Valves occupy a core position in many fields of fluid control, and their good operating status is directly related to the reliability, safety and operating efficiency of the entire system. Therefore, it is of critical significance to deeply understand the importance of valve maintenance and master practical maintenance methods.
The importance of valve maintenance is first reflected in ensuring the stable operation of the system. Whether it is a large pipeline system in industrial production, or a water supply and heating system in civil buildings, once the valve fails, such as not being able to open or close normally, leakage and other problems, it may lead to fluid transmission interruption or out of control, which affects the entire production process or the normal life of residents. For example, in the petrochemical production, the high temperature, high pressure, flammable and explosive or toxic media transported in the pipeline, if the valve leaks, may cause serious accidents such as fire, explosion or environmental pollution, bringing huge economic losses and irreversible social impact to the enterprise. Through regular maintenance, the potential problems of the valve can be found and solved in time to ensure that it is always in good working condition and escort the stable operation of the system.
From an economic point of view, valve maintenance helps reduce operating costs. Valve as a mechanical equipment, its service life is limited. If the maintenance work is ignored, the valve may be prematurely damaged due to wear, corrosion, seal failure and other reasons, and have to be replaced in advance. Replacing the valve not only requires the purchase of new valve equipment, but also involves a series of costs such as installation, commissioning and possible shutdown losses. On the contrary, through reasonable maintenance measures, such as regular lubrication, inspection of seals, adjustment of operating parameters, etc., can effectively extend the service life of the valve, reduce the frequency of replacement, so as to reduce equipment procurement and maintenance costs, improve the economic benefits of enterprises.
So, in actual operation, what are the practical valve maintenance methods? The first is a regular visual inspection. Maintenance personnel should conduct an appearance inspection of the valve at least once a week to check whether the valve body has obvious physical damage such as rust, cracks, and deformation, whether the valve stem is clean, and whether the hand wheel or electric actuator is intact and flexible. For some key parts of the valve, the inspection frequency should be appropriately increased. For example, valves in hazardous areas of chemical production plants or on high temperature and high pressure pipelines may need to be inspected daily.
The second is lubrication management. Lubrication is one of the key factors for the normal operation of valves. According to the type of valve, working environment and frequency of use, determine the appropriate lubrication cycle and grease type. In general, an appropriate amount of grease should be added between the valve stem and the stuffing box at intervals (such as one month) to reduce friction and prevent the valve stem from sticking. For some valves under special working conditions, such as valves in low temperature environments, it is necessary to choose lubricating grease with good low temperature performance; In high temperature environments, high temperature resistant grease should be used. At the same time, during the lubrication process, attention should be paid to cleaning up the old grease to avoid the mixing of new and old grease affecting the lubrication effect.
In addition, the sealing performance testing and maintenance. The sealing performance of the valve directly determines whether there is a risk of leakage. Pressure testing, ultrasonic testing and other methods can be used to regularly test the sealing performance of the valve. For soft sealed valves, such as rubber-sealed ball valves, if the sealing rubber is found to have signs of aging, deformation or damage, the seals should be replaced in time. For metal sealed valves, such as gate valves, globe valves, to regularly check the disc and seat sealing surface wear, minor wear can be repaired by grinding, serious wear may need to replace the sealing surface or the entire valve.
In addition, the valve operation test can not be ignored. At regular intervals (e.g., three months), the valve is tested for full range operation, including manual and electric operation (if applicable). Check whether the valve is smooth in the opening and closing process, there is no blocking, beating or abnormal sound, and whether the opening indicator of the valve is accurate. For the electric valve, it is also necessary to test the response speed, control accuracy of its electrical control system and whether the communication with the upper computer is normal.
Finally, establish a sound valve maintenance file. Record every valve inspection, maintenance, repair, operation test and other details, including date, time, operator, inspection items, found problems, measures taken and results. Through the analysis of the maintenance file, the operation law of the valve can be summarized, the possible faults can be predicted, and the basis for making a more scientific and reasonable maintenance plan can be provided.
In short, valve maintenance is of irreplaceable importance for ensuring the safe and stable operation of the system and reducing operating costs. Through the implementation of the above practical maintenance methods and the continuous maintenance work, it can ensure that the valve always plays its due fluid control function, and provides strong support for the development of various industries.
