浅谈调节阀的安装和调试_中国电动阀门网_新浪博客

译文:
  引言 随着科学技术的进步,生产过程自动化中用来控制流体流量的调节阀已普遍应用于各个行业。对于热力、化工控制系统,作为最终控制过程介质各项质量及安全生产指标的调节阀,在稳定生产、优化控制、维护及检修成本控制等方面起着举足轻重的作用。在调节阀的应用中,计算与选型是前提,安装与调试是关键,使用与维护是目的。调节阀如果安装不当,或者调试不好,就起不到调节的作用,甚至会成为系统的累赘。 1、调节阀的安装 1.1安装的基本原则 调节阀的安装应遵循国家有关标准,按照设计图纸和设计文件的规定严格执行。例如,建筑安装工程质量检验评定标准、工业自动化仪表施工及验收规范、电气设备安装工程施工及验收规范等;安装所需的设备、辅助设备及主要材料应符合现行国家标准的有关规定。 1.2安装前的检验 调节阀及附件从出厂到安装前,在运输途中受到运输工具所激发的随机振动和装卸时受到的各种冲击,以及在运输和储存过程中,环境的温度、湿度等变化,这些都可能造成调节阀及附件的性能发生变化。因此,有必要在安装前进行部分性能的检验。 调节阀安装前的检验主要包括下列内容:外观、静态特性、泄漏量、空载全行程时间、耐压强度、绝缘性能、气密性和密封性等,其中前5项为必检项目。当然,对检验的场所也有一定的要求。例如:环境温度要求在10~35℃;空气相对湿度不大于75%;场地有足够的空间,且光线充足或有照明条件;周围不能有剧烈的振源和强磁场干扰;电源、气源符合要求等。 1.3安装注意事项 调节阀的安装,必须确保安全性,确保使用性能,易于操作和维护,节约安装费用。下面就针对这四点谈一谈安装时需要注意的具体问题。 1.3.1确保安全性 1)防止泄漏 安装过程不允许调节阀产生泄漏。在使用过程中,如果在填料涵、法兰垫片等部位形成缝隙或微孔就可能产生泄漏。如果流体介质的操作条件苛刻,比如高温、高压、流体有腐蚀性,那么损坏将加剧,泄漏的危险性就更大。防止泄漏的方法很多,在安装过程中,填料的选择、密封方法的选择、选用密封性能好的调节阀等,都是必须考虑的因素。 2)安装放泄阀 任何一个管路设计和安装,在切断时都不可避免地积有高压流体,如果积聚流体的潜在能量很大,应在调节阀的两侧安装放泄阀,这样,在系统切断之后,调节阀中残留的高压流体的能量能得到释放,保护人员安全,有利于调节阀的维修,也可以考虑选用能限制流量的放泄阀。 3)安全的管线 在安装调节阀前,全部安装管件和管线都要吹扫干净,因为管线中的砂粒、水垢、铁屑等会损坏调节阀内表面,尤其是要求严格的密封面。当系统压力波动严重时,建议在管线上安装缓冲设施。如果被排放的流体是有害气体或液体,那么排放流体用的管线必须连接到安全地点,也可以连接到安全的特定容器中,这样可以保护人员不受伤害,同时也不会对环境造成污染。 1.3.2确保使用性能 安装调节阀时,要尽量保证其性能不受影响。这种影响会破坏调节阀选择时所考虑的各种因素。 1)调节阀上、下游切断阀和旁路阀的安装 上、下游切断阀与调节阀之间的直管段长度应考虑管路阻力和对流体流动状态的影响。直管段长度长,有利于流体经切断阀后的稳定,可使流体流动平稳,减少紊流影响,降低噪声;直管段长度短,流体经切断阀后还未稳定就进入调节阀,使噪声增大,但直管段长度短有利于降低管路阻力,提高调节阀两端压降,使流量特性的畸变减小,有利于控制系统的稳定运行。因此,应权衡利弊,综合考虑。按照经验,通常上游侧应有10D~20D的直管段,下游侧有3D~5D的直管段(D为管道直径),必要时应设置整流装置。 调节阀拆卸维修时,可用旁路阀对生产过程进行操作。当被控流量过大,用调节阀无法正常调节时,作为应急措施,也可用旁路阀作为调节阀的并行连接方案,对过程进行控制。为降低成本,大口径调节阀安装手轮执行机构,可代替旁路阀进行操作。旁路阀的安装应便于操作,它与调节阀及上、下游切断阀一起组成调节阀组。因此,安装调节阀时应与切断阀和旁路阀配套考虑,并同时完成施工安装。旁路阀公称直径与管道公称直径相同,耐压等级也与工艺耐压等级一致。 2)泄放阀、放空阀、排污阀的安装 为便于调节阀拆卸,在拆卸前必须进行阀前和阀后压力的泄放,泄放阀应安装在调节阀与上、下游切断阀之间。放空阀和排污阀用于排放流体中夹带的不凝气体和冷凝液,假若安装时被控流体是气体或蒸汽时,为便于冷凝液的排放,排污阀宜安装在调节阀组的{zd1}处;而被控流体是液体时,为便于不凝气体的排放,放空阀宜安装在调节阀组的{zg}处。 3)调节阀与管道的连接 调节阀与管道的连接方式有螺纹连接、法兰连接和焊接连接等区别。螺纹连接方式用于小口径调节阀的安装,必须同时安装可拆卸的活动连接件;法兰连接方式有普通式法兰连接和夹持式连接两种,管道连接法兰的公称直径应与调节阀的通径一致,耐压等级也应与调节阀的耐压等级一致,法兰面与管道轴线的垂直度允许偏差为l°;尽量避免采用焊接连接方式。调节阀连接时,不应使连接管道内部出现新的凸出物,例如,密封垫、焊接缝等不应在管道内凸出。同时,应注意调节阀内流体的流向应与阀体上标注的箭头方向一致,特殊情况下可不受此限制。 4)执行机构的安装 通常,执行机构与调节阀阀体直接连接,但液动执行机构、长行程执行机构等与调节阀阀体分开时,安装执行机构时应注意执行机构的连杆和机械活动部件应灵活,无松动或卡扭等现象;连杆长度合适,保证在全行程范围内动作稳定、灵活可靠;手轮执行机构有侧装和顶装两种,安装时应留有操作空间,手轮操作应灵活,没有卡死或扭转现象,有手轮转动方向与阀开度关系的标注,限位装置应调整合适,起到保护作用;液动执行机构应低于控制器安装,如果必须高于控制器安装时,其高度差应不超过1.0m,并且应在管路集气处安装排气阀,靠近控制器处安装自动切断阀。 5)阀门定位器的安装 阀门定位器的阀位检测装置与调节阀阀杆或阀轴直接连接,因此,安装时应保证反馈信号能够正确、及时地反映阀位信号和变化。通常,阀门定位器与调节阀配套供应,由制造厂完成两者的连接。当生产过程控制需要添加阀门定位器时,应保证阀门定位器阀位检测装置动作的正确、可靠和灵活,反馈杆支点的机械间隙应尽量小,阀门定位器的信号管线应正确连接,气源管线和输出管线、输入管线应标记;阀门定位器的阀位显示信号应有利于操作和维护人员观测。

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原文:
Introduction With the scientific and technological progress, the production process automation used to control the fluid flow control valve has been widely used in various industries. For the thermal, chemical control systems, as the ultimate control of the process of media production targets of the quality and safety control valve, in the stable production, optimal control, maintenance and repair cost control plays an important role. In the regulation of valve applications, the calculation and selection is the prerequisite, installation and commissioning is the key, use and maintenance is the purpose. Regulating valve case of improper installation, or debugging is not good, not even come into the role of regulation, and even become a drag on the system. 1, regulating valve installation 1.1 The installation of the basic principles of Regulating valve installation should follow the relevant national standards, in accordance with design drawings and design documents provided strictly enforced. For example, the construction and installation, inspection and uation of quality standards, industrial automation instrument construction and acceptance specifications, electrical equipment installation engineering construction and acceptance of standards, etc.; to install the required equipment, auxiliary equipment and key material should be consistent with the relevant provisions of existing national standards. 1.2 Pre-installation inspection Regulating valve and accessories from the factory to the installation before, during transportation by carriers excited by the random vibration and handling is subject to a variety of shocks, as well as in transport and storage process, the environment temperature, humidity and other changes, which can result in the performance of control valve and accessories change. Therefore, it is necessary to carry out part of the performance of pre-installation testing. Regulating valve pre-installation inspection includes the following elements: appearance, static characteristics, leakage volume, load the whole journey time, compressive strength, insulation performance, air tightness and sealing and so on, which will check for the previous five items. Of course, the test sites have certain requirements. For example: ambient temperature requires 10 ~ 35 ℃; air relative humidity of not more than 75%; the venue has sufficient space and adequate light or lighting conditions; around the local oscillator can not have sharp and strong magnetic field interference; power supply, gas supply meets the requirements. 1.3 Installation Notes Regulating valve installation, the need to ensure safety, ensure the use of performance, ease of operation and maintenance, saving installation costs. Here's for the installation of these four points now need to pay attention to specific issues. 1.3.1 to ensure the safety of 1) To prevent leaks The installation process does not allow control valve leakage generated. The use of process, if the filling-han, flange gaskets and other parts of the formation of cracks or micro-leakage may arise. If the fluid medium harsh operating conditions, such as high temperature, high pressure, corrosive fluid, then the damage will be aggravated and the greater the risk of leakage. There are many ways to prevent the leakage in the installation process, the choice of filling and sealing method of choice, choose a good valve sealing performance, are all factors that must be considered. 2) installation of relief valve Any one pipeline design and installation, cut off the plot when they inevitably have high-pressure fluid, if significant accumulation of fluid in the potential energy should be installed on both sides of valve relief valve, so that the system cut off, the control valve in the residual energy of high-pressure fluid can be released, to protect the safety of personnel is conducive to the maintenance of control valve may also be considering the selection to limit traffic relief valve. 3) the safety of pipeline Before installing the valve, all fittings and pipeline installation should be clean, purge, because pipes in the sand, scale, iron filings, etc. may damage the inner surface of valve, particularly in demanding sealing surface. When the system pressure fluctuation in severe cases, it is recommended to install a buffer in the pipeline facilities. If the emission of harmful gas or liquid fluid is then used to discharge fluid piping must be connected to a safe location, you can also connect to the security of a specific container, so that can protect workers from harm, while it will not cause environmental pollution. 1.3.2 ensure the use of performance Install control valve, you should try to ensure that its performance is not affected. This effect would undermine the control valve selection taken into account various factors. 1) control valve on the upstream and downstream shut-off valve and bypass valve installation Upstream and downstream shut-off valve and control valve length of straight pipe between the pipe should be considered fluid flow resistance and the impact of the state. The length of straight pipe length is conducive to flow through the shut-off valve after the stability of steady fluid flow can reduce the impact of turbulent flow and reduce noise; straight pipe lengths short, the fluid through the shut-off valve after the valve has not yet entered a stable, so that the noise increase large, but the short length of straight pipe pipe helps reduce resistance, improve the control valve pressure drop at both ends, so that the distortion of reduced flow characteristics are conducive to the stability control system operation. Therefore, we should balance, comprehensive consideration. In accordance with experience, usually the upstream side due 10D ~ 20D of straight pipe upstream and downstream side of a 3D ~ 5D of the straight pipe section (D is pipe diameter), if necessary, should be set up rectifier unit. Valve demolition maintenance, the bypass valve can be used to operate the production process. When charged with the amount of traffic, with the regulating valve can not be properly adjusted, as a contingency measure, can also be used as a control valve bypass valve in parallel connection scheme, the process control. In order to reduce the cost of installing large-diameter hand wheel valve enforcement agency can replace the bypass valve to operate. Bypass valve installation should be easy to operate, with control valve and the upstream and downstream shut-off valve with integral regulator valve. Therefore, the control valve should be installed with shut-off valves and bypass valves matching considerations, and at the same time to complete construction and installation. Bypass valve nominal diameter and nominal diameter pipe the same pressure level pressure level is also consistent with the process. 2) The discharge valve, venting valves, valve installation of sewage In order to facilitate control valve demolished, the demolition must be carried out before the valve before and after the pressure discharge valve, bleed valve should be installed in the control valve and the upstream and downstream between the shut-off valve. Venting valves and valves for the discharge of sewage flow in the entrainment of the non-condensable gases and condensate, if the installation was charged with the fluid is gas or steam, the condensate order to facilitate the discharge of sewage valve regulating valve installed in the appropriate minimum Department; when charged with fluid is a liquid, in order to facilitate the non-condensable gases, venting valve should install the highest office in the regulation valve. 3) regulating valve and pipe connections Regulating valve and pipeline connection with threaded connections, flanged and welded connections distinction. Threaded connections for small-caliber valve installed, you must also install the activities of removable connector; flange connections of ordinary-type flange connection and two kinds of gripper-type connection, pipe connection flange nominal diameter should be adjusted valve diameter consistent pressure levels should also be level with the pressure regulating valve in line with the pipe flange vertical axis degree of allowable deviation of l °; try to avoid the use of welded connections. Regulating valve connection, should not link the emergence of new pipelines within the projections, for example, gaskets, welding seam should not have the inner bulge in the pipeline. At the same time, should pay attention to the flow of fluid within the valve body should be marked on the arrow in the same direction, in special circumstances may from time restriction. 4) The installation of the implementing agencies In general, the implementing agencies directly connected with the regulating valve body, but the hydraulic implementing agencies, implementing agencies and other long-stroke and valve body separately, the installation of the implementing agencies should pay attention to the executing agency of the connecting rod and mechanical moving parts should be flexible, non - twist phenomena such as loose or card; rod length of appropriate, to ensure travel within the movement in the whole stable, flexible and reliable; hand wheel implementing bodies have two kinds of side-loading and top loading, the installation should be left room for maneuver, hand-wheel operation should be flexible , there is no stuck or reverse the phenomenon, there are hand-wheel rotation direction and the valve opening marked the relationship, limit devices should be adjusted to fit, has protective effects; hydraulic controller, implementing agencies should be lower than the installation, if the controller must be higher than the installation, the height difference should not exceed 1.0m, and shall remain in gas gathering pipelines to install exhaust valve, close to the controller, to install automatic shut-off valve. 5) The installation of the valve positioner Valve positioner of the valve position detecting device and control valve stem or valve shaft directly connected, therefore, should ensure that feedback signals can be installed correctly in a timely manner to reflect valve position signal and change. Typically, the valve positioner and the control valve supporting supply, from factory to complete the connection between the two. When the production process control valve positioner needs to be added, should ensure the valve positioner valve position detecting device action is correct, reliable and flexible, mechanical feedback rod pivot gap should be as small as possible, valve positioner signal lines should be properly connected , gas pipelines and export pipelines source, enter the pipe should be marked; valve positioner valve position display signal should be conducive to the operation and maintenance personnel observations


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