Specific steps for replacing the valve body
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Does anyone have the specific steps for replacing the valve body? Could you share them?
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It would be best to explain what type of valve it is and why the valve body needs to be replaced
The internal components of ball valves, control valves, check valves, butterfly valves, globe valves, gate valves, and safety valves are all different. Which type would you like to know about?
You still don’t understand; I’m talking about the valve body, not the valve itself. When referring to the valve body, it denotes the flap valve located between the coke oven bridge pipes and the gas collection pipes. If the corrosion is severe or there are cracks, it needs to be replaced.
Plan for Replacing Valve Bodies in the Coke Oven Workshop: The bridge tubes of the valve bodies have suffered severe damage due to prolonged use, which affects the smooth progress of safe production as well as compliance with environmental standards; therefore, they need to be replaced. To ensure that the replacement work is carried out safely and smoothly, this plan is formulated as follows: 1. Replacement time: From [start time] to [end time] on November 19, 2017. 2. Requirements for the maintenance work: 1) It is necessary to prepare in advance all the materials and tools required for the replacement. The bolts that need to be removed should be pre-oiled to make them easier to loosen, thereby facilitating the removal process on the day of maintenance and saving time. 2. It is required that maintenance workers study the maintenance plan carefully, so as to be fully aware of the replacement procedures and save time on maintenance work. During maintenance, the operators must work closely together with clear roles assigned to ensure the replacement and repair tasks are completed successfully. 3. It is required that on the day of maintenance, workshop managers and repair workers must arrive at the work site 30 minutes in advance to carry out the maintenance on time. III. Steps for replacement: 1. Preparation work: toward the end of coking, loosen the bolts in the gas collection channels at the base of the rising tube and on the valve body of the bridge tube alternately, and cut away the platform located adjacent to the valve body to be replaced. On the day of replacing the valve body, it is necessary to communicate with the chemical production workshop, stop the operation of the electrostatic precipitator, close the flap of the valve body, remove the corresponding ammonia water pipes, and open the furnace lid of the intermediate dust removal hole; the 1# and 3# dust removal holes must remain closed at all times. Then loosen the remaining bolts connecting the rising tube to the bridge tube, and the valve body to the gas collection duct. 2. Before lifting the old valve body, contact the chemical production workshop to adjust the pressure in the gas collection pipe at that section; once this has been confirmed, start adjusting the ammonia pressure in that section of the coke oven. Use valves to control the ammonia flow and reduce the ammonia level in the gas collection duct (the ideal condition is no ammonia flow after the valve body is removed). 3. Once all the above preparations are complete, start lifting the old valve body along with the bridge tube and the rising pipe (it is also possible to lift the bridge tube and the rising pipe first, and then the valve body). After the riser tube has risen 10–20 cm above the base, asbestos board and steel plate are inserted. The person holding the plug for sealing the gas collection duct immediately sealed the opening of the duct, began cleaning the flange of the gas collection pipe, and got ready to lift in the new valve body. 4. Once the flange is clean, start lifting the new valve body. When it is nearly in place, remove the plug and quickly align and install the new valve body. After the new valve body is installed, close the valve flap and fill it with water. 5. Begin lifting the rising pipe and the bridge pipe; once the bridge pipe is in place, seal the joint at the fork, and connect the water seal of the rising pipe with the ammonia spray pipe. 6. Finally, use an iron rod to pry open the asbestos sheet of the rising pipe, remove the temporary chimney, and cover the furnace lid as well as the rising pipe lid. Once the entire replacement process is complete, restore the pressure in the gas collection duct and the ammonia solution. IV: Organizational structure
On-site supervisor:
On-site safety officer:
On-site technical supervisor:
On-site guardian:
Maintenance supervisor:
V: Tools and equipment to be used:
Wrenches (27–30 mm): 2
Wrenches (30–32 mm): 2
Scraper: 1
Welding machine, oxygen, acetylene gas, cutting torch, welding tongs, welding wire, rubber asbestos board (3 mm): 5 m², steel plate (6 mm): 4.5 m², asbestos rope (DN22): 10 m, mud bucket: 1, temporary chimney (DN530): 1 (length = 4 m), gas collection duct plug: 1, air pipe (DN25): 1, steam pipe (DN25): 1, small crowbars: 2, 25-ton crane: 1. Crane arrival time: Month Day Hour Minute. 6. Maintenance personnel: Person in charge of maintenance: Xuan Haibo; Maintenance staff: Li Jiangping, Zhai Xiangyang, Liu Huaiwei, Han Xingming. 7. Safety measures: 1. The online pressure meters for the gas collection system should be calibrated in advance to ensure accurate readings. 2. Install U-tubes at the on-site gas collection pipes for monitoring purposes. 3. Maintenance personnel must wear full protective gear; during the replacement process, care should be taken to avoid poisoning and burns, and operators should work from an upwind position whenever possible. 4. Control the ammonia solution level in the gas collection duct; the specific level must be measured in advance. When the level exceeds the outlet of the duct, a guide plate should be installed outside the outlet to direct any excess liquid toward the machine side, thereby preventing it from flowing to the top of the furnace. It is absolutely forbidden for this liquid to enter the carbonization chamber. 5. During the replacement of the coke oven valve body, it is necessary to keep the pressure in the gas collection duct corresponding to that section at between 0 and 10 Pa, to prevent the duct from becoming under negative pressure; open flames must also be strictly avoided. 6. Open flame is strictly prohibited after disassembling the valve body. 7. The fire control team leader is responsible for coordinating with the chemical production workshop to adjust the pressure in the gas collection ducts and ensure stable pressure. 8. Prepare steam pipes to prevent fires or use smothering methods to extinguish fires, and ensure proper safety supervision. 9. Check whether the crane’s wire rope is secure. 10. Follow the lifting safety operation procedures strictly. VIII. Risk Analysis: Hazards such as falls from heights, crushing injuries, burns, scalds, welding fumes, and carbon monoxide poisoning exist.
On-site supervisor:
On-site safety officer:
On-site technical supervisor:
On-site guardian:
Maintenance supervisor:
V: Tools and equipment to be used:
Wrenches (27–30 mm): 2
Wrenches (30–32 mm): 2
Scraper: 1
Welding machine, oxygen, acetylene gas, cutting torch, welding tongs, welding wire, rubber asbestos board (3 mm): 5 m², steel plate (6 mm): 4.5 m², asbestos rope (DN22): 10 m, mud bucket: 1, temporary chimney (DN530): 1 (length = 4 m), gas collection duct plug: 1, air pipe (DN25): 1, steam pipe (DN25): 1, small crowbars: 2, 25-ton crane: 1. Crane arrival time: Month Day Hour Minute. 6. Maintenance personnel: Person in charge of maintenance: Xuan Haibo; Maintenance staff: Li Jiangping, Zhai Xiangyang, Liu Huaiwei, Han Xingming. 7. Safety measures: 1. The online pressure meters for the gas collection system should be calibrated in advance to ensure accurate readings. 2. Install U-tubes at the on-site gas collection pipes for monitoring purposes. 3. Maintenance personnel must wear full protective gear; during the replacement process, care should be taken to avoid poisoning and burns, and operators should work from an upwind position whenever possible. 4. Control the ammonia solution level in the gas collection duct; the specific level must be measured in advance. When the level exceeds the outlet of the duct, a guide plate should be installed outside the outlet to direct any excess liquid toward the machine side, thereby preventing it from flowing to the top of the furnace. It is absolutely forbidden for this liquid to enter the carbonization chamber. 5. During the replacement of the coke oven valve body, it is necessary to keep the pressure in the gas collection duct corresponding to that section at between 0 and 10 Pa, to prevent the duct from becoming under negative pressure; open flames must also be strictly avoided. 6. Open flame is strictly prohibited after disassembling the valve body. 7. The fire control team leader is responsible for coordinating with the chemical production workshop to adjust the pressure in the gas collection ducts and ensure stable pressure. 8. Prepare steam pipes to prevent fires or use smothering methods to extinguish fires, and ensure proper safety supervision. 9. Check whether the crane’s wire rope is secure. 10. Follow the lifting safety operation procedures strictly. VIII. Risk Analysis: Hazards such as falls from heights, crushing injuries, burns, scalds, welding fumes, and carbon monoxide poisoning exist.