The process and specific work of valve maintenance

Valve is one of the most important components in the field of power production. Its main function is to adjust the flow and pipeline transportation. Therefore, some use problems and failures will often occur in the daily use process. If it cannot be checked and repaired in the first time, it will cause relatively serious production and economic consequences. It can be seen that strengthening the repair and maintenance of valves plays a very important role in the power production industry.

In the production process of the electric power industry, the valve has brought a lot of convenience to it, and the scope of use also has a certain wide range, such as effective control of the transmission flow, each adjacent pipeline is effectively connected, etc. Not only that, the valve also plays a very active role in the early construction and later maintenance of the pipeline. In fact, as long as every piece of equipment in operation has the potential to fail and fail, and so do valves. Therefore, once the valve fails, it will not only affect the quality of power production, but also it affects its production efficiency at the same time. Therefore, relevant technical personnel must carry out regular inspection and maintenance to control the economic loss caused by valve failure within the minimum range.

Valve controllers common faults and main causes

1. Failures caused by valve quality not meeting standards and installation errors

In the process of electric power production, the quality of its valves directly determines the level of its role. Therefore, production enterprises should strictly control its quality level to ensure that every valve produced can meet the relevant regulations and use standards in terms of quality (whoever copies my article without taking the source will be unlucky for a lifetime). In the process of purchasing, it is also necessary to be rigorously tested and only put into use to ensure that there are no quality problems. However, in order to obtain more economic benefits for themselves, some enterprises, to reduce its input cost, some inferior valves with quality problems are selected, thereby increasing the hidden danger of failure. In addition, there is no quality problem in ensuring valve quality under the premise of the problem, it is also necessary to improve its installation requirements, and use the correct installation technology to avoid the phenomenon of valve failure caused by incorrect installation.

2. Valves are used too frequently and maintenance is not timely

Not only valve equipment, but all equipment has a certain limit in the process of use. If there is a high frequency of use, it will speed up the damage and aging of the valve. Especially in the field of power production, most of the raw materials are highly corrosive, which greatly increases the uncertainty of the valve in use. At the same time, it also has a certain impact on the service life of the valve.

3. Incorrect installation of valve body

For the main body welding in 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 carrying out the valve body. During the repair welding operation, if there are certain problems in the welding technology, the probability of valve failure such as valve body cracking and gaps between the valve body and the base will increase.

4. Malfunctions caused by improper operation

For the staff who control the valve, the most important and the most basic must have good operating skills, because only with a certain operating ability can reduce the error rate in the actual operation process. However, in the actual operation process, because some technicians cannot operate according to the relevant specifications, the control of the operating lever, the phenomenon of excessive force occurs, and the valve protection body cannot make over-force protection in time, thus causing the valve to malfunction.

5. Valve packing error

When packing the valve, we must pay attention to its addition amount. If the addition is too much, the degree of compaction is too high, which will increase the failure rate of the valve during use.

Test work and preliminary maintenance before the valve is put into use

1. Preventive measures before the valve is put into use

Carrying out maintenance maintenance on the valve before it is put into use can greatly reduce the probability of failure in operation, and this is to ensure that the valve can be maintained for a long time and necessary for efficient operation. Therefore, for power companies, it is necessary to formulate a corresponding maintenance system based on the basic types of valves. It mainly covers the basic installation, daily maintenance and fault repair of the valve. 

First of all, when purchasing valve equipment, it must be combined with relevant national regulations and related use requirements, and purchase valve equipment; after completing the purchase of valves, it is necessary to assign special transport vehicles to transport them back to the production workshop. During the process, the valve must be well fixed to avoid damage during transportation. 

Secondly, when the valve equipment is installed, it should be carried out in time to maintain. When all installations are completed, it needs to be cleaned up in time, including water stains, oil stains and stains, etc., to avoid the normal operation of the valve and the overall service life will be unnecessarily affected. In addition, the technical department needs to evaluate the operating environment and service life of the valve components that have been installed and forecast, timely replacement and adjustment of valves that have expired. Finally, power companies also need to formulate the most targeted maintenance for different valve types.

According to the repair plan and system, regular maintenance and repair are carried out, so that the probability of failure of the valve is effectively reduced, and its service life is greatly extended.

2. Maintenance work before the valve is put into operation

Regular maintenance of the valve before it is put into service 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, relevant certificates are also required, such as outer packaging, certificate of conformity and installation instructions. The products should be properly stored, and the moisture-proof and anti-corrosion work should be done well. After being transported to the designated place, the relevant technical personnel also need to conduct a comprehensive inspection. Check whether there is damage to the outer packaging, whether the content of the certificate is clear and complete, whether the switch in the valve part can rotate smoothly, etc. 

Secondly, after using the hoisting machine to carry out during the transfer operation, it is necessary to ensure the safety of the hook, avoid scratches and damages to the valve nozzle by the sharp parts of the hook, and avoid the increase of valve production due to the above phenomena. The probability of failure, and even lead to valve scrap. 

Finally, in the welding operation of the valve, different greases should be selected in combination with the basic type of the valve, and also it is necessary to properly protect the valve and pipeline; after the installation of the valve process is completed, it needs to be checked again to see if the interface position is loose. If the phenomenon occurs, check whether the sewage outlet and the pressure outlet are in a locked state; in addition, during the welding operation, it is very easy to damage the valve due to the damage of the valve.

Therefore, after the welding operation is completed, it is necessary to conduct a comprehensive inspection of the pressure capacity.

3. Installation and debugging of valve

When testing the valve pressure, the method of injecting water into the pipeline is usually used, which mainly uses the water pressure to measure the final pressure bearing capacity of the valve. Before the operation, it is necessary to use some pigs with the same diameter as the pipeline to clean up the debris inside the valve and pipeline; during the water injection process, it is necessary to verify that the valve is completely open, and supervise its working state throughout the process to check whether there is any leakage. Once a problem occurs, it must be done as soon as possible.

Stop water injection and take effective solutions. For valve components that fail during the water injection process, it must be used during the maintenance process.

Comprehensive evaluation of the quality, if it is found that it cannot be used, it should be replaced in time; when the water injection operation is completed, the staff needs to adjust the valve to a half-open state and test the pressure bearing capacity. The pressure measurement time needs to be controlled within 4 to 24 hours. After the pressure measurement work is completed, it is necessary to completely clean up and eliminate the pressure measurement in the pipeline and valve.

Try the water and adjust the valve to fully open. In the process of pressure measurement, it is necessary to conduct on-site supervision by professionals to prevent the operator's wrong operation.