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.

球阀阀座密封系统

Ball valve seat sealing system

典型球阀的阀座密封系统如图1所示，嵌在阀座上的密封环和阀球之间形成密封副，注脂设备通过注脂接头、内置止回阀及阀座内部注脂通道将润滑脂（清洗液）注入阀座密封环位置，从而实现对密封副的润滑和密封。注脂嘴的下端通过螺纹与阀体直接相连，上端暴露于大气中，注脂嘴上、下端面之间承受的压力即为管线流体的压力。如果注脂嘴结构失效，就会引起流体介质泄漏。

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.

多数球阀在外部注脂嘴之后都设计有内置止回阀，内置止回阀被直接旋进阀体，与注脂接头互不影响，目的是为了实现在线条件下可以拆卸更换外部注脂嘴。但是由于内置止回阀尺寸较小、结构简单，因此在实际工作中这种内部止回阀并不完全可靠。

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.

注脂嘴一般由盖帽、钢珠、弹簧和带连接螺纹的本体几部分组成，典型结构，如下页图2所示。从结构可见，注脂接头一般采用底部压边结构将弹簧、钢珠限制在注脂接头本体内。

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.压边失效和弹簧疲劳失效是导致注脂接头失效的重要原因。如下页图4－1所示是故障前注脂嘴结构；则是注脂接头内的止回球由于被污物（沙粒、金属碎屑、固化脂等）卡住或弹簧失效而无法回复到原位，从而失去止回功能导致泄漏发生。此外还有止回球钢珠破损等原因造成注脂嘴产生泄漏。

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.

阀座注脂接头直接和管输系统相连接。阀腔内压力排空并不意味着带压拆卸注脂嘴是的。因为即使是新安装的止回阀也不是、不可靠的。如果此时从阀体上拆卸外部注脂接头，管线压力就可能通过注脂通道经失效的内部止回阀将外部注脂接头打飞，从而带来严重后果。如果注脂接头内置止回阀失效，势必导致大量泄漏的发生。如在阀室或建筑物内，有可能引发紧急关断、火灾甚爆炸。

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.

在高压天然气管输系统中，大多数内置止回阀无法有效防止阀门小泄漏的发生。可以向阀门密封系统重新注入少量的清洗液（或流动性好的润滑脂），浸泡一段时间后就可以有效防止这类泄漏的发生。阀门注脂嘴注入清洗液后，小球和弹簧四周固化的污物在清洗液的浸泡下，将会很快瓦解或者变软，使止回球和弹簧得到复位，可以有效防止泄漏。如注脂嘴泄漏量大，则会导致注脂 操作不易实施。因此在注入清洗液前，需要安装泄漏自锁适配器（如图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

安装过程中，将金属密封泄漏锁紧接头的顶部卡到注脂接头上，然后顺时针拧金属密封泄漏锁紧接头，就可将金属密封泄漏锁紧接头安装到原注脂嘴上。通过垫圈或金属密封圈可以获得有效的密封性能。金属密封泄漏锁紧接头安装完毕后，可以先向阀门注入少量的清洗液，如VAL－TEX2000型清洗液，当清洗液接触到止回阀界面时，泄漏就可以被有效阻止。在止回阀准确落入阀座前，要进行多次清洗液（或流动性较好的润滑脂）注脂尝试。停止气体泄漏后，维检修操作者仍可向阀门注入润滑脂（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.

采用专用泄压工具泄压后更换注脂嘴

Replace the grease nozzle after using a dedicated pressure relief tool to relieve pressure

如果在特殊情况下必须尝试在线拆卸更换外部注脂嘴，那么可以使用一种SO－BV工具（如下页图6）。SO－BV工具底部通过螺纹连接在注脂嘴上，通过顺时针旋转顶部T形手柄使得顶杆向下运行从而推开注脂嘴的内部止回阀，如果阀体上的内部止回阀已经失效，那么管线内的高压流体介质将通过SO－BV工具的外部开口流出，就可以明确判断阀体上的内部止回阀已经失效，无法在线拆卸更换外部注脂嘴。如果SO－BV工具的外部开口没有高压介质流出，就可以尝试在线拆卸更换外部注脂嘴。

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.

将SO－BV工具连接到注脂嘴上之前，逆时针旋转SO－BV工具上的T型手柄使顶杆上行位置，然后拆除密封注脂接头上的金属盖帽，将SO－BV工具连接在注脂接头的螺纹上并旋紧。然后顺时针旋转SO－BV工具上的T型手柄，顶杆下行，使得注脂接头内的球形止回阀“离座”，可以使得阀体内的物质通过泄放孔和后端的阀门被释放出（如下页图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).

反方向旋转SO－BV工具上的T型手柄，抽出顶杆，使得注脂接头的内置止回球在弹簧的弹力下重新“回座”（ 如图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).

采用带压更换工具进行在线更换注脂嘴

Using pressure replacement tools for online replacement of grease nozzles

通过采用TDW公司的T101b钻孔机及其附件，对失效注脂嘴进行在线带压拆卸和更换。T101b钻孔机可实现密闭状态下被夹持工件的螺旋式上升和下降（便于螺栓的拧紧和松开），亦可以实现内部夹持工件的垂直上升和下降 （便于注脂嘴螺栓拧紧到位后夹持器与工件脱开），T－101b带压更换工具（如图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).

通过在失效的球阀注脂嘴四周表面固定T101b带压更换成套工具，实现注脂嘴的带压拆卸和更换工作。为保证施工过程中的密封效果，需提前加工护板短节和抱箍，并准备高压O型密封圈，还需加工护板短节和抱箍结构（如下页图10、11）。护板短接及底部的O型圈、球阀表面和2英寸阀门在抱箍的作用下，使注脂嘴四周形成一个密封腔 。带压更换成套工具装配后如图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.

取注脂嘴操作时，将夹持器底部的内六角扳手头与注脂嘴外六方螺杆固定好 ，打开2英寸阀门，将钻孔机与夹持器（套筒头及驱 柄）连接，逆时针转动钻孔机的棘齿摇把，转动大约12转，可以将注脂嘴移出。注脂嘴移出后继续转动，提升给进管，直到注脂嘴到达2英寸阀门表面。钻杆每转8转的行程约为1英寸，提升距离可以在钻杆上读取。当注脂嘴提升到达2英寸阀门表面时，立即关闭2英寸阀门，对钻孔机进行泄压，拆卸下短接和适配器 ，将注脂嘴取下。

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.

安装新注脂嘴时 ，在夹持器套筒扳手头内安装新注脂嘴，并将套筒头上的沉头螺栓锁死，使注脂嘴在旋紧过程中不会从套筒内脱出。其余安装过程与取注脂嘴程序相反。为保证操作的气密性，进行上述任何一步操作过程时，都必须进行验漏，保证系统的气密性。

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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