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How to deal with the "running, leaking, dripping and leaking" phenomenon of valves in the chemical pump industry?

05 Sep 2021Email

In the petrochemical industry, chemical pumps are the most commonly used equipment, and the phenomenon of "running, leaking, dripping, and leaking" of pipeline valves is more common. The best way to solve "running, running, dripping, and leaking" is to prevent it before it happens. How to find the problem before the valve fails and avoid the accident? This article mainly summarizes the prevention measures against oil leakage, water leakage, steam leakage, smoke leakage, ash leakage, coal leakage, powder leakage, and gas leakage, for reference.

chemical pump

1. Prevent the valve from leaking water and steam

1. After entering the factory, all valves are subjected to different levels of water pressure test.

2. Valves that need to be disassembled and repaired must be ground.
3. In the process of maintenance, carefully check whether there is any additional packing and whether the packing gland is tightened.
4. Before installing the valve, check whether there is dust, sand, iron oxide and other sundries inside the valve. If there is any above-mentioned debris, it must be cleaned up before installation.
5. All valves must be equipped with corresponding grade gaskets before installation.
6. Tighten the fasteners when installing the flange door. When tightening the flange bolts, they must be tightened in a symmetrical direction.
7. In the process of valve installation, the valve must be installed correctly according to the system and pressure. Random installation, mixed installation, and reverse installation are strictly prohibited. For this reason, all valves must be numbered and recorded according to the system before installation.
2. Prevent "running, leaking, dripping and leakage" on the joint surface of equipment and pipe fittings

1. Flange gaskets above 2.5Mpa are all metal wound gaskets.
2. The flange gasket of 1.0Mpa-2.5Mpa adopts asbestos gasket and is painted with black lead powder.
3. The flange sealing gasket of water pipes below 1.0Mpa adopts rubber gasket and is painted with black lead powder.
4. The packing of chemical pump adopts PTFE composite packing.
5. The asbestos rope used for the sealing part of the smoke, wind and coal pipes is twisted and flatly added to the joint surface at a time. It is strictly forbidden to force it after tightening the screws.

Three, prevent the valve from leaking

1. For pipeline installation and construction, a good quality awareness must be established, and the iron oxide scale and the inner wall of the pipeline must be consciously cleaned, leaving no debris, and ensuring that the inner wall of the pipeline is clean.
3. First of all, ensure that 100% of the valves entering the site must undergo a hydraulic test.
3. Valve grinding must be carried out conscientiously. All valves (except imported valves) are required to be sent to the grinding team to be disassembled for inspection and repair, and responsibilities must be fulfilled. Records and marks must be made consciously for easy traceability. Important valves should be listed in detail for secondary acceptance, to meet the requirements of "stamping, inspection and recording".
4. When the pipeline is flushed, it should be opened wide and lightly closed to prevent damage to the valve core.

Fourth, the correct operation of the valve

1. Regardless of whether you understand the valve instructions, you must operate in accordance with the instructions.
2. Do not use too much force or too much force when opening and closing the valve, and the valve cannot be opened beyond the upper limit point. After the valve is fully opened, the handwheel should be reversed a little or one turn;
3. The handle or handwheel should be firmly connected to the valve stem, and the threaded connection should have a stopper;
4. The fasteners used for connection should withstand the corrosion of the medium, and have certain mechanical strength and wear resistance.
5. Do not use booster rods lightly for valves in normal use.
6. Do not open or close the valve by two people.
7. When closing the valve, do not operate with extreme force because you are worried that it is not closed tightly. The strength of your hand is sufficient.
8. When the valve is out of service, add lubricating oil and other necessary maintenance.

V. Precautions against leakage of pulverized coal

1. All flanges must be installed with sealing materials.

2. The areas prone to powder leakage are the inlet and outlet coal valves of the coal mill, the coal feeder, the manufacturer's flange, and all the parts with flange connections. For this reason, conduct a comprehensive inspection of all parts of the manufacturer's equipment that are capable of leaking powder. If there is no additional sealing material, perform a second installation and tighten the fasteners.

3. For the phenomenon of powder leakage at the welded joint of the pulverized coal pipe, the following measures shall be taken.

3.1 Before welding, the welding area must be polished out of metallic luster and the groove required for welding must be polished.

3.2 The gap must be reserved before the counterpart, and it is strictly forbidden to force the counterpart.

3.3 Welding consumables must be used correctly, and must be preheated as required when the weather is cold.

 

6. Preventive measures for oil system leakage and oil running

1. During the installation of the oil pipeline, all flange connections or threaded unions must be equipped with oil-resistant rubber gaskets or oil-resistant asbestos gaskets.

2. The leakage points of the oil system are mainly concentrated on the flange and the threaded union, so the bolts must be evenly tightened when installing the flange. Prevent leaks or tightness from happening.

3. In the process of oil filtering, maintenance personnel must always stick to their posts, and it is strictly forbidden to leave their posts and shift positions.

4. The oil filter mechanism must be stopped when replacing the oil filter paper.

5. When installing the temporary oil filter connecting pipe (high-strength plastic transparent hose), the joint must be bound firmly with lead wire to prevent the oil from jumping off and running out of oil after the oil filter has been running for a long time.

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