Views: 0 Author: J-VALVES Publish Time: 2023-11-26 Origin: Site
In the field of industrial fluid control, VALVES, as key equipment, have their technological development always closely linked to industry demands. With the continuous progress of industries such as petrochemical, natural gas, and electric power, the performance requirements for valves are gradually increasing. From traditional gate valves to modern FULLY WELDED TRUNNION BALL VALVES, valve technology has undergone significant iterations. This article will explore this technological iteration path and analyze the future development trends of valves.
I. CHARACTERISTICS AND LIMITATIONS OF TRADITIONAL GATE VALVES
(1) Characteristics of Traditional Gate Valves
• Structural Characteristics: Gate valves control the on-off of fluid by the up-and-down movement of the gate. They have a full-bore design, with low resistance when fluid passes through, and are suitable for working conditions with large flow rates.
• Sealing Performance: Gate valves have relatively good sealing performance. They usually adopt a double-gate design and can provide bidirectional sealing.
• Applicable Working Conditions: Gate valves are suitable for working conditions with high temperature, high pressure, and large flow rates, such as steam systems and boiler feedwater systems.
(2) Limitations of Traditional Gate Valves
• Slow Operation Speed: The opening and closing speed of gate valves is relatively slow. Usually, it is necessary to rotate the handwheel or electric actuator multiple times, so they are not suitable for emergency shut-off working conditions.
• High Maintenance Cost: The structure of gate valves is relatively complex. The gate and valve seat are prone to wear and require regular maintenance, resulting in high maintenance costs.
• Sealing Reliability: Under extreme working conditions (such as high temperature, high pressure, and corrosive media), the sealing performance of gate valves may decline, increasing the risk of leakage.
II. CHARACTERISTICS AND ADVANTAGES OF FULLY WELDED TRUNNION BALL VALVES
(1) Characteristics of Fully Welded Trunnion Ball Valves
• Structural Characteristics: FULLY WELDED TRUNNION BALL valves adopt a fully welded structure, with strong integrity and no risk of external leakage. The trunnion design facilitates installation and maintenance and at the same time enhances the stability of the valve.
• Sealing Performance: Ball valves have excellent sealing performance. The ball fits tightly with the valve seat and can maintain good sealing under high pressure and high temperature.
• Operational Performance: Ball valves have a fast opening and closing speed. Only a 90° rotation is needed to complete the on-off operation, which is suitable for working conditions that require quick shut-off.
• Applicable Working Conditions: FULLY WELDED TRUNNION BALL VALVES are suitable for working conditions with high pressure, high temperature, and corrosive media, such as oil and natural gas transmission and chemical pipelines.
(2) Advantages of Fully Welded Trunnion Ball Valves
• High-strength Connection: The fully welded structure eliminates the leakage risk of flange connections in traditional valves and improves the safety of the system.
• Quick Shut-off Ability: The fast opening and closing ability of ball valves makes them perform excellently in emergency shut-off working conditions and can effectively prevent the expansion of accidents.
• Low Maintenance Cost: The structure of ball valves is relatively simple, convenient for maintenance, and has a low maintenance cost.
• Intelligent Integration: Fully welded trunnion ball valves can be integrated with intelligent control systems to achieve remote monitoring and automatic control, improving the intelligent level of the system.
III. COMPARISON OF TECHNOLOGICAL ITERATION PATHS
The following is a detailed comparison between traditional gate valves and fully welded trunnion ball valves in the technological iteration path:
Characteristics | Traditional Gate Valves | Fully Welded Trunnion Ball Valves |
Structural Design | Full-bore design, low fluid resistance. | Fully welded structure, no risk of external leakage; trunnion design facilitates installation and maintenance. |
Sealing Performance | Double-gate design, good bidirectional sealing performance. | The ball fits tightly with the valve seat, with excellent sealing performance and suitable for high-pressure and high-temperature working conditions. |
Operational Performance | Slow opening and closing speed, requiring multiple rotations of the handwheel or electric actuator. | Fast opening and closing speed, only a 90° rotation is needed to complete the on-off operation, suitable for emergency shut-off working conditions. |
Applicable Working Conditions | Suitable for working conditions with high temperature, high pressure, and large flow rates, such as steam systems and boiler feedwater systems. | Suitable for working conditions with high pressure, high temperature, and corrosive media, such as oil and natural gas transmission and chemical pipelines. |
Maintenance Cost | Complex structure, the gate and valve seat are prone to wear, and the maintenance cost is high. | Simple structure, convenient for maintenance, and the maintenance cost is low. |
Intelligent Integration | Traditional gate valves usually do not have intelligent functions. | Can be integrated with intelligent control systems to achieve remote monitoring and automatic control, improving the intelligent level of the system. |
IV. FUTURE DEVELOPMENT TRENDS OF VALVES
(1) Intelligentization
• Intelligent Control: In the future, valves will be increasingly integrated with intelligent control systems, such as AI, edge computing, 5G and other technologies, to achieve real-time monitoring and automatic control of valve status. For example, the intelligent valve controller developed by GE can optimize pipeline pressure and flow in real time, and the accuracy rate of fault early warning reaches 98%.
• Remote Operation: Through 5G and industrial Internet technologies, valves can achieve remote operation, reducing human intervention and improving the operation efficiency and safety of the system. For example, the 5G valve cluster deployed in the CNOOC Zhanjiang Refining & Chemical Base has a remote control delay of less than 5 milliseconds.
(2) Greening
• Low Leakage Design: With the improvement of environmental protection requirements, the demand for low-leakage valves will increase significantly. For example, the EU EN 1591 standard compulsorily requires the petrochemical industry to use low-leakage valves with a double-sealing structure.
• Recyclable Materials: In the future, valves will increasingly use recyclable materials, such as PP, PVDF, etc., to reduce the impact on the environment.
(3) High-endization
• Ultra-high Parameter Valves: With the development of industrial technology, the demand for ultra-high parameter valves will increase. For example, the localization rate of high-temperature alloy valves capable of withstanding 1000 °C has increased from 10% in 2020 to 35% in 2025.
• Customization Service: In the future, valves will pay more attention to customization services to meet the special needs under different working conditions.
V. SUMMARY
The technological iteration from traditional gate valves to FULLY WELDED TRUNNION BALL VALVES reflects the continuous progress of the valve industry in terms of performance, safety, and intelligentization. FULLY WELDED TRUNNION BALL VALVES, with their advantages such as high-strength connection, quick shut-off ability, low maintenance cost, and intelligent integration, are gradually becoming the first choice in the field of industrial fluid control. In the future, with the deepening of the trends of intelligentization, greening, and high-endization, valve technology will continue to innovate to meet the increasingly stringent industry demands.
