pressure in the valve chamber does not mean that dismantling the grease nozzle under pressure is safe. Because even newly installed check valves are not safe and unreliable. If the external grease fitting is removed from the valve body at this time, the pipeline pressure may blow off the external grease fitting through the failed internal check valve through the grease channel, resulting in serious consequences. If the built-in check valve in the grease fitting fails, it will inevitably lead to a large amount of leakage. If inside a valve chamber or building, it may cause emergency shutdown, fire, or even explosion.
在高壓天然氣管輸系統(tǒng)中，大多數(shù)內(nèi)置止回閥無(wú)法有效防止閥門(mén)小泄漏的發(fā)生。可以向閥門(mén)密封系統(tǒng)重新注入少量的清洗液（或流動(dòng)性好的潤(rùn)滑脂），浸泡一段時(shí)間后就可以有效防止這類(lèi)泄漏的發(fā)生。閥門(mén)注脂嘴注入清洗液后，小球和彈簧四周固化的污物在清洗液的浸泡下，將會(huì)很快瓦解或者變軟，使止回球和彈簧得到復(fù)位，可以有效防止泄漏。如注脂嘴泄漏量大，則會(huì)導(dǎo)致注脂 操作不易實(shí)施。因此在注入清洗液前，需要安裝泄漏自鎖適配器（如圖5）。
In high-pressure natural gas transmission systems, most built-in check valves cannot effectively prevent the occurrence of small valve leaks. A small amount of cleaning solution (or lubricating grease with good fluidity) can be injected into the valve sealing system again, and soaking for a period of time can effectively prevent the occurrence of such leaks. After injecting cleaning solution into the valve grease nozzle, the solidified dirt around the ball and spring will quickly disintegrate or become soft under the immersion of the cleaning solution, allowing the check ball and spring to be reset and effectively preventing leakage. If the leakage of the grease nozzle is large, it will make the grease injection operation difficult to implement. Therefore, before injecting cleaning fluid, it is
安裝過(guò)程中，將金屬密封泄漏鎖緊接頭的頂部卡到注脂接頭上，然后順時(shí)針擰金屬密封泄漏鎖緊接頭，就可將金屬密封泄漏鎖緊接頭安裝到原注脂嘴上。通過(guò)墊圈或金屬密封圈可以獲得有效的密封性能。金屬密封泄漏鎖緊接頭安裝完畢后，可以先向閥門(mén)注入少量的清洗液，如VAL－TEX2000型清洗液，當(dāng)清洗液接觸到止回閥界面時(shí)，泄漏就可以被有效阻止。在止回閥準(zhǔn)確落入閥座前，要進(jìn)行多次清洗液（或流動(dòng)性較好的潤(rùn)滑脂）注脂嘗試。停止氣體泄漏后，維檢修操作者仍可向閥門(mén)注入潤(rùn)滑脂（或者清洗液）。
During the installation process, clamp the top of the metal seal leakage locking joint onto the grease fitting, and then turn the metal seal leakage locking joint clockwise to install the metal seal leakage locking joint onto the original grease fitting. Effective sealing performance can be achieved through gaskets or metal sealing rings. After the installation of the metal seal leakage locking joint, a small amount of cleaning solution, such as VAL-TEX2000 cleaning solution, can be injected into the valve first. When the cleaning solution contacts the check valve interface, the leakage can be effectively prevented. Before the check valve accurately falls into the valve seat, multiple attempts should be made to inject cleaning fluid (or lubricating grease with good fluidity) into the grease. After stopping gas leakage, maintenance operators can still inject lubricating grease (or cleaning fluid) into the valve.
采用專(zhuān)用泄壓工具泄壓后更換注脂嘴
Replace the grease nozzle after using a dedicated pressure relief tool to relieve pressure
如果在特殊情況下建議嘗試在線(xiàn)拆卸更換外部注脂嘴，那么可以使用一種SO－BV工具（如下頁(yè)圖6）。SO－BV工具底部通過(guò)螺紋連接在注脂嘴上，通過(guò)順時(shí)針旋轉(zhuǎn)頂部T形手柄使得頂桿向下運(yùn)行從而推開(kāi)注脂嘴的內(nèi)部止回閥，如果閥體上的內(nèi)部止回閥已經(jīng)失效，那么管線(xiàn)內(nèi)的高壓流體介質(zhì)將通過(guò)SO－BV工具的外部開(kāi)口流出，就可以明確判斷閥體上的內(nèi)部止回閥已經(jīng)失效，無(wú)法在線(xiàn)拆卸更換外部注脂嘴。如果SO－BV工具的外部開(kāi)口沒(méi)有高壓介質(zhì)流出，就可以嘗試在線(xiàn)拆卸更換外部注脂嘴。
If it is necessary to attempt to disassemble and replace the external grease nozzle online in special circumstances, an SO-BV tool can be used (as shown in Figure 6 on the following page). The bottom of the SO-BV tool is connected to the grease nozzle through a threaded connection. By rotating the top T-shaped handle clockwise, the top rod runs downward to push open the internal check valve of the grease nozzle. If the internal check valve on the valve body has failed, the high-pressure fluid medium in the pipeline will flow out through the external opening of the SO-BV tool. This can clearly determine that the internal check valve on the valve body has failed and cannot be disassembled or replaced online for the external grease nozzle. If there is no high-pressure medium flowing out of the external opening of the SO-BV tool, you can try to disassemble and replace the external grease nozzle online.
將SO－BV工具連接到注脂嘴上之前，逆時(shí)針旋轉(zhuǎn)SO－BV工具上的T型手柄使頂桿上行至位置，然后拆除密封注脂接頭上的金屬蓋帽，將SO－BV工具連接在注脂接頭的螺紋上并旋緊。然后順時(shí)針旋轉(zhuǎn)SO－BV工具上的T型手柄，頂桿下行，使得注脂接頭內(nèi)的球形止回閥“離座”，可以使得閥體內(nèi)的物質(zhì)通過(guò)泄放孔和后端的閥門(mén)被釋放出（如下頁(yè)圖7）。
Before connecting the SO-BV tool to the grease fitting, first rotate the T-handle on the SO-BV tool counterclockwise to raise the top rod to the maximum position. Then remove the metal cap on the sealed grease fitting, connect the SO-BV tool to the thread of the grease fitting, and tighten it. Then rotate the T-handle on the SO-BV tool clockwise, and the top rod will go down, causing the spherical check valve in the grease fitting to "unseat", allowing the material in the valve body to be released through the relief hole and the valve at the rear end (as shown in Figure 7 on the following page).
反方向旋轉(zhuǎn)SO－BV工具上的T型手柄，抽出頂桿，使得注脂接頭的內(nèi)置止回球在彈簧的彈力下重新“回座”（ 如圖8）。
Rotate the T-handle on the SO-BV tool in the opposite direction and pull out the top rod, causing the built-in check ball of the grease fitting to "reseat" under the spring force (as shown in Figure 8).
采用帶壓更換工具進(jìn)行在線(xiàn)更換注脂嘴
Using pressure replacement tools for online replacement of grease nozzles
通過(guò)采用TDW公司的T101b鉆孔機(jī)及其附件，對(duì)失效注脂嘴進(jìn)行在線(xiàn)帶壓拆卸和更換。T101b鉆孔機(jī)可實(shí)現(xiàn)密閉狀態(tài)下被夾持工件的螺旋式上升和下降（便于螺栓的擰緊和松開(kāi)），亦可以實(shí)現(xiàn)內(nèi)部夾持工件的垂直上升和下降 （便于注脂嘴螺栓擰緊到位后夾持器與工件脫開(kāi)），T－101b帶壓更換工具（如圖9－1，9－2）。
By using TDW's T101b drilling machine and its accessories, the failed grease injection nozzle was disassembled and replaced online under pressure. The T101b drilling machine can achieve spiral lifting and lowering of the clamped workpiece in a closed state (for easy tightening and loosening of bolts), as well as vertical lifting and lowering of the internal clamped workpiece (for easy detachment of the gripper from the workpiece after the grease nozzle bolt is tightened in place), and the T-101b pressure replacement tool (as shown in Figures 9-1 and 9-2).
通過(guò)在失效的球閥注脂嘴四周表面固定T101b帶壓更換成套工具，實(shí)現(xiàn)注脂嘴的帶壓拆卸和更換工作。為保證施工過(guò)程中的密封效果，需提前加工護(hù)板短節(jié)和抱箍，并準(zhǔn)備高壓O型密封圈，還需加工護(hù)板短節(jié)和抱箍結(jié)構(gòu)（如下頁(yè)圖10、11）。護(hù)板短接及底部的O型圈、球閥表面和2英寸閥門(mén)在抱箍的作用下，使注脂嘴四周形成一個(gè)密封腔 。帶壓更換成套工具裝配后如圖12所示。
By fixing the T101b pressure replacement kit on the surface around the failed ball valve grease nozzle, the disassembly and replacement of the grease nozzle under pressure can be achieved. To ensure the sealing effect during the construction process, it is necessary to process the protective plate short joint and hoop in advance, prepare high-pressure O-ring seals, and also process the protective plate short joint and hoop structure (as shown in Figures 10 and 11 on the following pages). The short connection of the protective plate, the O-ring at the bottom, the surface of the ball valve, and the 2-inch valve form a sealing chamber around the grease injection nozzle under the action of the clamp. After assembling the pressure replacement kit, it is shown in Figure 12.
取注脂嘴操作時(shí)，將夾持器底部的內(nèi)六角扳手頭與注脂嘴外六方螺桿固定好 ，打開(kāi)2英寸閥門(mén)，將鉆孔機(jī)與夾持器（套筒頭及驅(qū) 柄）連接，逆時(shí)針轉(zhuǎn)動(dòng)鉆孔機(jī)的棘齒搖把，轉(zhuǎn)動(dòng)大約12轉(zhuǎn)，可以將注脂嘴移出。注脂嘴移出后繼續(xù)轉(zhuǎn)動(dòng)，提升給進(jìn)管，直到注脂嘴到達(dá)2英寸閥門(mén)表面。鉆桿每轉(zhuǎn)8轉(zhuǎn)的行程約為1英寸，提升距離可以在鉆桿上讀取。當(dāng)注脂嘴提升到達(dá)2英寸閥門(mén)表面時(shí)，立即關(guān)閉2英寸閥門(mén)，對(duì)鉆孔機(jī)進(jìn)行泄壓，拆卸下短接和適配器 ，將注脂嘴取下。
When operating the grease nozzle, first fix the inner hexagonal wrench head at the bottom of the holder with the outer hexagonal screw of the grease nozzle, open the 2-inch valve, connect the drilling machine to the holder (socket head and drive handle), and rotate the ratchet handle of the drilling machine counterclockwise for about 12 turns to remove the grease nozzle. After removing the grease nozzle, continue to rotate and lift the feed pipe until the grease nozzle reaches the surface of the 2-inch valve. The stroke of the drill pipe is approximately 1 inch per 8 revolutions, and the lifting distance can be read on the drill pipe. When the grease nozzle is lifted to the surface of the 2-inch valve, immediately close the 2-inch valve, relieve pressure on the drilling machine, remove the short circuit and adapter, and remove the grease nozzle.
安裝新注脂嘴時(shí) ，在夾持器套筒扳手頭內(nèi)安裝新注脂嘴，并將套筒頭上的沉頭螺栓鎖死，使注脂嘴在旋緊過(guò)程中不會(huì)從套筒內(nèi)脫出。其余安裝過(guò)程與取注脂嘴程序相反。為保證操作的氣密性，進(jìn)行上述明顯一步操作過(guò)程時(shí)，都建議進(jìn)行驗(yàn)漏，保證系統(tǒng)的氣密性。
When installing a new grease nozzle, first install the new grease nozzle in the socket wrench head of the holder, and lock the countersunk bolt on the socket head to ensure that the grease nozzle does not come out of the socket during the tightening process. The rest of the installation process is the reverse of the grease nozzle procedure. To ensure the airtightness of the operation, any of the above steps must be leak tested to ensure the airtightness of the system.
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