高炉轴流风机系统的止回阀技术改造研究
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摘要
蝶式缓冲止回阀是通用机械产品。国内外企业生产的蝶式缓冲止回阀，主体结构相同，仅在密封型式和适用温度上有所区别。蝶式缓冲止回阀，具有自动开启和自动关闭的特点，属自动阀类，同时具有压力损失大的缺点，是高炉轴流风机系统的传统配套装置。
本文对止回阀进行了技术改造，即为止回阀配备控制系统，不仅没有改变止回阀自动开启、自动关闭的功能，还使其具备了节能的功能，同时完善了止回阀防止和控制高炉轴流风机喘振和逆流的功能。
首先，文章对止回阀进行了基础研究：分析止回阀风门／蝶板的运动；计算和实测止回阀的压力损失；计算和实测止回阀风门／蝶板的开启力和关闭力。研究结果表明：止回阀风门／蝶板的回转运动能在0°～90°开度之间顺利进行；止回阀的压力损失随着止回阀开度的增大而减少：止回阀的开启力大于关闭力。
然后，文章提出了止回阀的改造目标和技术要求。对止回阀的改造方案，进行了比较和选择。明确了高炉轴流风机止回阀控制系统执行机构的设计条件和技术要求，完成了执行机构的方案论证和方案设计，阐述了执行机构的组成和工作原理，对执行机构进行了选型设计，应用UG技术的CAD功能，完成了执行机构的设计。得到了0／1号高炉轴流风机止回阀控制系统执行机构的虚拟装配图。
文章概述了高炉轴流风机止回阀控制系统的电控部分和信号检测部分，重点阐述了信号检测部分气流传感器的选型。
文章通过介绍风机的损失和效率，阐明了改造后止回阀的节能原理和节能效果。根据全国第三次工业普查公布的统计数字，我国风机压缩机类通用机械总装机容量为1.6亿kW，其中风机约为4900万kW，水泵约为1000万kW，年耗电3200亿kW，占全国耗电总量的1／3，占工业用电量的40％，其中部分轴流风机装备了冶金行业，据本文的分析和计算，如果止回阀开度从40°增大到60°，损失的风机输入功率可以减少21％，或者说可以节约21％的风机输入功率。由此可见，采用改造后的高炉轴流风机控制系统后，可以在冶金企业产生较大的节能效果。通过阐述风机的喘振现象、喘振机理、喘振的危害和判断方法以及防止控制措施，分析了改造后止回阀的自动防止控制喘振的性能。通过介绍风机逆流现象及其检测和控制措施，分析了改造后止回阀的防止控制逆流性能。
最后，文章介绍了高炉轴流风机止回阀控制系统现场调试的条件和方法以及结果，对控制系统执行机构和电控部分以及信号检测部分，分别进行了功能分析以及提升力和维持力的分析。
The butterfly disc non-slam check valve is a kind of universal mechanical product.It's primary structure produced by domestic enterprise is the same as the master frame manufactured by foreign corporation.But it's seal type and temperature range is dissimilar.In normal the butterfly disc non-slam check valve operatin,the butterfly disc is opened by forward flow to a position where flow and gravity forces are blanced.With loss of forward flow the butterfly disc non-slam check valve will auto-close as the hydraulic damper permits smooth non-slam closure. The butterfly disc non-slam check valve is self-action valve for this feature.It has a disadvantage as higher pressure loss.The check valve is equipped by the blast furnace axial flow air compressor traditionarily.
The check valve has been rebuilt technically in this paper.That is to set up a control system for the check valve.Not only the function to open and close the butterfly disc for the check valve has not been changed,but also the capability of economizing energy has been had.Meanwhile the abilities of anti-surging and anti-countercurrent have been perfect.
First of all the basic study bas been carried out for the check valve in this thesis.That is to analyze the rotative movement and to calculate and measure the pressure loss and to account and test the open force and close force for the butterfly disc of the check valve.The research result have showed that the rotatory montion can be performed in the opening range of 0°-90°successfully and the pressure loss has been reduced greatly when the opening was increased a little and the open force is greater than the close force for the butterfly disc of the check valve.
Afterwards the rebuilding aim has been put out for the check valve in this article.The rebuilding schemes have been compared to each other and has been selected.The conditions and the technical demands have been brouhgt forward definitely for the executing frame work of the blast furnace axial flow air compressor check valve control system. The scheme argumentation and the scheme design of the executing frame work have been finished. The working principle of the executing frame work has been introduced.The choice of design type for the executing frame work has been accomplished. We have obtained the virtual assembly drawing for No.0 and No.1 executing frame work of the blast furnace axial flow air compressor check valve control system as a result of we have fulfilled the design of the executing frame work for appling CAD fuction of the UG technology.
The treatise has summarize the control party and the signal detection party for the blast furnace axial flow air compressor check valve control system. The emphasis is to present the scheme design of the airflow sensor for the signal detection party.
The dissertation has illustrated the principle and effect of economizing energy for the rebuilt check valve while the loss and efficiency were stated for the air compressor. The national total furnishment capability of universal machine for the fanner and compressor is 160 million kW and it's consuming electrical power is 2/3 of national consuming electrical power and is 40 per cent of consuming electrical power in the industry for 32000 million kW annually based on the statistic data for the national 3th industry investigation. The furnishment capability of fanner is about 49 million kW and the furnishment capability of pump is about 10 million kW thereof. The metallurgy industry has been equipped by a part of axial flow air compressor therein. If the check valve opening increases from 40°to 60°, the lossed shaft horsepower of axial flow air compressor decreases 21 per cent based on the analysis and calculating in this paper i.e. the shaft horsepower of axial flow air compressor can be economized 21 per cent. Therefore,more effect of economizing energy bring about in the metallurgy enterprise after the blast furnace axial flow air compressor check valve control system rebuilt can be used. This paper has analyzed the capability of auto-prevent and auto-control surge for the rebuilt check valve while the phenomena and the mechanism and the harm and the method of distinguish and prevent and control for the surge have been explained. The discourse has analyzed the anti-countercurrent performance of the rebuilt check valve while the phenomena of countercurrent and the measure to prevent and control countercurrent have been introduced.
The testing condition and ways and means and result in the corporation have been expounded for the blast furnace axial flow air compressor check valve control system in the end. The function analysis and the analyses of elevating force and maintaining force have been carried through in the paper for the executing frame work and the control party and the signal detection party of the control system.
本文对止回阀进行了技术改造，即为止回阀配备控制系统，不仅没有改变止回阀自动开启、自动关闭的功能，还使其具备了节能的功能，同时完善了止回阀防止和控制高炉轴流风机喘振和逆流的功能。
首先，文章对止回阀进行了基础研究：分析止回阀风门／蝶板的运动；计算和实测止回阀的压力损失；计算和实测止回阀风门／蝶板的开启力和关闭力。研究结果表明：止回阀风门／蝶板的回转运动能在0°～90°开度之间顺利进行；止回阀的压力损失随着止回阀开度的增大而减少：止回阀的开启力大于关闭力。
然后，文章提出了止回阀的改造目标和技术要求。对止回阀的改造方案，进行了比较和选择。明确了高炉轴流风机止回阀控制系统执行机构的设计条件和技术要求，完成了执行机构的方案论证和方案设计，阐述了执行机构的组成和工作原理，对执行机构进行了选型设计，应用UG技术的CAD功能，完成了执行机构的设计。得到了0／1号高炉轴流风机止回阀控制系统执行机构的虚拟装配图。
文章概述了高炉轴流风机止回阀控制系统的电控部分和信号检测部分，重点阐述了信号检测部分气流传感器的选型。
文章通过介绍风机的损失和效率，阐明了改造后止回阀的节能原理和节能效果。根据全国第三次工业普查公布的统计数字，我国风机压缩机类通用机械总装机容量为1.6亿kW，其中风机约为4900万kW，水泵约为1000万kW，年耗电3200亿kW，占全国耗电总量的1／3，占工业用电量的40％，其中部分轴流风机装备了冶金行业，据本文的分析和计算，如果止回阀开度从40°增大到60°，损失的风机输入功率可以减少21％，或者说可以节约21％的风机输入功率。由此可见，采用改造后的高炉轴流风机控制系统后，可以在冶金企业产生较大的节能效果。通过阐述风机的喘振现象、喘振机理、喘振的危害和判断方法以及防止控制措施，分析了改造后止回阀的自动防止控制喘振的性能。通过介绍风机逆流现象及其检测和控制措施，分析了改造后止回阀的防止控制逆流性能。
最后，文章介绍了高炉轴流风机止回阀控制系统现场调试的条件和方法以及结果，对控制系统执行机构和电控部分以及信号检测部分，分别进行了功能分析以及提升力和维持力的分析。
The butterfly disc non-slam check valve is a kind of universal mechanical product.It's primary structure produced by domestic enterprise is the same as the master frame manufactured by foreign corporation.But it's seal type and temperature range is dissimilar.In normal the butterfly disc non-slam check valve operatin,the butterfly disc is opened by forward flow to a position where flow and gravity forces are blanced.With loss of forward flow the butterfly disc non-slam check valve will auto-close as the hydraulic damper permits smooth non-slam closure. The butterfly disc non-slam check valve is self-action valve for this feature.It has a disadvantage as higher pressure loss.The check valve is equipped by the blast furnace axial flow air compressor traditionarily.
The check valve has been rebuilt technically in this paper.That is to set up a control system for the check valve.Not only the function to open and close the butterfly disc for the check valve has not been changed,but also the capability of economizing energy has been had.Meanwhile the abilities of anti-surging and anti-countercurrent have been perfect.
First of all the basic study bas been carried out for the check valve in this thesis.That is to analyze the rotative movement and to calculate and measure the pressure loss and to account and test the open force and close force for the butterfly disc of the check valve.The research result have showed that the rotatory montion can be performed in the opening range of 0°-90°successfully and the pressure loss has been reduced greatly when the opening was increased a little and the open force is greater than the close force for the butterfly disc of the check valve.
Afterwards the rebuilding aim has been put out for the check valve in this article.The rebuilding schemes have been compared to each other and has been selected.The conditions and the technical demands have been brouhgt forward definitely for the executing frame work of the blast furnace axial flow air compressor check valve control system. The scheme argumentation and the scheme design of the executing frame work have been finished. The working principle of the executing frame work has been introduced.The choice of design type for the executing frame work has been accomplished. We have obtained the virtual assembly drawing for No.0 and No.1 executing frame work of the blast furnace axial flow air compressor check valve control system as a result of we have fulfilled the design of the executing frame work for appling CAD fuction of the UG technology.
The treatise has summarize the control party and the signal detection party for the blast furnace axial flow air compressor check valve control system. The emphasis is to present the scheme design of the airflow sensor for the signal detection party.
The dissertation has illustrated the principle and effect of economizing energy for the rebuilt check valve while the loss and efficiency were stated for the air compressor. The national total furnishment capability of universal machine for the fanner and compressor is 160 million kW and it's consuming electrical power is 2/3 of national consuming electrical power and is 40 per cent of consuming electrical power in the industry for 32000 million kW annually based on the statistic data for the national 3th industry investigation. The furnishment capability of fanner is about 49 million kW and the furnishment capability of pump is about 10 million kW thereof. The metallurgy industry has been equipped by a part of axial flow air compressor therein. If the check valve opening increases from 40°to 60°, the lossed shaft horsepower of axial flow air compressor decreases 21 per cent based on the analysis and calculating in this paper i.e. the shaft horsepower of axial flow air compressor can be economized 21 per cent. Therefore,more effect of economizing energy bring about in the metallurgy enterprise after the blast furnace axial flow air compressor check valve control system rebuilt can be used. This paper has analyzed the capability of auto-prevent and auto-control surge for the rebuilt check valve while the phenomena and the mechanism and the harm and the method of distinguish and prevent and control for the surge have been explained. The discourse has analyzed the anti-countercurrent performance of the rebuilt check valve while the phenomena of countercurrent and the measure to prevent and control countercurrent have been introduced.
The testing condition and ways and means and result in the corporation have been expounded for the blast furnace axial flow air compressor check valve control system in the end. The function analysis and the analyses of elevating force and maintaining force have been carried through in the paper for the executing frame work and the control party and the signal detection party of the control system.
引文
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