Control valve major breakthrough: full-featured ultra-light control valve

Abstract: The first generation control valve has three problems of bulky, incomplete function and poor reliability. As a breakthrough direction of new products, a "full-function ultra-light control valve" has been developed. As soon as it came out, it was highly appraised and highly valued by users and design institutes. As a new product, it will gradually replace the current leading products and become the mainstream of the control valve in the next century. Keywords: full-function; ultralight; control valve 1, the history of regulating valve As early as 60 years ago, single seat valve, double seat valve, diaphragm valve, angle valve, butterfly valve, ball valve, three-way valve, sleeve valve , Eccentric rotary valve nine categories of control valves have come out, but in the next thirty years time, the product no major breakthroughs, let alone upgrading, people just work hard to improve and perfect. A successful example is the 70's CV3000 and the 80's domestic small single-seat valve, sleeve valve. They are down 30% from the weight and height of the old-fashioned product, but there is no breakthrough in terms of functionality and reliability. Therefore, single-seat valves, double-seat valves and sleeve valves, which represent only the 60-70's, are still the dominant products of regulating valves to date, which is obviously incompatible with the rapid development of automation technology. Therefore, the valve industry urgently needs the advent of a new generation of products. 2, the main existing problems of leading products In order to find the breakthrough direction of the control valve, we must first fully understand the problems existing in the control valve. In 1997, we made a special investigation of the control valve, reflecting a total of nine issues: 1) too stupid 3313%; 2) a large variety of used to bring 6711% of the troubles; 3) a large leak accounted for 4215% ; 4) often blocking the card, slow action accounted for 2518%; 5) short life expectancy of 1317%; 6) the thrust is not enough, the valve is not strict accounted for 916%; 7) small flow coefficient, a small adjustment range of 512% 413% of the leakage; 9) oscillation, vibration, whistling accounted for 117%. Producing these problems is undoubtedly related to the valve's own defects, the quality of production, the quality of use, but only from the valve defects to find the reasons for the following three major issues. 2.1, bulky regulating valve ranging from tens of kilograms, hundreds of kilograms, weighing hundreds of kilograms, and even thousands of kilograms. It brings great trouble to the control valve transportation, lifting, installation and maintenance. 2.2, incomplete functional dysfunction, coexistence of multiple varieties will inevitably form, so that complementary functions. It gives considerable inconvenience to the calculation, selection, maintenance, spare parts, plant management, etc. of the regulating valve. 2.3, poor reliability Poor reliability is bound to appear, such as "leakage, drop, plug, card, poor action" and other issues. It brings great difficulty to the normal operation of the system. 3, the breakthrough direction of new products From the beginning of this century until now, the control valve is still at the level of old products. According to the above problems of old products, we first set the breakthrough direction of new products. 3.1, the weight of the breakthrough should at least be the leading products in the old products single seat valve, seat valve, sleeve valve weight decreased by 60% to 80%, but also smaller than the fine valve 30% to 50% in order to truly achieve Small, light, instrumentation. 3.2, functional breakthrough With a multi-functional or full-featured products to replace many of the features of incomplete products, so as to greatly reduce the variety of regulating valve specifications; in order to control valve applications --- calculation, selection, factory management, Spare parts and other spare parts to bring simplified. 3.3, a breakthrough in reliability one by one breakthrough in the first generation of unreliable factors, to improve the quality of the system operation. 4, a new type of control valve --- full-featured ultralight valve was born to find the breakthrough direction of the control valve, we focus on organizational research, spent more than two years of hard work, and finally the old products exist in the bulky, incomplete, poor reliability The three major issues have been a major breakthrough in the birth of new products. It highlights three major characteristics. 4.1, ultralight 1) Intuitive comparison The product is small, light weight, the appearance can be clear at a glance. For visual comparison, we connect it with the same diameter single seat valve, double seat valve, sleeve valve for intuitive comparison, see below. 2) The weight comparison Full-featured ultra-light valve and the prevailing leading products single-seat valve, two-seated valve, sleeve valve weight by specification one by one to compare (comparison table omitted). The comparison results are: Pneumatic valve weight reduced by 60% to 70%; electric valve weight reduced by 70% to 80%. 4.2, full-featured 1) the function of regulating valve research and description In order to break through the function, we must first figure out the use of regulating valve, see Table 1. Table 1: The use of regulating valve function No. Using the function Function Description 1 Adjust the main function, which manifested in five aspects: flow characteristics, adjustable ratio, small opening work performance, Kv value and speed of action 2 cut off reflects the internal quality of the valve Indicators, valve leakage should be as small as possible 3 overcome the pressure to ensure that the valve moves freely and cut off, and cut-off function inseparable 4 anti-blocking valve to ensure the normal operation of clean media occasions; to prevent the pipe slag slag valve 5 Corrosion Resistant Media corrosion (corrosive media), erosion (including particles and high pressure differential medium) and cavitation (flash media) 6 pressure resistance reflects the strength and safety indicators 7 valve Temperature to meet the different conditions of the valve Strength and performance requirements 8 Appearance of the small size, light weight, instrumentation and beauty 9 weight easy to use (lifting, transportation, installation and maintenance, etc.) 2) full-featured ultra-light valve to achieve the full realization of the functional description Table 2 Table 2 full-featured ultra-light valve features No. Features Explain 1 Adjustable performance is good Adjustable range R = 100 ~ 200 P, N, M 3 to 7 times; small opening adjustment performance; Kv Is a single seat valve, double seat valve, sleeve valve 2 to 3 times the performance of 2 good cut off the valve plug and valve seat into line contact, good contact, hard seal leakage rate of 10 - 6 ~ 10 - 7, Block and sleeve leakage rate (10 - 3 ~ 10 - 4) to reduce the 1 ‰ 3 overcome the maximum pressure drop of the media together on the center of rotation torque is small, so cut off the pressure difference, up to PN value, is a single seat valve 5 ~ 20 times 4 Anti-blocking performance is good Medium through, the flow path is simple, anti-blocking performance is far superior to the single seat valve, double seat valve and sleeve valve 5 good corrosion resistance The valve uses a corrosion and erosion resistant measures , With excellent corrosion and erosion resistance 6 Pressure performance Good forging body, PN up to 32MPa 7 good temperature resistance High temperature packing, the applicable temperature range: - 60 ℃ ~ +600 ℃ 8 Size Small, light weight The best structural design, the weight of the machine is more single, double seat valve, sleeve valve to reduce 60% to 80%; height drop 50% to 70% 9 Exterior appearance Optimum design, the actuator and the valve Good combination, the whole machine is symmetrical and beautiful 3) Comparison with other valve functions Full-function ultra-light control valve and other Categories regulating valve functions shown in table 3. Product Type Adjust cut off to overcome the pressure difference Anti-blocking corrosion pressure temperature resistance Weight Appearance The best function Number Function Straight travel single seat valve √ 0 × × √ √ √ × × 4 13 Straight travel double seat valve √ × √ × 0 √ √ × × 4 13 Straight stroke sleeve valve √ × √ × 0 √ √ × × 4 13 Straight stroke angle valve √ 0 × 0 √ √ √ × × 4 14 Straight stroke three-way valve √ 0 × × 0 √ √ × × 3 11 Straight-stroke diaphragm valve × √ × √ √ × × × × 2 9-way travel butterfly valve √ √ 0 √ 0 0 √ √ 0 5 19 Angle travel ball valve √ √ √ √ √ √ √ 0 × 7 22 Eccentric rotation rotary valve √ √ √ √ √ √ √ × × 21 21-stroke full-featured ultralight control valve √ √ √ √ √ √ √ √ √ 9 27 Symbol (score) Note: "√" means the best (3 points); "0 "Said basic can (1 point);" × "means poor (zero). 4.3, high reliability Only from the weight, functional breakthrough is not enough, the reliability of the valve must also be greatly improved, fully functional ultra-light valve to solve the main: 1) the reliability of the stem seal --- large stiffness stem and Wear-resistant filler, life expectancy is 2 to 3 times the PTFE packing; 2) core, the reliability of the seat seal --- core, the seat with a hard seal, and wear-resistant alloy surfacing for further protection, its life expectancy is PTFE Such as soft valve seat, stainless steel seat is unparalleled; 3) electric valve with high reliability of the electronic actuator --- 5 to 10 years free maintenance, a better solution to the poor reliability of the electric actuator; 4) pneumatic Valve adopts rack and pinion piston actuator --- directly connected with the valve, simplifying the structure; gear rack rotation sensitive, small backlash, reliable action; 5) Enough actuator torque --- to overcome the pressure, friction torque , There is sufficient room to make it move freely; 6) media through, streamlined design --- to prevent blocking cards to improve the reliability of action; 7) to reduce the valve seat friction --- to further improve the valve core, valve Life. 4.4, performance indicators and the main parameters Model: pneumatic ZSRH, electric (electronic) ZDRH; nominal diameter: DN20 ~ 400; nominal pressure: PN116 ~ 32; flow characteristics: approximate logarithm, approximate straight line; 100 ~ 200; Leakage rate: 1 × 10-6 ~ 1 × 10-7; Allowable pressure difference: [Δp] ≤PN; Operating temperature: -60 ℃ ~ 600 ℃. 4.5, the use of effects and the significance of 1) the use of full-featured ultra-light valve since the cast one year, up to now have produced thousands of units, 10 manufacturers use, the effect is obvious, because of its ultra-light, full-featured, high The reliability of the features that have been used by manufacturers and design institutes special attention. 2) The significance of the application Full-featured ultra-light valve (now has the national patent) to fundamentally solve the main problems existing in the old products, bringing the history of the control valve four major breakthroughs - First, the weight of the breakthrough; Second, the function On the breakthrough; Third, the reliability of the breakthrough; Fourth, the application of the electric valve breakthroughs (changed in the past due to the poor reliability of the electric valve valve has been greatly limited the history), has become a real new product. It will gradually replace the current dominant position of single-seat valve, double-seat valve and sleeve valve of old products and become the mainstream of the control valve in the new century. If so, it will be our great contribution to the history of the development of control valves in China. No. Use Function Function Description 1 Adjust the main function, which is manifested in five aspects: flow characteristics, adjustable ratio, small opening work performance, Kv value and speed of action 2 cut off reflect the intrinsic quality of the valve, the valve leakage should be The smaller the better 3 overcome the pressure to ensure that the valve moves freely and cut off, and the cut-off function is inseparable 4 anti-blocking valve to ensure the normal operation of clean media occasions; to prevent the pipe slag residue stuck valve 5 corrosion resistant media corrosion ( Corrosive media), erosion (containing particles and high differential pressure medium) and cavitation (flash media) 6 Pressure resistance reflects the strength and safety of the valve indicator 7 Temperature to meet the different temperature conditions of the valve strength and performance requirements 8 Appearance (Lifting, transportation, installation and maintenance, etc.) No. Features Explain 1 Adjustable performance and good adjustable range R = 100 ~ 200 is P, N, M of 3 ~ 7 times; small opening adjustment performance is good; Kv value is single-seat valve, double seat valve, sleeve valve 2 to 3 times 2 cut off the valve spool and the valve into a good line contact, good seal, hard seal leakage rate 10 - 6 ~ 10 - 7, more than a single seat, double And the sleeve leakage rate (10 - 3 ~ 10 - 4) reduced by 1 ‰ 3 overcome the maximum pressure force of the medium on the center of the small moment of cooperation, so cut off the pressure difference, the maximum up to PN value is the single seat valve 5 ~ 20 times 4 Anti-blocking performance Good medium through, simple flow path, anti-blocking performance is far superior to the single-seat valve, double seat valve and sleeve valve 5 good corrosion resistance The valve uses a corrosion-resistant and erosion-resistant measures, With excellent corrosion and erosion resistance 6 pressure performance good forgings body, PN up to 32MPa 7 good temperature resistance with high temperature packing, the applicable temperature range: - 60 ℃ ~ +600 ℃ 8 small size , Light weight, the best structural design, so that the weight of a single machine, double seat valve, sleeve valve to reduce 60% to 80%; height drop of 50% to 70% 9 Exterior Appearance Optimum design, the actuator and the valve best Combination of the machine well-balanced and beautiful Product Type Adjust cut off to overcome pressure differential Anti-blocking corrosion pressure Temperature resistance Weight Appearance Best function Quantity Function Straight travel single seat valve √0 × × √√√ × × 413 Straight travel double seat valve √ × √ × 0√√ × × 413 Straight travel sleeve valve √ × √ × 0√√ × × 413 Straight travel angle valve √0 0√√√ × × 414 Straight stroke three-way valve √0 × × 0√√ ×× 311 Straight stroke diaphragm valve × √ × √√ ×××× 29 Angular stroke butterfly valve √√0√00√√0519 Angle travel ball valve √ √ √ √ √ √ √ 0 × 722 Angle Travel Eccentric Rotary Valve √ √ √ √ √ √ √ × × 721 Angle Travel Full Function Ultralight Regulator √√√√√√√√√√927