In sanitary fluid transport systems for industries like food, pharmaceuticals, and bioengineering, butterfly valves are widely popular due to their simple structure, quick opening/closing, and ease of cleaning. However, many users have a misconception: believing that simply purchasing a high-quality sanitary butterfly valve is enough to ensure perfect system operation. In fact, the old saying “30% depends on the product, 70% depends on the installation” holds true in the valve industry as well. An improper installation can significantly degrade the performance of even a top-tier brand’s valve, potentially leading to leaks, contamination, or equipment damage.
To ensure the stability and reliability of your sanitary system, here are five key installation points and three common mistakes that must be avoided.
5 Key Installation Points for a Foolproof Setup
- Pre-Installation “Check-up”: Cleaning and Inspection
After unpacking, never install the valve directly. First, thoroughly inspect the valve interior and sealing surfaces to ensure there are no impurities, dust, or oil residue left from transportation or storage. Simultaneously, verify that the disc opens/closes smoothly, and that the O-rings or PTFE gaskets are intact and correctly positioned. This is the first step to preventing contamination.
- Align Flanges, Apply Even Force
Place the valve evenly between the two pipeline flanges, ensuring the arrow on the valve body points in the expected direction of media flow. Then, manually insert the bolts through the flange holes and initially tighten the diagonal bolts first to roughly center the valve between the flanges. This is key to preventing abnormal stress on the valve body.
- Tighten Bolts “Gently”
This is the most critical step in the entire installation process. You must use a torque wrench and follow the manufacturer’s recommended torque values, tightening in a crisscross pattern, gradually and in multiple passes. Avoid tightening one side completely at once or using excessive force, as this can cause valve body distortion or crush and damage the sealing gasket, leading to irreparable internal leakage.
- Ensure Sufficient Clearance for the Disc
After installation, manually operate the valve through several full open and close cycles to ensure the disc rotates 360 degrees without any obstruction. Check that the valve’s actuator (like a handle or pneumatic head) does not interfere with the pipeline or other equipment, leaving safe space for future operation and maintenance.
- Post-Installation Pressure and Cleaning Tests
Before officially putting the pipeline system into service, always conduct pressure tests and cleaning (CIP/SIP) procedures. During testing, carefully check for any seepage at the connection points between the valve and the flanges. This not only tests the valve’s sealing performance but is also the most direct acceptance check of the installation quality.
Three Common Mistakes to Learn From
- Mistake One: Overtightening Brutally
This is the most common and fatal error. The idea that “tighter means no leak” is completely wrong. Overtightening the bolts will severely compress and damage the soft sealing material, causing permanent deformation or rupture, which ironically leads to leakage.
- Mistake Two: Neglecting or Using Incorrect Gaskets
Forgetting to install the sealing gasket or using an incompatible, non-sanitary gasket (like a common rubber gasket). Sanitary systems must use specified sanitary gaskets (e.g., EPDM, FKM, PTFE) to ensure cleanliness, chemical resistance, and sealing effectiveness.
- Mistake Three: Incorrect Installation Direction
Ignoring the flow direction arrow on the valve body. Although some butterfly valves are bi-directional, installing according to the indicated direction ensures optimal sealing performance and service life. Incorrect installation direction might affect the valve’s sealing performance and flow characteristics under specific conditions.
Summary
Correct installation is the lifeline for ensuring the long-term stable operation of sanitary butterfly valves. By following the points above and avoiding common pitfalls, the high-quality valve you purchased can truly deliver its full value and safeguard your production process.
When you need reliable, high-quality sanitary valves, choosing a trustworthy supplier is just as crucial as correct installation. Adamant Valves specializes in providing industrial valve solutions that meet stringent sanitary standards.
