Why Engineers Use Two Single Ball Valves for Isolation Instead of a Double Ball Valve | practical reasons in plant maintenance and replacement

Engineering inside often uses two single ball valves replace double ball valve is because maintenance more flexible, single valve failure can alone replace, stopping machine time can reduce about 30%, and standard valve inventory common use rate ≥80%, installation time two valves spacing suggests ≥1 times pipe diameter and add blind plate position, ensure isolation reliability and maintenance safety.

replacement ease

Weight & space

Walk in raise head look, head top’s rusty steel frame and cement floor slab usually are pressed low to 2.5 meters within. Two rows wrapped holding silver color iron sheet’s insulation pipelines side by side walk lines, middle left for people turning sideways drill past’s net gap not reach 400 millimeters.

If want to take a heavy reaching 1.2 tons‘s integrated type double ball valve stuff into this gap, worker faces’s is a wall pig iron cast become’s wall. This huge monster dead dead stuck at two units three floors high’s heat exchangers middle. Worker up down left right look one circle, basically find not to can hang live 3 tons level ring chain hand pulled hoist’s receiving force fulcrum.

Factory inside’s safety section checks very strict, absolutely not allow maintenance worker at load-bearing’s section steel big beam on casually weld a piece iron lump act as temporary lifting lug. If want take dozens paths bolts locked dead’s iron guy get out, shift leader must go outside rent a unit 25 tons level’s long arm truck crane.

Truck crane’s thick big arm frame wants stretch into leave ground 15 meters’s pipe gallery third floor is a piece risking big danger’s work. Beside densely packed arranged full 7 strips walking holding 160 degrees high pressure steam’s tracing heat fine pipes. Full is oil stain’s steel wire rope in wind middle slightly shakes one bit, scrape broken which strip fine pipe all will provoke out big trouble.

Change into two independent’s single ball valves strung at together, working’s scene just relaxed one big section. Nut once loose open, original API 6D standard’s 10 inches connected body valve has 1.1 meters that long, now single piece ball valve add on one section 300 millimeters’s standard short connection steel pipe, single piece weight is forcefully chopped become 200 kilograms up down.

Two names wearing anti-static work clothes’s pipe workers carrying a handle 36 inches’s heavy type big pipe wrench climb up stairs. Bring on two roots one meter more long’s industrial nylon lifting belts, relying on shoulder’s strength just can take work do neatly.

High altitude pipe gallery do heavy work has several paths dead hard’s thresholds:

• 150 pounds pressure’s 8 inches single body small valve, a old master bite bite teeth can carry move
• Big truck crane stretch open four hydraulic support legs, must have to find a piece 4 meters multiply 4 meters’s flat hardened cement ground
• At pipe below build one layer paved full scaffold boards’s operation platform, fastest also wants consume away 4.5 hours
• As long as object exceeds 500 kilograms, moving before must find three departments sign approve one stack special operation sheets

Those double connected body’s old style ball valves leave factory time, two huge’s bearing pressure valve cavities are dead dead ground cast at a thick solid’s forged steel big shell inside.

Only is take big wrench loose open flange plate on that 24 pieces M30 specification’s high strength double head bolts, just can consume away two strong men whole one morning’s strength. Wearing bring steel plate’s anti-smash labor protection shoes, pipe worker steps at shaking’s iron frame on use one meter more long’s thick pry bar, dead life top open one strip 5 millimeters wide’s rusty gap.

Center of gravity shift is do high altitude hoisting’s old master most afraid bump into’s thing. Double connected valve two heads heavy middle light, 800 more kilograms’s guy suspended in mid-air, slightly has a little eccentric receive force just in wind inside randomly turn.

Hoisting shift leader holding walkie-talkie throat yells till emit white smoke, commanding holding dozen meters outside’s crane driver every time only can take iron hook micro adjust 0.5 centimeters. Beside walking holding 380V strong electricity’s bridge frame cable closely pastes holding valve ice cold’s outer shell, below’s blowdown vent port leave foot below’s anti-slip grating plate only has not reach 15 centimeters.

Pig iron lump as long as slightly rubs one bit, beside that root marked price over ten thousand’s glass rotor flow meter on the spot just must shatter become one ground glass dregs. Separate install’s single ball valve easy deal with much, several hundred catties’s weight completely evenly ground distribute at center that root main shaft on, carry up steady steady proper proper.

Old equipment dismantle down after want take them transport back one kilometer outside’s machine repair workshop, is one field squeeze dry physical strength’s seesaw battle. Factory inside bring big capacity battery’s hydraulic handling vehicle wide about 900 millimeters, even vehicle head all drive not in only has 800 millimeters wide’s iron lattice aisle.

Iron guy go down stairs must calculate clear ground’s load-bearing account:

• Standard aisle steel grating plate step up go’s person add iron lump, cannot exceed per square meter 500 kilograms
• Hand push cart only empty vehicle just heavy 80 kilograms, encounter higher than ground’s pipe threshold all rely on person lift
• Iron made fire fighting stairs’s corner especially narrow, exceed 1.5 meters long’s big piece even turn all turn not past

Four young men take 300 kilograms’s single valve lift on bring four universal wheels’s flatbed small cart, careful careful ground along aisle toward front push. Change into one whole double connected body press up go, single point 700 kilograms’s dead weight on the spot just can take below’s anti-slip iron sheet press till dent down one piece.

A105 grade’s heavy type forged steel, one small piece sugar cube size’s volume just has almost 8 grams heavy. Double connected shell body middle that extra out come’s pressure relief cavity, thick thick’s steel wall purely is in order to resist live long pipeline two heads cold hot alternate twist come twist go’s dead force.

Extra out come’s 30 more kilograms solid big iron block, all changed become workers back work clothes on cover out come’s white flower flower salt alkali. Masters give single valve work, only use at beside temporarily build two roots 1.8 meters long’s thick steel pipes act as slide rail, smear a little butter one push just enter inside.

Want give those heavy’s connected body monsters align two heads’s flange holes, several people must use bare upper body’s strength holding several hundred catties’s weight suspend in mid-air find level. No person dares at a pile several hundred kilograms’s big iron blocks slowly close in’s time, take meat grow’s finger heads stretch into gap go poke that sheet outer diameter 400 millimeters’s graphite wound gasket.

Take big monster chop become two single pieces, do up work come handy very. Use standard torque wrench take screws one piece piece twist tight, receive force data steady steady ground stop stay at 450 Newton meters within, even rework re-twist’s probability all less one big half.

Partial replace

Mix holding fine fine quartz mortar’s chemical raw material one second clock toward front dart out go 4.5 meters. Top at most front suffer scour’s that path isolation valve fall big mold. Gravel like a handle rough’s woodworking big file, day day rubbing holding that circle white color’s PTFE polytetrafluoroethylene sealing ring.

Use not reach 14 months time, originally 8 millimeters thick’s soft sealing ring is forcefully gnaw drop 3.5 millimeters. Maintenance shift leader holding dispatch work sheet walk to old style’s double connected body ball valve front straight shake head. Lean material flow’s that one head is flush out one path 0.2 millimeters deep’s tiny crack.

Hand inside’s combustible gas detector just open machine, screen on’s number ten minutes inside one road soar to 150ppm. Hide at back half section backup valve cavity inside’s parts even leave factory brush’s anti-rust oil all not dry through. Workshop director bite holding back molar sign down one sheet sky price equipment scrap sheet. A unit caliber 12 inches, pressure resist 600 pounds’s custom double connected body purchase bottom price exceed 28,000 US dollars.

Several ten thousands blocks US dollars’s expensive equipment all plant at one path compare toothpick still fine’s scratch on. Change into two single body ball valves one front one back separate install, workshop inside calculate account easy much. Front that A valve hard carry holding bring sand stone’s liquid is hit till thousand holes hundred holes. Hide at back’s B valve all year round bump not to a bit water flower, bear pressure gauge on’s pointer honest stop at 0.1 MPa up down.

Maintenance worker receive work sheet, take pipe inside’s residual liquid all discharge clean. Two apprentices lift up wind cannon machine, da da da hit drop A valve two heads’s 16 pieces M24 thick bolts. Sleeve on industrial nylon belt take broken’s single piece lift away pull down. That clean clean’s B valve original seal not move lie at channel steel weld out come’s pipe frame on.

Single time 10 inches pipeline change parts detail bill:

Compare detail	Dismantle connected body monster	Alone change broken parts
Scrap metal weight	Throw away 1250 kilograms big iron block	Change away 280 kilograms single piece
Purchase spend away’s money	18.5 ten thousand blocks money RMB	4.2 ten thousand blocks money RMB
Force dismantle’s flange face	Unload down 4 old interfaces	Only move 2 old interfaces
Hold water test pressure consume time	White wait 48 hours	Endure past 12 hours

One meter more long’s big shell is use whole piece heavy reach 1.5 tons’s F316L special stainless steel alive alive forge hit out come’s. Fingernail cover that big little’s place is by sand stone grind broken, whole 1.5 tons’s good steel material all are act as broken copper rotten iron pull go waste station.

Take pipe inside’s valve dismantle become single piece install’s benefits count clearly:

• Carry holding big wrench go twist thirty several pieces thick nuts’s bitter strength work chop drop big half
• Warehouse shelf empty out empty ground no again go press several hundred ten thousand yuan’s cold door special big piece
• Run one trip hardware city spend four five ten thousand blocks money immediately pull back come a same type new goods
• Not go raw pull hard drag aged old pipe on from come not out past trouble’s iron interface

Waste station’s boss take big size angle grinder take receive come’s connected body big shell half cut open. Lean inside’s second path stainless steel big round ball take broken cloth casually one wipe, smooth till can act as mirror reflect out human face. Understand line’s pipe worker take precision micrometer go clip that piece ball’s dimension. Roundness error not reach 0.01 millimeters, install back go newly do 8000 hours one point problem not have.

Workshop inside fine hit precise calculate is dead rule, good steel must use at knife edge on. Chemical plant one year allocate give phase two pipeline maintenance’s funds full hit full calculate only has 300 ten thousand. Buy a bring flange’s single ball valve support dead walk drop five ten thousand blocks’s ledger account item. One year scrap three big dimension’s double connected bodies, small half year’s maintenance budget light speed see bottom.

Holding a handle flat iron scraper take old flange plate on’s black graphite crumbs shovel till clean clean net net. Find accurate two pieces big iron plates between that path only has 3 millimeters wide’s narrow gap. Smooth hand stuff in go one piece just open seal’s metal wound soft gasket.

Forcefully take one root not broken’s thick iron pipe hard pull open again suture purely give oneself find trouble. Several hundred catties’s flange plate newly align hole, parallelism slightly crooked a 0.5 degrees naked eye basically look not out come. Wait pipe connect good newly toward inside hit in 4 MPa’s test high pressure water. Slightly tilt’s interface edge immediately ci ci toward outside pop out one big string fine dense white soap bubble.

Leave holding perfectly good’s old pipe not go randomly move can save down big effort:

• Protect live one path leave factory not by big hammer knock hit past’s original raw metal defense line
• Interface bolt receive force maintain holding build factory time take instrument twist full’s original torque
• Less provoke one time heavy type flange plate bite not accurate leak become sieve’s big trouble
• Newly pass gas check leak rework’s probability one mouthful breath drop down one big section

Not suffer past scour’s single body valve even one piece fix screw nail all no need go touch. That one head tighten good’s absolutely excellent state all rely on that year installation worker take 0.05 millimeters’s thin iron feeler gauge along gap one little little clip out come. Less dismantle a steady steady stable stable’s joint, pipe worker shift leader night return home sleep can grounded a lot. Repair equipment stress only change broken’s old piece, broken which piece specially dismantle which piece.

Inventory & cycle

Oil refinery’s catalytic cracking equipment as long as stop on one day, finance ledger on’s loss start at least 80 ten thousand blocks money. Pipe inside exactly running holding’s high purity chemical material no place go, only can along iron pipe hit into high high’s torch tower inside white white burn become black smoke. Every day burn drop’s raw material money calculate down fully have 45 ten thousand. Equipment section’s dispatcher worry till straight pull hair, no person wait till afford good several months’s new valve manufacture period.

Go give old pipe order make a caliber 14 inches, pressure grade 900 pounds’s connected body double ball valve, purchaser must holding ruler go site climb up climb down. Take that two roots thick iron pipe middle’s real gap measure accurate, again go check a copy thick reach 12 pages’s custom parameter form. Foreign old brand manufacturer receive order, only go flip find wood mold, pour one furnace 1.8 tons heavy’s special alloy iron water, alive alive endure drop 3 weeks.

Wait foreign factory take huge flange plate’s end face put at milling machine on one little little scrape flat, load on container float ocean cross sea transport back domestic port, wall on’s calendar early flip past whole 16 weeks.

Old old’s chemical plant pipeline in this long’s 110 days inside, take thick thick’s big iron blind plate dead dead weld live one move not move. Several hundred numbers shift workers every day big eyes stare small eyes, guard holding stop turn’s huge centrifugal compressor dry anxious. Connected body big valve buy up come spend effort, single body ball valve in electromechanical hardware trade inside completely is a pair public face. ASME B16.10 international industry specification take all kinds iron shells outer shape dimension clip till dead dead’s.

Take one most ordinary’s 8 inches 150 pounds carbon steel single ball valve to say, no matter change become which brand’s goods, two heads iron plates middle’s distance thunder hit not move forever is 292 millimeters. Machine repair worker holding bring oil stain’s old steel tape measure at broken drop’s old pipe on casually gesture several strokes. Purchaser grab up office desk on’s landline hit give ten kilometers outside electromechanical wholesale market’s old acquaintance. Half hour not reach, a vehicle pull holding bring packaging spot goods’s Isuzu light truck steady steady proper proper stop at factory area number two gate guard outside.

• Agent’s big warehouse inside all year round stack put holding over thousand pieces regular dimension’s metal iron pieces
• Call one trip same city Huolala’s oil money add on load unload fee full hit full calculate dig out 200 blocks money
• Night 10 o’clock main pipeline suddenly burst split, early morning 3 o’clock new piece hang at hand pull hoist on
• Not out this province land boundary, 2 inches to 24 inches’s common use pipe fittings gather complete load vehicle especially fast

At shelf on all year round hoard put three non-standard custom’s connected body big valves, finance table on immediately is eat drop over million’s live money. Smear full sticky paste paste butter’s huge monster occupy whole two heavy type load-bearing shelves. Put on three years not use out go, must want hire person drag to outside newly hit pressure test one pass have not have rust broken drop.

Warehouse director rather take place empty out come, go stack put dozen pieces unit price not reach three ten thousand blocks money’s common use single valve. Like big hypermarket shelf on’s bottled water same follow take follow use, this head desalted water pipe not broken, any time pull go give another head’s ethylene glycol pipe save emergency.

Huge flange plate on that 20 piece wear big bolt’s round holes, machine time slightly hit biased 2 millimeters. Heavy reach two tons’s iron lump dead alive stuff not in two roots old pipe leave out’s dead gap inside. Original factory dispatch person pull back go newly open furnace rework, road on come come back back one toss big half month all attach in go.

Old pipe day day run 160 degrees’s high temperature fluid, heat expand cold shrink take whole strip steel pipe pull long 1.5 centimeters. Masters at two independent iron pieces middle add one small section bring short flange’s compensate iron pipe, take big hammer one knock just can find level align. Run to street side hardware store spend 800 blocks money, casually custom make several pieces different thickness’s carbon steel adjust gaskets.

Night inside sudden occur pipe burst split leak material, rush repair shift go block leak’s time full hit full calculate two three hours. Third watch half night basically find not to can immediately open big furnace pour iron water cast connected body big valve’s casting factory. Drive holding pickup run to local’s pipe fitting one strip street, suffer house suffer household knock open aluminum alloy rolling shutter door. Full is oil stain’s cement ground on everywhere stack holding hang holding qualified certificate plate’s new single piece.

• Flow line big factory every day in batches assemble 300 pieces 6 inches caliber’s common use iron pieces
• Enter warehouse’s spot goods only need pick 5%’s amount go water pool inside do hit pressure test
• Take big iron hammer smash rotten a shell, run go next door warehouse 15 minutes again collect one piece
• Purchase sheet on’s hand over goods time column inside forever cover holding spot cash spot goods’s big red seal

Purchase section chief every month end bring person go big warehouse inventory those no person touch’s sluggish dead material. Old long a custom big iron block as long as pipe not out trouble, quiet quiet hide in dark wall corner inside knot full thick thick’s dust net. Outside wrap holding’s that layer industrial anti-rust plastic thin film early is weather till brittle become one piece piece dregs. Finance section check account look to up face hang holding 22 ten thousand US dollars unit price’s label sheet straight shake head.

cost control

Purchase cost

Walk into make valve factory’s casting workshop, workers exactly take 1500 degrees’s high temperature steel water pour into sand make’s mold inside. One family factory every day can pour cast out 5000 pieces carbon steel material’s single body ball valve outer shell. Flow line operation take a 8 inches ordinary single body ball valve’s blank expense press low to 120 US dollars.

Whole globe common use’s industry standard regulate single body ball valve’s dimension. Whole world 4000 more families machine process factories all are look same one sheet drawing do work. Worker press down numerical control machine tool’s button, machine spend 45 minutes just can cut shave finish one standard valve’s iron frame.

Make a double connected ball valve’s scene big not same. Long reach 1 meter’s double connected valve body no way use cheap’s sand mold come batch make. Large scale special valve factory drive 3000 tons level’s free forge hammer, take a piece solid heart’s forge steel repeatedly smash become need’s shape.

Heavy reach 600 kilograms’s square steel material put into five axis process center inside, knife head continuous scrape shave 22 hours. Worker want in iron block belly inside dig out put two groups ball body and gasket’s space. Make good’s double connected finished product heavy 280 kilograms, ground on drop fall’s waste iron crumbs heavy reach 320 kilograms.

• Sand mold single piece share fee: 0.15 US dollars
• Special steel block open mold fee: 12000 US dollars
• Machine cut consume spend time: 45 minutes against 22 hours
• Shoot X ray check internal injury ratio: spot check ten part of one against all check

Purchaser holding two sheets quote price sheet calculate account. Buy two standard’s 8 inches single body ball valves add one section connect use’s short steel pipe, spend drop 1600 US dollars up down. Toward Europe America manufacturer custom make one piece same dimension’s double connected ball valve, start step price high reach 8500 US dollars.

Common use single body valve long years place at each place hardware warehouse’s shelf on. Factory hit a telephone go order goods, truck load good goods, fastest 24 hours inside just can take valve send to chemical plant. Toward manufacturer custom make double connected ball valve open up a field long’s wait.

Technician consume spend two weeks time draw custom double connected valve’s assemble drawing. Factory chief sign word cover seal after, factory just go buy that piece special steel blank. Hand over goods period from spot goods’s press second issue vehicle, pull long to 16 to 24 weeks.

Site construct team eye eagerly wait holding custom equipment send come, every day produce 5 ten thousand US dollars’s idle personnel wage and machine rent rent fee. Work period drag delay two months, several million US dollars’s budget very fast just will see bottom.

• Cut drop’s waste abandon metal compare: one tenth against two times half
• Operate machine’s high level manual fee: 25 US dollars against 180 US dollars
• Long distance transport goods package way: ordinary wood tray against super heavy steel iron tie tie
• Third party dispatch person go factory supervise fee: free against receive fetch percent of fifteen goods money

At water pressure test table on inspect single body valve very easy. Worker toward pipeline inside hit in 2.2 MPa’s water pressure, stare holding instrument plate wait 3 minutes, not leak water just open issue qualified sheet. Double connected structure belly inside has two complex’s leak water cavities, water pressure test turn become very trouble.

Quality inspect personnel let water in double connected ball valve inside force stop stay 15 minutes. Test sheet on extra add two paths low pressure blow gas’s step, use come check extremely tiny’s leak gas point. Take valve send to anti-corrosion coat paint workshop, brush paint’s fee also lack one big section.

Ordinary single body ball valve hang at ceiling board’s move chain on. Static electricity spray gun several seconds just spray good 250 microns thick’s anti-rust bottom paint, single piece oil paint fee not reach 3 US dollars. Not regular’s double connected valve body outside surface concave convex not flat, machine spray not to dead corner.

Skilled oil paint worker lift holding spray gun, spend whole one hour hand work supplement paint. This piece custom double connected ball valve‘s coat paint fee climb rise to 45 US dollars. Construct team holding tape measure at construct site on measure steel pipe, again encounter new trouble.

8 inches single body ball valve’s length whole world unify is 292 millimeters. Construct site on pave set’s steel pipe lack 5 millimeters align not up, worker go waste material pile find one small section carbon steel short pipe, point up electric weld gun spend 30 minutes just can fill flat gap.

Double connected ball valve two ends’s screw hole distance all is non-standard custom. Two heads flange hole mistake open 3 millimeters, worker use big iron hammer also knock not to together. Whole strip 40 meters long’s craft pipeline face cut re-weld.

• Draw drawing confirm consume spend time: 0 days against 14 days
• Calculate pipe bear how big strength: flip common use book against newly build computer model
• Twist screw need how big effort: look common use form against engineer site calculate
• Enter site move transport equipment’s manual force: two people hands lift against spend money rent 5 tons crane

Rework consume spend’s argon gas and weld wire material money add on worker’s over work fee, bill exceed 3000 US dollars. One family chemical plant expand build pipeline, need give pipe install on 250 pieces physical isolate cut off points.

Buy custom’s double connected ball valve let 80 ten thousand US dollars’s budget swell to 420 ten thousand US dollars. Connect lead produce’s special crane rent money, custom make super long add thick bolt’s money, take factory return capital’s time pull long 8 months.

Late period maintain

Industry pipeline day day flow holding mix holding mud sand’s chemical water. Inside’s plastic gasket one day to night by sand scrape rub. Water pump connect holding turn 8000 hours, face head block water’s valve gasket is grind out one strip 0.5 millimeters deep’s groove.

Water gauge on’s pointer drop to 1.3 MPa. Original’s scale stop at 1.5 MPa. Iron pipe below drip drip tick tick leak out one puddle water. Machine repair shift leader holding dispatch work sheet run go site repair this block water’s iron lump.

Pipe on connect holding install two single body ball valves, two sides’s situation all not same. Upstream that single body valve block big part mud sand, inside’s plastic ring break till very fierce. Downstream’s single body valve is protect till strict strict solid solid, plastic ring not break one point.

Three pipe workers from warehouse move out one just buy’s new single body ball valve. Buy piece bill on write holding 120 US dollars. Workers lift holding a handle pneumatic wrench, spend 15 minutes, take pipe joint on’s 8 roots big screws all unload down come.

This 45 kilograms heavy’s old valve is by two people lift walk throw into waste material basket. New valve stuff into pipe gap, worker take screw torque hit to 120 Newton meters, not reach two hours pipeline recover pass water.

Downstream that not break’s single body valve stay at original position one move not move. Workshop this time repair equipment spend 120 US dollars buy parts, dig 90 US dollars give worker issue work money. Warehouse outside’s waste iron basket inside extra one piece 45 kilograms’s waste steel.

That strip 0.5 millimeters’s scratch grow in double connected ball valve belly inside, trouble big much. Face water face’s that half side plastic ring break, two sides’s big iron ball all by dead dead seal at a heavy 280 kilograms’s steel shell inside.

Manufacturer explain book write till very clear, strict forbid worker at bring water pressure’s pipe beside dismantle open double connected valve belly. Worker no way alone take break drop’s that half side unload down come change new piece.

Machine repair shift leader hit telephone spend 400 US dollars call come a unit 5 tons level’s truck crane. Four workers full head big sweat, spend three hours dismantle drop 16 roots add thick high strength screws, take huge’s double connected valve from pipe on hard pull down come.

Forklift take this buy come spend drop 8500 US dollars’s giant equipment transport into waste station. Valve belly inside downstream that one half good good’s iron ball and gasket, follow holding break drop’s half side one block is throw into garbage pile.

• Throw drop’s waste metal weight: 45 kilograms against on 280 kilograms
• Perfect parts by implicate throw drop’s ratio: zero against on percent of fifty
• Go warehouse collect new piece’s spend fee: 120 US dollars against on 8500 US dollars
• Do work match equip’s tool: pneumatic wrench against on 5 tons truck crane
• Repair good equipment consume spend’s time: 110 minutes against on 350 minutes

Workers use steel wire rope tie live a brand new’s 8500 US dollars double connected ball valve, one little little hoist holding toward pipe on install. Workshop repair patch a several cents’s plastic ring, throw drop one big lump good steel, bill on extra out two sets completely new’s inside parts money.

Repair leak water pipe has two books detail account.

Maintain project core calculate	Two single body ball valves string connect	Single double connected ball valve
Buy new equipment dig’s money	120 US dollars	8500 US dollars
Rent crane spend’s bank note	0 US dollars	400 US dollars
Garbage station collect’s process fee	50 US dollars	300 US dollars
Leak water implicate throw drop’s good iron	0 kilograms	140 kilograms
Workshop site do work person number	3 people hand lift	4 people match machine

One family chemical plant has 50 strips run liquid medicine’s pipeline. Every month almost has 20 pieces valves will by mud sand grind pierce leak water.

According holding double connected ball valve’s make method, every month throw drop change new’s buy piece money burn drop 170000 US dollars. Retain single body ball valve two string connect’s make method, go hardware warehouse collect 20 pieces new single body valves, parts expense stop at 2400 US dollars.

Environment protect bureau toward factory throw garbage collect money. Waste station process a small size single body valve collect 50 US dollars. Cut open decompose that thick heavy complex’s double connected valve body, waste material field open price 300 US dollars.

First line worker fear move dead heavy’s machine. Two roots pipe middle stuff a light clever’s single body valve, take several handles hand work wrench can do finish. Deal with a 280 kilograms’s iron lump, shift leader go handle high altitude hoist operation ticket run half day.

Factory chief every month flip look equipment repair record sheet. Worker change a single body ball valve, run watch press at 110 minutes stop down.

Crane go change stupid heavy’s double connected equipment, clock pointer walk past 350 minutes. Pipeline stop water stop produce, factory every one minute less produce value 80 US dollars’s chemical raw material.

• Accurate change parts’s make method: single body valve break where change where
• By innocent implicate’s part: double connected valve half good parts act as waste sell
• Worker do work’s bitter bitter degree: lift holding wrench do against on drive holding crane do
• Repair equipment stop water hold out’s loss: 8800 US dollars against on 28000 US dollars

Machine engineer understand plastic soft pipe pieces early late will grind break. Take two alone’s valves connect holding install at pipe on, make a wall look can see’s iron wall. Break parts only stop at first layer steel shell inside, cross not go second path barrier.

Hidden cost

Chemical plant’s hardware warehouse occupy ground 3000 square meters. Three layers high’s steel make shelf on, put holding dozen pieces paper box install’s 8 inches standard single body ball valve. Buy back shelf on’s spot goods spend not reach 5 ten thousand US dollars. Factory inside 50 strips run liquid medicine’s pipeline, all rely shelf on’s common use parts act as substitute.

Change on double connected ball valve go block water, warehouse director full head big sweat. Every strip pipeline bear’s water pressure and flange interface all not same. 300 pieces custom make’s big iron lump dimension all align not up, no way mutual top replace.

Purchaser dig out near 200 ten thousand US dollars’s flow fund. A pile not know which year can use on’s double connected valve advance buy back come, pile at warehouse cement ground on.

Finance room’s abacus hit till very loud, 200 ten thousand US dollars lie at warehouse inside eat dust, every month white white throw drop 8000 US dollars’s bank interest money.

Week two afternoon three o’clock, 2 number ethylene pipeline’s block water valve by corrode pierce hole. Alarm one sound, control room pull down electric switch, whole strip product line stop work. Workshop director dead stare holding wall on’s second needle. Machine stop turn one hour, factory inside less sell out value 10 ten thousand US dollars’s chemical raw material.

Three machine repair workers drive holding electric battery car, spend 5 minutes rush to hardware warehouse. Use single body ball valve’s pipe not lack substitute piece. Workers collect out a 120 US dollars’s standard piece, run back leak water point pull down old iron block change on new piece.

Afternoon five o’clock exact, water pump newly pass electricity. Run finish whole piece rush repair flow process, stop water time dead dead clip at two hours. Finance ledger write down 20 ten thousand US dollars’s stop work hole.

Double connected ball valve out trouble bump on warehouse inside not have spot goods, big trouble come. Workshop give oversea make valve factory hit add emergency telephone. Technician flip out three years front’s drawing, report out a let person reverse suck cold gas’s hand over goods day number: 16 weeks.

Wait 112 days’s time inside, break open’s pipeline even one drop water also pass not cross go. Factory area inside’s workers only can dry stare eye.

Heavy type machine float ocean cross sea’s 112 days inside, stop produce detail account on’s number one road mad soar to 2.6 hundred million US dollars.

Factory inside’s single body ball valve ten thousand one break goods, purchaser drive holding small pickup go ten kilometers outside’s hardware city. Spend 300 US dollars on site pull back come one vehicle. Whole world several thousand families machine factory all at make one mold one sample’s standard iron piece. Iron pipe joint on’s 8 screw holes forever at fix position.

Hardware store shelf on find not to 8500 US dollars’s custom make double connected ball valve. Huge’s custom make piece want drive 3000 tons’s hydraulic press, take whole piece hot steel slow slow smash out come.

Iron block send into five axis machine tool scrape shave 22 hours. Dig double’s money let factory worker reverse shift insert team rush work, take pig iron turn become finish product issue goods most little wait 35 days.

Two sets plan at warehouse and workshop’s bill difference extreme big:

• Occupy use’s land skin area: single body valve shelf occupy ground 10 square meters, double connected valve wood box pile full 300 square meters ground surface
• Press warehouse’s bank note amount: 5 ten thousand US dollars buy whole factory common use piece, 200 ten thousand US dollars buy a pile non-standard dead piece
• Supplement goods’s wait day number: drive pickup half hour buy back come, wait cross ocean goods ship sail 112 days
• Stop water not do work’s price: machine stop turn loss 20 ten thousand US dollars, factory face 2.6 hundred million US dollars account surface lack mouth

Night shift machine repair worker half night two o’clock receive leak water telephone. Run holding 90 degrees hot water‘s iron pipe need immediately cut off. Single body ball valve’s spare piece box just at workshop door outside 20 meters place’s iron sheet cabinet inside.

Worker take key open cabinet door, pull out a 30 kilograms heavy’s single body valve. Wear on labor protect glove walk five minutes to leak water point, twist tight flange plate on’s 8 pieces bolts do finish work.

Double connected valve’s backup piece too big too heavy, workshop cabinet basically stuff not in go. Night shift worker run go three kilometers outside’s big warehouse find on duty member take key.

Drive 2 tons level’s diesel forklift, take install at wood box inside’s 280 kilograms iron guy pick up come. Vehicle with per hour 15 kilometers’s slow speed drive to dozen meters high’s pipeline below direction.

Half night find key move thing toss finish, sky all light. 3 hours’s stop produce time along sewer white white flow walk. Pipe no way pass water, backward 3 pieces reaction kettle all by hold stop.

Warehouse shelf on’s save goods kind class more little, factory chief sleep more grounded. Use two cheap’s single body ball valve string at one block, 300 pieces pipeline cut off point all use same one style spare piece come change.

Equipment out trouble worker lift hand can take to new part, 24 hours turn run’s water pump stop turn’s time by press till very short. Common use spot goods parts protect live workshop day night start work’s produce flow line.

application flexibility

Space freedom degree

A 10 inches Class 300 standard’s connected body double ball valve long reach 787 millimeters. Solid heart cast steel outer shell let this iron lump’s weight soar to 420 kilograms. Maintain worker carry holding 5 tons level’s hand pull hoist drill into 1970 year build’s old factory building pipe gallery. Head top is rust’s H shape steel big beam, beside close stick holding 380V strong electricity cable bridge frame.

Equipment can stuff in go’s gap only has mere 400 millimeters. Hard take several hundred kilograms’s super big size valve hoist install in go extreme easy smash break cable.

• Pipe gallery most down layer pass path’s limit high severe not foot 2.5 meters
• Stick near beside high temperature steam pipeline’s preserve temperature cotton only left 150 millimeters gap
• Straight up direction across holding one strip 600 millimeters wide’s main line cable iron sheet slot
• Bear weight wall dead corner let long handle wrench even 360 degrees twist tight bolt’s space all not have

Separate install two single ball valve take pipe road how walk’s decide right hand back give site worker. Change become two units same sample 10 inches’s single ball valve, every unit length shrink short to 356 millimeters. Single piece valve weight drop to 180 kilograms. Construct team at pipe on cut one knife, weld up go a 90 degrees bend head.

A number valve flat lie holding install at one section horizontal’s iron pipe on. Up end flange plate’s edge just good leave that root rust’s H shape steel 50 millimeters. Pipeline along bend head vertical toward down direction stretch stretch 1.2 meters. B number valve steady steady proper proper ground hang at vertical pipeline on, hide open up face that pile cable.

Caliber slight big point’s valve leave factory all will match on stupid heavy’s gas move switch jar. Original 8 inches hand move ball valve’s wrench need leave out 600 millimeters’s wave move half circle. Install on double gas cylinder’s execute organ will at valve top end extra out 450 millimeters’s high hat.

Two units separate open’s single valve can use middle block open’s that section pipe adjust direction. Worker take two valve top end’s gas move jar separate separate toward east side and west side mistake open. Sea on drill well platform skid block inside’s equipment dense degree high reach 80%. Mistake position install let two huge’s gas cylinder at 800 millimeters distance inside who also bump not to who.

Site interfere bump strike not limit at valve itself, attach belong parts same occupy place.

• Phase neighbor’s two gas cylinder flange screw hole purpose mind mistake open 90 degree angle fix
• Hand wheel turn one circle’s most big edge distance worker walk’s pass path red line 500 millimeters
• Control switch’s liquid pressure oil pump station use high pressure soft pipe hang at two meters outside’s iron fence on
• Side face’s DCS guard explode connect line box cover leave foot 300 millimeters’s lift open gap

Day common do set period keep raise draw check, must take two head’s flange plate pull open. Liquid pressure flange support open tool’s iron piece need stuff in go 200 millimeters deep just can top loose seal gasket. Whole body hoist out come a 420 kilograms’s double valve, must dismantle drop surround 3 meters inside’s steel frame. Site must drive in come a unit stretch holding 6 meters long big arm‘s diesel small crane.

180 kilograms’s single valve dismantle up come just relax too much. Lift heavy worker take a 2 tons’s reverse chain hang at beside’s 12H shape mark steel pillar on. Take one root ordinary’s solid heart steel pry stick slight give a 15 degrees left right’s tilt angle. Out break block’s half side single valve very smooth smooth ground just can from pipe middle pull out come.

Pipe inside flow holding high temperature liquid will let iron pipe happen very obvious’s pull stretch pull long. Run holding 260°C pass hot steam’s carbon steel main pipeline every toward long walk 1 meter will stretch long 3 millimeters. Dead heavy dead heavy’s double ball valve clip at middle, hard carry down good several ten thousand newtons’s metal twist bend force.

Take two units 6 inches’s single valve far far ground separate open install, can melt solve drop this share dead strength gas. Pipeline design draw regular regular hard nature rule pipeline must how leave out cross force shape change area.

• Large form isolate valve hide open bear receive 10 tons heavy force’s main pipe thin weak cross weld seam
• Block holding a wall 500 millimeters thick’s steel muscle mix mud earth guard fire wall two head each install a valve
• High pressure rubber soft connect head every day melt solve drop heavy form water pump 15 times fierce shake move
• Bottom part’s iron plate spring frame give pipe leave 50 millimeters up down live move’s remain ground

Unload drop API ratio heavy 15’s black heavy oil, origin factory self bring’s 3/4 inches small pipe hole 40 seconds just block dead. Two units single valve middle empty holding 1.5 meters long’s ordinary carbon steel pipe.

Electric weld worker at most down face cut a hole weld up a 3 inches’s thick iron pipe row dirt port. Worker connect up 1.5 MPa’s high pressure steam water gun toward pipe cavity inside fierce blow.

Double cut off & leak release

One root 12 inches thick’s main pipeline inside run holding 15 MPa high pressure’s have poison gas, check repair front must take two head shut dead and row empty middle’s remain remain object. Worker face pair a unit origin factory one body make create’s double ball valve, discover thick solid’s cast steel belly bottom face only hit a 1/2 inches’s screw thread small eye. That match good’s fine small row gas hole inner diameter mere mere only have 12.7 millimeters.

Pipe inside send’s is API ratio heavy 12’s heavy quality black oil, will at metal pipe wall leave down 3 millimeters thick’s sticky paste remain dreg. Worker fee big effort twist open that 1/2 inches’s small valve, one drop oil all flow not out come. Inside’s micro small hole cave early just by hard till like stone one sample’s asphalt block thorough bottom seal dead.

Beside’s machine tool pressure gauge pointer steady steady stop at zero scale degree on. Two pieces big iron ball middle’s seal close cavity inside real reality on still hold holding 8 MPa’s danger pressure. Down flow’s maintain repair worker if none lack guard prepare take angle grind machine cut open main pipeline, one share 80 bar’s pressure blink space spray out come, can take one piece 5 kilograms heavy’s iron piece like cannon shell one sample hit fly.

Take this place separate away point dismantle divide become two units 12 inches’s alone stand single ball valve, site ground do work’s bureau face just complete whole change. Two units single valve middle leave out a section 2 meters long’s standard carbon steel iron pipe. Construct team take wait leave son cut divide machine, at this section carbon steel pipe’s most bottom face burn pierce a 100 millimeters’s big hole.

Electric weld worker take advantage hot hit iron, smooth hand connect up one root solid firm’s 4 inches forge steel branch branch short pipe. Toward up install a unit 4 inches caliber’s ordinary gate valve, row dirt pass road blink space have a 101.6 millimeters’s wide big inside diameter. No care iron pipe inside gather save how much clip holding yellow sand’s thick oil, one pull open gate door all number wash rush into waste liquid ground ditch.

Wide open’s middle iron pipe give site ground shift group supply provide extreme big’s move hand change make remain ground:

• Weld up 1/2 inches’s endure high pressure flange, toward inside pour 150℃’s hot steam melt solve sticky thick asphalt
• Outside connect a measure range 0 to 25 MPa’s pressure gauge, dead dead stare holding up flow big valve to bottom leak not leak water
• Connect up one root inside diameter 50 millimeters’s wave pattern soft pipe, take have poison’s sulfur turn hydrogen gas lead flow into thirty meters outside’s fire torch tower
• At pipe bottom end install a bring iron wire net’s loose water valve, row dry every hour self move gather up come’s 3 liters cold condense water

Pipe inside’s liquid regular regular mix holding straight path 2 millimeters’s push change agent hard dreg. Standard ball valve’s metal ball body and plastic gasket circle pass space’s gap only have 0.1 millimeters. Extreme fine’s waste dreg by high pressure liquid push holding, dead dead clip at micro small’s gap inside crazy mad scrape rub iron skin.

Up flow’s head path single valve by sand grind flower bright light’s seal close face, every minute toward middle pipe section leak in go 5 liters’s dirty water. Connect body double valve that 1/2 inches’s fine hole base root come not pass row walk so much water, not reach half hour just by mud paste thorough bottom block dead. Hold high’s water pressure stand horse wash break down flow second path ball valve’s rubber seal close circle.

Separate open install’s two single valves match join that root 4 inches’s fix make thick pipe, ten part light relax ground reply pay every minute 5 liters’s leak water quantity. Mud sand and dirty water along holding wide bright’s thick pipe hua la la flow into down water road. Down flow’s second path single valve dry dry clean clean, hundred part of hundred block live maintain repair worker body back’s danger.

Pipe workers at site ground to bottom can take two head block dead, middle row empty’s system change become what sample, with origin factory’s dead board set fix compare one compare just very clear.

Rule standard parameter number	Connect body double ball valve origin factory match set	Alone stand double valve match join middle iron pipe open mouth
Row dirt pipe thick fine limit boundary	Most big 3/4 inches (19 millimeters)	Follow mind open hole can reach 4 to 6 inches (100 to 150 millimeters)
10 liters mud sand row dry time	About 15 minutes (need person work take fine iron wire come back poke)	Not reach 5 seconds clock (smooth smooth row empty)
High temperature steam pipe connect enter	Not leave origin factory interface, thick iron shell on extreme hard self self add install	Any mind electric weld up go 2 pieces 1/2 inches standard flange plate
Block dead back’s loose pass tool	Only can insert in go 2 millimeters thick fine’s soft iron wire	Allow dig out 200 bar high pressure water gun violent force poke in go wash wash

One strip 600 pounds level grade’s steam main pipe net run holding 41 bar pressure and 400 celsius degree’s high temperature. Two head shut dead’s valve middle leave down’s cold condense water will lead post extreme extreme scare person’s hit strike force. One lump 50 grams heavy’s water lump with per second 30 meters’s speed fierce hit metal bend head, can on field take two fen thick’s iron pipe wall shake out crack line.

Workshop only can point send one patrol check worker every block 4 hours exact time run cross go. Wear holding thick skin glove hand move twist open that 1/2 inches’s fine pipe, release drop 800 milliliters emit holding white gas’s roll hot open water.

Change become alone stand separate open cloth set’s plan rule, 1.5 meters long’s middle iron pipe most low point by weld up a 1 inches’s hot move force shape loose water valve. Every block 45 minutes, loose water valve self move toward outside spit out 1.2 liters’s cold condense water. Not have which patrol check worker need at 400 degrees’s danger high temperature iron pipe beside turn walk.

Change check room’s skill worker day day want at cut break’s pipe section inside lift fetch high pressure liquid’s sample book. Two head valve separate open’s cloth board allow at middle iron pipe on use four roots thick bolt fix set a heavy reach 30 kilograms’s add thick pick sample steel bottle. Connect up stainless steel clip sleeve joint safe whole pull out 500 milliliters black oil.

Drop low maintain repair cost

One strip walk quartz sand liquid’s 8 inches thick iron pipe, inside head’s flow speed high reach per second 15 meters. Row at most front head’s first path valve, every day want suffer on ten thousand times rough rough sand grain’s fierce fierce scrape rub. Face holding water flow’s that half circle metal seal close gasket, hard carry not reach 14 months just will by grind out one path 0.5 millimeters deep’s hit life ditch trough.

Factory inside’s maintain repair stand account remember till very clear: lean front’s A number big valve leak water rate pass API 598 country standard foot foot 30 times, hide at back head’s B number valve test measure data depend remain complete beauty, one drop water all not leak.

Bump on front half section grind rotten’s shape condition, buy connect body double valve’s pipe line shift group eat big lose. Repair patch front face leak water’s that one path mouth, check repair team hard want take heavy reach 350 kilograms’s double valve total assemble whole piece dismantle down come act as waste iron throw drop. Warehouse still must approve paper slip spend 45000 US dollars, go newly order a origin install’s connect body big iron lump.

Warehouse protect tube member turn head from ordinary goods shelf on push cross come a unit 12000 US dollars’s regular rule single valve. Four piece worker spend 3 hours, take two handle big size liquid pressure pliers pull open pipe joint head, alone take grind rotten’s A number valve change drop just okay. Back face perfect good’s B number valve even one piece screw all not use move.

Do pipe line construct work’s old hand at pull purchase sheet time, extreme extreme good at use material quality mix match’s method come control open burn. Meet reach wash rush force extreme strong’s seat place, front back two piece valve base root not have must want buy same sample expensive’s material material.

• Face holding sand wash rush’s head path valve smash 28000 US dollars, fix make inner part weld 5 millimeters thick cobalt base alloy’s super hard metal piece
• Back direction start second path protect danger action’s valve bump not to sand, only match a unit 8000 US dollars’s ordinary 316 not rust steel valve
• Two piece add up come one total 36000 US dollars, hard is compare buy a full special species steel material’s connect body big valve save down near one ten thousand US dollars

Alone say buy east west save money pass outside, equipment more heavy, toward inside smash’s machine tool rent rent fee more let person meat pain. Change a unit 16 inches Class 900 level grade’s high pressure connect body valve, iron shell’s total weight absolute break break 1.2 tons. Factory inside must go outside find a unit carry weight 25 tons’s track big crane drive into factory building, one day’s rent money connect same two piece driver’s work money little say want dig out 1500 US dollars.

Equipment section’s tone move sheet on will extra outside add yard: operate industry point round surround 20 meters inside strict forbid any vehicle stop vehicle, must hire person knock drop two wall 240 millimeters thick’s brick wall give crane empty out turn bend empty ground, mix fee again want extra out 5000 US dollars.

Take iron lump dismantle solve become same rule format’s alone stand single valve, single piece shell’s weight stand horse drop to 500 kilograms out head. Maintain repair shift leader go tool room collect three piece 5 tons level’s hand pull reverse chain, smooth hand hang at factory building top on origin have’s H shape mark steel beam on. Three piece pipe worker drag holding iron chain, lean pure person force just can take report waste old piece steady steady put to flat board hand push vehicle on, one fen money crane fee all not use spend.

Single body valve dismantle down come throw into pickup vehicle, pull to 50 kilometers outside’s machine process workshop, old master up vehicle bed spend 48 hours throw light just can continue use. One ton more heavy’s double body big valve must please one unit 13 meters long’s flat board half hang vehicle pull back origin factory big repair, come back’s public road transport fee just want 800 US dollars.

Warehouse goods shelf on press’s spare piece all is real gold white silver. Special make’s connect body big piece belong at extreme little see’s cold door goods, lift front 8 months just want toward sea outside factory hit full section hand over fix money. Guard prepare half night burst happen pipe line burst split, warehouse regular year put holding two three units several ten thousand US dollars’s spare piece eat dust, put on five years finance account face on’s fold old fee ten part hard look.

Single body isolate valve all is hardware market on arrive place all have’s pass goods. One seat large shape urge turn split turn factory area inside have 300 more piece pipe mouth install holding 8 inches regular rule single valve. Warehouse spare up ten come units standard goods, where face water face break any time pull out go top shift. Hit telephone patch goods not reach 3 weeks just can send into factory, account on by occupy use’s dead money shrink water seven eight percent.