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How Should Chinese Enterprises Address the “Difficult Birth” of Domesticating High-End Valves?


Release Date:

2020-12-11

The “2012–2016 China Valve and Plug Manufacturing Industry Development Prospects and Investment Forecast Analysis Report” indicates that, since 2012, the path toward domestic production of high-end valves has been exceedingly challenging. At present, basic components have become a bottleneck restricting the advancement of China’s manufacturing sector toward higher-end technologies, underscoring the need to further intensify efforts to localize high-end equipment parts. The “difficult birth” of domestically produced high-end valves: Currently, China’s valve market (valve market analysis) already offers a wide range of products, including heating valves, environmental protection valves, and construction valves. Although, in recent years, thanks to the efforts of domestic enterprises, some mid- to high-end pump and valve products have achieved localization, certain items still rely on imports. According to data provided by the China General Machinery Industry Association, since the beginning of this year, the major imported pump products include hydraulic reciprocating plunger pumps, other hydraulic reciprocating displacement pumps, rotary axial piston pumps, other centrifugal pumps with speeds below 10,000 rpm, liquid pump components, and vacuum pumps. Valve products mainly comprise pressure-reducing valves, hydraulic transmission valves, pneumatic transmission valves, safety valves or relief valves, and valve components. In the field of high-pressure valves, reliance on imports persists, making this an area where China’s valve industry must focus its breakthrough efforts in the future. The industrial positioning of the High-End Valve Industrial Park is to build a Chinese high-end valve city characterized by high-end sophistication, complete sets, internationalization, and headquarters functions—aiming to attract 200 high-end valve enterprises within three to five years, secure over RMB 20 billion in investment, achieve annual sales revenue exceeding RMB 50 billion, and ultimately reach an annual sales scale of more than RMB 100 billion. At present, both domestic policy support and the existing level of technological capability are insufficiently conducive to the R&D of high-end valves. Overall, as the national policy for revitalizing the equipment manufacturing industry is progressively implemented, general basic manufacturing will receive even greater priority support. Major users of valves—including the petrochemical, power, metallurgical, chemical, and urban construction sectors—are expected to increase their demand for valve products; however, the feasibility of import substitution varies significantly across different sub-sectors in China, highlighting the urgent need for greater policy guidance and research support for high-end valves. Why is the localization of high-end valves so difficult? According to an analysis by a representative of the China General Machinery Industry Association, there are four primary reasons for this phenomenon: First, long-term underinvestment in R&D. Domestic enterprises exhibit a clear gap in product technology development philosophy compared with some advanced foreign companies. Insufficient funding for scientific research and R&D has become a major constraint on valve manufacturers’ independent innovation. According to incomplete statistics from the pump industry, R&D spending accounts for less than 2% of total corporate revenue, a figure far lower than that of well-known foreign firms, indicating very limited industry-wide R&D investment. Relevant statistics show that the entire pump industry’s annual R&D expenditure in China is still less than the R&D budget of a single foreign company. Second, weak indigenous innovation capacity. It is understood that the Chinese machinery manufacturing industry has been slow in digesting and absorbing imported technologies, with most enterprises exhibiting limited technological innovation capabilities; 57% of core technologies for major mechanical products still rely on imports. Although most products in China’s pump manufacturing industry have now essentially achieved domestic production, domestic firms largely undertake only low-end processing stages, leaving considerable room for improvement in both the breadth and depth of localization. For example, key core technologies for nuclear-grade pumps used in complete sets of nuclear power plant equipment, as well as for high-pressure boiler feedwater pump assemblies in million-kilowatt ultra-supercritical and supercritical thermal power plant systems, which are currently being localized, still largely depend on imports. Third, weak customer willingness to purchase domestic products. Even when domestic products meet or exceed foreign standards in performance metrics, some customers remain inclined to buy foreign-made equipment, thereby increasing the difficulty of introducing China’s first-of-its-kind major technological equipment—such as valve and pump technologies—into the market. Despite the fact that many domestically produced high-end pump products boast comparable technical levels, some end-users continue to refuse to adopt them, citing a lack of operational track record and other reasons. Fourth, a lack of research into industry-wide common technologies. Following institutional reforms, some research institutes that once served the industry have become fragmented enterprises, with significant changes in their organizational structure and core mission. As a result, their role in providing technical support to the industry has weakened, slowing down the development of new technologies and processes and making it difficult to align design, process, material, and manufacturing standards with international benchmarks. In response, experts have put forward three recommendations: First, establish a new mechanism to encourage enterprise-driven innovation. Based on the national comprehensive plan and regional layout for the pump and valve manufacturing industry, set up a number of regionally focused laboratories, test bases, and product development centers for leading technologies and products. Leverage strong science-and-education institutions to establish technology-transfer hubs, and encourage and support the establishment of R&D centers dedicated to pump and valve manufacturing technologies. Second, improve the technology-promotion system. Reasonably organize grassroots technology-promotion organizations, gradually building a diversified technology-promotion system led by national-level bodies, with clear division of labor, effective collaboration, and comprehensive service coverage. Finally, strengthen the science-and-technology training system and enhance intellectual-property protection. Establish and refine the linkage between training services provided by universities, research institutes, and secondary vocational schools and basic education, fully leveraging the strengths of institutions at all levels. Further improve the market environment for new-product innovation, actively promote new-product development, and require enterprises and research institutions to establish sound internal regulations for managing independently developed new products.

  The “2012–2016 China Valve and Plug Manufacturing Industry Development Prospects and Investment Forecast Analysis Report” indicates that, since 2012, the path toward domestic production of high-end valves has become exceedingly challenging. At present, basic components have emerged as a bottleneck restricting the advancement of China’s manufacturing sector toward higher value-added, high-end development, underscoring the need to further intensify efforts to achieve domestic sourcing of high-end equipment components.

  The Localization of High-End Valves Has Been Difficult to Achieve At present, China’s valve market (as analyzed in the valve market report) is already capable of supplying a wide range of products, including heating valves, environmental protection valves, and building-use valves. Although, thanks to the efforts of domestic enterprises in recent years, some mid- to high-end pump and valve products have been localized, a number of key items still rely on imports. According to data provided by the China General Machinery Industry Association, since the beginning of this year, the major pump products imported in large quantities include hydraulic reciprocating plunger pumps, other hydraulic reciprocating displacement pumps, rotary axial piston pumps, other centrifugal pumps with rotational speeds below 10,000 rpm, liquid pump components, and vacuum pumps. As for valve products, the main categories include pressure-reducing valves, hydraulic transmission valves, pneumatic transmission valves, safety valves or relief valves, and valve components. In the field of high-pressure valves, reliance on imports persists, making this an area where China’s valve industry must focus its efforts to achieve breakthroughs in the future. The industrial positioning of the High-End Valve Industrial Park is to build a Chinese hub for high-end valves that is characterized by high sophistication, complete product sets, internationalization, and headquarters-based operations. Over the next three to five years, the park aims to attract 200 high-end valve companies, secure more than RMB 20 billion in investment, and achieve annual sales revenue exceeding RMB 50 billion—ultimately striving to reach annual sales of over RMB 100 billion.

  At present, both domestic policy support and the existing level of technological capability are insufficiently conducive to the R&D of high-end valves. Overall, as the national policy to accelerate the revitalization of the equipment manufacturing industry is progressively implemented, general basic manufacturing will receive even greater priority in terms of development support. Major end-users such as the petrochemical, power, metallurgical, chemical, and urban construction sectors will see growing demand for valve products; however, the feasibility of import substitution for valves varies significantly across China’s various sub-sectors, underscoring the urgent need for stronger policy guidance and increased research and development support for high-end valves.

  Why Has the Domestication of High-End Valves Been So Difficult to Achieve? According to an analysis by a responsible official of the China General Machinery Industry Association, there are primarily four reasons for this phenomenon.

  R&D investment has long been inadequate. Domestic enterprises lag significantly behind some advanced foreign companies in their approach to product technology and innovation. Insufficient funding for scientific research and R&D has become a major constraint on valve manufacturers’ independent R&D efforts. According to incomplete statistics from the pump industry, R&D spending accounts for less than 2% of companies’ total revenue, a figure that is markedly lower than that of well-known international firms, indicating very limited industry-wide R&D investment. Relevant data show that the pump industry in China spends less on R&D over the entire year than a single foreign company allocates to research alone.

  Weak capacity for independent innovation. According to available information, the Chinese machinery manufacturing industry has been slow in digesting and absorbing imported technologies, with most enterprises exhibiting limited capabilities in technological innovation; 57% of the core technologies underlying major mechanical products still rely on imports. Although most products in China’s pump manufacturing sector have now achieved basic domestic production, domestic firms predominantly undertake only low-end processing stages, indicating that both the breadth and depth of localization remain to be enhanced. For instance, even in domestically produced nuclear power plant equipment—such as nuclear-grade pumps—and in million-kilowatt ultra-supercritical and ultra-ultra-supercritical thermal power plant equipment—such as high-pressure boiler feedwater pump assemblies—the critical core technologies largely continue to depend on imports.

  Customers exhibit a relatively low willingness to purchase domestically produced products. Although domestic products have performance metrics that are on par with their foreign counterparts, some customers still prefer to procure foreign-made equipment and technology, thereby increasing the difficulty of bringing China’s first-of-its-kind major technological (valve and pump) equipment to market. Despite the fact that many domestically produced high-end pump products boast a substantial level of technical sophistication, certain end-user departments continue to refuse to adopt them, citing reasons such as the lack of operational performance records.

  Research on industry-wide common technologies is lacking. Following institutional reforms, some research institutes that once provided services to the industry have transformed into independent enterprises operating in isolation, resulting in significant changes in their organizational structure and core priorities. Consequently, their role in providing technical support to the industry has steadily weakened; the development of new technologies and processes has slowed considerably; and it has become increasingly difficult to align domestic standards for design, process engineering, materials, and manufacturing with international benchmarks. In light of this situation, relevant stakeholders have put forward three recommendations:

  First, establish new mechanisms to encourage enterprises to pursue independent innovation. In accordance with the national comprehensive plan for the pump and valve manufacturing industry and the regional development plan, a number of regionally focused laboratories for the development of leading technologies and products, testing bases, and product R&D centers will be established. Leveraging science and education institutions with strong innovation capabilities, technology-transfer hubs will be set up. Furthermore, the establishment of R&D centers for pump and valve manufacturing technologies will be encouraged and supported.

  Secondly, we will improve the technology dissemination system. This involves appropriately establishing grassroots organizations for the promotion of manufacturing technologies and gradually developing a diversified system in which national manufacturing technology promotion agencies play the leading role, with clear division of labor, effective collaboration, and comprehensive service delivery.

  In addition, it is necessary to improve the science and technology training system and strengthen the intellectual property protection framework. Efforts should be made to establish and refine the linkage between the training service functions of universities, research institutions, and secondary vocational schools and basic education, thereby fully leveraging the strengths of institutions at all levels. Furthermore, the market environment for new-product innovation should be refined, new-product development should be actively promoted, and enterprises and research institutions should establish and完善 robust internal regulations and procedures for the independent development and management of new products.

Latest News

Several Recommendations for the Storage and Maintenance of Idle Valves

1. Why should hard-sealed shut-off valves be preferred whenever possible? Shut-off valves are required to have the lowest possible leakage; soft-sealed valves offer the lowest leakage and thus excellent shut-off performance, but they are not wear-resistant and have poor reliability. From the dual perspective of minimal leakage and reliable sealing, soft-sealed shut-off valves are inferior to hard-sealed ones. For example, the full-function ultra-light regulating valve features a seal protected by a wear-resistant alloy overlay, delivering high reliability and a leakage rate as low as 10⁻⁷, which already meets the requirements for shut-off valves. 2. Why can’t double-sealed valves be used as shut-off valves? The advantage of a double-seat valve’s spool is its force-balanced design, which allows for a large pressure differential; however, its major drawback is that the two sealing surfaces cannot maintain simultaneous, tight contact, leading to significant leakage. If such a valve is artificially and forcibly employed in shut-off service, the performance will clearly be poor—even after numerous improvements, such as the double-seal sleeve valve, it remains unsuitable. 3. Why is the double-seat valve prone to oscillation at small openings? For single-seat valves, stability is good when the fluid flow is from open to closed; conversely, stability is poor when the flow is from closed to open. In a double-seat valve, the lower seat operates in the closed-to-open flow direction, while the upper seat operates in the open-to-closed flow direction. Consequently, at small openings, the closed-to-open seat is likely to induce valve vibration—this is precisely why double-seat valves are not suitable for operation at small openings. 4. Why do straight-stroke regulating valves have poor anti-blocking performance, whereas angle-stroke valves perform better? In straight-stroke valves, the valve plug throttles vertically, while the fluid flows horizontally in and out, inevitably causing sharp turns and bends within the valve chamber and resulting in a highly complex flow path (resembling an inverted “S” shape). This creates numerous dead zones where sediment can accumulate over time, eventually leading to blockage. In contrast, angle-stroke valves throttle horizontally: the fluid enters and exits horizontally, easily carrying away impurities, and the flow path is simple with minimal space for sediment accumulation, hence their superior anti-blocking performance. 5. Why are the stems of straight-stroke regulating valves relatively thin? Straight-stroke regulating valves operate on a simple mechanical principle: sliding friction is high, whereas rolling friction is low. In a straight-stroke valve, the stem moves up and down; even slight tightening of the packing can cause it to grip the stem tightly, resulting in substantial hysteresis. To mitigate this, the stem is designed to be very slender, and low-friction PTFE packing is often used to reduce hysteresis. However, this approach has drawbacks: a thin stem is more prone to bending, and the packing has a shorter service life. The best solution is to use rotary-stroke valve stems—that is, angle-stroke regulating valves—whose stems are 2–3 times thicker than those of straight-stroke valves and employ long-life graphite packing. Such valves offer superior stem rigidity and longer packing life, while also exhibiting lower friction torque and reduced hysteresis. 6. Why do angle-stroke valves have a larger shut-off pressure differential? Angle-stroke valves can handle a larger shut-off pressure differential because the resultant force generated by the fluid acting on the valve plug or disc exerts only a small moment on the rotating shaft, allowing them to withstand higher pressure differentials. 7. Why hasn’t the sleeve valve lived up to expectations as a replacement for single- and double-seat valves? Introduced in the 1960s, the sleeve valve saw widespread use both domestically and internationally in the 1970s, and by the 1980s it had become the dominant type in newly commissioned petrochemical plants. At the time, many believed that the sleeve valve could replace single- and double-seat valves, becoming the second-generation product. However, today this is no longer the case: single-seat valves, double-seat valves, and sleeve valves are all used equally. The reason is that, although the sleeve valve improves throttling characteristics, stability, and ease of maintenance compared with single-seat valves, its weight, anti-blocking performance, and leakage levels remain comparable to those of single- and double-seat valves. How, then, could it possibly replace them? Consequently, these valve types continue to be used side by side. 8. Why do rubber-lined butterfly valves and fluoropolymer-lined diaphragm valves have a short service life when used with desalinated water? Desalinated water contains low concentrations of acids or bases, which are highly corrosive to rubber. Corrosion manifests as swelling, aging, and reduced strength, leading to poor performance of rubber-lined butterfly valves and diaphragm valves. Essentially, this is due to the rubber’s poor resistance to corrosion. Although fluoropolymer-lined diaphragm valves were later developed to improve corrosion resistance, the fluoropolymer diaphragms themselves are vulnerable to repeated folding and tearing, resulting in mechanical damage and a shortened service life. The best solution today is to use ball valves specifically designed for water treatment, which can last 5–8 years. 9. Why is the use of piston actuators in pneumatic valves increasing? For pneumatic valves, piston actuators can fully utilize the air supply pressure, allowing for a more compact actuator design with greater thrust compared with diaphragm actuators. Additionally, the O-rings in piston actuators are more reliable than those in diaphragm actuators, making their adoption increasingly common. 10. Why is selection more important than calculation? Compared with calculation, selection is far more important and far more complex. Calculation involves only a simple formula-based computation; the key issue is not the precision of the formula itself, but rather the accuracy of the process parameters provided. Selection, on the other hand, encompasses many factors, and even a minor oversight can lead to improper selection, resulting in wasted human, material, and financial resources, suboptimal performance, and various operational problems, such as reduced reliability, shortened service life, and compromised operating quality.

2020-12-11


Working Principle, Safe Operating Procedures, and Troubleshooting of Pressure Testing Pumps

Working Principle of Pressure Testing Pumps Pressure testing pumps are primarily used as pressurizing equipment for various pressure vessels and equipment—such as chemical containers, pump bodies, valves, and pipelines—during pressure testing. Consequently, their most distinctive feature is their ability to deliver very high discharge pressures; typical pressure testing pumps can reach several hundred atmospheres, while ultra-high-pressure models may exceed ten thousand atmospheres. However, their flow rates are generally quite low, often less than 1 m³/h. Nevertheless, the small output flow does not prolong the testing time, because pressure testing of a vessel does not require the pump to completely fill the container before the test can be considered complete. The usual procedure involves first filling the vessel with liquid, then connecting a fitting to the pump’s outlet. Leveraging the principle that liquids transmit force uniformly, once the pump reaches a certain pressure at its outlet, the same pressure is simultaneously applied inside the vessel, thereby achieving the desired test pressure. The working fluid for pressure testing pumps is typically water, though pure mineral oil may also be used. These pumps are generally available in two main types: manual and electric. Manual pressure testing pumps, due to their high discharge pressure, are usually single-acting reciprocating plunger pumps. They consist mainly of a pump body, plunger, hand crank, and drain valve. Electric pressure testing pumps have a basic structure largely similar to manual models. Their cylinder comprises four single-acting plungers. The transmission mechanism relies on an electric motor driving a worm gear reduction unit, which in turn uses an eccentric cam on the worm wheel shaft to drive the plungers in a reciprocating motion. Safety Operating Procedures for Pressure Testing Pumps 1. Conduct pressure tests strictly in accordance with the specified requirements; test pieces must be clean, tidy, and easy to inspect. 2. Prior to testing, inspect the electrical system and grounding conditions, calibrate the pressure gauge, verify that the pump is operating properly and adequately lubricated, and ensure that the maximum scale of the pressure gauge is at least 1.5 times the test pressure. 3. During pre-test preparations, arrange the positions of the inlet and outlet ports. When filling the vessel with water for testing, first open the vent hole and remove the pressure gauge to allow all air inside the vessel to escape. Once water begins to flow from both the vent hole and the pressure gauge connection, reinstall the gauge and close the vent hole. 4. Increase pressure slowly and never exceed the specified limit; after the test piece has reached the target pressure, striking or hammering is prohibited. If defects are discovered in the test piece or associated piping, reduce the pressure to zero before addressing them; working under pressure is strictly forbidden. 5. For negative-pressure or low-pressure test pieces and small vessels, it is permissible to raise the pressure in one step to the designated level and then hold it for inspection. Larger-volume test pieces, however, should be pressurized and inspected in stages. 6. Test pieces must be placed securely and stably, and the tested areas must pass inspection without any leakage. 7. After completing the pressure test, drain the water and relieve the pressure before removing bolts. In winter, be sure to drain all water immediately after testing to prevent freezing damage to equipment. 8. Tighten bolts evenly to avoid localized deformation that could lead to rupture. 9. Pressure testing pumps must be operated by designated personnel; each test requires at least two people, with a dedicated supervisor on duty until the water has been fully drained. 10. Mark any defects found during inspection and record them in the pressure test log. Common Faults in Pressure Testing Pumps Pressure Does Not Rise or Rises Slowly 1. Loose switch, deformed steel ball, or non-sealing inlet valve. 2. Clogged filter screen or water inlet pipe, or leaks at pipe connections. 3. Leakage at the plunger area. Solutions: 1. Tighten the switch and replace the (3) steel ball, (14) glass ball, or G9Crl3 steel ball. 2. Replace the medium and clear any blockages to eliminate leaks. 3. Replace the YX sealing ring (9). Short Holding Time 1. Minor leakage at the outlet valve. 2. Leaks at other component connections. Solutions: 1. Clean the valve core and replace the sealing ring. 2. Tighten connection bolts and replace seals.

2020-12-11


Analysis of the Causes of Sticking in ZZYP Gas Control Valves and Corresponding Improvements

1. Introduction Rizhao Iron & Steel Co., Ltd.’s Power Plant Gas Comprehensive Utilization Power Generation Workshop currently operates eight 50 MW blast furnace gas-fired generating units, with a total installed capacity of 400 MW. It is currently the largest blast furnace gas–based cogeneration plant among domestic metallurgical enterprises, supported by eight 220 t/h boilers whose fuel is the surplus blast furnace gas generated during ironmaking. 2. Causes Analysis Based on years of experience in operating these regulating valves and thorough research, we have identified the following primary causes of valve sticking: 2.1 Improper Installation Method Most valves are currently installed vertically, with the valve disc axis perpendicular to the horizontal plane. While this arrangement ensures that the actuator is located at the top of the gas pipeline, the rear bearing of the valve is positioned at the bottom, where moisture and impurities in the gas tend to settle or accumulate over time. This buildup gradually fills the clearance between the bearing and the shaft, leading to corrosion and eventual jamming of the valve shaft. 2.2 Unreasonable Design Structure Repeated disassembly and maintenance have revealed that the clearance between the valve stem bushing and the valve body is often filled with foreign matter such as sludge, water, and rust deposits. Moreover, the original design features an excessively long bushing, causing the front and rear bushings to bear the frictional forces generated by the reciprocating motion of the valve stem. Over time, dust in the gas and rust particles from the pipeline easily enter these clearances, increasing rotational resistance. The accumulated debris eventually fills the gaps, effectively welding the valve stem, bushing, and valve body together and severely restricting the valve’s ability to move freely. 2.3 Gas Corrosion Currently, all blast furnace gas pipelines in domestic steel plants suffer from severe corrosion. The most noticeable manifestation is frequent pitting and cracking of expansion joints, resulting in gas leaks along the pipeline. Corroded valves and pressure-reducing devices also fail to operate properly. The corrosive nature of blast furnace gas poses serious safety risks to both equipment operation and the integrity of the gas pipeline network. Our own gas pipelines likewise exhibit localized corrosion, including gas leakage through perforations and dripping condensate from expansion joint bellows. These conditions clearly have a significant impact on the valves. To analyze the extent of gas corrosion, we collected gas samples from two separate gas pipelines in the power generation workshop for laboratory analysis. Table 1: Composition Analysis of Blast Furnace Gas (%VOL) High-temperature components such as H2, CO, and H2O also exert considerable corrosive effects on steel. Given the high water content in the gas—particularly since the power generation system is typically located at the downstream end of the gas network—the pipeline often contains substantial amounts of condensate. Testing has shown that the pH of condensate in Rizhao Steel’s gas pipelines ranges from approximately 5 to 6, with an electrical conductivity of about 2762 μS/cm. In addition, the condensate contains high concentrations of iron ions, chloride ions, and sulfate ions. Some studies indicate that Cl⁻ and SO₄²⁻ can induce stress corrosion. In terms of corrosion morphology in gas pipelines and associated equipment, non-uniform corrosion predominates, specifically manifesting as: (1) under-deposit corrosion, also known as crevice corrosion; (2) pitting corrosion; (3) localized corrosion; (4) erosion-corrosion; and (5) stress corrosion. The presence of condensate inherently increases the corrosivity of the pipeline, with higher conductivity accelerating the corrosion rate. The combined effect of contamination and corrosive properties in the gas medium is a major contributing factor to valve sticking. 2.4 Improper Operation Since the current blast furnace gas regulating valves do not operate in a closed-loop automatic control mode, their opening degrees are manually set by operators via the DCS. When the load remains relatively stable for extended periods, the valve disc may stay fixed at a particular angle without regular movement, which can also lead to inflexible valve operation. 3. Improvement Measures 3.1 Installation Method The installation method should be changed from vertical to horizontal to prevent impurities, moisture, and contaminants in the gas from settling in the bushing clearance due to gravity. 3.2 Reducing Gas Acidity Given the significant harm caused by acidic gas to the entire gas pipeline system, large valves, expansion joints, and other components, this issue has drawn the attention of senior management. The company has adopted a neutralization strategy by injecting alkaline solution into the gas pipeline at the TRT inlet. Analysis of condensate samples from the power generation gas pipeline indicates a pH value of around 6. 3.3 Improving the Diseased Bushing Design The bushing dimensions should be reduced: the front bushing length should be shortened from 400 mm to 200 mm, and the rear bushing length from 800 mm to 200 mm. In terms of material, stainless steel, as specified in JB/T1759-2010, should be replaced with cast copper alloy, grade ZCuSn10Pb1. Even if minor scaling occurs inside the clearance, the significantly reduced bushing length will cut friction by one-half to three-quarters, making valve operation much smoother. We are also offering this improvement proposal free of charge to the supplier, requesting that future valve spare parts be custom-made according to our specifications. During maintenance inspections, it was also found that the packing gland on the upper part of the valve stem was overly tight, and in some cases, the packing gland screws broke due to excessive torque. When re-machining the packing gland, the clearance should be appropriately increased, and the gap should be thoroughly greased to prevent gas leakage. 3.4 Process Improvements The operating procedures should be revised to require boiler operators to conduct operational tests on all blast furnace gas regulating valves every shift and meticulously record the setpoint and feedback values in designated forms. This will prevent the valve disc from remaining fixed at a single opening degree for prolonged periods, thereby reducing the risk of scaling and seizing of the valve stem. 3.5 Maintenance Strategy Four spare regulating valves should be procured, and a rotating replacement maintenance approach should be implemented. Whenever there is an opportunity to shut down the boiler, the valve exhibiting the most severe sticking, as determined by the operators’ routine testing, should be replaced. The removed valve should then undergo disassembly, inspection, and refurbishment, followed by lubrication and maintenance before being returned to service, thus minimizing downtime. 3.6 Lubrication and Maintenance Monthly lubrication and maintenance should be performed on the packing glands and front and rear bearings of online-operating blast furnace gas regulating valves, with thorough equipment inspections conducted to promptly monitor operating conditions. Instrumentation and control personnel should ensure that the control components (valve positioners) are protected against rain and corrosion, regularly check air supply pressure, inspect all air connection points for blockages or leaks, and verify the quality of compressed air. In addition, the compressed air supply pressure should be appropriately increased to enhance the output force of the actuators. Instrumentation personnel should adjust the pressure regulator upstream of the positioner to maintain a stable pressure of around 0.5 MPa. Each time a major boiler overhaul is scheduled, the pipeline should be cleaned to remove sludge, debris, and other impurities, thereby reducing wear and corrosion. 4. Implementation Results By establishing revised operating procedures and ensuring that operators continuously monitor the status of the regulating valves, we have achieved comprehensive equipment management—a practical attempt at condition-based maintenance. Following these improvements, the frequency of maintenance has decreased, with the average maintenance interval extending from the original 2–3 months to 6–8 months. The workload for maintenance personnel has been significantly reduced, and crucially, the flexibility and reliability of the regulating valves have been ensured, providing robust equipment support for the safe and stable operation of the boilers. This solution can also be extended to other large valves on the gas pipeline network.

2020-12-11


Current National Standards Catalog (Valves)

Serial No. Standard Number Standard Name Replaced Standard Number Adoption Status 1 GB/T 8464-1998 Internal-threaded Valves for Plumbing GB 8464-87 GB 8465.1–.8-87 2 GB/T 12220-1989 General-purpose Valves—Marking JB 106-78 MOD ISO 5209-1977 3 GB/T 12221-1989 Flanged Metal Valves—Structural Lengths JB 97–98-75 JB 1686–1688-75 NEQ ISO 5752-1982 4 GB/T 12222-1989 Multi-turn Valves—Connection of Actuating Devices MOD ISO 5210/1~/3-1982 5 GB/T 12223-1989 Partial-turn Valves—Connection of Actuating Devices MOD ISO 5211/1~/3-1982 6 GB/T 12224-1989 Steel Valves—General Requirements 7 GB/T 12225-1989 General-purpose Valves—Technical Specifications for Copper Alloy Castings 8 GB/T 12226-1989 General-purpose Valves—Technical Specifications for Gray Iron Castings 9 GB/T 12227-1989 General-purpose Valves—Technical Specifications for Ductile Iron Castings 10 GB/T 12228-1989 General-purpose Valves—Technical Specifications for Carbon Steel Forgings 11 GB/T 12229-1989 General-purpose Valves—Technical Specifications for Carbon Steel Castings 12 GB/T 12230-1989 General-purpose Valves—Technical Specifications for Austenitic Steel Castings 13 GB/T 12232-1989 General-purpose Valves—Flanged Iron Gate Valves 14 GB/T 12233-1989 General-purpose Valves—Iron Globe and Lift Check Valves 15 GB/T 12234-1989 General-purpose Valves—Flanged and Butt-welded Steel Gate Valves 16 GB/T 12235-1989 General-purpose Valves—Flanged Steel Globe and Lift Check Valves 17 GB/T 12236-1989 General-purpose Valves—Steel Swing Check Valves 18 GB/T 12237-1989 General-purpose Valves—Flanged and Butt-welded Steel Ball Valves 19 GB/T 12238-1989 General-purpose Valves—Flanged and Wafer-connected Butterfly Valves NEQ BS 5155-1984 20 GB/T 12239-1989 General-purpose Valves—Diaphragm Valves 21 GB/T 12240-1989 General-purpose Valves—Iron Plug Valves 22 GB/T 12241-1989 Safety Valves—General Requirements MOD ISO 4126-1984 23 GB/T 12242-1989 Safety Valves—Test Methods for Performance 24 GB/T 12243-1989 Spring-loaded Direct-acting Safety Valves NEQ JIS 8210-1978 25 GB/T 12244-1989 Pressure-reducing Valves—General Requirements 26 GB/T 12245-1989 Pressure-reducing Valves—Test Methods for Performance 27 GB/T 12246-1989 Pilot-operated Pressure-reducing Valves 28 GB/T 12247-1989 Steam Traps—Classification MOD ISO 6704-1982 29 GB/T 12248-1989 Steam Traps—Terminology NEQ ISO 6552-1980 30 GB/T 12249-1989 Steam Traps—Marking NEQ ISO 6553-1980 31 GB/T 12250-1989 Steam Traps—Structural Lengths JB 2762-79 NEQ ISO 6554-1980 32 GB/T 12251-1989 Steam Traps—Test Methods GB 4981-85 NEQ ISO 6948-1981 33 GB/T 13927-1992 General-purpose Valves—Pressure Testing NEQ ISO 5208-1982 34 GB/T 13932-1992 General-purpose Valves—Iron Swing Check Valves 35 GB/T 15185-1994 Iron and Copper Ball Valves 36 GB/T 15188.1-1994 Valve Structural Lengths—Butt-welded Valves JB 96-75 JB 1686-75 37 GB/T 15188.2-1994 Valve Structural Lengths—Wafer-connected Valves 38 GB/T 15188.3-1994 Valve Structural Lengths—Internal-threaded Valves JB 96-75 JB 1686-75 39 GB/T 15188.4-1994 Valve Structural Lengths—External-threaded Valves JB 96-75 JB 1686-75

2020-12-11


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