Valve modification

阀门改造 is a system engineering that optimizes the functionality, improves performance, or replaces existing valves as a whole based on equipment aging, technological upgrades, or safety requirements. The following are key transformation scenarios and technical solutions:
1、 Case Study of Industrial Core Scene Transformation
Petrochemical plant upgrade
Yulin Refinery replaced old valves with domestically produced stainless steel hard seal ball valves (Q41F-64P type) during the renovation of the atmospheric and vacuum distillation unit. The valve is designed with a "three body structure+flexible graphite alloy seat" to achieve high temperature resistance of 550 ℃ and high pressure of 25MPa, with a leakage rate of less than 0.0001%. It is equipped with NB IoT sensors to monitor 12 parameters in real time, and the fault response time is shortened to less than 4 hours.
Economic benefits: Compared to imported valves, it reduces costs by 37% and saves over 8 million yuan in procurement costs for a single project.
Renovation of flood discharge system for hydropower station
Traditional gate valves have been replaced with electric cone valves due to issues such as corrosion, blockage, and sealing failure. The conical valve core design achieves linear regulation of water flow and reduces the risk of cavitation vibration; Integrated electric actuators support remote control, with response speeds far exceeding manual/hydraulic valves.
Transformation process: including safety assessment → cold cutting and dismantling of old valves → base reinforcement → precision installation of new valves → system integration and debugging, with a service life of up to 50 years.
Pump station valve maintenance and renovation
Nanshan Tai Electric Irrigation Station strictly controls the three aspects of butterfly valve jamming and hydraulic failure:
Safety Control: Technical briefing before construction, with safety officers assigned throughout the process;
Quality control: Strictly follow installation specifications in low-temperature environments;
Progress: Coordinate manpower and equipment for continuous operation, complete key renovations such as DN800 electric butterfly valve within 2 days.
2、 Key technical directions
Anti vibration strengthening
The hydrogen compressor valve can solve the risk of fracture caused by long-term vibration by modifying the locator feedback rod, reinforcing the gas source pipe, and installing a protective valve.
Intelligent upgrade
Implant sensors into industrial valves and connect them to digital platforms to achieve predictive maintenance (such as the case of Yulin Refinery); Civilian valves can improve operational efficiency by adding automatic control modules.
3、 General renovation process
Assessment and diagnosis: testing the sealing performance, operating mechanism status, and adaptability to working conditions;
Scheme customization: Select based on flow/pressure requirements (such as hard sealed ball valves for high temperature conditions and conical valves for limited space scenarios);
Construction management: Strictly implement energy isolation (LOTO), environmentally friendly dismantling of old valves, and precision calibration of new valves;
Acceptance and maintenance: 72 hour working condition simulation test+operator training.
4、 Civilian scene renovation
The old-fashioned ball valve in the bathroom needs to be replaced as a whole:
Close the main water source and remove the old valve (threaded or hot-melt connection);
After installing the new valve, conduct a 0.8MPa pressure test to ensure no leakage.
Note: For industrial transformation, priority should be given to technical solutions with a high degree of credibility, while for civilian scenarios, practical guidelines can be referenced.