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Repair and Maintenance

Valve Maintenance And Troubleshooting Procedures

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1st.

Safety management during valve maintenance

  • Prepare relevant management documents such as "HSE Operation Instructions" and "HSE Operation Plan", fill in the "HSE Operation Checklist" on time, and monitor the implementation of the "HSE Operation Instructions" and "HSE Operation Plan" on site at any time.
  • Provide comprehensive safety education and training to all employees to enhance their safety awareness and protect the safety of other personnel and equipment on the construction site while protecting their personal safety.
  • Be equipped with all necessary labor protection gear, wear uniform work clothes, safety helmets, labor protection shoes, and special protective equipment such as acid-proof, alkali-proof, and fire-proof.
  • Develop production emergency rescue plans, accept customer safety education, safety management and supervision and inspection, and ensure safe production and maintenance.
  • Avoid nighttime production and maintenance. If nighttime production and maintenance are required, explosion-proof lighting must be used.
  • The valve repair and maintenance site must be cleaned and regulated every day to ensure environmental friendliness. During the entire valve repair process, it is ensured that there is no personal injury (casualty) and no environmental pollution accidents.
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2nd.

HSE management system and measures

1. HSE Policy and Principles:
  • HSE management policy: "Safety first, prevention first, improve the environment, protect health"
  • HSE management principles: Production must comply with HSE management requirements, and HSE work is the premise of all work.
2. HSE management measures:
  • In addition to receiving safety education from the safety officer, all employees must also receive safety education in the workshop, understand the relevant safety rules and regulations in detail, and receive special safety education. Special operations personnel must have a safety operation certificate issued by the Technical Quality Supervision Bureau and must hold the certificate before they can take up their posts; training and education on dangerous processes and those requiring special safety technical measures must be conducted according to maintenance needs.
  • According to the actual situation, the safety officer conducts various special HSE inspections. If hidden dangers are found, the construction team should make serious rectifications and eliminate the potential accident hazards in a timely manner.
  • During maintenance, a special lifting platform must be used on site to ensure the safety of construction workers.
  • Maintenance and construction machinery and equipment must be in good condition and have complete safety facilities. Mobile equipment used in restricted areas must be inspected and approved by relevant departments before use. Machinery and equipment, mobile equipment, cranes, etc. must be managed and used by designated personnel. Special equipment operators must have safety operation certificates. Relevant safety operating procedures must be strictly followed during operation.

3rd.

Valve maintenance and troubleshooting

1. Daily maintenance
  • Check the lubrication of the valve's oil cup, oil nozzle, valve stem thread and valve stem nut regularly. The exposed valve stem should be coated with grease or protected with a protective sleeve.
  • Check the valve seals and fasteners regularly and handle any leaks or looseness promptly
  • Clean the pneumatic and hydraulic devices of the valve regularly.
  • Check the valve's anti-corrosion layer and thermal insulation layer regularly, and repair any damage in a timely manner.
  • Flange bolt threads should be protected with rust inhibitor.
  • If valve parts, such as handwheels and handles, are damaged or lost, they should be replaced as soon as possible and should not be replaced with a wrench to avoid damaging the square of the valve stem.
  • For water valves and steam valves that have been out of service for a long time, care should be taken to drain the accumulated water. If there is a screw blockage at the bottom of the valve, it can be opened to drain the water.
2. Common faults and solutions
No. Fault phenomenon Cause of issue Approach
1 Valve opening and closing failure The packing is too tight and the gland is skewed Adjust the tightness of the stuffing box bolts and the gland pressure
Opening and closing parts fall off Replacement of valves
Bent valve stem, damaged valve stem threads, scale accumulation Straighten the valve stem, repair the valve stem threads and descale
The closing force of the gate valve is too large or the valve stem expands due to heat Tap the valve body flange while turning the handwheel
The bracket bearing is loose and presses against the hand wheel Re-fix the bearing gland
Cold season freezing Steam properly heated valve
2 Packing leakage Packing gland loose Tighten the packing gland
Insufficient filling Add filler
Filler technical performance does not meet Replacement of packing
The valve stem is rough, bent, and has axial grooves Improve surface finish, straighten valve stems, and repair grooves
3 Middle flange leakage Uneven tightening of flange bolts Consistent bolt torque
The technical performance of the padding material does not meet the requirements Replace the bedding
Flange sealing surface is defective Repair sealing surface
4 Valve internal leakage Foreign matter falls into the valve and sticks to the sealing surface Remove foreign matter
The spherical surface at the end of the valve stem is deformed or hanging Repair the sphere
Wear of the opening mechanism of the double-disc gate valve Repair the expansion mechanism
Sealing surface damage Training
5 No condensation The valve on the steam pipeline before the valve is damaged or not opened If the valve is damaged, it needs to be repaired. If the valve is not open, it should be opened.
The elbow of the steam pipeline before the valve is blocked Clean the dirt in the pipeline, and the pipeline bending should meet the requirements
The filter is clogged with dirt Clean the filter regularly
The trap is full of dirt Repair the filter and clean the dirt inside the valve
The control room is filled with air and non-condensable gas, so the valve cannot be opened. Open the valve cover to discharge non-condensable gas
The valve on the bypass pipe and the sewage pipe before the valve is leaking Repair or replace valve
6 Exhaust steam The valve cover is not tight, the pressure in the control chamber cannot be established, and the valve plate cannot be closed. Tighten the valve cover or replace the valve disc
The valve seat sealing surface and valve disc are worn Regrind, if it cannot be repaired, replace it
There are impurities between the valve chamber and the valve plate Open the valve cover to remove debris
7 Drainage continues Drastic increase in water discharge in steam pipes The boiler sometimes bubbles and sends out a large amount of water. A steam-water separator should be installed to solve this problem.
The selected steam trap displacement is too small The problem should be solved by replacing the steam trap with a large drainage capacity or connecting it in parallel.
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Zhejiang Newton Fluid Control Co.,Ltd.

Comprehensive Steam and Thermal Energy System Solutions Manufacturer

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