As a key equipment for industrial fluid control, the stable operation of Huaying electric globe valve is directly related to production safety and efficiency. Developing a scientific and systematic maintenance plan for complex working conditions such as high temperature, high pressure, strong corrosion, and high-frequency opening and closing is the core measure to extend valve life and reduce failure rates.

1、 Daily inspection: Building a strong safety defense line

Daily visual and operational inspections of valves are required. Pay close attention to whether the valve body is corroded, deformed, or leaking, especially in corrosive working conditions such as chemical raw material transportation. It is necessary to check the surface of the valve body daily for signs of rust. Simultaneously monitor the sound, vibration, and temperature of the electric actuator during operation. If any abnormal heating or noise is detected, immediately shut down the machine to investigate the wear of the motor bearings or gears.

For high-temperature working conditions, it is necessary to check the cleanliness of the heat sink daily to prevent dust accumulation and heat accumulation. For example, in the steam system of a nuclear power plant, blockage of the heat sink may cause accelerated aging of the sealing packing. It is necessary to monitor the valve body temperature in real time through an infrared thermometer to ensure that it does not exceed the allowable upper limit of the material.

2、 Periodic maintenance: layered risk management and control

Monthly maintenance requires completing three core tasks:

Sealing performance test: After closing the valve, observe the pressure decay rate through the downstream pressure gauge. If the pressure drops more than per minute0.5%Adjust the packing gland or replace the seal.

Lubrication system maintenance: Add lithium based grease to the valve stem threads, gearbox, and other parts. The amount of grease added should be sufficient to prevent the valve stem from sticking due to insufficient lubrication.

Operation test: Conduct manual and electric opening and closing tests, record the number of opening and closing cycles and response time. If the number of cycles increases by more than10%Or if the response time is prolonged, it is necessary to check the wear of the valve stem nut or the efficiency of the motor transmission.

Quarterly maintenance focuses on electrical systems and internal cleaning:

Use a megohmmeter to measure the insulation resistance of the motor. If it is lower than0.5MΩDrying treatment or replacement of windings is required.

Clean the filter before the valve to prevent particle media from blocking the flow channel. For example, in semiconductor ultrapure water systems, filter blockage may cause an increase in valve disc opening and closing torque, leading to damage to the sealing surface.

Check the accuracy of the limit switch and travel controller to ensure that there is an error in the opening indication≤±1%.

3、 Annual overhaul: Refactoring equipment health baseline

Comprehensive disassembly and maintenance of valves are required every year

Key component inspection: Perform ultrasonic testing on the valve body to check for high-temperature creep or low-temperature embrittlement cracks; Perform metallographic analysis on the sealing surface of the valve disc, and if the hardness is lower thanHRC45Welding repair is required.

Replacement of vulnerable parts: Unified replacement of packing boxOSealing components such as O-rings, as well as those with wear exceeding0.5mmThe valve stem.

Performance verification: Conduct water pressure and motion tests to ensure that1.5There is no leakage under double rated pressure, and the electric opening and closing time meets the process requirements.

4、 Special working condition response: customized protection strategy

For low-temperature conditions, it is necessary to clean the medium before the valve is closed, and install an electric heat tracing strip on the valve stem to prevent frost cracking. At the gathering and transmission station of the Chuandongbei gas field, the valve failure rate was successfully reduced through dual protection of insulation cotton wrapping and electric tracing70%.

For highly corrosive media, it is necessary to apply epoxy resin anti-corrosion coating to the valve body every quarter and install it in front of the valveYType filter, interception greater than0.1mmThe particles. A certain photovoltaic enterprise has improved the service life of valve sealing surfaces through this plan1Year extended to3Year.

5、 Digital Empowerment: From Passive Maintenance to Predictive Operations

Introducing IoT sensors to collect real-time data on valve temperature, vibration, pressure, etc., throughAIAlgorithm analysis of device health status. For example, when the vibration frequency of the valve stem exceeds the reference value20%At this time, the system automatically triggers a warning to check the alignment of the gearbox or motor. After applying this technology in a certain steel plant, unplanned downtime has been reduced45%.

The maintenance of Huaying electric globe valve needs to be constructed“routine inspection-Periodic maintenance-Annual major overhaul-Special protection-Digital warning”Five level system, customized implementation based on process characteristics. Through scientific maintenance, valve reliability can be significantly improved, providing long-lasting support for industrial fluid control.