1. How many years is the service life of the gas pressure regulator?
Since the pressure regulator is the main equipment in the pressure regulating facility, the maintenance of the gas pressure regulator is to ensure safety. The key management link of gas supply. Once the pressure regulator fails, unregulated higher-pressure gas will be directly transported downstream, with disastrous consequences. Therefore, various gas management units are increasingly paying attention to issues such as the maintenance and service life of gas pressure regulators.
1. The difficulty of uniformly stipulating the service life of pressure regulators
As for the service life of gas pressure regulators, not only in our country, but also in developed countries There is no clear service life specified for various types of voltage regulators. Under normal circumstances, manufacturers have certain instructions on the maintenance of voltage regulators in the instruction manual, but they never mention the life of the overall equipment. This is not because the manufacturer intentionally avoids the problem, but because of the following factors:
① At present, domestic voltage regulator products do not adopt a non-detachable assembly structure for the overall equipment or core components of the equipment. Most faults can be solved Solved by repair.
② For existing voltage regulators, there are no relevant standards, regulations, or documents stipulating which components in their structure can represent the life of the entire equipment, and there are no fatigue limit requirements or fatigue test requirements.
③There are many types of voltage regulators and their components are made of different materials.
Therefore, it is difficult to make unified regulations on the service life of gas pressure regulators.
2. Factors causing damage to the gas pressure regulator
There are many factors that affect the normal use of the gas pressure regulator. , mainly can be summarized into the following three types.
①Influence of gas temperament
a. If the gas contains a certain amount of S02, H2S, aromatic hydrocarbons, tar and other substances, it is easy to cause rubber parts to of damage.
b. If the gas contains a certain amount of S02, H2S, H2O, O2 and other substances, it will cause corrosion damage to copper, iron and other metal parts.
e. If the gas contains a certain amount of particle dust, after long-term use, it will affect the sliding fit gap of metal parts, leading to equipment failure and malfunction.
d. If the gas contains a certain amount of particulate dust, and the flow rate is large, the high-speed dust will cause damage to the casing and other components. This type of damage caused by wear or impact is more common at gate stations.
e. If the gas contains a certain amount of substances that are prone to phase change at room temperature, such as elemental sulfur, naphthalene, anthracene, light oil and other substances, liquid accumulation will occur and form on the valve stem, inner cavity, diaphragm, etc. The surface grains are attached, affecting the normal use of the voltage regulator.
②Influence of actual operating conditions
a. If the pressure difference between the inlet and outlet is too large and the flow rate is large, it will affect metal parts, especially Cavitation damage occurs to the casing.
b. The ambient temperature is too high or too low. In some cases, the medium temperature is too low when the pressure is greatly reduced and the heating is poor, which will cause damage to the film and other rubber parts.
c. If the equipment is improperly selected, the difference between the actual throughput capacity range and the rated throughput capacity of the equipment is too large, which may easily cause overall or partial damage to the moving parts of the equipment.
③The impact of the equipment itself
a. Defects in the structure of the equipment itself.
b. Material defects in the spare parts used in the equipment.
Among the above factors that affect the normal use of gas pressure regulators, some will cause local damage that can be repaired, while others will cause permanent damage to the entire equipment.
3. Factors related to equipment replacement
In the development history of gas pressure regulators in my country, there have been several major updates and elimination processes. First of all, it is due to structural considerations, such as Reynolds-type voltage regulators. The main reason for updating is because of its complex structure, difficult maintenance, and large floor area. Secondly, for safety reasons, equipment with external exhaust function should be updated, such as piston pressure regulators and other pressure regulators that use external exhaust mode. These are two large-scale pressure regulator replacements that are basically the same for gas companies in various places. Gas companies in various regions also have their own unique equipment management models and methods of replacing equipment, which depend on specific circumstances.
4. Service life of the voltage regulator
The specific service life of the voltage regulator is related to the specific use environment and cannot be generalized.
For example, in the medium-low pressure area pressure regulating cabinet of a gas company, the pressure regulator has been used for several years without any problems. However, when used in plants with high pressure B and above, due to gas impurities and Due to the higher pressure, the valve body of the pressure regulator was punctured and its service life was only a few months.
To sum up, the service life of the voltage regulator is generally 2 years due to damage caused by gas temperament. At lower operating pressures, the regulator has a slightly longer service life. Some voltage regulators have been running for 10 to 20 years without any problems under good operating environment, gas temperament and other conditions. According to the actual situation, generally under normal use environment, the service life of the rubber diaphragm of the voltage regulator does not exceed 3 years, and the metal material can be used for 10 years.
In the absence of relevant standards, regulations, or documents stipulating the life span of the entire voltage regulator equipment, it is recommended thatThe following methods are used for identification:
① It is believed that a voltage regulator with serious defects in the structure itself and relevant substitute products has reached the end of its service life.
② It can be considered that the service life of the pressure regulator has been reached if the valve body has been permanently damaged.
③ It can be considered that a voltage regulator that has been used for a long time and has severely worn moving parts has reached the service life of the voltage regulator.
④ It can be considered that a voltage regulator that has been repaired too frequently and whose performance cannot be guaranteed has reached the end of its service life.
2. Gas pressure regulatorHow to maintain
Safety precautions for maintenance Matters
1. When performing regular maintenance, there must be more than two skilled operators performing the operation, and the operation must be carried out in strict accordance with the maintenance operating procedures.
2. During the maintenance and dispersion process, the surrounding environment should be carefully checked to ensure that there is no open flame. In addition, the operation can only be carried out after the gas is completely dissipated.
3. After the maintenance work is completed, the maintenance personnel must record the maintenance process and results in the “Pressure Regulator Box (Cabinet) Maintenance File”.
Routine maintenance
According to the temperament, routine inspection should be carried out at least once a month:
1. Use gas alarm equipment (or soap solution) Check the pressure regulator for external leakage.
2. Check whether the outlet pressure or closing pressure of the pressure regulator is within the specified range.
3. For voltage regulators with cut-off, check whether the tripping mechanism of the cut-off device can work normally, and check whether it is closed tightly after cutting off.
4. Check the filter pressure difference gauge. If the pressure difference is too large, the filter needs to be cleaned.
5. Clean the outside of the gas pressure regulator.
Regular inspection and maintenance
According to the temperament, the voltage regulator should be inspected regularly every 3-6 months:
1 , perform a check on the closing pressure of the pressure regulator.
2. Check the starting pressure setting value of the cutter.
3. Clean and maintain the internal parts of the pressure regulator and pilot, check the wearing parts such as valve seals, balance membranes, and O-rings, and promptly replace those that have become swollen, aged, or damaged. Seals with uneven indentation; replace worn and deformed parts promptly.
4. Clean and maintain the interior of the cutting mechanism and discharging mechanism, check the wearing parts such as valve seals, balance membranes, and O-rings, and promptly replace those that are swollen, aged, or indented. Uneven seals; promptly replace worn and deformed parts.
5. Clean the filter and replace the filter element as appropriate.
6. Check the appearance of the paint coating on the pipeline and each component. If it is seriously peeling off, please remove the rust and repaint.
Maintenance procedures
1. Use soap solution (or leak detector) to check whether the pressure regulator is leaking.
2. Check whether the outlet pressure of the pressure regulator is normal.
3. Close the inlet and outlet valves of the pressure regulator.
4. Empty the gas in the cavity.
5. Clean (or replace) the filter.
6. Clean the main body of the pressure regulator and replace the wearing parts.
7. Clean the pilot and replace the easily damaged ones.
8. Purge the signal tube.
9. Clean the main body of the shut-off valve and replace the wearing parts.
10. Clean the main body of the safety relief valve and replace the wearing parts.
11. Assemble the pressure regulator, open the inlet valve of the pressure regulator, and check for leaks.
12. After passing the test, debug the gas pressure regulator to cut off the pressure, safely relieve the pressure, and close the pressure in accordance with the regulations.
13. Adjust the outlet pressure and supply air.
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