On-site valve fault monitoring system and effective troubleshooting measures
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[Keywords] valve fault monitoring system troubleshooting measures 1 common valves and their common problems in the process of failure and use In the chemical industry, the valve is used to control the flow of chemicals in the chemical pipeline is an important annex, mainly used to cut off, communicate pipe fluid Flow, adjusting the flow rate in the tube and the flow rate, in order to achieve the effect and role of a considerable pressure drop after the fluid passes through the valve. According to their use, chemical valves can be divided into five categories, namely cut-off valves, control valves, diverter valves, check valves, and safety valves. Among them, the cut-off valve is mainly used to cut off or turn on the medium flow. Including gate valve, globe valve, diaphragm valve, ball valve, plug valve, butterfly valve, plunger valve, ball plug valve, needle valve instrument and so on. The regulator valve is mainly used to regulate the flow of media, pressure and so on. Including regulating valve, throttle valve, pressure reducing valve and so on. Check valves are used to prevent reverse flow of media. Includes various types of check valves. Diverter valves are used to separate, dispense, or mix media. Including various distribution valves and traps. Safety valves are used for safety protection in media overpressure. Includes various types of safety valves. According to its role, it can be divided into his action valve and automatic action valve.
Chemical valve must be inspected before use, including five aspects of inspection.
(1) Check whether there are defects such as trachoma and cracks on the inside and outside surfaces of the valve;
(2) Check whether the joint between the valve seat and the valve body is firm, and whether the valve plug and the valve seat are consistent, and whether the sealing surface is defective;
(3) Check whether the connection between the valve stem and the valve plug is flexible and reliable. Whether the valve stem is bent or not, the thread has no phenomenon of damage or corrosion;
(4) Check the fillers and gaskets for aging damage;
(5) Check whether the valve switch is flexible.
There are three types of problems in the use of valves.
(1) Flange and thread leakage at the connection between the valve and the pipe;
(2) Leakage of filler culverts, leakage of lumbar pad, and failure to open the valve stem;
(3) The leakage between the valve plug and the valve seat is not strict.
Therefore, we must pay attention when choosing chemical valves. In the chemical industry, valves with a straight-through flow path are generally used. Straight-through valves have a low flow resistance. In addition, valves that close and open the medium are often selected because they are easy to regulate flow. With regard to the fact that valves can control the use of flow, ball valves and plug valves are suitable for commutation diverting. There is also a type of valve, the sliding of which is closed along the sealing surface with a wiping action, and this applies to media with suspended particles. What we usually see, use more chemical valves include globe valves, ball valves, gate valves, safety valves, check valves, plug valves, and so on.
2 Problems in valve fault monitoring With the advancement of China's science and technology and the development of industry, all industries and industries have become increasingly dependent on mechanical products, and at the same time, the requirements for the safety of mechanical products have become more and more. High, more and more strict. At the same time, the continuous development of mechanical products has become more and more complex, and the factors that influence the failure have become complicated, and the losses caused by their failures are also increasing. Therefore, it is very necessary to systematically analyze the mechanical failure, especially the valve failure.
The following problems have mainly appeared in the current fault monitoring:
(1) The monitoring of the valve selection is not in place. When selecting the valve, the quality of the valve is not paid attention to. The poor quality of the selected valve leads to a short service life and is not conducive to improving the work efficiency.
(2) The lack of monitoring during the use of the valve, the use of the valve did not strictly in accordance with its rules of use, resulting in serious damage to the valve;
(3) Valve maintenance and monitoring work is not in place. Failure of the valve to maintain during long-term use can result in damage.
3 On-site valve fault monitoring and effective troubleshooting measures There are two kinds of sudden and gradual faults in valve faults. We mainly investigate on-site valve faults, that is, sudden faults. The failure of the valve is mainly a productive failure, that is, production is not strictly performed in accordance with the production procedure specified by the valve during the production process, thus causing a failure. The other is a structural failure, that is due to a series of problems in the design of the valve, and resulting in failure. Operational failure means that the use of the valve is not based on its operating conditions and related procedures. In addition, there are some failures that are caused by the failure of some components. Therefore, our monitoring of faults should also focus on these aspects. The main ones are the monitoring of the production process, the monitoring of the operation process, the monitoring of the valve quality and usage, and the main components of the valve that are prone to problems. Monitoring.
3.1 Monitoring of the production process In the production process, the staff must strictly follow the production procedure of the valve. However, the monitoring of the production process of the valve is not the part that the valve user can control, but the valve manufacturer must pay attention to. section. So how can valve users effectively control this part? The part that the valve user can control is the control of the selection of the valve. When the valve user selects the valve, it must strictly follow the principle of quality priority, and the valve with poor quality or relatively poor quality cannot be selected because of cost saving.
3.2 Monitoring of valve usage This mainly means that the valve will experience ageing, corrosion, etc. during the production process. We must monitor the use of the valve in real time. This part is mainly divided into two parts. Part of it is to arrange special staff for regular, irregular inspections of the valve and maintenance, regular maintenance and maintenance of the valve, so that problems can be identified, problems can be solved, and problems can be prevented. The effect appears. On the other hand, it mainly refers to the data management of the valve, the use of information technology and the development of big data, a comprehensive analysis of the indicators of the valve, thereby achieving the prevention of problems, the purpose of preventing failure.
3.3 Monitoring the Operation Process In response to this, we must first perform strict pre-job training for employees and require that employees use them in strict accordance with the operating conditions of the valves. We must increase employees' awareness in this regard. The second is the establishment of relevant management and supervision systems and accountability systems, and the corresponding punishments for staff who do not strictly follow the valve operation procedures, and allow the staff to effectively monitor each other.
3.4 To supervise the main and prone parts of the valve. In the course of production activities, we must conduct real-time monitoring of key components and perform statistical data on the components that have occurred. Then we will analyze the data and find out The components that are most likely to fail are caused by the attention of the workers. In the future production process, these components must be given more attention and monitored in a focused manner, which is also conducive to improving work efficiency.
This shows that no matter which part of the valve is monitored, we must comprehensively use modern computer technology, information technology, etc., to carry out intelligent monitoring and management, save manpower and material resources, improve work efficiency, and effectively prevent the occurrence of failures.
4 Summary Valves play an important role in all walks of life. Once a valve fails, it will cause considerable economic losses and other losses in production activities. Monitoring of the valve can effectively avoid the occurrence of valve problems, even if Problems with valves can also make effective measures in time. Therefore, it is necessary to monitor the valves during the production process. But at the same time, fault monitoring of the valve must also be efficient. For the monitoring of on-site valve faults, we must make effective troubleshooting measures to prevent real-time failures.
References [1] Ji Wenping, Song Chang. Failure Analysis and Research of Electric Valves[J]. Chemical Industry Management, 2017(01):164-165.
[2]Liu Xiuying.Autonomous repair of valve faults and on-site maintenance management[J].Refining and Chemical Industry,2016,27(04):28-29.
[3]Lu Haijin.Analysis of Common Faults and Maintenance of Valves[J].Heilongjiang Science and Technology Information,2014(19):69.
[4] Huang Yan, Zhou Mi, Huang Weixing, Li Xiaozhong, Luo Zhiyuan. Valve fault analysis and classification [J]. Valve, 2007(06): 41-44.
[5] Fang Benxiao. Valve failure and its prevention [J]. Valve, 1994(03): 24-28.
The unit, China National Petroleum Corporation, Dongfang City, Hainan Province, 572600
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