摘要： 本文講述了蝶閥的分類(lèi)及特點(diǎn)，并重點(diǎn)講述了三偏心蝶閥的發(fā)展。同時(shí)介紹了日本tritec三偏心蝶閥的特殊設(shè)計(jì)。 關(guān)鍵字： 三偏心蝶閥 結(jié)構(gòu) 發(fā)展 tritec三偏心蝶閥
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ouword{var newwords;newwords = unescapewords;document.writenewwords;} ouword;在許多亞太國(guó)家中、由于受本國(guó)的閥門(mén)設(shè)計(jì)制造水平的局限、以及傳統(tǒng)教科書(shū)的影響、對(duì)碟閥的偏見(jiàn)仍很大。而與此同時(shí)、歐美的*發(fā)達(dá)工業(yè)國(guó)家卻正在大力推廣、積極使用碟閥。
道理很簡(jiǎn)單、碟閥已今非昔比。巴蝶閥門(mén)株式會(huì)社的三偏心碟閥tritec、其適用范圍已可以耐壓高達(dá) 2500 磅級(jí)、耐溫低至 -196 ℃、高達(dá) 700 ℃、密封達(dá)到 0 泄漏、調(diào)控比高達(dá)100:1以上。也就是說(shuō)、在各種嚴(yán)酷、關(guān)鍵的過(guò)程控制管線(xiàn)上、不論是開(kāi)關(guān)閥還是調(diào)控閥、只要選型得當(dāng)、現(xiàn)在都可以放心地使用碟閥、而且成本低廉。蝶閥的性能與其自身不斷地偏心、演變、發(fā)展密切相關(guān)。為滿(mǎn)足各種工況要求、蝶閥先后經(jīng)歷了從同心向單偏心、雙偏心和三偏心的演變。碟閥的演變過(guò)程及3偏心碟閥的發(fā)展和應(yīng)用簡(jiǎn)單介紹如下∶ 一、蝶閥分類(lèi) 1、同心蝶閥 該種蝶閥的結(jié)構(gòu)特征為閥桿軸心、蝶板中心、本體中心在同一位置上。結(jié)構(gòu)簡(jiǎn)單、制造方便。常見(jiàn)的襯膠蝶閥即屬于此類(lèi)。缺點(diǎn)是由于蝶板與閥座始終處于擠壓、刮擦狀態(tài)、阻距大、磨損快。為克服擠壓、刮擦、保證密封性能、閥座基本上采用橡膠或聚四氟乙烯等彈性材料、但也因而在使用上受到溫度的限制、這就是為什么傳統(tǒng)上人們認(rèn)為蝶閥不耐高溫的原因。
2、單偏心蝶 為解決同心蝶閥的蝶板與閥座的擠壓?jiǎn)栴}、由此產(chǎn)生了單偏心蝶閥、其結(jié)構(gòu)特征為閥桿軸心偏離了蝶板中心、從而使蝶板上下端不再成為回轉(zhuǎn)軸心、分散、減輕了蝶板上下端與閥座的過(guò)度擠壓。但由于單偏心構(gòu)造在閥門(mén)的整個(gè)開(kāi)關(guān)過(guò)程中蝶板與閥座的刮擦現(xiàn)象并未消失、在應(yīng)用范圍上和同心蝶閥大同小異、故采用不多。 3、雙偏心蝶閥 在單偏心蝶閥的基礎(chǔ)上進(jìn)一步改良成型的就是目前應(yīng)用zui廣泛的雙偏心蝶閥。其結(jié)構(gòu)特征為在閥桿軸心既偏離蝶板中心、也偏離本體中心。雙偏心的效果使閥門(mén)被開(kāi)啟后蝶板能迅即脫離閥座、大幅度地消除了蝶板與閥座的不必要的過(guò)度擠壓、刮擦現(xiàn)象、減輕了開(kāi)啟阻距、降低了磨損、提高了閥座壽命。刮擦的大幅度降低、同時(shí)還使得雙偏心蝶閥也可以采用金屬閥座、提高了蝶閥在高溫領(lǐng)域的應(yīng)用。但因?yàn)槠涿芊庠韺傥恢妹芊鈽?gòu)造、即蝶板與閥座的密封面為線(xiàn)接觸、通過(guò)蝶板擠壓閥座所造成的彈性變形產(chǎn)生密封效果、故對(duì)關(guān)閉位置要求很高（特別是金屬閥座）、承壓能力低、這就是為什么傳統(tǒng)上人們認(rèn)為蝶閥不耐高壓、泄漏量大的原因。 4、三偏心蝶閥 要耐高溫、必須使用硬密封、但泄漏量大；要零泄漏、必須使用軟密封、卻不耐高溫。為克服雙偏心蝶閥這一矛盾、又對(duì)蝶閥進(jìn)行了第三次偏心。其結(jié)構(gòu)特征為在雙偏心的閥桿軸心位置偏心的同時(shí)、使蝶板密封面的圓錐型軸線(xiàn)偏斜于本體圓柱軸線(xiàn)、也就是說(shuō)、經(jīng)過(guò)第三次偏心后、蝶板的密封斷面不再是真圓、而是橢圓、其密封面形狀也因此而不對(duì)稱(chēng)、一邊傾斜于本體中心線(xiàn)、另一邊則平行于本體中心線(xiàn)。 這第三次偏心的zui大特點(diǎn)就是從根本上改變了密封構(gòu)造、不再是位置密封、而是扭力密封、即不是依靠閥座的彈性變形、而是*依靠閥座的接觸面壓來(lái)達(dá)到密封效果、因此一舉解決了金屬閥座零泄漏這一難題、并因接觸面壓與介質(zhì)壓力是成正比的、耐高壓高溫也迎刃而解。 二、三偏心蝶閥的發(fā)展 三偏心碟閥自問(wèn)世以來(lái)、為滿(mǎn)足日益嚴(yán)酷的工況要求、其本身也經(jīng)歷著自我完善和不斷發(fā)展的過(guò)程。即便zui基本的零泄漏、理論上三偏心碟閥都可以做到、但實(shí)際上還是有賴(lài)于周密的設(shè)計(jì)、精密的制造。巴蝶閥門(mén)株式會(huì)社在吸取、總結(jié)其他品牌三偏心碟閥的長(zhǎng)短處的基礎(chǔ)上、推出了自己的*特色的三偏心碟閥tritec、其特點(diǎn)如下∶
1、api 規(guī)格 *、api609已事實(shí)上成為工業(yè)重要管線(xiàn)上用閥門(mén)的規(guī)格。而tritec則全面嚴(yán)格按照api609規(guī)格的1997年版設(shè)計(jì)、制造。更可貴的是、tritec的基本設(shè)計(jì)不僅僅局限于api一個(gè)規(guī)格、bs5155 ansi b16.34 、asme sec viii等各大規(guī)格都能對(duì)應(yīng)、這保證了tritec在所有的工業(yè)領(lǐng)域都有用武之地。
2、雙重安全構(gòu)造 tritec嚴(yán)格按照api609的規(guī)格要求、為防止因受流體壓力、溫度的影響而引起的蝶板變形、閥桿錯(cuò)位、密封面咬合、在蝶板上下側(cè)分別裝有兩個(gè)各自獨(dú)立的止推環(huán)、從而保證了閥門(mén)在任何工況下的正常工作；
同時(shí)、為防止未知原因所引起的閥桿破損、飛出而造成的突發(fā)事故、在閥門(mén)下端內(nèi)外兩處設(shè)計(jì)了各自獨(dú)立的閥桿飛出防止機(jī)構(gòu)、這也從側(cè)面保證了tritec的壓力等級(jí)可以做到高達(dá) 2500 磅級(jí)。
3、無(wú)死區(qū)設(shè)計(jì) tritec在設(shè)計(jì)過(guò)程中、特別考慮了在調(diào)控領(lǐng)域中的應(yīng)用問(wèn)題、充分利用三偏心蝶閥的密封原理、做到了閥門(mén)開(kāi)關(guān)時(shí)蝶板不刮擦閥座、閥桿的扭矩通過(guò)蝶板直接傳遞至密封面、也就是說(shuō)蝶板與閥座間幾乎無(wú)磨擦現(xiàn)象發(fā)生、從而杜絕了打開(kāi)普通閥門(mén)是所常見(jiàn)的跳躍現(xiàn)象、*了閥門(mén)的低開(kāi)度范圍內(nèi)因磨擦等各種不安定因素所造成的調(diào)控不能現(xiàn)象、即*了死區(qū)（不感帶）、這意味著tritec幾乎可以從0開(kāi)度開(kāi)始即進(jìn)入可調(diào)控區(qū)域、直至90開(kāi)度、其正常調(diào)控比是一般蝶閥的2倍以上、調(diào)控比zui高可高達(dá)100:1以上。這為tritec作為調(diào)控閥使用創(chuàng)造了良好的條件、特別是在大口徑時(shí)、截止閥的成本*、另外、截止閥無(wú)法實(shí)現(xiàn)零泄漏、在需要緊急關(guān)斷的工況中、必須在截止閥的旁側(cè)加裝關(guān)斷閥、而tritec集調(diào)控與關(guān)斷于一身、其經(jīng)濟(jì)效益是極其可觀的。
4、本體閥座構(gòu)造 三偏心蝶閥的閥座安裝構(gòu)造有兩種、大多數(shù)是為圖方便而安裝在蝶板上，但tritec則采用了本體閥座構(gòu)造、將閥座安裝在本體上。其優(yōu)點(diǎn)是與蝶板閥座相比、大大減少了閥座直接接觸介質(zhì)的機(jī)會(huì)、從而降低了閥座受沖蝕的程度、延長(zhǎng)了閥座的使用壽命。
5、薄層片閥座結(jié)構(gòu) tritec的閥座由不銹鋼薄片與石墨薄片層疊而成、這種結(jié)構(gòu)可以有效地防止介質(zhì)中的微小固形物的影響和熱膨脹所可能引起的密封面咬合、即使出現(xiàn)微小的損傷、也不會(huì)產(chǎn)生泄漏、而這在對(duì)雙偏心蝶閥或其它三偏心蝶閥來(lái)說(shuō)是不可想像的。
6、可更換式密封 tritec的密封副可謂獨(dú)樹(shù)一幟、不但本體閥座可以更換、而且由于蝶板密封面與蝶板是獨(dú)立的、蝶板密封面可也可以更換、也就是說(shuō)當(dāng)?shù)迕芊饷媸軗p時(shí)、不必再興師動(dòng)眾地運(yùn)回制造廠(chǎng)或大舉分解閥門(mén)、只需調(diào)換蝶板密封面即可、這不但大大降低了保養(yǎng)成本、還大大減少了維修工時(shí)和檢修強(qiáng)度與難度。
7、均衡固定結(jié)構(gòu) 從三偏心蝶閥的密封面形狀特點(diǎn)出發(fā)、tritec的密封副固定方式采用了螺栓橢圓形分布固定、不但定位、而且還使每個(gè)螺栓都均衡受力、杜絕了因應(yīng)力分布不均而產(chǎn)生的密封副松動(dòng)、泄漏。
8、本質(zhì)耐火構(gòu)造 很多閥門(mén)都聲稱(chēng)具有耐火構(gòu)造、但其中極大部分閥門(mén)為了減少泄漏量而采用了軟硬雙重閥座構(gòu)造、其實(shí)這很危險(xiǎn)。因?yàn)榛馂?zāi)時(shí)軟密封閥座的不*燃燒會(huì)使金屬支持閥座產(chǎn)生應(yīng)力、溫差變形、從而導(dǎo)致耐火機(jī)能失靈。所以、目前歐美正在逐漸排除這類(lèi)名不副實(shí)的耐火閥。tritrc因?yàn)槭橇阈孤⑺圆恍枰浢芊獾慕橹?、屬名副其?shí)的本質(zhì)耐火構(gòu)造、并獲有api607、api6fa和bs6755part2的耐火檢驗(yàn)合格認(rèn)可證書(shū)。這保證了tritec可以被應(yīng)用于石油、石化等各種危險(xiǎn)區(qū)域。在保守的英國(guó)、其北海油田的各個(gè)關(guān)鍵部位所使用的閥門(mén)、幾乎全被tritec囊括即是的例證。 9、高密封填料構(gòu)造 在閥門(mén)的泄漏問(wèn)題上、傳統(tǒng)上往往都集中于閥座的泄漏、即內(nèi)漏、而忽略了填料部的泄漏、即外漏。而實(shí)際上、在目前環(huán)境問(wèn)題被日益重視的當(dāng)代社會(huì)、外漏危害性遠(yuǎn)大于內(nèi)漏已成為不爭(zhēng)的事實(shí)。tritec三偏心蝶閥屬回轉(zhuǎn)型閥門(mén)、其閥桿動(dòng)作僅為90°回轉(zhuǎn)而已、這與閘閥、截止閥等閥桿動(dòng)作為螺旋多回轉(zhuǎn)往復(fù)運(yùn)動(dòng)相比、其填料部所受磨損程度很低、相對(duì)地使用壽命很長(zhǎng)、更由于tritec在填料密封等防止外部泄漏構(gòu)造上、采取了zui高標(biāo)準(zhǔn)設(shè)計(jì)、從而可以在按照epa21規(guī)格下進(jìn)行外部泄漏測(cè)試時(shí)、標(biāo)準(zhǔn)密封性能保證在100ppm以下。而實(shí)際上在現(xiàn)有的tritec的測(cè)試成績(jī)中、在勞埃德的監(jiān)測(cè)情況下、外部泄漏值低至7ppm。這些指標(biāo)都意味著tritec可以在化工等各種領(lǐng)域中的有毒、有害介質(zhì)管線(xiàn)中大顯身手。
三、三偏心蝶閥的應(yīng)用 綜上所述、三偏心蝶閥作為閥門(mén)科技的結(jié)晶、揚(yáng)各種閥門(mén)之長(zhǎng)、避各種閥門(mén)之短、必將越來(lái)越受到廣大用戶(hù)和設(shè)計(jì)人員的重視。巴蝶閥門(mén)株式會(huì)社的tritec、其zui大壓力等級(jí)可以到達(dá)2500磅級(jí)、標(biāo)準(zhǔn)口徑可以做到48英寸、而且對(duì)夾、凸耳、法蘭、環(huán)接、對(duì)接焊、夾套、各種結(jié)構(gòu)長(zhǎng)度等都可以對(duì)應(yīng)、更由于tritec的材料選擇余地很大、高低溫及各種酸、堿等腐蝕性介質(zhì)也都能對(duì)應(yīng)自如。特別是在大口徑方面、以其零泄漏的優(yōu)勢(shì)、在關(guān)斷閥上、正在不斷地取代粗大的閘閥和球閥、同樣、以其優(yōu)異的調(diào)控機(jī)能、在調(diào)控閥上、也正在不斷地取代笨重的截止閥。作為事實(shí)、到目前為止、tritec已被使用在包括中國(guó)在內(nèi)的石油天然氣開(kāi)采、海上平臺(tái)、石油精練、石油化工、無(wú)機(jī)化工、能源發(fā)電等各大工業(yè)領(lǐng)域的過(guò)程控制等各種重要管線(xiàn)上。