1、The Chinese version of standards has precedence to their English translations which are only for internal reference.本英文版为内部资料，仅供参考，以中文版为准。Maintenance and Service Procedure for Petrochemical Equipment General EquipmentMaintenance and Service Procedure for Valves阀门维护检修规程SHS 01030-92(For Trial Implemen
2、tation)Promulgated by SINOPECSINOPEC Publishing House12Contents1. General 2. Period and Content of Maintenance3. Maintenance and Quality Standard4. Testing and Acceptance5. Service and TroubleshootingAppendix A Option of Materials for Abrasive Tools (For Reference)Appendix B Codes and Application Ra
3、nges of Abrasive MaterialsAppendix C Size Ranges of Abrasive Materials (For Reference)Appendix D Option of Flanges, Bolts and Gaskets (For Reference)Appendix E Option of Common Packings31. General 1.1 Subject Matter and Application Range 1.1.1 In this Procedure the period and content of the maintena
4、nce, maintenance and quality standard, testing and acceptance, service and troubleshooting of general-purpose valves are defined or described.1.1.2 This Procedure is applicable to such gate valves, stop valves, ball valves, butterfly valves, check values and safety valves that are used in the Petroc
5、hemical industry with the max. working pressure being 98.1 MPa (gauge pressure) and the working temperature ranging from -196 to + 850C.1.2 Reference for Preparation SY-21019-73 Maintenance and Service Procedure for Valves of Refineries GB 12241-12243-89 Safety Valves ZBJ16-006-89 Tests and Checks o
6、f Valves.2. Period and Content of Maintenance2.1 Maintenance PeriodThe maintenance period of valves shall be determined by all enterprises themselves in accordance with the features of the production plant, performances of the medium, corrosion speed and operating cycle.2.2 Maintenance Content2.2.1
7、Clean and check the valve body and partial valve parts.2.2.2 Replace or repair partial valve parts.2.2.3 Lap the seal surface.2.2.4 Repair the surfaces of the spacer flange and end flange.2.2.5 Replace or add the packing, replace the gasket.3. Maintenance and Quality Standard3.1 Preparatory Work for
8、 Maintenance.3.1.1 Get ready all related technical documents.3.1.2 Get ready all necessary machines and tools, measuring tools and materials.3.1.3 Thoroughly remove the valve medium as per the related regulations on safety.3.2 General Requirements.3.2.1 There shall be a label hung on the valve, indi
9、cating the maintenance no. working 4pressure, working temperature and medium.3.2.2 For removed parts which have special requirements for the direction and position, such direction and location shall be checked for correctness or marked out.3.2.3 Clean all the valve parts, removing all contaminants f
10、rom them.3.2.4 Replace all the non-metallic seal surfaces that are damaged.3.2.5 For correct selection and use of the materials for abrasive tools and abrasive materials, refer to Appendices A (For Reference), B (For Reference) and C (For Reference) respectively.3.2.6 For bolts and gaskets the worki
11、ng temperature of which is above 250C, appropriate anti-seizure agent shall be applied on them.3.2.7 Copper gaskets shall be annealed before installation.3.2.8 All bolts shall be installed neatly. For gate valves and stop valves, the bolts of the spacer flanges shall be tightened when the valves are
12、 in the open state.3.3 Quality standard of Maintenance3.3.1 The valve nameplate shall remain intact and the lead seal of the safety valve shall keep sound and perfect.3.3.2 The valve casting shall have no such defects as cracks, serious shrinkage cavities and slag inclusion.3.3.3 The surface of the
13、valve forging to be machined shall have no such defects as sandwiching, double-skin, cracking and black spots.3.3.4 The weld joint of valve weldment shall have no such defects as cracks, slug inclusion, gas holes, and poor formation.3.3.5 The bolt of the valve shall not be loosened and the end of th
14、e bolt shall be 2-3 threads out of the nut. The parts of the actuating system shall be complete and operable.3.3.6 Seal Surface3.3.6.1 The seal surface shall be checked for proper imprint of the contact surface with the developer.a. For gate valves, stop valves and check valves, the imprint lines sh
15、all be continuous with the width being not less than 1mm and the imprint being uniform. The extreme position of the imprint line of the gate valve disc on the seal surface shall be no less than 3mm from the excircle (including the width of the imprint line).b. The imprint line of the ball valve shal
16、l be continuous with the width being not less than that of the outer diameter of the seal ring of valve body and the imprint being uniform.3.3.6.2 The cumulative decrease in thickness of the seal surface of the safety valve after lapping shall be not more than 2mm.3.3.6.3 The thickness of the build-
17、up welding layer of the safety valves seal surface shall not be less than 2mm.53.3.6.4 The roughness of the seal surface after lapping shall not be lower than 1.6 and not be lower than 0.4 for safety valves.3.3.7 Valve Body, Valve Bonnet and Gaskets3.3.7.1 The connection between the valve seat and v
18、alve body shall be firm, tight and free of leakage.3.3.7.2 The valve disk fits the guide perfectly and there shall be no jamming and derailing at any position.3.3.7.3 The max. out-and-in fit clearance of the spacer flange of the valve shall meet the requirements set out in Table 1.Table 1mmSpacer Fl
19、ange Dia.4285 90-125 130-180 185-250 255-315 320-400 405-500Max. Clearance0.40 0.45 0.50 0.55 0.65 0.75 0.803.3.7.4 The seal surface of the flange shall be clean and free of scraps.3.3.7.5 Dyeing inspection shall be made for the contact surface of the steel gasket and seal box and the imprint line s
20、hall be continuous.3.3.7.6 The flanges shall be parallel and the installation distance shall be in compliance with the requirements of Table 2.Table 2mmNominal Diameter DN 100 150200 250Min. Installation Clearance 2 2.5 33.3.7.7 For selection of flanges, bolts and gaskets, refer to Appendix D (For R
21、eference).3.3.7.8 The bolts for which special requirements for tightening moments are set shall be tightened in accordance with such requirements and the error in respect of the tightening moment shall not be bigger than 5%.3.3.7.9 The max. fit clearance of the packing gland and bottom sleeve with t
22、he ports of the stuffing box shall meet the requirements set out in Table 3.Table 3mmBore of Stuffing Box 2226 2834 3644 4870 75106 1226Max. Clearance 0.20 0.25 0.27 0.30 0.35 0.403.3.7.10 The max. fit clearance between the inside diameter of the packing gland and the valve stem shall be in complian
23、ce with the requirements set out in Table 4.Table 4mmValve Stem Dia. 1416 1822 2428 3250 5580 90Max. Clearance 1.00 1.20 1.40 1.50 1.80 2.203.3.7.11 The packing gland shall be free of any damages and deformation.3.3.8 Actuating Device3.3.8.1 The connection between the valve stem and actuating device
24、 shall be reliable and shall not become loose of itself.3.3.8.2 When the end of the valve stem is connected with the valve disk at the time when the valve is closed, the disk shall aligned with the valve body.3.3.9 Valve Stem3.3.9.1 There shall be no pits, scraps and axial clefts on the surface of t
25、he valve stem and the roughness of such surface shall be 1.6.3.3.9.2 The tolerance value of linearity along the whole length of the valve stem shall be in compliance with the requirements set out in Table 5.3.3.9.3 The tolerance value of roundness of the valve stem shall be in compliance with the re
26、quirements set out in Table 6.Table 5mmWhole Length of Valve Stem L500 5001000 1000Tolerance of Linearity0.30 0.45 0.60Table 6mmValve Stem Dia. Tolerance of Roundness30305050600.090.120.15760 0.183.3.9.4 The tolerance value of axiality of the axes of the buttress thread and the upper seal cone with
27、the axis of the valve stem shall be in compliance with the requirements set out in Table 7.Table 7mmWhole Length of Valve Stem L500 5001000 1000Tolerance of Axiality 0.15 0.30 0.453.3.9.5 The head of the valve stem shall be free of any indentations and deformation.3.3.9.6 The sphere at the end of th
28、e stem of the safety valve shall be round and smooth.3.3.9.7 The surface of the safety valve spring shall be free of cracks and the bearing planes of both the ends of the spring shall be perpendicular to the axis.3.3.10 Nuts of Valve Stem3.3.10.1 The max. fit clearance of the excircle of the valve s
29、tem and the support opening shall meet the requirements set out in Table 8.3.3.10.2 The hand wheel and bearing gland shall not be loosened.Table 8mmOutside Diameter 3550 5580 80Max. Fit Clearance 0.25 0.30 0.353.3.11 Packing Seal3.3.11.1 The packing for miter joint shall have an oblique angle of 30
30、made and the joints of every two neighboring turns of the packing shall be staggered by 120 and the packing shall be compressed fast turn by turn.3.3.11.2 After the stuffing is inserted, the packing gland shall be pressed into the stuffing box by no less than 2mm. The exposed portion shall not be le
31、ss than two thirds of the height of the packing gland that can be pressed into the stuffing box.3.3.11.3 After the packing is filled, the valve stem shall rotate, go up and down freely without seizure and leakage.3.3.11.4 For selection of appropriate packing materials, refer to Appendix E (For Refer
32、ence).3.3.12 Assembling of Valve3.3.12.1 When the double parallel slides of the valve reach the “Close” position, the expander mechanism shall open immediately to enable the slides to coincide with the seal 8surface of the valve body. The slides shall not separate or come off during operation.3.3.12
33、.2 The flange and guide bushing of the safety valve body shall be aligned for fitting.3.3.12.3 The indicating and limit mechanisms shall be correctly located.3.3.12.4 The installation of the actuating device shall ensure flexibility and operability of the device and meet the relevant technical requi
34、rements.4. Testing and Acceptance4.1 General requirements4.1.1 When making the sealing test, no grease shall be applied on the seal surface. However, it is allowed to have a coat of protecting agent with the viscosity being not greater than that of kerosene applied on it.4.1.2 For valves of Austenit
35、ic stainless steel, the test medium shall be mater and the chlorine content of the water shall not exceed 25 ppm. For valves of carbon steel and 16 Mn R, the water temperature shall not be lower than 5 and for valves of other low-alloy steel, the water temperature shall not be lower than 15.4.1.3 Wh
36、en the gas pressure test is made instead of the hydraulic test, the approval from the relevant authority shall be obtained and corresponding preventive measures taken beforehand.4.1.4 After the pressure test is completed, the fluid deposited in the valve chest shall be removed immediately.4.2 Pressu
37、re Test of Common Valves4.2.1 Test Medium4.2.1.1 For test of the valve casing, tests on high-pressure upper seal and high-pressure seal, the medium shall be water, kerosene or any non-corrosive fluid with the viscosity not bigger that of water.4.2.1.2 For tests on low-pressure seal and low-pressure
38、upper seal, the medium shall be air or any inert gas.4.2.2 Test Pressure4.2.2.1 For test of the valve casing, the test pressure shall be 1.5 times the nominal pressure.4.2.2.2 For tests on high-pressure seal and high-pressure upper seal, the test pressure shall be 1.1 times the nominal pressure.4.2.
39、2.3 For tests on low-pressure seal and low-pressure upper seal, the test pressure shall be 0.6 Mpa.4.2.2.4 For the sealing test of the check valve, the test pressure shall be the nominal pressure.4.2.3 Test Duration and Permitted Max. Leakage94.2.3.1 The pressure-holding time of the test of the valv
40、e casing shall be in compliance with the requirements set out in Table 9. There shall be no leakage from and structural damage to the casing (including the stuffing box and spacer flange).Table 9Nominal Dia. ,mm 250Pressure-holding Time, min1 2 34.2.3.2 The pressure-holding time of the seal test and
41、 upper seal test shall be in compliance with the requirements set out in Table 10. The allowed max. leakage rate of the seal box shall be in compliance with the requirements of Table 11.Table 10Nominal Dia., mm 500Seal Test 15 30 60 120Pressure-holding Time s Upper Seal Test 15Table 11Check Valve wi
42、th Metallic SealNominal Dia. DNGate Valve, Check Valve Drop or No. (of Bubbles)/minPlug Valve Drop or No. Of Bubbles/minAll Valves with Elastic SealBall Valve, Butterfly Valve with Metallic SealLiquid TestCm3/minGaseous TestM3/h5065150200300350012202801220280* When leakage is measured on the basis o
43、f gas, one bubble (volume under the barometric pressure) = 300mm3 and When measured on the basis of liquid, 16 drops = 1000mm34.3 Pressure Test of Safety Valve4.3.1 Pressure Test on StrengthThe pressure for the strength test shall be 1.5 times the max. working pressure. For pressure-holding time, see Table 12. If the results show no leakage and deformation, the strength shall be considered up to standard.4.3.2 Test on Setting Pressure (or Cracking Pressure)
