In industrial fluid control systems, manual valves are core components, and their stability and reliability are crucial to the operation of the entire system. Factors such as long-term use, medium corrosion and improper operation may cause leakage failures in manual valves during use. Leakage will not only cause system pressure to drop, affecting production efficiency, but may also pose a potential threat to the environment and personnel safety.
Analysis of the causes of leakage failures
The causes of manual valve leakage can be mainly attributed to the following aspects:
Aging or damage of seals: The seals in manual valves, including sealing rings and sealing gaskets, are subject to long-term medium corrosion and temperature fluctuations, and are prone to aging, hardening or deformation, resulting in reduced sealing performance, thereby causing leakage.
Wear of valve seats and valve discs: Valve seats and valve discs are key components of manual valves. They are subject to long-term medium erosion and friction, and are prone to wear, resulting in uneven sealing surfaces, which in turn cause leakage.
Loose or damaged bolts: The bolted parts of the manual valve, such as flange connection bolts, may become loose or damaged if they are not tightened in place or are subject to long-term vibration, resulting in loose sealing surfaces and leakage.
Impurities and rust: If there are impurities or rust inside the manual valve, it will damage the flatness of the sealing surface and cause leakage risk.
Solutions to leakage failures
For manual valve leakage failures, the following strategies can be effectively solved:
Replace the seal: When a manual valve leaks, the state of the seal should be checked first. If it is found to be aged or damaged, it needs to be replaced in time. When replacing, it is important to choose the right material and specification to ensure the recovery of the sealing performance. Before installing a new seal, be sure to clean the sealing surface to remove impurities and rust to ensure a good sealing effect.
Grinding and repairing valve seats and valve discs: For valve seats and valve discs that are severely worn, grinding and repairing is an effective solution. Use professional grinding tools and abrasives to grind the valve seats and valve discs to restore their flatness. After grinding, check the quality of the sealing surface to ensure that it meets the relevant standards. If the grinding effect is not ideal, it is recommended to replace the new valve seat and valve disc.
Tighten the bolts: For leaks caused by loose bolts, check the tightening state of the bolts. If loose or damaged, tighten or replace them in time. During the tightening process, it is very important to use the appropriate torque to avoid other problems caused by over-tightening or over-loosening. At the same time, check whether there are cracks or damage in the bolted joints, and repair or replace them if necessary.
Clean impurities and rust: For leaks caused by impurities and rust, the inside of the manual valve should be thoroughly cleaned to remove all impurities and rust. Use professional cleaning agents and tools to ensure the cleanliness of the inside of the valve. At the same time, check whether there is corrosion and wear inside the valve, and repair or replace it if necessary.
Strengthen daily maintenance and inspection: In order to effectively prevent the occurrence of manual valve leakage failures, daily maintenance and inspection are particularly important. Regularly check the sealing performance of the manual valve, the bolt connection status, the wear of the valve seat and valve disc, and whether there are impurities and rust inside. If problems are found, they need to be dealt with in a timely manner. At the same time, establish a complete maintenance and inspection record to track the use and maintenance history of the manual valve to ensure the long-term stable operation of the system.
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