VAL-TEX球閥維護(hù)訓(xùn)練課程

1、val-tex球閥維護(hù)訓(xùn)練課程val-tex球閥維護(hù)訓(xùn)練課程 編輯整理：尊敬的讀者朋友們：這里是精品文檔編輯中心，本文檔內(nèi)容是由我和我的同事精心編輯整理后發(fā)布的，發(fā)布之前我們對文中內(nèi)容進(jìn)行仔細(xì)校對，但是難免會有疏漏的地方，但是任然希望（val-tex球閥維護(hù)訓(xùn)練課程）的內(nèi)容能夠給您的工作和學(xué)習(xí)帶來便利。同時(shí)也真誠的希望收到您的建議和反饋，這將是我們進(jìn)步的源泉，前進(jìn)的動(dòng)力。本文可編輯可修改，如果覺得對您有幫助請收藏以便隨時(shí)查閱，最后祝您生活愉快 業(yè)績進(jìn)步，以下為val-tex球閥維護(hù)訓(xùn)練課程的全部內(nèi)容。25val-tex ball valve maintenancetraining semina

2、rval-tex球閥維護(hù)訓(xùn)練課程purpose 目的to outline some basic procedures and provide a workingknowledge for the proper maintenance of ball valves給出球閥維護(hù)維修的基本程序和工作知識required valve maintenance閥門的維修要求asme guide forgas transmission piping systems 1992192.745 federal standard美國機(jī)械工程師協(xié)會對氣體輸送管線的指導(dǎo)-1992 192。745 聯(lián)邦標(biāo)準(zhǔn)-valve

3、maintenance: transmission systems. each transmission line valve that might be required during any emergency must be inspected and partially operated at intervals not exceeding 15 months but at least once each calendar year。 閥門維修：輸送系統(tǒng)。每個(gè)應(yīng)急的輸氣管線閥門必須在不超過間隔15個(gè)月時(shí)間里進(jìn)行檢驗(yàn)和部分操作，并且每日歷年至少一次。asme guide forgas d

4、istribution piping systems 1992192。747 federal standard美國機(jī)械工程師協(xié)會對分輸管線系統(tǒng)的指導(dǎo)1992 192。747 聯(lián)邦標(biāo)準(zhǔn)- valve maintenance： distribution systems. each valve, the use of which may be necessary for the safe operation of a distribution system, must be checked and serviced at intervals not exceeding 15 months but a

5、t least once each calendar year.- 閥門維修：輸送系統(tǒng)。每個(gè)用于安全運(yùn)行的分輸系統(tǒng)閥門必須在不超過間隔15個(gè)月時(shí)間里進(jìn)行檢驗(yàn)，并且每日歷年至少一次。features most ball valves have in common：大多數(shù)球閥共有的特點(diǎn)1。 trunnion mounted balls 固定式閥球2. spring loaded floating seats 彈簧預(yù)緊浮動(dòng)式閥座3. upstream sealing 上游密封4. body block and bleed 閥體關(guān)斷和排放功能5. secondary sealant injection

6、 ports 二級密封之注入口some special features found in certain ball valves： 某些球閥的特殊特點(diǎn)1。 top entry 頂裝式2。 end entry 側(cè)裝式3. replaceable/repairable seats 可更換/可維修閥座5。 indexing seat rings: many cameron ball valves have a unique feature indexing seat rings。 they may not be available in all sizes of the newer cameron

7、 ball valves， but many of your older cameron ball valves will have them. 旋轉(zhuǎn)閥座：大多數(shù)卡麥隆球閥具有獨(dú)有的旋轉(zhuǎn)閥座.這或許不適用于所有尺寸的最近的卡麥隆球閥，但大多數(shù)老的卡麥隆球閥均有。very important！非常重要most of the procedures that we will discuss will apply to all ball valves.please consider the following comments as suggestions。 if our procedures or

8、recommendations are contrary to your company policies， we suggest you discuss these differences with your supervisor or manager to determine which valve maintenance procedures you should follow。 we have done everything possible to avoid such a conflict， but we firmly feel that your company policies

9、come first.我們所討論的大多數(shù)程序適用于所有球閥。請以下的意見作為建議.如果我們的程序或推薦與您公司的政策相背，我們建議您與您的主管或經(jīng)理討論這些偏差一決定您應(yīng)該遵循哪個(gè)程序。我們盡可能的避免這種情況的發(fā)生，但我們認(rèn)為您公司的政策應(yīng)優(yōu)先。lets look at the following three common ball valve problems and consider possible solutions。讓我們看看下列的三中常見的球閥問題并考慮可能的解決方案1.hard to operate or inoperable valves 操作困難或無法操作閥門2。stem

10、leakage 閥桿泄漏3.seat leakage 閥座泄漏hard to operate or inoperable valves - external causes外部原因引起的操作困難或無法操作when you have a ball valve problem, you should always start working at the top of the valve and work to the bottom. there are definite areas you should check including the operator and the alignment

11、of the ball before you assume that the seats are leaking. in order to do this we must:當(dāng)你有閥門問題時(shí)，你應(yīng)該首先從閥門的頂部和底部開始解決。有一些固定的區(qū)域你應(yīng)該檢查，包括執(zhí)行器和在你假設(shè)閥座泄漏前檢查球的角度。為了這樣做,我們必須：1。 determine the operator type， is it: 確定執(zhí)行器的類型 a。manually operated 手動(dòng)操作 b。gear operated 齒輪箱操作 c.power actuated by： 動(dòng)力執(zhí)行器1。 electric curren

12、t 電動(dòng)2. supplied air 氣動(dòng)3. hydraulic fluid 液動(dòng)4。 any combination of the above 以上的任何一種組合a. manually operated ball valves: 手動(dòng)操作的球閥as a rule， if there are any external obstructions that may be interfering with the operation of the valve they will be visible and must be corrected or removed。 if the valve r

13、emains hard to operate or is inoperable after these corrective actions have been taken， we must assume that it is due to an internal problem.作為一個(gè)原則，如果有任何外部的影響閥門操作的障礙，這種障礙應(yīng)是可見的，必須排除。如果閥門仍然難于操作或無法操作，我們必須假設(shè)故障由內(nèi)部問題引起。b. gear operated ball valves： 齒輪箱操作球閥1. inspect all internal parts of the gear operator

14、 for damage to：檢查所有齒輪操作器內(nèi)部部件確認(rèn)是否損壞了:a。 bearings 軸承b. gear teeth 齒輪齒c. shear pins 安全銷2. check to see that the gear is properly lubricated and that all metalto-metal contact points are thoroughly coated with grease.檢查齒輪箱看是否潤滑良好，所有金屬對金屬的接觸是否完全涂上潤滑脂。3. the grease used in these areas is normally petroleu

15、m based and is subject to water contamination。 during cold weather conditions this water can cause icing in the operator， rendering the valve inoperable。 if this occurs， disassemble the gear housing and remove all ice， water and contaminated grease。 repack these areas with fresh grease. if extremely

16、 cold conditions are anticipated， you may want to select a low temperature grease such as a glycol-based grease。用于這些地方的潤滑脂通常為石油基的，會被水污染。在寒冷天氣,這些水可引起操作器結(jié)冰，使閥門無法操作。如果出現(xiàn)這種情況,拆開齒輪箱去除所有的冰，水和受污染的潤滑脂。重新涂上新的潤滑脂.如果特別季節(jié)特別寒冷，你可能需要低溫潤滑脂如：乙醇基的潤滑脂。4. make sure that the gear operator is securely bolted to the valv

17、e and is not loose。確認(rèn)齒輪操作器用螺栓固定在閥門上沒有松動(dòng)。c.power actuated ball valves： 動(dòng)力操作球閥:check the valve actuator manual for maintenance instructions to determine the proper inspection procedures. you will find that most valve manufacturers will recommend that you:查閱閥門執(zhí)行器維修手冊以確定合適的檢驗(yàn)程序。你將發(fā)現(xiàn)大多數(shù)閥門制造商會推薦你:1.verify

18、 that the power source, whether it is electrical, an air supply or hydraulic fluid is properly connected and is supplying sufficient power to the actuator. take corrective action if necessary.確認(rèn)動(dòng)力源，無論是電動(dòng)，壓縮空氣或液壓連接良好并且動(dòng)力供應(yīng)充足。如有必要，進(jìn)行調(diào)整。2. inspect all hoses, cords, gears and all moving parts for proper

19、 alignment and excessive wear。 take corrective action if necessary.檢查所有軟管、繩索、齒輪和所有動(dòng)作部件的對準(zhǔn)及負(fù)荷。如有必要，進(jìn)行調(diào)整。3. check the valve actuator for movement （if the operator is loose and moves under high torque conditions this may prevent the valve from opening and closing fully)。檢查閥門執(zhí)行器動(dòng)作（如執(zhí)行器在高扭矩下松動(dòng)，這可能會妨礙閥門全開

20、或全關(guān)）.4. if necessary, uncouple the actuator from the valve and verify that it is working properly. this will allow you to isolate any problems it may have。如有必要，拆下執(zhí)行器,檢查工作狀況.這將可使你排除故障.hard to operate or inoperable valves internal causes內(nèi)部原因引起的難于操作或無法操作閥門when you have eliminated all the external consi

21、derations on a valve that is hard to operate or is inoperable， the next step is to identify the possible internal problems that the valve may have by checking the following four areas。當(dāng)你排除了所有的使閥門難于操作或無法操作的外部原因后，下一個(gè)步驟是確定可能的內(nèi)部問題，可能需要檢查閥門下述四個(gè)區(qū)域。 1。load screws （found only on cameron valves）： 壓緊螺絲（只適用于卡麥

22、隆閥門）if the stem seal has been leaking, there is a possibility that the load screws may have been tightened too tightly. this will bind the ball against the body shell. the load screws should not be either too loose or too tight.如果閥桿曾經(jīng)泄漏，有一種可能性是壓緊螺絲上的太緊。這樣會使球體與閥體壓的過緊。壓緊螺絲不應(yīng)過松或過緊. 2.icing:結(jié)冰most gas l

23、ines will contain some water (condensate). water will settle in the lowest spot in the valve。 this is normally the lower trunnion or body section of a ball valve. in freezing conditions this turns to ice.多數(shù)氣管線含有一些水（凝析物）.水會存在閥門的最低點(diǎn)。這通常會是下樞軸或球閥閥體下部。在寒冷情況下，這會結(jié)冰.corrective action: 改善辦法:a. prior to the o

24、nset of freezing weather， block and bleed the valve by using the body bleed fitting to blow the water out of the body cavity. 寒冷季節(jié)到來前，通過排污口關(guān)斷并排放閥腔的水。or: 或b. if ice has already formed， use some acceptable method to melt the ice (i.e。 use some form of safe heat such as a heated enclosure around the va

25、lve， or possibly by injecting some non-icing liquid such as alcohol into the body cavity of the valve).如果已結(jié)冰，采用適當(dāng)?shù)姆椒ㄈ诨?如：采用安全的加熱如加熱閥體外殼,或注入閥腔一些除冰液如酒精） 3.seatto-ball seizure： 閥座和球卡?。篿f a valve with a floating seat has not been operated for a long period of time， the seat will tend to take a “set aga

26、inst the ball。 this condition requires additional force to break the ball loose and allow operation of the valve. high line pressure will also contribute to this increased initial operating torque。如果一臺浮動(dòng)閥座的球閥很長時(shí)間不操作,閥座會可能與球抱死。這種情況要求額外的力使球松動(dòng)從而操作閥門。高的管線壓力也將增加操作扭矩。corrective action： 改善辦法:a. apply addit

27、ional reasonable force to operate the valve. if this fails to achieve the results， then: 增加適當(dāng)?shù)牧聿僮鏖y門.如果不行則：b. inject valve flush or lube sealant into the valve to attempt to force the seat away from the ball， then， if possible， cycle the valve several times. 注入閥門清洗液或潤滑密封脂將閥座頂離球體,然后,如有可能,開關(guān)閥門幾次。4。 se

28、izure of the seat ring: 閥座環(huán)卡死 trash from the line, sand, dust, rust or old， hardened sealants that contain solids can build up in the seat ring area and interfere with the movement of seats. seat ring seizure often results in leakage between the seat and the ball。管線里的垃圾、沙子、灰塵或老化、硬化密封脂包含固體能堆積在閥座環(huán)周圍并且

29、影響閥座動(dòng)作.閥座環(huán)卡死通常會引起閥座與球間的泄漏。corrective action： 改善辦法inject “valve flush” to dislodge as much of the trash as possible. if you can， cycle the valve several times to further break up the debris.注入閥門清洗液移去垃圾。如果可能操作幾次閥門使雜質(zhì)碎裂。note： 注：we recommend injecting a nonsetting lube sealant into both seat ring areas

30、to protect them from trash and corrosion。我們推薦注入不固化潤滑密封脂在閥座區(qū)域以保護(hù)閥座不生銹和堆積異物。stem leakage閥桿泄漏most ball valves are designed with both an upper and a lower stem seal. if the stem of a ball valve is not leaking, leave it alone。 unnecessary maintenance on the stem may create problems。 generally, ball valve

31、s have either o-rings， t- seals or molded seals in the stem area。 if you can detect leakage in the stem area， you must assume that the lower stem seal is defective and is allowing the pressure to reach the upper stem seal. if there is leakage in the stem area, check to see if the valve has a fitting

32、 where lube sealant can be added as a temporary seal to stop the leak。 inject the lube sealant slowly and then only until the leak stops， and no more！! 大多數(shù)球閥均設(shè)計(jì)有閥桿的上和下密封.如果球閥的閥桿不泄漏，不要采取任何行動(dòng)。閥桿處不必要的維護(hù)可能引起故障。一般說來,球閥閥桿處的密封無外乎o型環(huán)，t型密封和其他形狀密封.如果你在閥桿處測出泄漏，你必須假設(shè)下閥桿密封泄漏，從而泄漏到上閥桿密封。如果閥桿處有泄漏，檢查是否有注口可以注入潤滑密封脂進(jìn)

33、行臨時(shí)密封。密封脂加注應(yīng)緩慢，當(dāng)泄漏止住時(shí)就應(yīng)停止加注,不要加多了.caution： excessive pressure in the stem area may extrude the seals or pressure lock the valve. 注意： 閥桿處額外的壓力會壓緊密封或鎖死閥桿。on the cameron ball valve you can tighten the load screws located on the top of the stem. this will raise the ball and result in force being exerted

34、 on the seals， shutting off the leak. 對于卡麥隆球閥,你可以上緊閥桿頂不的壓緊螺絲。這樣會提起球增加密封的壓緊力，消除泄漏。tighten the load screws in 1/8 turn or less and only until the leak stops!！ over-tightening will cause the valve to become hard to operate or inoperable. this is due to the excessive friction created between the stem se

35、als， the body and the ball.擰緊壓緊螺絲1/8轉(zhuǎn)止到泄漏停止！過緊會引起閥門操作困難或無法操作。這是因?yàn)殚y桿密封、閥體和球間的摩擦增加。consult the manufacturers valve maintenance manual to determine if the upper stem seal can be replaced while the valve is under pressure。 caution should always be used during any procedure where the possibility exists o

36、f being exposed to line pressure. 參考閥門制造廠的手冊以確定是否閥桿上密封可帶壓更換。注意管線壓力可能泄漏應(yīng)小心操作無論采用任何程序。seat leakage 閥座泄漏a common ball valve problem is leakage past the valve seats. keep in mind that most ball valves seal on the upstream side. 一個(gè)常見的球閥故障是閥座泄漏。記住大多數(shù)球閥的密封是上游密封。seat leakage can occur with the valve in eith

37、er the open or the closed position。 as a result, for many ball valves it is possible to check the seats for sealing with the valve in either position。 the grove ball valve is a notable exception to the rule。 it can only be checked in the closed position. remember, in the open position there is a low

38、er volume of gas in the valve body cavity because the solid part of the ball is facing that cavity。 閥座泄漏在閥門開和關(guān)時(shí)均可能發(fā)生.作為結(jié)論，多數(shù)球閥可在閥開和閥關(guān)時(shí)檢查閥座的密封。格羅夫球閥是需要注意的例外，只可以在關(guān)位檢查閥座密封。記住，開位時(shí)閥腔的氣體會少些,因?yàn)殚y球的實(shí)體部分對著閥腔。test procedures for seat leakage:閥座泄漏測試程序1. for a quick check， ensure that the valve is in the full op

39、en position. this will reduce the volume of gas in the body cavity and the amount of time it takes to blow the valve down （except grove valves）. before performing any work downstream of the valve， follow these same procedures with the valve in the closed position. the grove ball valve can only be bl

40、own down in the closed position。 快速檢查時(shí),確定閥門在全開位。這樣將減少閥腔氣體的量,從而減少閥門排放的時(shí)間(格羅夫球閥出外)。在進(jìn)行閥門下游的任何工作時(shí)，將閥門置于關(guān)位，采用同樣的步驟排放閥腔。格羅夫球閥只可以在關(guān)位排放。2. verify the full rotation of the ball。 remember the ball rotates 90 degrees. any ball that fails to move through the last three （3） degrees of rotation, whether it is be

41、ing opened or closed， will leak。 some of the older ball valve designs will leak if they are as little as one (1) degree off full rotation. your margin of error is minimal. 確認(rèn)閥球轉(zhuǎn)到位。記住球閥是90度旋轉(zhuǎn)的。任何球閥無論開關(guān)位，如果差3度到位都會泄漏。一些老的球閥設(shè)計(jì)可能差1度到位都會泄漏。偏差很小。3. manually operated ball valves usually have load screws or

42、indicators on the stem that will assist you in verifying that the ball has completed its rotation. 手動(dòng)球閥通常在閥桿處有壓緊螺絲或指示器,可以幫助你確認(rèn)閥球的旋轉(zhuǎn)到位.4. check the stem stops: 檢查閥桿止動(dòng)：a. stem stops for small diameter valves are normally visible. 對于小尺寸閥門，閥桿止動(dòng)通?？梢姟. many of the larger diameter ball valves have a sight

43、 hole located in the stem area which allows for visual inspection of the stem stops。 check this area for rust, dirt, paint or buildup of any kind between the stem and the stem stop. this buildup can prevent the valve from achieving full rotation and cause it to leak. 許多大口徑球閥在閥桿處有觀察孔，可以目測檢驗(yàn)閥桿止動(dòng)。檢查是否在

44、閥桿和閥桿止動(dòng)間有任何銹蝕、灰塵、油漆或堆積物。這些堆積物可能是閥門無法旋轉(zhuǎn)到位而引起泄漏。c. if the valve is buried, enough rust can fall off the stem extension to prevent full rotation of the ball and cause the valve to leak. if the stem stops are not visible and you cannot see the top of the stem, it is sometimes possible to listen for a pr

45、essure decrease or increase to determine if the ball is completing its full 90 degree rotation.如果閥門是埋地的，加長閥桿會產(chǎn)生并落下足夠的銹蝕妨礙閥球旋轉(zhuǎn)到位并引起閥門泄漏。如果閥桿止動(dòng)不可見并且你也無法看到閥桿頂部，有時(shí)通過聽壓力增加和下降的聲音來決定閥球的90度旋轉(zhuǎn)到位。note: the cameron valve has a spline type stem。 if the stem sleeve or other attachments have been installed with t

46、he spline misaligned， the valve will leak. 注：卡麥隆閥門的閥桿是花鍵形式.如果閥桿驅(qū)動(dòng)套或其他附件與之裝配角度錯(cuò)位,閥門將泄漏。5. actuator and gear operated valves should be fully cycled several times to attempt to verify that full rotation of the ball has taken place。 occasionally， such as when an actuator is put on a ball valve， the stop

47、s are removed from the valve。 in some cases， such as with a wkm ball valve， the stop is internal. misalignment of any of these stops may cause the valve to leak.執(zhí)行器和手動(dòng)齒輪操作的閥門應(yīng)該開關(guān)多次來檢驗(yàn)閥球的旋轉(zhuǎn)位置到位。有時(shí)，當(dāng)一個(gè)執(zhí)行器安裝到球閥上，閥桿止動(dòng)會從閥門中去掉。有時(shí),如wkm球閥，止動(dòng)是內(nèi)置式。止動(dòng)的錯(cuò)位可能引起閥門泄漏。6. the body bleed fitting is normally a small va

48、lve. this fitting is located on the lower body of the ball valve. slowly open this fitting and allow the body cavity pressure to escape。 if the valve body will not bleed down, rotate the ball into the seats until the flow is either stopped or reduced as much as possible. watch out for foreign partic

49、les which may be released during this procedure. if the body cavity pressure bleeds all the way down, you can assume that the seats are holding。 on the other hand, if pressure continues to escape you can assume that the pressure is leaking by the seats。閥體排放口通常是一個(gè)小閥門。排放口在球閥閥體的底部。慢慢打開排放閥讓閥體壓力釋放出來.如果閥體

50、無法排空,旋轉(zhuǎn)閥球直到排放停止或盡可能的減小。注意排空時(shí)，小顆粒可能排出。如果閥腔可以排空，你可以認(rèn)為閥座密封完好。另一方面，如果始終有壓力排出，你可以認(rèn)為閥座泄漏了。note： if you cannot find the body bleed fitting, there is a possibility that a pipe plug may have been installed in the ball valve in place of it。 the safe removal of this pipe plug and the installation of the proper

51、 fitting will be discussed later.注：如果你無法找到排放閥,一種可能是有堵頭安裝在球閥的相應(yīng)位置.安全地移去堵頭然后安裝排放閥將稍候討論。internal causes of seat leakage:閥座泄漏的內(nèi)部原因1. the seats in the valve are seized not free to float. any solids build-up that is deposited in the seat pocket， such as line rust， dirt or the clay residues of certain old

52、hardened sealants can cause a leak.閥座卡住不能自由浮動(dòng)。任何堆積在閥座區(qū)域的固體如管線銹蝕、污物或固化的密封脂都會引起泄漏.2. similar buildup between the ball and the seat may also create a leak path。相似的閥座和閥球間的堆積也會產(chǎn)生泄漏途徑。3. the ball and/or seats are cut or damaged： once the ball or the seat in a valve is severely cut, you may have to inject

53、lube sealant every time that you want the valve to seal。 as good as it is， lube sealant will not permanently replace a molded teflon or nylon insert， a rubber oring or a metalto metal seal。 every time the valve is operated, a portion of the material will be lost and， depending on the severity of the

54、 leak, the lube sealant must periodically be replenished。球和/或閥座受損或損壞：一旦球或閥座有缺口，你可能不得不每次需要密封時(shí)都得注入密封脂.密封脂無法取代成型的特福隆或尼龍軟密封、橡膠o形環(huán)或金屬對金屬密封.閥門每次操作，部分密封脂會失掉，根據(jù)不同的泄漏，密封脂必須周期性的補(bǔ)充.corrective action would be identical in all of the cases outlined above. 上述列出情況的改善辦法thoroughly flush the valve with val-tex valve

55、flush and follow the flush with a good grade of lube sealant that does not contain any solid fillers. if the valve still fails to seal, a heavier bodied lube sealant may be necessary。 as a last resort， a lube sealant with teflon present as a solid filler may be needed。 repeated use of any product wi

56、th teflon is not recommended because the teflon can plug the sealant paths in the valve. if you must use a lube sealant with teflon, we recommend that you alternate between it and a non-teflon sealant to help reduce the concentration of teflon in the sealant path.徹底地用valtex閥門清洗液清洗閥門。然后注入不含固體顆粒的潤滑密封脂

57、。如果閥門仍無法密封，加強(qiáng)的潤滑密封脂可能需要采用。作為最后的手段，可采用含有特福隆固體填充的潤滑密封脂。重復(fù)使用任何含有特福隆顆粒的產(chǎn)品是不推薦的，因?yàn)樘馗Ｂ∧芏伦￠y門密封脂通道。如果你必須使用含特福隆顆粒的密封脂，我們推薦你交替使用含特福隆顆粒和不含特福隆顆粒的密封脂以減少在密封脂通道的特福隆顆粒的量。tools required：所需工具 1. valve wrench or crescent wrench: used to open and close the valve. 閥門扳手或可調(diào)扳手：用于開關(guān)閥門。 2. open or box end wrenches: used to tighten bolts and remove pipe plugs and worn lube fittings.固定扳手：用于緊螺栓和去掉堵頭和用舊的密封脂注嘴.pipe wrenches should never be used on a valve!！!在閥門上不應(yīng)采用管鉗3. penetrating oil: use mds or