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GHNLGVF | China Dagang Valve's R&D and manufacturing practice on key technologies of hard-sealed high-temperature and wear-resistant ball valves
2024.10.04
Abstract
With the continuous advancement of industrialization, especially in high-temperature, high-pressure and corrosive environments such as petroleum, chemical industry, electric power, and metallurgy, hard-sealed high-temperature and wear-resistant ball valves have gradually become one of the core components for the stable operation of equipment. CHNLGVF丨中國大乾閥門, as an important participant in the field of ball valve R&D and manufacturing, has focused on the development of key technologies for hard-sealed high-temperature and wear-resistant ball valves in response to current market demand. This article mainly discusses the development and application of these technologies, and proposes solutions to improve ball valve performance to ensure the high quality, reliability and durability of ball valve products.
Ball valve hard seal overview
Hard-sealed ball valves are different from traditional soft-sealed ball valves. They mainly achieve sealing through metal-to-metal contact and have the advantages of high temperature resistance, high pressure resistance and corrosion resistance. It is widely used in harsh working conditions that require long-term stable sealing, especially in high-temperature working conditions above 600°C.
Structural features of ball valve hard seal
The sealing pair of a hard-sealed ball valve is composed of a valve seat and a valve core, both of which are usually made of high-hardness, wear-resistant materials, such as carbide, stainless steel, cobalt-chromium-tungsten alloy, etc. In order to ensure that it does not deform or leak during long-term operation, the surface of the valve seat and ball must undergo special processing, such as hardening treatment, coating process, etc., to improve its wear resistance.
1.2 Applicable working conditions of hard-sealed ball valves
Hard-sealed ball valves are widely used in high-temperature and high-pressure environments, such as metallurgy, petrochemicals, gas transportation and other industries. Its main function is to provide fast cutting and precise adjustment, while maintaining good sealing and wear resistance under harsh working conditions.
Analysis of key technologies of high temperature and wear-resistant ball valves:
1. The use of high-temperature and wear-resistant materials for ball valves, such as ceramic materials, can effectively improve the service life of ball valves under high-temperature and wear conditions.
2. The application of advanced surface treatment technology, such as nitriding and carburizing, can enhance the wear resistance and high-temperature resistance of ball valves.
3. The design of the sealing structure of ball valves should be optimized to ensure reliable sealing performance under high-temperature and wear conditions.
4. The use of advanced manufacturing processes, such as precision casting and CNC machining, can improve the overall performance of high-temperature and wear-resistant ball valves.
Material selection and research and development
The temperature resistance and wear resistance of ball valves mainly depend on the selection of materials. In high-temperature environments, materials must have high strength, toughness, and heat resistance, as well as resistance to oxidation and corrosion. Carbide, nickel-based alloys and ceramic materials are currently common high-temperature and wear-resistant materials.
CHNLGVF丨中國大乾閥門
China Dagang Valve
Heat treatment process and surface treatment technology
To improve the overall wear resistance and service life of the ball valve, CHNLGVF adopts advanced surface treatment processes, such as plasma spraying, laser cladding, etc. These processes can form a protective layer of high hardness and wear resistance on the surface of the valve, significantly improving the high temperature resistance and corrosion resistance of the ball valve.
In the heat treatment process, the use of vacuum heat treatment technology can make the hardness of the ball valve uniform, avoid stress concentration inside the material, and improve the mechanical performance and service life of the ball valve. At the same time, nitriding treatment is also widely used on the surface of the valve seat to further improve its wear resistance and fatigue resistance.
Optimization of sealing structure design
The sealing performance of hard-sealed ball valves largely depends on the design of the sealing structure. CHNLGVF has optimized the sealing structure many times and adopted double eccentric design and elastic preload sealing technology, which effectively reduces the opening and closing torque of the valve and improves the adaptive ability of the sealing pair under high temperature and high pressure conditions. This design enables the ball valve to maintain stable sealing during long-term operation and reduces the risk of leakage.
Manufacturing practices and process improvements
Application of CNC machining technology
To ensure the processing accuracy of ball valves, CHNLGVF has introduced advanced CNC processing technology, especially in the processing of balls and valve seats. High-precision CNC machine tools and automated processing equipment are used to precisely control the roundness and surface roughness of the ball, improving the sealing performance of the ball valve. The combination of CNC machining and online detection systems enables real-time monitoring of ball valve processing accuracy, significantly enhancing production efficiency and product qualification rate.
Assembly and debugging
The assembly and debugging of ball valves are important links that affect their final performance. In order to ensure the sealing and operating flexibility of each ball valve, CHNLGVF has formulated strict assembly specifications and introduced intelligent debugging equipment. During the assembly process, automated centering technology is used to accurately match the ball and valve seat, avoiding the introduction of human error. At the same time, the debugging process uses a computer simulated fluid testing system to ensure the opening and closing flexibility and sealing performance of the ball valve under different working conditions.
Quality inspection and reliability testing
CHNLGVF丨China Daqian Valve has conducted comprehensive quality inspection and reliability testing for ball valves under different working conditions. Before leaving the factory, all ball valves must pass high temperature and high pressure tests, fatigue tests, corrosion resistance tests, etc. to ensure that they can operate stably for a long time under extreme conditions. At the same time, based on industry standards, the company has formulated more stringent internal testing standards to ensure that every product meets the high requirements of customers.
Technology improvement and optimization strategies
Research and Development (R&D) and application of new materials
In order to further improve the high temperature wear resistance of ball valves, CHNLGVF will devote itself to the research and development of new materials, especially in the fields of high melting point alloys, ceramic composite materials and other fields. By cooperating with scientific research institutions and conducting tests and applications of new materials, ball valves can still maintain good performance under higher temperatures and more demanding working conditions.
Improvement of coating technology
Existing coating technologies still have certain limitations under certain extreme working conditions. In the future, the development of coating technologies will move towards higher strength and higher corrosion resistance. CHNLGVF plans to introduce plasma enhanced chemical vapor deposition (PECVD) technology to further improve the bonding strength and wear resistance of the coating.
Intelligent manufacturing and digital management
With the advancement of Industry 4.0, intelligent manufacturing and digital management will become the mainstream trend in ball valve production in the future. CHNLGVF丨中國大乾閥門 will increase its investment in intelligent manufacturing technology and realize full-process digital management from design, production to testing by introducing digital production lines, cloud computing and big data analysis technology. This not only improves production efficiency, but also continuously optimizes product performance through data analysis and improves quality control levels.
Conclusion
The R&D and manufacturing of hard-sealed high-temperature and wear-resistant ball valves is a complex system project, involving the integration of technologies in multiple fields such as material science, machining, and heat treatment processes. CHNLGVF丨中國大乾閥門 has successfully mastered the core technology of ball valves through continuous technological innovation and manufacturing practice, and has achieved remarkable results in the field of high temperature and wear resistance. In the future, with the further development of new materials and new technologies, the performance of hard-sealed ball valves will continue to improve to meet more demanding industrial needs. CHNLGVF丨中國大乾閥門 will continue to promote technological progress and contribute to the high-quality development of the global ball valve industry.
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