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Delivery: <= 6 days. True-PDF full-copy in English will be manually translated and delivered via email. DL/T 2025.1-2019: Guide of the maintenance for power plant valve - Part 1: general provisions Status: Valid
Basic dataStandard ID: DL/T 2025.1-2019 (DL/T2025.1-2019)Description (Translated English): Guide of the maintenance for power plant valve - Part 1: general provisions Sector / Industry: Electricity & Power Industry Standard (Recommended) Classification of Chinese Standard: F23 Classification of International Standard: 27.040 Word Count Estimation: 43,414 Date of Issue: 2019-06-04 Date of Implementation: 2019-10-01 Quoted Standard: GB 150.4; GB/T 5796.4; GB/T 21465; GB/T 22652; GB 26164.1; GB/T 26480; DL/T 838; DL/T 869; DL/T 1821; DL/T 5210.1; DL/T 5210.5; NB/T 47014; NB/T 47015; NB/T 47018.1; NB/T 47044; JB/T 6438; TSGD 3001 Issuing agency(ies): National Energy Administration Summary: This standard specifies the requirements for the organization, process, process, debugging, quality management, acceptance and other aspects of valve maintenance of power station steam (gas) water, oil and other systems. It mainly provides guidance for the technical management and quality control of the technical personnel of power plants and valve maintenance units to organize and carry out related valve maintenance. This standard is applicable to the overhaul of the valves and their driving devices of the steam (gas) water, oil and other systems of the power station. DL/T 2025.1-2019: Guide of the maintenance for power plant valve - Part 1: general provisions---This is a DRAFT version for illustration, not a final translation. Full copy of true-PDF in English version (including equations, symbols, images, flow-chart, tables, and figures etc.) will be manually/carefully translated upon your order.Guide of the maintenance for power plant valve-Part 1.general provisions ICS 27.040 F 23 Record number. 63143-2018 People's Republic of China Electric Power Industry Standard Guidelines for overhaul of power station valves Part 1.General 2019-06-04 released 2019-10-01 implementation Issued by National Energy Administration Table of contentsForeword...I 1 Scope...1 2 Normative references...1 3 Terms and definitions...1 4 Maintenance interval and scope...2 5 Valve maintenance process...2 6 Maintenance preparation...3 6.1 General requirements...3 6.2 Requirements of the construction unit...3 6.3 Personnel requirements...3 6.4 Safety requirements...4 6.5 Site requirements...4 6.6 Requirements for tools and testing equipment...4 6.7 Valve maintenance conditions...5 7 Maintenance process requirements...5 7.1 Surface grinding...5 7.2 Grinding the sealing surface...7 7.3 Repair welding...9 8 Valve replacement...11 8.1 Valve replacement principle...11 8.2 Parts replacement...11 8.3 Replacement principle of drive unit...11 8.4 Inspection of new valve...11 8.5 Valve installation...12 9 Valve commissioning...12 9.1 Commissioning organization...12 9.2 Debugging conditions...12 9.3 Debug project...12 10 Quality Control and Acceptance...13 10.1 Quality Control...13 10.2 Acceptance of the valve...13 10.3 Technical data management...14 Appendix A (Normative Appendix) Risk Control Measures for Power Station Valve Inspection...16 Appendix B (Informative Appendix) Attached Table of Valve Maintenance Information...19 Appendix C (Normative Appendix) Off-line valve sealing test method...25 Appendix D (Informative Appendix) Quality Management Attachment Table for Valve Maintenance Process...28ForewordThis power station valve maintenance guide is a series of standards, divided into the following 9 parts. --Part 1.General Provisions --Part 2.Butterfly Valve --Part 3.Check Valve --Part 4.Ball Valve --Part 5.Gate Valve, Globe Valve --Part 6.Safety Valve --Part 7.Regulating Valve --Part 8.Special valves for power stations --Part 9.Driving Device This part is Part 1.General Provisions. This part is drafted in accordance with the rules given in GB/T 1.1-2009 "Guidelines for Standardization Work Part 1.Standard Structure and Compilation". Please note that certain contents of this document may involve patents. The issuing agency of this document is not responsible for identifying these patents. This part was proposed by the China Electricity Council. This part is under the jurisdiction of the Power Plant Valve Standardization Technical Committee. Drafting organizations of this section. State Power Investment Corporation Henan Electric Power Maintenance Engineering Co., Ltd., Xi'an Thermal Power Research Institute Co., Ltd., Jiangsu Yuda Power Station Auxiliary Valve Manufacturing Co., Ltd., Harbin Power Station Valve Co., Ltd. of Harbin Electric Group, Shenneng (Hong Kong) International Co., Ltd., Wuhan Boiler Group Valve Co., Ltd., Shaanxi Yihao Technology Development Co., Ltd. The main drafters of this section. Wang Yusheng, Li Yongkang, Dai Langcai, Zhang Tao, Liu Zhengqiang, Wan Shengjun, Jia Rongpin, Pang Guoxin, Zhang Zuodong, Feng Yan, Zheng Lifeng, Liu Jianmin, Sun Lili, Chang Cheng, Han Wenqi, Wu Yonghong, Zhang Xiao, Zhai Qiwu. This section is the first release. The opinions or suggestions during the implementation of this part are fed back to the Standardization Management Center of the China Electricity Council (Baiguang Road, Beijing) Er Tiao No. 1, 100761). Power Station Valve Inspection and Repair Guidelines Part 1 General Rules1 ScopeThis part specifies the requirements for the organization, procedures, and quality management of the valve maintenance of power plant steam (gas) water, oil and other systems. Mainly provide guidance for the technical management and quality control of related valve maintenance for the technical personnel of power plants and valve maintenance units. This part is applicable to the overhaul of valves and their driving devices in power station steam (gas) water, oil and other systems.2 Normative referencesThe following documents are indispensable for the application of this document. For dated reference documents, only the dated version applies to This document. For undated references, the latest version (including all amendments) applies to this document. GB 150.4 Pressure Vessel Part 4.Manufacturing, Inspection and Acceptance GB/T 21465 Valve Terminology GB/T 22652 Qualification of Surfacing Welding Process for Valve Sealing Surface GB 26164 Electrical Safety Work Regulations GB/T 26480 Inspection and testing of valves GB/T 5796.4 Trapezoid Bolt Part 4.Tolerance DL/T 838 Guidelines for equipment maintenance of power generation enterprises DL/T 869 Welding technical specification for thermal power plant DL/T 5210.1-2012 Electric Power Construction Quality Acceptance and Evaluation Regulations Part 1 Civil Engineering DL/T 5210.5 is wrong! The reference source was not found. Electric Power Construction Quality Acceptance and Evaluation Regulations Part 5.Piping and System DL/T 5210.7 Construction Quality Acceptance and Evaluation Regulations of Electric Power Construction Part 7.Welding NB/T 47014 welding procedure qualification for pressure equipment NB/T 47015 Pressure Vessel Welding Regulations NB/T 47018.1 Technical Conditions for Ordering Welding Materials for Pressure Equipment Part 1.General Purchasing Rules NB/T 47044 Power Station Valve JB/T 6438 Technical requirements for plasma arc surfacing of valve sealing surface TSGD3001-2009 Pressure Pipe Installation License Rules GB 26164 Electrical Safety Work Regulations3 Terms and definitions"GB/T 21465 error! The reference source was not found. ", the terms defined in "DL/T 838" and the following terms and definitions apply In this standard. 3.1 Inspection Measure, inspect, test, etc., the performance of the inspection items, and compare the results with the requirements of the standard to determine The activity carried out on whether the performance is qualified. 3.2 Finished product protection Finished product protection refers to the protection of the owner’s existing equipment, devices, parts and parts during construction or transportation. At the same time, During the construction process, take proper measures for some completed branches, sub-projects or parts to avoid damage caused by the construction of other parts work. 3.3 Side station The side station refers to the on-site follow-up supervision activities carried out by the inspectors on the construction quality of key parts or key procedures.4 Maintenance interval and scope4.1 The maintenance interval of power station valves can follow the maintenance interval of the host equipment. 4.2 The main steam system, main water supply system, cooling and heating system, circulating water system, and condensate The valves of the system should be overhauled. 4.3 The other levels of maintenance should be based on valve characteristics, technical conditions, component life cycles, anti-accident measures plans and various monitoring information. Determine the maintenance items of the valve, and arrange the annual inspection of the valve. 4.4 The maintenance interval can be reasonably extended on the basis of the specified maintenance interval according to the technical condition of the valve. The technical condition of the valve does not allow it to continue When working, maintenance should be arranged and measures should be taken to prevent accidents.5 Valve maintenance processValve maintenance should be carried out in accordance with the maintenance process, which is shown in Figure 1. Figure 1 Valve maintenance process6 Preparation for maintenance6.1 General requirements 6.1.1 Before the valve is overhauled, a technical diagnosis should be carried out to check the internal leakage and external leakage of the valve to determine the basic problems of the valve. 6.1.2 The necessary spare parts should be prepared before the valve is overhauled. 6.1.3 The construction unit should complete the preparation of the project construction organization design and submit it for review and approval before the overhaul. The construction organization design should include. 1) Clarify the organization and management system, safety, health and environmental supervision system and quality management system of the maintenance project. 2) Clarify the responsibilities of personnel in each system. 3) Human resource plan for maintenance project. 4) Use plan of special or special machinery and equipment. 5) The unit maintenance implementation plan should be compiled, and the maintenance schedule network diagram and control table should be drawn. 6) The overhaul should draw a fixed site management diagram for the overhaul, and the overhaul should be managed according to the fixed site diagram. 6.1.4 Before the valve is overhauled, a valve maintenance work card (see Appendix A1) should be compiled, and work instructions and special maintenance items should be compiled for important valves. The project should prepare a special technical plan. 6.2 Requirements of the construction unit 6.2.1 The construction unit shall obtain the qualification certificate of the corresponding level in accordance with the law, and contract the project within the scope permitted by its qualification level. 6.2.2 The construction unit shall obtain a safety production license according to law. 6.2.3 The construction unit shall engage in pressure pipeline installation within the corresponding qualification scope specified in TSGD 3001-2009. 6.3 Personnel requirements 6.3.1 The maintenance personnel should be familiar with the structure, performance and principle of the system and equipment, and familiar with the maintenance process, procedures, debugging methods and Quality standards, familiar with safe working procedures. 6.3.2 Maintenance personnel shall have corresponding qualifications and meet the requirements of on-site work. 6.3.3 The maintenance personnel shall undergo safety training and pass the examination before entering the site, and the maintenance operations in special areas shall be in accordance with relevant regulations and requirements of the owner Maintenance work can only be carried out after passing the training examination. 6.4 Safety requirements 6.4.1 The maintenance work shall comply with the relevant requirements of safety management to ensure the safety of personnel and equipment during the maintenance process. 6.4.2 Before maintenance work, check and verify the shutdown, depressurization and discharge of media. 6.4.3 When the valve maintenance site is in a flammable and explosive place, a toxic and harmful place, or a restricted space, it must be protected in accordance with the corresponding regulations Measures. 6.4.4 The working area used should be checked before the maintenance work starts to confirm compliance with relevant regulations. 6.4.5 Insulation materials for valves dismantled during valve maintenance should be treated in accordance with environmental protection requirements, and materials with reuse value should be Effective stacking management ensures a clean and orderly maintenance environment. 6.4.6 The maintenance personnel should be familiar with the safety risks and corresponding safety measures in the maintenance area (see Appendix A). 6.5 Site requirements 5.5.1 Maintenance site setting. 1) The valve maintenance area should be effectively and safely separated from other equipment and valves, and the construction unit shall carry out in accordance with the requirements in the maintenance area It is allowed to use after the site layout and acceptance. 2) The valve maintenance site should consider its bearing capacity, and the valve placement position should not be greater than the bearing capacity of the area. 3) The ground of the maintenance area should be well protected, and the maintenance function modules should be divided (tool placement area, measuring tool placement area, lifting equipment Storage area, spare parts storage area, maintenance area, garbage storage area, etc.). 4) The maintenance area should be effectively isolated (a cross-working anti-dropping net is set above). 5) Safety warning signs should be set up in the inspection area. 6) Information boards are set in the inspection area, and the content of the information boards can be adjusted according to their own conditions. 7) The ground of the inspection area should be protected by finished products. 5.5.2 Repair site restoration. 1) After the overhaul is completed, the overhaul site should be cleaned up to ensure that the site is cleared after the work is completed. 2) After the overhaul, the equipment is in its original color, the signs are complete, and the protective facilities are complete, meeting the requirements of safe and civilized production. 6.6 Requirements for tools and testing equipment 6.6.1 Prepare a list of maintenance tools and appliances according to the content of the maintenance valve before maintenance. 6.6.2 The tools and equipment used in the inspection and repair process should meet the relevant national standards and be qualified. 6.6.3 The measuring tools and testing instruments used in the process of overhaul shall comply with the relevant national standards and be inspected regularly. 6.6.4 The special equipment used in the inspection and repair process shall comply with the national special equipment manufacturing and use regulations, and shall be inspected by an inspection-qualified unit. Pass the inspection and the certificate is within the validity period. 6.7 Valve maintenance conditions 6.7.1 The current system has been shut down or the valve has been disconnected from the system. 6.7.2 The discharge valve at the bottom of the system and the top vent valve should be open. 6.7.3 Put the valve in the switch state suitable for maintenance. 6.7.4 The pressure inside the valve is reduced to zero (gauge pressure). 6.7.5 There is no residual medium in the connecting system before and after the valve. Overhaul the valves of the common mother control system to monitor the bottom of the mother pipe The quality leakage check valve does not show continuous line or no more than 15 drops per minute of medium leakage. After opening the exhaust valve on the top of the main pipe No medium discharge in the runner is the reference basis. 6.7.6 The temperature of the valve body of the high temperature and high pressure valve drops below.200 ℃, and the valve can be insulated and removed.7 Maintenance process requirements7.1 Surface grinding 7.1.1 The surface grinding of the valve is mainly to remove the rust, burrs, local deformation, slight grooves and local bumps on the surface of the valve parts. Rationale. 7.1.2 Polished parts mainly include valve body assembly parts, bonnet, valve stem, valve stem nut, valve plate/disc, upper seal fitting, self-sealing Seal valve quadruple ring (six ring), pressure ring, bracket bearing chamber and fasteners, etc. 7.1.3 The following grinding methods can be used according to the parts and defects. 1) Mechanical processing and grinding, such as turning, boring, and grinding on mechanical equipment. 2) On-site portable mechanical grinding, such as grinding and polishing with portable grinder. 3) Manual grinding, such as filing, grinding, grinding with special tools, matching grinding, etc. 4) Sanding with emery cloth. 7.1.4 See the table for the surface grinding positions, grinding methods and quality requirements of valve parts. Valve stem, valve body, fasteners, fastening screws Refer to Appendix B for commonly used materials. 7.2 Grinding the sealing surface 7.2.1 The valve seat grinding can be carried out by electric grinder or manual tool. The valve plate/disc can be manual flat grinding and electric grinding If the defect groove is too deep, the machine tool repair and grinding method can be used. 7.2.2 Choose grinding tools and methods according to valve structure and type. Valves with DN≤50mm can be ground with manual tools. Valves with DN≥50mm can be ground with electric tools. 7.2.3 Grinding is divided into coarse, medium, fine and fine grinding. The sealing surface defects include pits, scratches, erosion grooves, etc., which can be selected according to the defect. 1) When the defect depth is less than 0.40mm, you can choose a grinding machine for grinding treatment. 2) If the defect depth is greater than 0.10mm or less than 0.40mm, rough grinding can be used. 3) If the depth of the defect is less than 0.10mm or greater than 0.03mm, medium grinding can be used. 4) Fine grinding can be used if the defect depth is less than 0.03mm. Fine grinding is generally used to improve the surface roughness and accuracy of the sealing surface. 5) When the defect depth is greater than 0.40mm, if conditions permit, the machine can be repaired to make the defect depth less than 0.40mm. Then use a grinding tool to grind. There is no condition for machine tool repair. You can directly choose rough grinding to medium and fine grinding. 7.2.4 The grinding speed and pressure requirements are as follows. 1) When manual grinding is used, the movement speed is controlled at 8 m/min～15m/min. 2) The grinding speed is controlled at 100r/min when the valve disc diameter is less than 80mm. When it is larger than 100mm, the grinding speed is controlled at 50r/min. 3) The pressure applied to the grinding machine during grinding should not be too high, generally the unit pressure should not exceed 150kPa～1200kPa. 7.2.5 The grinding head and grinding seat can be prepared according to the size and angle of the valve seat, valve plate/disc, and when grinding the sealing surface of the cone globe valve, Configure the valve seat grinding mold with the same angle. 7.2.6 When assembling grinding tools on the valve seat, valve plate/disc, the centering and verticality of the tool and the valve seat, valve plate/disc should be ensured to avoid Research bias. 7.2.7 During the grinding process, the alignment and verticality of the grinding machine and the valve seat, valve plate/disc should be maintained, and frequent inspection and adjustment should be made to prevent grinding deviation. 7.2.8 The grinding of the valve seat and disc sealing surface should meet the design coincidence requirements, and the valve plate sealing surface of the wedge-type single disc gate valve should be wide enough The minimum wear stroke should be considered when turning and grinding, and the sealing surface of the valve plate should not be lower than the center of the sealing surface of the valve seat. 7.2.9 The abrasive materials include abrasive paste (var sand), diamond emery cloth, diamond powder, mineral oil (motor oil) and animal oil, etc. The selection requirements are as follows under. 1) Use manual tools to grind, you can choose suitable grind materials according to the conditions of the tools. 2) For fine grinding, you can use fine grinding materials, 250 mesh ~ 300 mesh sandpaper, and fine grinding can use 400 mesh sandpaper to add ore The natural oil and animal oil are ground with 400 mesh diamond powder. 3) Choose electric tool for grinding, generally choose diamond gauze and special grinding head for grinding. 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