Global valve technology development!

For more than 20 years, with the development of foreign large-scale complete sets of technologies, a series of new types of equipment and stand-alone machines have emerged. The development of new types of equipment related to valves is characterized by large-scale, high-parameter, high-performance automation and complete sets.

Refinery equipment: The largest refinery is 36.4 million t / year (Virgin Islands in the Caribbean) and 30 million t / year (Venezuela). At present, there are nearly 30 refineries with a capacity of more than 20 million t/year.

The processing capacity of the largest unit refinery: atmospheric pressure 24 million t/year, catalytic cracking 8.24 million t/year, reloading 5.69 million t/year, and hydrocracking 3.2 million t/year.

Oil, gas long-distance pipeline equipment: In recent years, long-distance pipelines have developed rapidly. One of the main reasons is that the low cost is only equivalent to 1/3 of the railway transportation; the second is buried in the ground and it is not easy to damage; the third is the rapid construction of the pipeline and the province of investment.

The longest oil pipeline is 4830Km (Iran) and 4665Km (former Soviet Union, Friendship Line). The longest pipeline pipeline is 4578km (Houston to New York, USA).

The longest gas pipeline is 7680km (from Alaska to Canada in the western United States).

The maximum pipeline diameter is 1620 and the proposed 2500.

The highest pipeline delivery pressure is 9-12MPa.

Synthetic ammonia equipment: up to 540,000 t/year and 500,000 t/year.

Ethylene equipment: The maximum capacity is 500,000 t/year to 800,000 t/year.

Maximum capacity of power generation equipment: 1.2 million kW for twin-shaft thermal power units (made in the United States, Switzerland), 1.2 million kw for single-axis thermal power units (former Soviet Union), and 1.3 million kW for largest nuclear power units

The maximum diameter and maximum pressure of the valve matched with these complete sets of equipment: The diameter of the largest flat gate valve is 1620mm, 2000 and 3050roll (USA, Japan); The diameter of the largest butterfly valve is 9750mm (designed by the British Bowen company, made in Switzerland); The maximum ball valve diameter 3050mm, without the weight of the drive device 184t (Switzerland, USA, Tennessee): The maximum water gate valve diameter 2750mm, 9MPa (Japan).

The economic effect of large-scale equipment: To sum up, first, increase production efficiency; second, reduce infrastructure investment; third, reduce raw material consumption.

Compared with 1 million tons of oil refining equipment with an annual processing capacity of 5 million tons, the investment per unit of production capacity is reduced by 50%.

A 6-million-ton/year oil refinery compared with two 3 million-ton/year oil refineries, the investment is only equivalent to 69% of the latter, steel consumption is 53%, floor space is 54%, and production cost is 75%. Labor productivity has increased to 170%.

The annual power consumption per ton product of the 200,000-ton synthetic equipment is 1450kW.h, and the new per-ton product of 460,000 tons of equipment consumes 50kw / h. It is only equivalent to 1/29 of the power consumption of the 200,000-ton device.

Compared with 200,000 units, 600,000 kW generating units have a unit cost reduction of 10% to 20%. The cost of power plant construction, unit power, steel consumption and manufacturing man-hours are reduced by 20%.

Complete equipment automation level, foreign petrochemical industry. The company's main production process has achieved direct digital control, and some people have also achieved computer-level control. Synthetic ammonia ethylene, urea, synthetic fiber, synthetic rubber and synthetic plastics and other chemical companies, there are actual closed-loop control and local optimization control. 200,000 kW or more large generators generally control the development of computers. Many countries in the long electrical pipeline system are computer controlled and equipped with a microwave communication system. The total control room has only 2-3 personnel on duty. Can monitor the entire line of work through television.

The control methods of these complete sets of equipment also require that the valve be adapted accordingly. Therefore, in the past 20 years, the control methods of foreign valves have also developed greatly. In addition to general manual, mobile, electric, pneumatic, hydraulic drive linkage, gas-liquid connection, automatic control of the valve species are increasing, and there is a trend of further development.

Series level

With the improvement of various types of complete sets of equipment, technological processes and performance, the series of foreign valves are still increasing, and in recent years there have been a few new varieties of valves. Such as: emergency shut-off valve, fast switching valve, fire damper, anti-static valve, temperature reducing valve, butterfly check valve, pressure relief valve, vacuum jacket valve, water-cooled or air-cooled valve, safety valve, safety valve And other new types of valves, including the general valve middle valve, butterfly valve and is the fastest-growing valve in 20 years. At present, the basic technical parameters of the highest foreign valves are shown in the above table.

Valve product quality level

A. Sealing reliability. According to the degree of sealing of the closure, the use and selection of products are determined abroad, and the degree of sealing is classified. Generally, it is divided into three levels. One and two grades are used where high sealing performance is required, and three grades are used for common medium and low pressure industrial valves. Although the leakage values are not the same, there are leakage regulations.

B. The valve opens and closes once. Some valves require opening or closing in a short time. The length of a switch indicates the pros and cons of the valve's performance. If the AMES research center opens a six-inch 300-pound gate valve in only 1ms, the medium-diameter DN350-400 fast-switching valve is only 0.6s, and the switching ball valve time reaches 0.05?O.1s, the ultra-sound manufactured by Okano Valve Corporation of Japan

The speed is 1s, the medium is air, DN40, PNl4MPa, the working temperature is 1267°C, the medium velocity is 11 times of the speed of sound, 3640m / s.

Manufacturing process level

Casting: foreign castings for the cupola and electric furnace double, cast steel for electric furnace refining. The quality of metal liquid is high, chemical composition is stable, the shape is resin sand, automatic film line or mechanical modeling (Mechanical modeling accounts for about 50% of microcomputer control, advanced equipment, high dimensional accuracy of castings, smooth surface, good sand-cleaning method.

Forging: Most of the foreign countries use die forging and have adopted multi-directional die forging and closed film forging. Maximum forging diameter up to DN500.

Heat Treatment: Most foreign heat treatment has been controlled heat treatment. Such as Japan's controllable processing has accounted for about 70% 80%, there are vacuum heat treatment. Nitriding also uses ion nitriding, soft nitriding, and chemical processing.

Mechanical processing: foreign processing equipment has been automated, numerical control and has adopted a machining center, there are application group control equipment for processing, commonly used group technology and machine tools, digital measuring tools, equipped with special cleaning Assembly workshop, advanced test equipment, complete, advanced leak detection methods.