2024 Key points and common problems of industrial valve testing

The importance of valve testing

⁤Valve testing is of great significance in industrial production: ⁤

⁤Valve testing can ensure the safety of industrial production and prevent leakage, explosion and other accidents. ⁤⁤Through regular testing, potential problems could be found and solved promptly to ensure the safety of operators and extend the life span of equipment. ⁤⁤It reduces wear and corrosion and lowers the cost of equipment maintenance and replacement. ⁤⁤It can ensure that the valve works within the specified parameters so that the equipment operates stably and downtime is reduced, thus improving production efficiency and increasing the revenue of the enterprise. ⁤

⁤Valve testing helps to adhere to production regulations and standard requirements to avoid encountering legal risks. ⁤⁤It also protects the environment by preventing the leakage of hazardous substances. ⁤

Since the valve body is a critical component that is constantly exposed to high flow pressures, regular inspections for potential problems are essential to ensure proper system operation and long service life.

Material Integrity and Pressure Boundaries

Checking the integrity of the valve body is a top priority. Although the valve body is made of high-pressure and corrosion-resistant materials, wear and tear will occur over time. Regular, detailed inspections can detect early signs of material fatigue, such as cracks and crevices that may not always be visible to the naked eye due to prolonged exposure to varying temperatures and pressures.

Surface condition and corrosion resistance

The chemical properties of the fluid passing through the valve are an important factor in causing corrosion. Inspectors should look for areas with obvious signs of corrosion and degradation of the protective coating. Utilize advanced inspection tools such as non-destructive testing techniques (NDT) for minor surface irregularities and deep corrosion that is not evident

Non-Destructive Testing (NDT)

Non-destructive testing (NDT) provides insight into the condition of the valve body without causing any damage to the body. Here are some of the key techniques:

• Ultrasonic Inspection: Widely used for detecting cracks, internal defects and measuring wall thickness.

• Radiographic Inspection: Utilizing X-rays or gamma rays to capture an image of the interior of the valve body, this method clearly reveals any hidden defects.

• Eddy current testing: This method utilizes the principle of electromagnetic induction to help identify surface and near-surface defects that are difficult to distinguish with the naked eye.

• Dye Inspection: This involves applying a visible fluorescent dye to the surface of the valve so that it penetrates any cracks. Once the developer is applied, these cracks become visible under ultraviolet light or naked eye observation, thus identifying defects that may have gone unnoticed.

Pressure and temperature fluctuations

Valves experience continuous pressure and temperature changes during operation. The longer they are experienced, the greater the probability of structural fatigue due to repeated expansion and contraction. Inspectors should be aware of the occurrence of signs of wear due to these cyclic stresses, thus ensuring that the valve body remains resilient for longer periods under varying operating conditions.

These techniques ensure that the valve body remains strong, and safe and increases durability, thus preventing failures and maintaining system integrity.

Visual inspection is one of the most basic inspection methods. Technicians will carefully inspect flange ends, gaskets and fasteners with the naked eye, and firstly, they will find parts with obvious cracks, corrosion, breakage and other phenomena.

Next, ultrasonic testing is used, especially for welded flanges. This method assesses thickness and can also detect very subtle cracks and breakage.

Finally, use a wrench with a torque to check the tension on threaded joints. This ensures that the fasteners are neither too loose nor too tight, maintaining a relatively stable condition so as not to compromise the tightness of the structure.

Regular inspections of valves are important for the efficiency and safety of industrial production.

Firstly, these inspections help to detect valves with high leakage rates, and failure rates and enable maintenance staff to replace valves before they develop major problems. This preventative approach minimizes the risk of unplanned downtime and ensures that production processes run smoothly and efficiently.

Second, adherence to industry standards such as API 598 and ISO 5208 ensures thorough and consistent inspections. Increased equipment reliability. On the other hand, workers are better protected and the probability of accidents is minimized!

It is recommended that companies incorporate valve inspections into their maintenance routines and perform them regularly. Avoid all phenomena that harm personnel safety, the environment, and corporate interests.