Zirconium hard-seal plug valve and welding preparation process thereof

Abstract

This application discloses a zirconium-coated hard-seal plug valve and its welding process, relating to the field of plug valve technology. The plug valve includes: a valve body assembly, a plug assembly, an insulation sleeve assembly, a connecting shaft, an actuator, an electrical control cabinet, and a remote control system. The plug assembly is housed within the valve body assembly. The end of the plug assembly furthest from the valve body assembly is connected to the actuator via the connecting shaft. The end of the actuator furthest from the connecting shaft is sequentially connected to the electrical control cabinet and the remote control system via a transmission line. An insulation sleeve assembly is provided externally to the valve body assembly. This application selects zirconium as the material for the parts of the plug valve that directly contact the medium to achieve corrosion resistance, while using non-zirconium materials for the parts that do not directly contact the medium to save manufacturing costs and without limiting the widespread use of zirconium-coated plug valves.

Description

Technical Field

[0001] This invention relates to the field of plug valve technology, specifically to a zirconium hard-seal plug valve and its welding preparation process. Background Technology

[0002] A plug valve is a type of valve that controls fluid flow by rotating a plug. The plug rotates 90° with the valve stem, aligning or separating the passage opening from the valve body passage, thus opening or closing the valve. The valve can be opened and closed simply by rotating it, making plug valves responsive and suitable for industrial applications requiring frequent opening and closing.

[0003] In operating conditions involving dilute hydrochloric acid, formic acid, or similar media, plug valves made entirely of zirconium are required to prevent corrosion and ensure the normal operation of chemical equipment. To prevent crystallization, an insulation jacket is welded to the outer wall of the zirconium plug valve. A heat transfer medium flows through the cavity of this jacket, and the heat transferred by the medium keeps the temperature of the medium inside the valve cavity above its crystallization temperature, ensuring smooth medium flow. Although the corrosiveness of the heat transfer medium is relatively weak, the insulation jacket of the zirconium plug valve is usually made of pure zirconium to meet welding requirements. my country's zirconium resources account for less than 1% of global reserves, making it an expensive rare metal. The high cost of plug valves and insulation jackets made entirely of zirconium deters many chemical companies and limits the widespread use of zirconium plug valves. In the opening and closing process of existing plug valves, the contact area between the plug and the valve body is large and requires repeated friction. When the plug rotates, the frictional torque is large. The hardness of zirconium material is not high, and it is easy to wear, causing the plug to jam or the seal to fail. In addition, the balance pressure hole in the existing plug valve is easily blocked by impurities, affecting the normal use of the valve.

[0004] Therefore, a zirconium-based hard-seal plug valve and its welding process are needed to solve the above-mentioned technical problems. Summary of the Invention

[0005] To achieve the above objectives, the present invention provides the following technical solution: In one aspect, a zirconium hard-seal plug valve includes: a valve body assembly, a plug body assembly, an insulation sleeve assembly, a connecting shaft, an actuator, an electrical control cabinet, and a remote control system;

[0006] The valve body assembly has a plug assembly inside its cavity. The end of the plug assembly away from the valve body assembly is connected to the actuator via the connecting shaft. The end of the actuator away from the connecting shaft is connected to the electrical control cabinet and the remote control system in sequence via a transmission line.

[0007] The insulation sleeve assembly is provided on the outside of the valve body assembly.

[0008] Furthermore, as a preferred embodiment, the valve body assembly includes: a valve body body, a valve body bottom cover, a first valve body flange, a second valve body flange, a first zirconium alloy, and a first titanium-zirconium alloy;

[0009] The valve body body is provided with a valve body bottom cover at the bottom end, one end of the valve body body is connected to the first valve body flange, and the other end is connected to the second valve body flange;

[0010] The first zirconium alloy is provided on the sealing surfaces of both the first valve body flange and the second valve body flange, the first titanium-zirconium alloy is provided on the sealing surface of the valve body body, and multiple reinforcing ribs are provided on the outer wall of the valve body body.

[0011] Furthermore, as a preferred embodiment, the plug assembly includes: a plug body, a plug connecting rod, a plug flow channel hole, a first pressure balance hole, a second pressure balance hole, a second titanium-zirconium alloy, and a unclogging component;

[0012] The plug body is connected to the plug connecting rod, and the end of the plug connecting rod away from the plug body is connected to the connecting shaft.

[0013] The plug body has multiple plug flow channel holes. The plug body has a first pressure balance hole symmetrically arranged on one side of the multiple plug flow channel holes and a second pressure balance hole arranged vertically on the other side. Multiple unblocking components are arranged at equal intervals on the inner walls of the multiple first pressure balance holes and the multiple second pressure balance holes.

[0014] The second titanium-zirconium alloy is disposed on the sealing surface of the plug body.

[0015] Furthermore, as a preferred embodiment, the side of the first titanium-zirconium alloy away from the valve body is a sealing protrusion, and the second titanium-zirconium alloy is fitted and sealed to the side of the sealing protrusion away from the valve body, forming a damage-prevention gap between the plug body and the valve body.

[0016] Furthermore, as a preferred embodiment, the unblocking component includes: a cylindrical cavity, a conical cavity, a guide block, a sliding column, a pressing rod, a torsion spring, a compression component, and a spring;

[0017] The plug body has an installation cavity, an installation block is provided in the installation cavity, and a cylindrical cavity and a conical cavity are provided in the installation block. The end of the cylindrical cavity away from the conical cavity is connected to a sliding cavity in the plug body.

[0018] The guide block is provided inside the cylindrical cavity. One end of the sliding column can slide through the guide block and is symmetrically connected to the extrusion rod through the torsion spring. The other end is slidably disposed in the sliding cavity. The compression member is provided on the outer wall of the sliding column. The outer wall of the compression member is slidably connected to the inner wall of the cylindrical cavity. The spring sleeved on the outer wall of the sliding column is connected between the compression member and the plug body.

[0019] Furthermore, as a preferred embodiment, the extrusion rod is provided with an extrusion layer.

[0020] Furthermore, as a preferred embodiment, the insulation sleeve assembly includes: a central transition ring, a first end transition ring, a second end transition ring, a main insulation sleeve, a first flow channel insulation sleeve, a second flow channel insulation sleeve, an insulation bottom cover, an insulation pipe assembly, and an exhaust pipe.

[0021] Wherein, one end of the first end transition ring is connected to the first valve body flange, and the other end is connected to the first flow channel insulation sleeve. The end of the first flow channel insulation sleeve away from the first end transition ring is connected to the valve body and the insulation bottom cover through the middle transition ring and the main body insulation sleeve, respectively.

[0022] One end of the second end transition ring is connected to the second valve body flange, and the other end is connected to the second flow channel insulation sleeve. The end of the second flow channel insulation sleeve away from the second end transition ring is connected to the valve body and the insulation bottom cover through the middle transition ring and the main body insulation sleeve, respectively.

[0023] The insulated bottom cover is provided with the discharge pipe, and the first flow channel insulation sleeve and the second flow channel insulation sleeve are both provided with the insulated pipe assembly.

[0024] Furthermore, as a preferred embodiment, the middle transition ring is a composite structure comprising a stainless steel base layer and a titanium cladding layer, the first end transition ring is a composite structure comprising a first stainless steel base layer and a first titanium cladding layer, and the second end transition ring is a composite structure comprising a second stainless steel base layer and a second titanium cladding layer.

[0025] Furthermore, as a preferred embodiment, the valve body body, the valve body bottom cover, and the plug body body are all made of zirconium alloy; the first valve body flange, the second valve body flange, the reinforcing rib, and the plug body connecting rod are all made of titanium alloy; and the main body insulation sleeve, the first flow channel insulation sleeve, the second flow channel insulation sleeve, the insulation bottom cover, the insulation connecting pipe assembly, and the discharge connecting pipe are all made of stainless steel.

[0026] Furthermore, as a preferred embodiment, on the other hand, a welding process for a zirconium hard-seal plug valve, based on a zirconium hard-seal plug valve, includes the following steps:

[0027] S1 welded valve body assembly;

[0028] S11: The valve body bottom cover and the valve body body are welded together through the first valve body weld;

[0029] S12: The first valve body flange is welded to the valve body body through the second valve body weld, and the second valve body flange is welded to the valve body body through the third valve body weld;

[0030] S13: The bevel between the valve body body and the first valve body flange and the second valve body flange is filled with the first zirconium alloy.

[0031] S14: Reinforcing ribs are welded onto the outer wall of the valve body;

[0032] S2 welded plug assembly;

[0033] S21: The plug body body and the plug connecting rod are welded together through the first plug body weld;

[0034] S3 welding insulation sleeve assembly;

[0035] S31: The valve body body and the titanium cladding of the middle transition ring are spot-welded together through the fifth weld, and the main body insulation sleeve and the stainless steel base layer of the middle transition ring are spot-welded together through the sixth weld.

[0036] S32: The first valve body flange and the first titanium cladding layer of the first end transition ring are spot-welded together by the first weld seam, and the first flow channel insulation sleeve and the first stainless steel base layer of the first end transition ring are spot-welded together by the third weld seam.

[0037] S33: The second valve body flange and the second end transition ring are spot-welded together by the second weld seam to form a whole titanium cladding layer, and the second flow channel insulation sleeve and the second end transition ring are spot-welded together by the fourth weld seam to form a whole stainless steel base layer.

[0038] S34: The main insulation sleeve and the first flow channel insulation sleeve are spot-welded together through the seventh weld and the main insulation sleeve and the second flow channel insulation sleeve are spot-welded together through the eighth weld.

[0039] S35: The main insulation sleeve and the insulation bottom cover are spot-welded together through the ninth weld, and the discharge pipe is spot-welded together with the insulation bottom cover through the tenth weld.

[0040] S36: The insulation pipes and insulation flanges in each insulation pipe assembly are welded together by the eleventh and twelfth welds, and each insulation pipe is spot-welded to the first flow channel insulation sleeve and the second flow channel insulation sleeve by the thirteenth weld.

[0041] S37: Seal the end of the discharge pipe with a screw plug and a gasket.

[0042] Compared with the prior art, the present invention provides a zirconium hard-seal plug valve and its welding preparation process, which has the following beneficial effects:

[0043] Advantage 1: This application uses a valve body assembly and insulation sleeve assembly made of composite materials, and completes the welding and fabrication of the insulation sleeve assembly by means of a central transition ring, a first end transition ring, and a second end transition ring in the composite structure. This application selects zirconium as the material for the parts of the plug valve that are in direct contact with the medium to achieve corrosion resistance, while selecting non-zirconium materials for the parts that are not in direct contact with the medium to save manufacturing costs and without restricting the widespread use of zirconium plug valves.

[0044] Advantage 2: Due to the presence of the sealing protrusion, during normal use of the plug valve, the second titanium-zirconium alloy on the sealing surface of the plug body will contact and seal with the sealing protrusion of the first titanium-zirconium alloy on the sealing surface of the valve body. Furthermore, a damage-preventing gap can be formed between the plug body and the valve body, reducing the original large contact area. This reduces the frictional torque when the plug valve is opened and closed, making the opening and closing of the plug valve more flexible and easy, and less likely to cause wear that could lead to the plug body jamming or sealing failure.

[0045] Advantage 3: This application can automatically clean up impurities in multiple first and second pressure balance holes based on their accumulation. Large, adhered impurities are crushed by the retraction of the two extrusion rods. Simultaneously, the disturbance effect of the retraction and repositioning of the two extrusion rods, combined with the throwing action during the reset process, significantly improves the flow efficiency of small impurities. This effectively avoids blockages that could affect the pressure balance function, thus improving the reliability and service life of the plug valve. Attached Figure Description

[0046] Figure 1 This is a schematic diagram of a zirconium-material hard-seal plug valve structure;

[0047] Figure 2 A schematic diagram of the valve body assembly of a zirconium hard-seal plug valve. Figure 1 ;

[0048] Figure 3 A schematic diagram of the valve body assembly of a zirconium hard-seal plug valve. Figure 2 ;

[0049] Figure 4 A schematic diagram of the valve body assembly of a zirconium hard-seal plug valve. Figure 3 ;

[0050] Figure 5 A schematic diagram of the plug body assembly of a zirconium hard-seal plug valve;

[0051] Figure 6 for Figure 4 Enlarged detail image of point A in the middle;

[0052] Figure 7 A schematic diagram of a zirconium-material hard-seal plug valve unblocking component;

[0053] Figure 8 A schematic diagram of the structure of a zirconium-material hard-seal plug valve insulation sleeve assembly. Figure 1 ;

[0054] Figure 9 A schematic diagram of the structure of a zirconium-material hard-seal plug valve insulation sleeve assembly. Figure 2 ;

[0055] Figure 10 A schematic diagram of the structure of a zirconium-material hard-seal plug valve insulation sleeve assembly. Figure 3 ;

[0056] Figure 11 A schematic diagram of the structure of a zirconium-material hard-seal plug valve insulation sleeve assembly. Figure 4 ;

[0057] Figure 12 A schematic diagram of the transition ring structure at the first end of a zirconium hard-seal plug valve;

[0058] Figure 13 A schematic diagram of the transition ring structure at the second end of a zirconium-material hard-seal plug valve;

[0059] Figure 14 A schematic diagram of the transition ring structure in the middle of a zirconium hard-seal plug valve;

[0060] In the diagram: 1. Valve body assembly; 11. Valve body main body; 12. Valve body bottom cover; 13. First valve body flange; 14. Second valve body flange; 15. First zirconium alloy; 16. First titanium-zirconium alloy; 17. Sealing protrusion; 18. Damage prevention gap; 19. Valve body flow channel; 2. Plug assembly; 21. Plug body main body; 22. Plug connecting rod; 23. Plug flow channel hole; 24. First pressure balance hole; 25. Second pressure balance hole; 26. Second titanium-zirconium alloy. Alloy; 27. Unblocking component; 271. Cylindrical cavity; 272. Conical cavity; 273. Guide block; 274. Sliding column; 275. Extrusion rod; 276. Extrusion layer; 277. Torsion spring; 278. Compression component; 279. Spring; 3. Insulation sleeve assembly; 31. Middle transition ring; 311. Stainless steel base layer; 312. Titanium cladding layer; 32. First end transition ring; 321. First stainless steel base layer; 322. First titanium cladding layer; 33. Two-end transition ring; 331, second stainless steel base layer; 332, second titanium cladding layer; 34, main insulation sleeve; 35, first flow channel insulation sleeve; 36, second flow channel insulation sleeve; 37, insulation bottom cover; 38, insulation pipe assembly; 39, discharge pipe; 310, screw plug; 3101, sealing gasket; 4, connecting shaft; 5, actuator; 6, electrical control cabinet; 7, remote control system; 8, reinforcing rib; 101, first valve body weld; 102, second... Valve body weld; 103, third valve body weld; 201, first plug weld; 301, first weld; 302, second weld; 303, third weld; 304, fourth weld; 305, fifth weld; 306, sixth weld; 307, seventh weld; 308, eighth weld; 309, ninth weld; 3010, tenth weld; 3011, eleventh weld; 3012, twelfth weld; 3013, thirteenth weld. Detailed Implementation

[0061] Please see Figures 1-14 The present invention provides a zirconium hard-seal plug valve, comprising: a valve body assembly 1, a plug body assembly 2, a heat insulation sleeve assembly 3, a connecting shaft 4, an actuator 5, an electrical control cabinet 6, and a remote control system 7;

[0062] Among them, the valve body assembly 1 has a plug assembly 2 in its inner cavity. The end of the plug assembly 2 away from the valve body assembly 1 is connected to the actuator 5 through the connecting shaft 4. The end of the actuator 5 away from the connecting shaft 4 is connected to the electrical control cabinet 6 and the remote control system 7 in sequence through the transmission line.

[0063] The valve body assembly 1 is externally provided with a heat insulation sleeve assembly 3.

[0064] In this embodiment, please refer to Figure 1As shown, the actuator 5 is used to receive instructions from the remote control system 7 and drive the plug assembly 2 to rotate via the connecting shaft 4, thereby realizing the opening and closing of the plug valve. The electrical control cabinet 6 is used to perform overall control of the entire control system.

[0065] In a preferred embodiment, the remote control system 7 controls the opening and closing of the plug valve as follows: The plug valve is equipped with a position sensor and a flow sensor. These two sensors send the valve position and flow signals to the I / O module and A / D conversion module for signal acquisition, command output, and conversion between analog and digital signals. Serial data is converted to IP data, or vice versa, via a wireless data transmission module. This data is then transmitted through a wireless communication network connected to a mobile phone or computer, thereby controlling the valve's start-up, closing, and flow regulation.

[0066] In a preferred embodiment, this application uses an intelligent electric actuator 5 and Internet of Things technology to drive the valve. The valve's opening, closing, flow regulation, and monitoring can all be operated remotely via mobile phone or computer. The flow regulation accuracy is high, saving time and effort and reducing the labor intensity of operators.

[0067] Furthermore, the valve body assembly 1 includes: a valve body body 11, a valve body bottom cover 12, a first valve body flange 13, a second valve body flange 14, a first zirconium alloy 15, and a first titanium-zirconium alloy 16;

[0068] Among them, a valve body bottom cover 12 is provided at the bottom end of the valve body body 11, one end of the valve body body 11 is connected to the first valve body flange 13, and the other end is connected to the second valve body flange 14.

[0069] The sealing surfaces of the first valve body flange 13 and the second valve body flange 14 are both provided with a first zirconium alloy 15, the sealing surface of the valve body 11 is provided with a first titanium-zirconium alloy 16, and the outer wall of the valve body 11 is provided with multiple reinforcing ribs 8.

[0070] In this embodiment, please refer to Figure 1 , Figure 2 and Figure 3 As shown, the manufacturing process of valve body assembly 1 is as follows: First, the valve body body 11 is cast. After passing the radiographic inspection, it undergoes vacuum annealing. The sealing surface of the valve body body 11 is then overlaid with a first titanium-zirconium alloy 16 (Zr20Ti80). The valve body bottom cover 12 is machined using a forging process and undergoes annealing after passing the inspection. The first valve body flange 13 and the second valve body flange 14 are machined using a forging process and undergo annealing after passing the inspection.

[0071] In a preferred embodiment, when machining the valve body 11, the internal structure is machined into a valve body flow channel 19 without abrupt changes in cross-section, resulting in low pressure loss, reduced local resistance during medium flow, improved flow characteristics, and greater suitability for high-velocity or viscous media conditions. Furthermore, the valve body 11 is machined using an abrasive flow process to polish the inner cavity, remove burrs from intersecting areas, and round off imperfections, preventing blockage caused by medium crystallization.

[0072] Furthermore, the plug assembly 2 includes: a plug body 21, a plug connecting rod 22, a plug flow channel hole 23, a first pressure balance hole 24, a second pressure balance hole 25, a second titanium-zirconium alloy 26, and a dredging component 27.

[0073] Among them, the plug body 21 is connected to the plug connecting rod 22, and the end of the plug connecting rod 22 away from the plug body 21 is connected to the connecting shaft 4;

[0074] The plug body 21 has multiple plug flow channel holes 23. The plug body 21 has a first pressure balance hole 24 symmetrically arranged on one side of the multiple plug flow channel holes 23, and a second pressure balance hole 25 arranged vertically on the other side. Multiple unblocking parts 27 are evenly arranged on the inner walls of the multiple first pressure balance holes 24 and the second pressure balance holes 25.

[0075] A second titanium-zirconium alloy 26 is provided on the sealing surface of the plug body 21.

[0076] In this embodiment, both the plug body 21 and the plug connecting rod 22 are manufactured using forging technology. After passing the inspection, they are both subjected to annealing and rough machining.

[0077] For a preferred embodiment, please refer to Figure 1 and Figure 5 As shown, the area between the upper end of the plug body 21 and the valve body 11 (e.g.) Figure 1 The area shown in region B is larger than the area between the lower end of the plug body 21 and the valve body 11 (as shown in region B). Figure 1 The area is shown in region C. Therefore, in this application, there are multiple first pressure balancing holes 24 (preferably two) and one second pressure balancing hole 25, but the number of both is not limited to this, as long as the number of first pressure balancing holes 24 is greater than that of second pressure balancing holes 25.

[0078] In a preferred embodiment, multiple first pressure balancing holes 24 and second pressure balancing holes 25 can reduce the opening and closing torque of the plug valve, maintain pressure balance at the upper and lower ends of the plug body 21, and prevent the plug assembly 2 from moving up and down. During a hydrostatic test, it is possible to observe whether there is leakage at the packing area and the middle flange area. The plug body 21 has three plug flow channel holes 23, which can prevent damage to the equipment caused by the impact of the medium when the plug valve is suddenly started, and effectively prevent water hammer when the high-pressure pump starts. The taper of the plug assembly 2 is changed from the traditional 1:7 or 1:6 to 1:5, reducing the friction between the plug assembly 2 and the valve body assembly 1, which is beneficial to the smooth opening and closing of the plug valve.

[0079] Furthermore, the side of the first titanium-zirconium alloy 16 away from the valve body 11 is a sealing protrusion 17, and the second titanium-zirconium alloy 26 is fitted and sealed with the side of the sealing protrusion 17 away from the valve body 11, forming a damage prevention gap 18 between the plug body 21 and the valve body 11.

[0080] In this embodiment, please refer to Figure 2 , Figure 3 , Figure 4 , Figure 5 and Figure 6 As shown, the first titanium-zirconium alloy 16, which is welded onto the sealing surface of the valve body 11, includes a base portion and a sealing protrusion 17, wherein the base portion is as follows: Figure 6 As shown to the right of the dashed line, the sealing protrusion 17 is as follows. Figure 6 As shown to the left of the dashed line. The size of the sealing protrusion 17 can be 2.5mm or other sizes, depending on the actual application requirements.

[0081] In a preferred embodiment, due to the presence of the sealing protrusion 17, during normal use of the plug valve, the second titanium-zirconium alloy 26 on the sealing surface of the plug body 21 will contact and seal with the sealing protrusion 17 of the first titanium-zirconium alloy 16 on the sealing surface of the valve body 11. Furthermore, a damage-preventing gap 18 can be formed between the plug body 21 and the valve body 11, reducing the original large contact area. This reduces the frictional torque when the plug valve is opened and closed, making the opening and closing of the plug valve more flexible and easy, and less likely to cause wear that could lead to jamming of the plug body 21 or sealing failure.

[0082] Furthermore, the unblocking component 27 includes: a cylindrical cavity 271, a conical cavity 272, a guide block 273, a sliding column 274, a pressing rod 275, a torsion spring 277, a compression component 278, and a spring 279;

[0083] The plug body 21 has an installation cavity, and an installation block is provided in the installation cavity. The installation block has a cylindrical cavity 271 and a conical cavity 272 that are connected to each other. The end of the cylindrical cavity 271 away from the conical cavity 272 is connected to the sliding cavity in the plug body 21.

[0084] A guide block 273 is provided inside the cylindrical cavity 271. One end of the sliding column 274 can slide through the guide block 273 and is symmetrically connected to the extrusion rod 275 through the torsion spring 277. The other end is slidably disposed in the sliding cavity. A compression member 278 is provided on the outer wall of the sliding column 274. The outer wall of the compression member 278 is slidably connected to the inner wall of the cylindrical cavity 271. A spring 279 sleeved on the outer wall of the sliding column 274 is connected between the compression member 278 and the plug body 21.

[0085] In this embodiment, please refer to Figure 5 and Figure 7 As shown, when impurities accumulate in the multiple first pressure balance holes 24 and second pressure balance holes 25, the unblocking component 27 can clean the accumulated impurities in real time as the amount of impurities gradually increases, and restore the flow of the multiple first pressure balance holes 24 and second pressure balance holes 25.

[0086] In a preferred embodiment, as the amount of impurities accumulates, the impurities accumulated between the two extrusion rods 275 exert a continuous extrusion force on the two extrusion rods 275, driving the sliding column 274 and the compression member 278 on its outer wall to move synchronously towards the sliding cavity of the plug body 21 along the axial direction of the cylindrical cavity 271. At the same time, the spring 279 is compressed and stores elastic potential energy. It should be noted that under the elastic force of the torsion spring 277, the outer walls of the symmetrically arranged extrusion rods 275 always abut against the inner wall of the conical cavity 272. The two extrusion rods 275 gradually converge towards each other along the conical inner wall of the conical cavity 272, exerting extrusion force on the accumulated impurities between them and crushing them, breaking the large, agglomerated impurities into smaller pieces. During the process of moving and converging, the two extrusion rods 275 simultaneously disturb the impurities accumulated in the channels of the multiple first pressure balance holes 24 and second pressure balance holes 25, so as to initially promote the flow and discharge of impurities. When the amount of impurities accumulated is insufficient to provide continuous squeezing force to drive the two squeezing rods 275 to continue moving and retracting, the spring 279 releases elastic potential energy, driving the two squeezing rods 275 to reset, and at the same time throwing the small pieces of impurities that have been broken in the gap between them into the channels of multiple first pressure balance holes 24 and second pressure balance holes 25, which further facilitates the discharge of impurities with the medium.

[0087] It should be noted that when the two extrusion rods 275 are in their initial position, they are engaged with the inner wall of the conical cavity 272. In other words, after the two extrusion rods 275 are reset under the action of the spring force 279, they will not disengage from the inner wall of the conical cavity 272.

[0088] In a preferred embodiment, this application can automatically clean up impurities based on the amount of sediment accumulated in the multiple first pressure balance holes 24 and second pressure balance holes 25. Large, adhered impurities are crushed by the retracting action of the two extrusion rods 275. Simultaneously, the disturbance effect of the retracting movement of the two extrusion rods 275 and the throwing effect during the resetting process significantly improve the flow efficiency of small impurities. This effectively avoids blockages that could affect the pressure balance function, thus improving the reliability and service life of the plug valve.

[0089] Furthermore, an extrusion layer 276 is provided on the extrusion rod 275.

[0090] In this embodiment, the extrusion layer 276 is made of a hard material, which is hard enough to compress the accumulated impurities and form small pieces of impurities.

[0091] Furthermore, the insulation sleeve assembly 3 includes: a central transition ring 31, a first end transition ring 32, a second end transition ring 33, a main body insulation sleeve 34, a first flow channel insulation sleeve 35, a second flow channel insulation sleeve 36, an insulation bottom cover 37, an insulation pipe assembly 38, and an exhaust pipe 39.

[0092] Among them, one end of the first end transition ring 32 is connected to the first valve body flange 13, and the other end is connected to the first flow channel insulation sleeve 35. The end of the first flow channel insulation sleeve 35 away from the first end transition ring 32 is connected to the valve body 11 and the insulation bottom cover 37 through the middle transition ring 31 and the main body insulation sleeve 34 respectively.

[0093] One end of the second end transition ring 33 is connected to the second valve body flange 14, and the other end is connected to the second flow channel insulation sleeve 36. The end of the second flow channel insulation sleeve 36 away from the second end transition ring 33 is connected to the valve body 11 and the insulation bottom cover 37 through the middle transition ring 31 and the main body insulation sleeve 34 respectively.

[0094] The insulation bottom cover 37 is provided with a discharge pipe 39, and the first flow channel insulation sleeve 35 and the second flow channel insulation sleeve 36 are both provided with insulation pipe assembly 38.

[0095] Furthermore, the middle transition ring 31 is a composite structure including a stainless steel base layer 311 and a titanium cladding layer 312, the first end transition ring 32 is a composite structure including a first stainless steel base layer 321 and a first titanium cladding layer 322, and the second end transition ring 33 is a composite structure including a second stainless steel base layer 331 and a second titanium cladding layer 332.

[0096] In this embodiment, please refer to Figure 12 , Figure 13 and Figure 14As shown, the length of the first titanium cladding layer 322 exposed on the outer circumference of the first end transition ring 32 is D1≥10mm, and the length of the first stainless steel base layer 321 exposed on the inner hole is D2≥10mm. The length of the second titanium cladding layer 332 exposed on the outer circumference of the second end transition ring 33 is D3≥10mm, and the length of the second stainless steel base layer 331 exposed on the inner hole is D4≥10mm. The length of the titanium cladding layer 312 exposed on the outer circumference of the middle transition ring 31 is D6≥10mm, and the length of the stainless steel base layer 311 exposed on the inner hole is D5≥10mm.

[0097] Furthermore, the valve body body 11, valve body bottom cover 12, and plug body body 21 are all made of zirconium alloy, the first valve body flange 13, the second valve body flange 14, the reinforcing rib 8, and the plug body connecting rod 22 are all made of titanium alloy, and the main body insulation sleeve 34, the first flow channel insulation sleeve 35, the second flow channel insulation sleeve 36, the insulation bottom cover 37, the insulation pipe assembly 38, and the discharge pipe 39 are all made of stainless steel.

[0098] In this embodiment, the valve body body 11 is made of cast zirconium alloy 705C, the valve body bottom cover 12 is made of forged zirconium alloy R60705, the first valve body flange 13 and the second valve body flange 14 are both forged titanium alloy TC4, and the reinforcing rib 8 is 3D printed titanium alloy TC4. The plug body 21 is made of cast zirconium alloy 705C, and the plug connecting rod 22 is forged titanium alloy TC4. The main body insulation sleeve 34, the first flow channel insulation sleeve 35, the second flow channel insulation sleeve 36, the insulation pipe and the discharge pipe 39 in the insulation pipe assembly 38 are all made of 304 stainless steel pipe, the insulation bottom cover 37 is made of 304 stainless steel plate, and the insulation flange in the insulation pipe assembly 38 is made of 304 stainless steel forging.

[0099] Furthermore, on the other hand, a welding process for a zirconium hard-seal plug valve, based on a zirconium hard-seal plug valve, includes the following steps:

[0100] S1 Welded valve body assembly 1;

[0101] S11: The valve body bottom cover 12 and the valve body body 11 are welded together through the first valve body weld 101. After the welding is completed, the first valve body weld 101 is subjected to radiographic inspection and acceptance.

[0102] S12: The first valve body flange 13 is welded to the valve body body 11 by the second valve body weld 102, and the second valve body flange 14 is welded to the valve body body 11 by the third valve body weld 103. The valve body body 11 and the first valve body flange 13 and the second valve body flange 14 are made of different materials. Compared with the valve body assembly 1 which is made of zirconium casting, the manufacturing cost is reduced.

[0103] S13: The bevel between the valve body body 11 and the first valve body flange 13 and the second valve body flange 14 is filled by the first zirconium alloy 15 and by vacuum electron beam welding technology (using ERZr4 welding wire).

[0104] S14: Liquid penetration testing is performed on the first valve body weld 101, the second valve body weld 102, the third valve body weld 103 and the first zirconium alloy 15. After the test is qualified, reinforcing ribs 8 are welded onto the outer wall of the valve body 11. Using additive manufacturing grafting technology, reinforcing ribs 8 are welded onto the outer wall of the valve body 11. ERTi-5 welding wire is used, and vacuum electron beam welding technology is employed to complete the welding of reinforcing ribs 8. Liquid penetration testing is then performed on the weld of the reinforcing ribs 8.

[0105] It is important to note that after all welds in S1 pass inspection, valve body assembly 1 must undergo stress-relieving annealing in a vacuum furnace, followed by machining. Valve body assembly 1 must also undergo a hydrostatic test, ensuring no leakage and no surface dampness.

[0106] S2 welding plug assembly 2;

[0107] S21: The plug body 21 and the plug connecting rod 22 are assembled and welded through the first plug weld 201. After the welding is completed, the first plug weld 201 needs to be ultrasonically tested.

[0108] It should be noted that after all welds in S2 pass inspection, the plug assembly 2 needs to be stress-relieved annealed in a vacuum furnace, followed by machining of the plug assembly 2, and then assembly of the valve body assembly 1 and the plug assembly 2. After assembly, a plug valve opening and closing action test and a water pressure strength test are performed, requiring no leakage and no structural damage. Then, a water pressure sealing test is performed. After all tests pass, the insulation sleeve assembly 3 is welded.

[0109] S3 welding insulation sleeve assembly 3;

[0110] S31: The valve body body 11 and the main body insulation sleeve 34 are indirectly welded by means of the middle transition ring 31. Specifically, the valve body body 11 and the titanium cladding layer 312 of the middle transition ring 31 are spot welded together by the fifth weld 305, and the main body insulation sleeve 34 and the stainless steel base layer 311 of the middle transition ring 31 are spot welded together by the sixth weld 306.

[0111] S32: The indirect welding of the first valve body flange 13 and the first flow channel insulation sleeve 35 is achieved by means of the first end transition ring 32. Specifically, the first valve body flange 13 and the first titanium cladding layer 322 of the first end transition ring 32 are spot welded together by the first weld 301, and the first flow channel insulation sleeve 35 and the first stainless steel base layer 321 of the first end transition ring 32 are spot welded together by the third weld 303.

[0112] S33: The second valve body flange 14 and the second flow channel insulation sleeve 36 are indirectly welded by means of the second end transition ring 33. Specifically, the second valve body flange 14 and the second titanium cladding layer 332 of the second end transition ring 33 are spot welded together by the second weld 302, and the second flow channel insulation sleeve 36 and the second stainless steel base layer 331 of the second end transition ring 33 are spot welded together by the fourth weld 304.

[0113] It should be noted that the main insulation sleeve 34, the first flow channel insulation sleeve 35, the second flow channel insulation sleeve 36, the insulation bottom cover 37, the insulation pipe assembly 38, and the discharge pipe 39 are all made of stainless steel and can be directly welded together as one piece. Specifically:

[0114] S34: The main insulation sleeve 34 and the first flow channel insulation sleeve 35 are spot welded together through the seventh weld 307, and the main insulation sleeve 34 and the second flow channel insulation sleeve 36 are spot welded together through the eighth weld 308.

[0115] S35: The main insulation sleeve 34 and the insulation bottom cover 37 are spot-welded together through the ninth weld 309, and the discharge pipe 39 and the insulation bottom cover 37 are spot-welded together through the tenth weld 3010.

[0116] S36: The insulation pipe and insulation flange in each insulation pipe assembly 38 are welded together by the eleventh weld 3011 and the twelfth weld 3012, and each insulation pipe is spot welded to the first flow channel insulation sleeve 35 and the second flow channel insulation sleeve 36 by the thirteenth weld 3013.

[0117] S37: The end of the discharge pipe 39 is sealed by the screw plug 310 and the sealing gasket 3101.

[0118] It should be noted that after the insulation sleeve assembly 3 is welded, the cavity of the insulation sleeve assembly 3 should be tested with compressed air, and there should be no leakage in the weld.

[0119] In a preferred embodiment, the parts of the plug valve that directly contact the medium are mainly the inner wall of the valve body 11 and the plug body 21. Therefore, this application uses a valve body assembly 1 and an insulation sleeve assembly 3 made of composite materials, and completes the welding of the insulation sleeve assembly 3 with the help of the central transition ring 31, the first end transition ring 32 and the second end transition ring 33 of the composite structure. This application selects zirconium as the material for the parts of the plug valve that directly contact the medium to achieve corrosion resistance, and selects non-zirconium as the material for the parts that do not directly contact the medium to save manufacturing costs, without limiting the widespread use of zirconium plug valves.

[0120] In practice, as the amount of impurities gradually increases, the impurities between the two extrusion rods 275 will gradually squeeze the two extrusion rods 275, causing the sliding column 274 and the compression component 278 on its outer wall to move synchronously. At the same time, the spring 279 begins to compress and store force. Guided by the conical inner wall of the conical cavity 272, the two extrusion rods 275 will gradually close together, squeezing the impurities in the middle position. During the movement and closing of the two extrusion rods 275, the impurities accumulated in the middle position of the multiple first pressure balance holes 24 and second pressure balance holes 25 will be disturbed, causing them to flow out. At this time, the amount of impurities accumulated is insufficient to squeeze the two extrusion rods 275 to continue moving and closing, and the spring 279 begins to release its elastic force, resetting the two extrusion rods 275 and throwing the impurities that have been squeezed into small pieces between them to the middle position of the multiple first pressure balance holes 24 and second pressure balance holes 25, facilitating their flow out. The welding process in this application has been described in detail above and will not be repeated here.

[0121] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A zirconium-material hard-seal plug valve, characterized in that: include: Valve body assembly, plug assembly, insulation sleeve assembly, connecting shaft, actuator, electrical control cabinet, and remote control system; The valve body assembly has a plug assembly inside its cavity. The end of the plug assembly away from the valve body assembly is connected to the actuator via the connecting shaft. The end of the actuator away from the connecting shaft is connected to the electrical control cabinet and the remote control system in sequence via a transmission line. The insulation sleeve assembly is provided on the outside of the valve body assembly; The plug assembly includes: a plug body, a plug connecting rod, a plug flow channel hole, a first pressure balance hole, a second pressure balance hole, a second titanium-zirconium alloy, and a unclogging component; The plug body is connected to the plug connecting rod, and the end of the plug connecting rod away from the plug body is connected to the connecting shaft. The plug body has multiple plug flow channel holes. The plug body has a first pressure balance hole symmetrically arranged on one side of the multiple plug flow channel holes and a second pressure balance hole arranged vertically on the other side. Multiple unblocking components are arranged at equal intervals on the inner walls of the multiple first pressure balance holes and the multiple second pressure balance holes. The unblocking component includes: a cylindrical cavity, a conical cavity, a guide block, a sliding column, a pressing rod, a torsion spring, a compression component, and a spring; The plug body has an installation cavity, an installation block is provided in the installation cavity, and a cylindrical cavity and a conical cavity are provided in the installation block. The end of the cylindrical cavity away from the conical cavity is connected to a sliding cavity in the plug body. The guide block is provided inside the cylindrical cavity. One end of the sliding column can slide through the guide block and is symmetrically connected to the extrusion rod through the torsion spring. The other end is slidably disposed in the sliding cavity. The compression member is provided on the outer wall of the sliding column. The outer wall of the compression member is slidably connected to the inner wall of the cylindrical cavity. The spring sleeved on the outer wall of the sliding column is connected between the compression member and the plug body.

2. The zirconium hard-seal plug valve according to claim 1, characterized in that: The valve body assembly includes: a valve body body, a valve body bottom cover, a first valve body flange, a second valve body flange, a first zirconium alloy, and a first titanium-zirconium alloy; The valve body body is provided with a valve body bottom cover at the bottom end, one end of the valve body body is connected to the first valve body flange, and the other end is connected to the second valve body flange; The first zirconium alloy is provided on the sealing surfaces of both the first valve body flange and the second valve body flange, the first titanium-zirconium alloy is provided on the sealing surface of the valve body body, and multiple reinforcing ribs are provided on the outer wall of the valve body body.

3. The zirconium hard-seal plug valve according to claim 2, characterized in that: The second titanium-zirconium alloy is disposed on the sealing surface of the plug body.

4. A zirconium-material hard-seal plug valve according to claim 3, characterized in that: The side of the first titanium-zirconium alloy away from the valve body is a sealing protrusion, and the second titanium-zirconium alloy is fitted and sealed to the side of the sealing protrusion away from the valve body, forming a damage-prevention gap between the plug body and the valve body.

5. A zirconium-material hard-seal plug valve according to claim 1, characterized in that: The extrusion rod is provided with an extrusion layer.

6. A zirconium-material hard-seal plug valve according to claim 2, characterized in that: The insulation sleeve assembly includes: a central transition ring, a first end transition ring, a second end transition ring, a main insulation sleeve, a first flow channel insulation sleeve, a second flow channel insulation sleeve, an insulation bottom cover, an insulation pipe assembly, and an exhaust pipe; Wherein, one end of the first end transition ring is connected to the first valve body flange, and the other end is connected to the first flow channel insulation sleeve. The end of the first flow channel insulation sleeve away from the first end transition ring is connected to the valve body and the insulation bottom cover through the middle transition ring and the main body insulation sleeve, respectively. One end of the second end transition ring is connected to the second valve body flange, and the other end is connected to the second flow channel insulation sleeve. The end of the second flow channel insulation sleeve away from the second end transition ring is connected to the valve body and the insulation bottom cover through the middle transition ring and the main body insulation sleeve, respectively. The insulated bottom cover is provided with the discharge pipe, and the first flow channel insulation sleeve and the second flow channel insulation sleeve are both provided with the insulated pipe assembly.

7. A zirconium-material hard-seal plug valve according to claim 6, characterized in that: The middle transition ring is a composite structure comprising a stainless steel base layer and a titanium cladding layer, the first end transition ring is a composite structure comprising a first stainless steel base layer and a first titanium cladding layer, and the second end transition ring is a composite structure comprising a second stainless steel base layer and a second titanium cladding layer.

8. A zirconium-material hard-seal plug valve according to claim 7, characterized in that: The valve body body, the valve body bottom cover, and the plug body body are all made of zirconium alloy. The first valve body flange, the second valve body flange, the reinforcing rib, and the plug body connecting rod are all made of titanium alloy. The main body insulation sleeve, the first flow channel insulation sleeve, the second flow channel insulation sleeve, the insulation bottom cover, the insulation connecting pipe assembly, and the discharge connecting pipe are all made of stainless steel.

9. A welding process for manufacturing a zirconium hard-seal plug valve, based on the zirconium hard-seal plug valve according to claim 8, characterized in that: It includes the following steps: S1 welded valve body assembly; S11: The valve body bottom cover and the valve body body are welded together through the first valve body weld; S12: The first valve body flange is welded to the valve body body through the second valve body weld, and the second valve body flange is welded to the valve body body through the third valve body weld; S13: The bevel between the valve body body and the first valve body flange and the second valve body flange is filled with the first zirconium alloy. S14: Reinforcing ribs are welded onto the outer wall of the valve body; S2 welded plug assembly; S21: The plug body body and the plug connecting rod are welded together through the first plug body weld; S3 welding insulation sleeve assembly; S31: The valve body body and the titanium cladding of the middle transition ring are spot-welded together through the fifth weld, and the main body insulation sleeve and the stainless steel base layer of the middle transition ring are spot-welded together through the sixth weld. S32: The first valve body flange and the first titanium cladding layer of the first end transition ring are spot-welded together by the first weld seam, and the first flow channel insulation sleeve and the first stainless steel base layer of the first end transition ring are spot-welded together by the third weld seam. S33: The second valve body flange and the second end transition ring are spot-welded together by the second weld seam to form a whole titanium cladding layer, and the second flow channel insulation sleeve and the second end transition ring are spot-welded together by the fourth weld seam to form a whole stainless steel base layer. S34: The main insulation sleeve and the first flow channel insulation sleeve are spot-welded together through the seventh weld and the main insulation sleeve and the second flow channel insulation sleeve are spot-welded together through the eighth weld. S35: The main insulation sleeve and the insulation bottom cover are spot-welded together through the ninth weld, and the discharge pipe is spot-welded together with the insulation bottom cover through the tenth weld. S36: The insulation pipes and insulation flanges in each insulation pipe assembly are welded together by the eleventh and twelfth welds, and each insulation pipe is spot-welded to the first flow channel insulation sleeve and the second flow channel insulation sleeve by the thirteenth weld. S37: Seal the end of the discharge pipe with a screw plug and a gasket.

Images