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Guangzhou Petrochemical's Multiple Measures Significantly Increases Programmed Valve Operating Cycle
[ China Instrument Network Instrument R&D ] Recently, the Guangzhou Petrochemical Instrument Control Center of Guangdong Province adopted multiple maintenance strategies such as technical research, preventive maintenance, and joint inspection to increase the operating cycle of the S Zorb device's programmable valve from three months before 2015 to Today's nine months laid the foundation for the long-term safe and stable operation of the device.
Program-controlled valve is a shut-off valve driven by pneumatic, hydraulic and other methods. The valve is connected to a DCS Distributed Control System or PLC to enable remote control of computer programs. The programmable valve is the key equipment of the pressure swing adsorption device, and it is an important component to guarantee the smooth completion of the pressure swing adsorption and the reliable operation of the system. The main processes of pressure swing adsorption include adsorption, pressure equalization, sequential release, reverse release, and flushing. The completion of each step is achieved through the programmable valve opening and closing at a certain time. Therefore, the programmable valve requires a large number of frequent actions.
S Zorb (catalytic gasoline adsorption and desulfurization) device can produce low-sulfur gasoline below 10ppm with lower octane loss, and thiophene sulfur, which is difficult to remove by hydrogenation, is the key device for the production of high-grade gasoline by Guangzhou Petrochemical, and It belongs to single series operation device. The process medium of the S Zorb device locking hopper is a circulating gas containing adsorbent powder, which is characterized by strong corrosion and large dust.
However, due to the fact that the design of the original program control valve did not consider the use of corrosion-resistant materials, it was difficult to adapt the process media of the closed hopper of the S Zorb device, resulting in internal leakage of the valve and valve body, disc springs, valve seats and other accessories caused by media corrosion. . In addition, the feedback switch that controls the programmable valve is also prone to failure due to dust accumulation at the touch point. Since the device was put into production in January 2010, it has to be checked and repaired once every three months, affecting the safe, stable and long-term operation of the device. In addition, the quality of program-controlled valves is directly related to the normal operation of the key equipment lock hopper.
Faced with the problem, the instrument control center set up a technical research team to tackle the problem. Through continuous exploration and practice, they proceeded from shallow to deep and solved problems from four perspectives.
First of all, the team members improved the sealing structure of the valve seat of the programmable valve, that is, adding a formed graphite seal ring on the basis of the original structure to prevent the process medium from passing through the clearance between the valve seat and the valve body to erode and damage the valve and other accessories. The improved corrosion resistance of the programmed valve has been greatly improved.
Secondly, for the defects in the design of electronic valves such as programmable valve solenoid valves and feedback switches, the team on the one hand carried out reformation and optimization of the gas circuit of the solenoid valve and used the combination of relay amplifier and low-power electromagnetic valve to the original electromagnetic valve. Replacement to reduce the impact of the malfunction of the solenoid valve diaphragm on the normal operation of the lock hopper; on the other hand, based on the principle of the feedback switch, an electronic device that can automatically clean the reverberation switch is installed in the programmable valve. At the same time, dust and impurities on the contacts of the reverberation switch were cleaned automatically and noticeable results were obtained.
Then, in order to further extend the operation cycle of the programmable valve, the instrument control center organized technical personnel to formulate “operation control valve fault finding†and “programmed valve fault fast processing†and other operational maintenance guidelines, and established the center technicians and personnel of the maintenance and transportation unit. A joint inspection team is formed to conduct full-time inspection and monitoring of the program-controlled valve to detect and deal with issues such as the unsmooth operation of the program-controlled valve and the stuck cylinder.
Finally, the technicians of the instrument control center also use the DCS system to periodically check the changing trend of the opening and closing action time of each programmable valve, and judge the working status of the programmable valve through its operating time, and carry out targeted preventive maintenance accordingly. .
According to reports, since the beginning of this year, the staff has performed maintenance on air-conditioning, cylinders, and packings of the programmable valves in advance according to the inspection and fault records, and replaced preventative maintenance measures such as insurance and relays, greatly reducing the failure rate of the programmable valves and improving Programmed valve operation reliability.
(Source: Sinopec News, Baidu Encyclopedia, Dao Baba)