详细介绍
#关键词 工业使用
Adjustment Method of Industrial Pressure Reducing Valve Regulator (Conventional Operating Conditions)
In industrial production systems, pressure reducing valve regulators are the core pressure control components of fluid transport systems, widely used in fields such as petrochemicals, power metallurgy, and biomedicine. Their core function is to stabilize and reduce the pressure of high-pressure fluids (usually ranging from 1.6-10MPa) in upstream pipelines or containers to the working pressure required by downstream equipment (ranging from 0.1-1MPa), while resisting interference factors such as flow fluctuations and medium temperature changes, ensuring the continuity and safety of production processes. Compared with household gas pressure reducing valves, industrial grade pressure reducing valves have a more complex structure, with common types including piston type, bellows type, and pilot type. They require higher regulation accuracy (pressure error must be controlled within ± 5%), so it is necessary to establish a standardized regulation process and operate scientifically based on operating parameters and equipment characteristics.
Systematic preparation before adjustment is the foundation for avoiding operational risks, with the core being "parameter verification, status investigation, and tool deployment". Firstly, it is necessary to clarify the pressure requirements in the process documents. The upstream input pressure, downstream working pressure, and maximum allowable fluctuation value should be accurately recorded. At the same time, the model and specifications of the pressure reducing valve (such as nominal diameter, pressure rating, medium compatibility) should be confirmed to match the working conditions - for example, fluorine lined pressure reducing valves should be used when transporting corrosive media, and high-temperature sealing components should be selected for high-temperature working conditions. Next, perform equipment status check: close the shut-off valves before and after the pressure reducing valve, open the bypass valve to balance the pressure, remove the filter end cover to clean impurities, and prevent valve core blockage; Check the calibration status of auxiliary instruments such as pressure gauges and pressure transmitters (calibration validity period should be within 3 months), blow the pipeline with nitrogen to ensure that there is no residual medium or debris. Finally, prepare specialized tools including torque wrenches, pressure calibrators, sealing grease, and spare sealing gaskets. At the same time, set up warning signs in the operating area, equip with portable combustible gas detectors (for flammable and explosive media) or toxic gas detectors, and operators need to wear anti-static work clothes, protective gloves, and goggles.
The step-by-step adjustment process should follow the principle of "slow pressure rise, precise adjustment, and stable observation" to avoid the impact of sudden pressure changes on downstream equipment. The first step is to open the upstream shut-off valve using an "intermittent opening" method, controlling the valve opening at 1/4 turn. After the upstream pressure stabilizes (with a fluctuation value of ≤ 0.05MPa observed through a pressure gauge), close the bypass valve. The second step is to initially adjust the pressure reducing valve. For piston type pressure reducing valves, rotate the adjusting screw compression spring clockwise to push the piston downwards to reduce the valve opening and lower the outlet pressure; The bellows type pressure reducing valve indirectly controls the valve disc opening by adjusting the nut to change the expansion and contraction of the bellows. In the initial adjustment stage, the outlet pressure needs to be adjusted to 10% -15% lower than the target pressure. For example, when the target pressure is 0.5MPa, it should be initially adjusted to 0.42-0.45MPa. The third step is fine tuning and status observation. Slowly open the downstream shut-off valve to 1/3 opening, allowing the fluid to slowly pass through the pressure reducing valve. At this time, monitor the outlet pressure in real time through a pressure calibrator. Adjust the adjusting component clockwise to increase the pressure, and counterclockwise to decrease the pressure. The adjustment amplitude should be controlled within 1/8 turn of the adjusting screw each time to avoid overshoot. After the pressure stabilizes at the target value, fully open the downstream shut-off valve, observe continuously for 30 minutes, record the pressure fluctuation, and ensure that the fluctuation value meets the process requirements.
Accuracy verification and safety prevention and control are the key to the completion of regulation work. Accuracy verification can be carried out using the "dual instrument comparison method". The portable pressure calibrator and pipeline pressure gauge can be connected to the outlet end at the same time, and the readings of the two instruments can be compared. If the error exceeds ± 5%, the instrument wiring or sensing components need to be re adjusted and checked. For pilot operated pressure reducing valves, it is also necessary to verify the response sensitivity of the pilot valve. By instantaneously increasing the downstream flow (such as opening the backup branch), observe the pressure recovery time of the main valve. Under normal circumstances, it should be ≤ 3 seconds. In terms of safety prevention and control, after the adjustment is completed, the upstream and downstream shut-off valves should be closed, and the flange connection of the pressure reducing valve should be tested for airtightness. The sealing surface should be coated with soapy water, and if no bubbles are generated, it is considered qualified; At the same time, organize adjustment records, label adjustment time, operators, pressure parameters, and equipment status, and establish equipment files. If there is a sudden increase in pressure or a stuck valve core during the adjustment process, the upstream shut-off valve should be immediately closed, the relief valve should be opened to reduce pressure, and the fault should be investigated before resuming the adjustment operation. It is strictly prohibited to forcibly adjust under abnormal pressure conditions.
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