Extending the Life of Your Valves
In the production process of the electric power industry, valves bring a lot of conveniences, and their application range is also extensive, such as effective control of transmission flow and effective connection of adjacent pipelines. Not only that, but the valve also plays a very active role in the pre-construction and post-maintenance of the pipeline. In fact, as long as the equipment is in operation, it is possible to have faults and problems, and so is the valve. Therefore, once the valve fails, it will not only affect the quality of electric power production but also affect its production efficiency. Therefore, relevant technicians must carry out regular overhaul and maintenance to minimize the economic loss caused by valve failure.
Common Faults and Main Causes of Valves
1. Valve quality is not up to standard
In the process of electric power production, the quality of the valve directly determines its function level. Therefore, production enterprises should strictly control their quality level to ensure that every valve produced can meet relevant regulations and use standards in terms of quality. In the process of purchasing, it also needs to be strictly tested. Only by ensuring that there are no quality problems can it be put into use. However, some enterprises choose some inferior valves with quality problems in order to obtain more economic benefits and reduce their input costs, thus increasing the hidden trouble. In addition, on the premise of ensuring that the valve quality does not have any quality problems, it is also necessary to improve its installation requirements and adopt correct installation technology to avoid valve failure caused by incorrect installation.
2. The valve is over-used and the maintenance is not timely.
Not only valve equipment, but also all equipment have certain limitations in the use process. If there is a high frequency of use, the damage and aging speed of valves will be accelerated. Especially in the field of electric power production, most of its raw materials are highly corrosive. This factor greatly increases the uncertainty of valves in use, and at the same time has a certain influence on the service life of valves.
3. The installation error of the valve body
For the main welding of valve equipment, it is necessary to have exquisite welding technology, so as to reduce the probability of valve failure caused by welding quality problems. When repairing and welding the valve body, if there are some problems in the welding technology, it will increase the probability of valve failures such as cracking of the valve body and gaps between the valve body and the base.
4. Failure caused by improper operation
For the staff in charge of the valve, the most important and basic thing is to have good operation skills, because only with certain operation ability can the error rate be reduced in the actual operation process. However, in the actual operation process, due to the fact that some technicians can't operate according to the relevant specification requirements, there is a phenomenon of excessive force for the control of the operating lever, and the protection body of the valve can't make excessive force protection in time, so the valve fails.
5. Valve packing error
When filling the valve, we must pay attention to its adding amount. If it is added too much and the degree of compaction is too high, it will increase the failure rate of the valve in use.
Testing Work and Early Maintenance before the Valve Is Put into Use
1. Preventive measures before valves putting in service
The maintenance of the valve before it is put into use can well reduce the failure probability in operation, and it is a necessary means to ensure the long-term and efficient operation of the valve. Therefore, for electric power enterprises, it is necessary to work out the corresponding maintenance system based on the basic types of valves, which mainly covers the basic installation, daily maintenance and fault maintenance of valves. First of all, when purchasing valve equipment, we must combine the relevant national regulations and relevant use requirements to purchase valve equipment. After the valve is purchased, a special transport vehicle needs to be assigned to transport it back to the production workshop. Of course, during transportation, the valve must be well fixed to avoid damage during transportation. Secondly, when the valve equipment is installed, it should be maintained in time, and it should be cleaned in time after all the installations are completed, including water stains, oil stains and stains, to avoid unnecessary influence on the normal operation of the valve and the overall service life. In addition, the technical department is also required to evaluate and predict the operating environment and service life of the installed valve components, and timely replace and adjust the valves that have already reached the expiration date. Finally, electric power enterprises also need to formulate the most targeted maintenance plans and systems for different valve types and carry out regular maintenance and overhaul, so as to effectively reduce the failure probability of valves and greatly prolong their service life.
2. Maintenance before the valve is put into operation
Normal maintenance of the valve before it is put into use can not only improve the efficiency of the normal operation of the valve but also reduce the probability of valve failure. First of all, in the transportation stage of the valve, under the premise of strictly complying with the relevant regulations, it is also necessary to properly keep the relevant certificates, such as the outer package, certificate of approval, installation instructions and other items, and do a good job in moistureproof and anticorrosion. After being transported to the designated place, the relevant technicians also need to conduct a comprehensive inspection to see if there is any damage to the outer packaging, whether the contents of the certificate are clear and complete, and whether the switches in the valve components can rotate smoothly. Secondly, when using the hoisting machine to transfer the valve, it is necessary to ensure the safety of the hook, to avoid the sharp part of the hook from scratching and damaging the valve nozzle, and to avoid the above phenomenon increasing the probability of valve failure and even leading to valve scrapping. Finally, when welding valves, different greases should be selected according to the basic types of valves, and valves and pipelines should be properly protected. After the installation of the valve process is completed, it needs to be checked again to see if there is looseness at the interface position and check whether the drainpipe mouth and the pressure discharge pipe mouth are locked. In addition, in the process of the welding operation, it is very easy for the valve to be damaged, which will have a certain influence on its airtightness and pressure capacity. Therefore, after the welding operation is completed, it is necessary to conduct a comprehensive inspection of the pressure capacity.
3. Installation and commissioning of valves
When testing the valve pressure, water injection in the pipeline is usually used, which mainly uses the water pressure to measure the final pressure-bearing capacity of the valve. Before the water injection operation, it is necessary to use some pigs with the same diameter as the pipes to clean the impurities inside the valves and pipes. In the process of water injection, it is necessary to ensure that the valve is fully open, and supervise its working state throughout the whole process to check whether there is any leakage. Once there is a problem, it is necessary to stop water injection for the first time and take effective measures to solve it. For the valve parts that fail in the process of water injection, the service quality must be comprehensively evaluated in the process of maintenance. If it is found that it cannot be used, it should be replaced in time. When the water injection operation is completed, the workers need to adjust the valve to the half-open state and test the pressure-bearing capacity, and the pressure measurement time needs to be controlled within 4-24h. After the pressure measurement is completed, the test water in the pipes and valves needs to be completely cleaned and drained, and the valve needs to be adjusted to the full-open state. In the process of pressure measurement, professional personnel must supervise on-site to prevent the valve from being damaged due to the wrong operation of operators.
Maintenance after the Valve Is Put into Use
1. Maintenance of valve transmission device
The transmission device is the most important component in valve equipment, and of course, it is also the component with the highest failure rate. Therefore, relevant personnel must do a good job in repairing and maintaining this component. Some types of valves will be in a fully open or fully closed state during actual operation, and only at important moments will they show a single change. Such an operating state will greatly reduce the wear degree of the transmission device. However, for some valves in important parts, they will always be in the state of frequent replacement of opening and closing during actual operation. In this state, the operating speed of the transmission device will be increased and its wear degree will also be increased. Therefore, in the process of installing the valve, it is necessary to implement the greasing work in important parts to ensure the durability of the valve actuator.
2. Matters needing attention in valve greasing
Valves in long-term operation are in great need of grease, but the added amount of grease must be strictly controlled. If there is too much grease, the valve will be too sensitive, which is very unfavorable for later regulation and control. On the contrary, if there is relatively little grease, it will increase the running resistance of the valve and the wear degree of the internal parts of the valve. Therefore, high quality and proper amount of grease are very important for the normal operation of the valve.
3. Maintenance of valve packing
The purpose of packing operation in the valve is to ensure the airtightness of the valve. If the packing in the valve fails or its weight is insufficient, it will have a very serious impact on its overall airtightness, and even cause the valve to lose its original function. It is not only the transport material in the pipeline that affects the packing in the valve but also the high temperature caused by the long-term operation. These factors will accelerate the aging speed of the packing in the valve. Therefore, in the routine repair and maintenance of the valve, it is necessary to do a good job of filling the valve in advance to ensure that there is no leakage and reinforce and tighten the surrounding screws. Some types of valves add some grease during packing operation, the purpose of which is to make the valve a good performance in the future use process. Of course, in the process of maintenance, it is necessary to add some grease inside the packing to endow a role of lubrication and protection.
Conclusion
Through the analysis of this article, it can be seen that in the whole electric power production industry, valves occupy a very important position and function, which is not only in the control of raw materials but also in the transportation of finished electric power products. There is a direct relationship between the loss degree of the valve and its opening and closing times. When the opening times are higher, the failure rate of the valve will increase. Therefore, in the process of use, the most scientific and effective operation mode should be adopted to reduce the failure probability of the valve. In addition, it is necessary to monitor the actual operating state of the valve in real-time, so as not to increase the economic loss of the enterprise due to the fault.
Common Faults and Main Causes of Valves
1. Valve quality is not up to standard
In the process of electric power production, the quality of the valve directly determines its function level. Therefore, production enterprises should strictly control their quality level to ensure that every valve produced can meet relevant regulations and use standards in terms of quality. In the process of purchasing, it also needs to be strictly tested. Only by ensuring that there are no quality problems can it be put into use. However, some enterprises choose some inferior valves with quality problems in order to obtain more economic benefits and reduce their input costs, thus increasing the hidden trouble. In addition, on the premise of ensuring that the valve quality does not have any quality problems, it is also necessary to improve its installation requirements and adopt correct installation technology to avoid valve failure caused by incorrect installation.
2. The valve is over-used and the maintenance is not timely.
Not only valve equipment, but also all equipment have certain limitations in the use process. If there is a high frequency of use, the damage and aging speed of valves will be accelerated. Especially in the field of electric power production, most of its raw materials are highly corrosive. This factor greatly increases the uncertainty of valves in use, and at the same time has a certain influence on the service life of valves.
3. The installation error of the valve body
For the main welding of valve equipment, it is necessary to have exquisite welding technology, so as to reduce the probability of valve failure caused by welding quality problems. When repairing and welding the valve body, if there are some problems in the welding technology, it will increase the probability of valve failures such as cracking of the valve body and gaps between the valve body and the base.
4. Failure caused by improper operation
For the staff in charge of the valve, the most important and basic thing is to have good operation skills, because only with certain operation ability can the error rate be reduced in the actual operation process. However, in the actual operation process, due to the fact that some technicians can't operate according to the relevant specification requirements, there is a phenomenon of excessive force for the control of the operating lever, and the protection body of the valve can't make excessive force protection in time, so the valve fails.
5. Valve packing error
When filling the valve, we must pay attention to its adding amount. If it is added too much and the degree of compaction is too high, it will increase the failure rate of the valve in use.
Testing Work and Early Maintenance before the Valve Is Put into Use
1. Preventive measures before valves putting in service
The maintenance of the valve before it is put into use can well reduce the failure probability in operation, and it is a necessary means to ensure the long-term and efficient operation of the valve. Therefore, for electric power enterprises, it is necessary to work out the corresponding maintenance system based on the basic types of valves, which mainly covers the basic installation, daily maintenance and fault maintenance of valves. First of all, when purchasing valve equipment, we must combine the relevant national regulations and relevant use requirements to purchase valve equipment. After the valve is purchased, a special transport vehicle needs to be assigned to transport it back to the production workshop. Of course, during transportation, the valve must be well fixed to avoid damage during transportation. Secondly, when the valve equipment is installed, it should be maintained in time, and it should be cleaned in time after all the installations are completed, including water stains, oil stains and stains, to avoid unnecessary influence on the normal operation of the valve and the overall service life. In addition, the technical department is also required to evaluate and predict the operating environment and service life of the installed valve components, and timely replace and adjust the valves that have already reached the expiration date. Finally, electric power enterprises also need to formulate the most targeted maintenance plans and systems for different valve types and carry out regular maintenance and overhaul, so as to effectively reduce the failure probability of valves and greatly prolong their service life.
2. Maintenance before the valve is put into operation
Normal maintenance of the valve before it is put into use can not only improve the efficiency of the normal operation of the valve but also reduce the probability of valve failure. First of all, in the transportation stage of the valve, under the premise of strictly complying with the relevant regulations, it is also necessary to properly keep the relevant certificates, such as the outer package, certificate of approval, installation instructions and other items, and do a good job in moistureproof and anticorrosion. After being transported to the designated place, the relevant technicians also need to conduct a comprehensive inspection to see if there is any damage to the outer packaging, whether the contents of the certificate are clear and complete, and whether the switches in the valve components can rotate smoothly. Secondly, when using the hoisting machine to transfer the valve, it is necessary to ensure the safety of the hook, to avoid the sharp part of the hook from scratching and damaging the valve nozzle, and to avoid the above phenomenon increasing the probability of valve failure and even leading to valve scrapping. Finally, when welding valves, different greases should be selected according to the basic types of valves, and valves and pipelines should be properly protected. After the installation of the valve process is completed, it needs to be checked again to see if there is looseness at the interface position and check whether the drainpipe mouth and the pressure discharge pipe mouth are locked. In addition, in the process of the welding operation, it is very easy for the valve to be damaged, which will have a certain influence on its airtightness and pressure capacity. Therefore, after the welding operation is completed, it is necessary to conduct a comprehensive inspection of the pressure capacity.
3. Installation and commissioning of valves
When testing the valve pressure, water injection in the pipeline is usually used, which mainly uses the water pressure to measure the final pressure-bearing capacity of the valve. Before the water injection operation, it is necessary to use some pigs with the same diameter as the pipes to clean the impurities inside the valves and pipes. In the process of water injection, it is necessary to ensure that the valve is fully open, and supervise its working state throughout the whole process to check whether there is any leakage. Once there is a problem, it is necessary to stop water injection for the first time and take effective measures to solve it. For the valve parts that fail in the process of water injection, the service quality must be comprehensively evaluated in the process of maintenance. If it is found that it cannot be used, it should be replaced in time. When the water injection operation is completed, the workers need to adjust the valve to the half-open state and test the pressure-bearing capacity, and the pressure measurement time needs to be controlled within 4-24h. After the pressure measurement is completed, the test water in the pipes and valves needs to be completely cleaned and drained, and the valve needs to be adjusted to the full-open state. In the process of pressure measurement, professional personnel must supervise on-site to prevent the valve from being damaged due to the wrong operation of operators.
Maintenance after the Valve Is Put into Use
1. Maintenance of valve transmission device
The transmission device is the most important component in valve equipment, and of course, it is also the component with the highest failure rate. Therefore, relevant personnel must do a good job in repairing and maintaining this component. Some types of valves will be in a fully open or fully closed state during actual operation, and only at important moments will they show a single change. Such an operating state will greatly reduce the wear degree of the transmission device. However, for some valves in important parts, they will always be in the state of frequent replacement of opening and closing during actual operation. In this state, the operating speed of the transmission device will be increased and its wear degree will also be increased. Therefore, in the process of installing the valve, it is necessary to implement the greasing work in important parts to ensure the durability of the valve actuator.
2. Matters needing attention in valve greasing
Valves in long-term operation are in great need of grease, but the added amount of grease must be strictly controlled. If there is too much grease, the valve will be too sensitive, which is very unfavorable for later regulation and control. On the contrary, if there is relatively little grease, it will increase the running resistance of the valve and the wear degree of the internal parts of the valve. Therefore, high quality and proper amount of grease are very important for the normal operation of the valve.
3. Maintenance of valve packing
The purpose of packing operation in the valve is to ensure the airtightness of the valve. If the packing in the valve fails or its weight is insufficient, it will have a very serious impact on its overall airtightness, and even cause the valve to lose its original function. It is not only the transport material in the pipeline that affects the packing in the valve but also the high temperature caused by the long-term operation. These factors will accelerate the aging speed of the packing in the valve. Therefore, in the routine repair and maintenance of the valve, it is necessary to do a good job of filling the valve in advance to ensure that there is no leakage and reinforce and tighten the surrounding screws. Some types of valves add some grease during packing operation, the purpose of which is to make the valve a good performance in the future use process. Of course, in the process of maintenance, it is necessary to add some grease inside the packing to endow a role of lubrication and protection.
Conclusion
Through the analysis of this article, it can be seen that in the whole electric power production industry, valves occupy a very important position and function, which is not only in the control of raw materials but also in the transportation of finished electric power products. There is a direct relationship between the loss degree of the valve and its opening and closing times. When the opening times are higher, the failure rate of the valve will increase. Therefore, in the process of use, the most scientific and effective operation mode should be adopted to reduce the failure probability of the valve. In addition, it is necessary to monitor the actual operating state of the valve in real-time, so as not to increase the economic loss of the enterprise due to the fault.
