A few days ago, a chemical company broke a piston rupture and piston rod fracture accident, the direct cause is that the connection type of the valve parts is unreasonable, the connection nut is loose, and the lift limiter falls into the cylinder, causing the piston to break and the piston rod to break. Industry analysts believe that seemingly inconspicuous parts, if chosen and maintained careless, will not only increase energy consumption, but also lead to security incidents.
Compressors are widely used in coal chemical and petrochemical industries. The valve is the most vulnerable part of the three major consumable parts of the compressor. Whether the reciprocating compressor can work more rationally, effectively, and economically depends largely on the structure and performance of the valve. Therefore, the valve is often referred to as the "heart" of the compressor. The failure of the valve causes the compressor to stop about 40% to 50% of the total number of stops. Therefore, whether the valve design is reasonable, whether the use is appropriate, and whether the service life is long, is whether the reciprocating compressor can run for a long period of time. Determine the conditions.
Prof. Pan Shulin of Guangxi University said in an interview with reporters that design technology determines the performance of the valve, which directly affects the energy consumption and safe operation of the compressor. When the designed valve lift is too small and the effective flow area is too small, the resistance loss of the air flow through the valve is too large, the actual pressure ratio is too large, the compressor discharge temperature is too high, and the piston, piston rod and other moving elements As the force increases, the reliability decreases. At the same time, it is easy to produce carbon deposits, threatening the safety and stable operation of the compressor and causing damage to the production. When the designed valve lift is too large, the collision speed of the valve plate with the valve seat and the lift limiter is too large, the disengagement and impact amplitude of the valve plate from the spring is too large, and the service life of the valve is shortened. When the design of the valve structure is unreasonable, the gas valve is easy to be blocked, and the compressor needs to be stopped frequently to clean the gas valve. When the designed valve movement law is unreasonable, the valve plate is closed early or closed late, so that the compressor displacement decreases.
Compressor power consumption in the coal chemical industry, petrochemical and other industries account for a large proportion of the power consumption, such as nitrogen and hydrogen compressor power consumption accounts for about 70% of synthetic ammonia power consumption. Ou Shengfang, general manager of Zhejiang Europe Valve Manufacturing Co., Ltd., said that if the design of the valve resistance, sealing is poor, the compressor power consumption will increase. A reasonable design of the valve, energy consumption of about 3% to 7% of compressor energy consumption; design of unreasonable valve, energy consumption is as high as 15% to 20% of compressor energy consumption.
However, at present, the lack of professional compressor valve designers in China, the training of valve professionals and the environment is poor. Pan Shulin introduced that China's Xi'an Jiaotong University and other colleges and universities have specialized in compressors in the 1950s and 1960s, but now there are very few personnel working on reciprocating compressors and valves.
The current valve manufacturing and manufacturing threshold is low, less investment. In a survey interview, the reporter learned that some production workshops without specialized design personnel in Wenzhou, Zhejiang Province, etc., have very few masters of resistance, flow, and movement patterns through which the air flow passes through the air valve. To cut the foot and position it is just to see whether the processed gas valve can be put into the cylinder, and the gas valve, which is the heart of the compressor, is treated as an ordinary hardware fitting. Compressor operating companies regard valve life as the sole purchase standard, so that some valve manufacturers have to reduce the valve lift in order to increase valve life, but this increases the resistance of the valve and increases power consumption, and the compressor As the temperature of the exhaust gas increases, the rate of carbon deposition increases and even wear of the piston rings and cylinders increases.
People in the industry believe that only those companies with stronger capabilities invest in gas valve development can change the situation that valve design can not keep up with demand. To be long-term, willing to invest in talent training, a small valve can also be refined and expanded.
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