原文：
　   1 概述 　　BS5163、BS51501.6MPaDN300～DNl000英标铸铁闸阀，在英国、新加坡、马来西亚和中东一些国家的供水管道和工业管道上被广泛使用，其结构特点见：开式齿轮传动闸阀见图1；闭式齿轮传动闸阀见图2。 　　本文着重阐述了1.6MPaDN300～1000英标铸铁闸阀的阀体壁厚、阀盖壁厚、闸板壁厚、阀杆直径的设计计算和设计验证——型式试验。

 　　2 设计

　　2.1阀体壁厚的设计计算 　　BS5163、BS5150标推中并未给出壳体最小壁厚的数据，仪表阀组设计时，必须对阀体壁厚进行设计计算。 　　设计时，将阀体中腔的截面形状设计为近似椭圆形，见图3，其壁厚S′B1的设计计算，是用椭圆形壁厚的计算公式导出的计算公式：式中K——近似椭圆形截面阀体壁厚系数，其中DN300～DN500，K取1.13，DN600～DNl000，K取1.07； 　　P——介质压力，设计时，P取1.6MPa； 　　a——近似椭圆形截面的长轴(mm)； 　　[σL]——铸铁(HT250)许用拉应力，[σL]取35.28MPa； 　　C——腐蚀余量，C取5(mm)。 　　DN300～DN1000阀体最小壁厚的设计计算结果见表1。 　　设计中发现，阀体壁厚的设计，除了考虑阀体强度之外，还应考虑阀体的刚度，即应将阀体体腔的变形(指在1.6MPa介质压力的作用下)控制在0.001DN范围之内，否则，阀体会因受力变形而无法达到密封。 　　解决阀体刚度的方法见图1，在阀体的外部、内腔设计加强筋，且阀体外部的加强筋与阀体的端法兰相连接，来达到增加阀体的刚性，必要时可设计成不等壁厚，即增加阀体近似椭圆形截面中腔部分的壁厚。

 　　2.2 阀盖壁厚的设计 　　设计时，阀盖壁厚S′B2通常不再进行设计计算，气动管路球阀直接取阀体壁厚的0.95作为阀盖的壁厚。DN300～DN1000阀盖最小壁厚数据见表2；阀盖加强筋的设计见图1。

 　　2.3 闸板壁厚的设计计算 　　BS5163、BS5150标准中，同样未给出闸板最小壁厚的数据，设计时，必须对闸板壁厚S′B3进行设计计算，其计算公式如下：式中d——通径(mm)； 　　P——介质压力，设计时，P取1.6MPa； 　　[σW]——铸铁(HT250)许用弯曲应力，[σW]取56.84MPa； 　　C——腐蚀余量，C取3(mm)。 　　DN300～DN1000闸板最小壁厚的设计计算结果见表3。

　　2.4阀杆直径的设计计算 　　BS5163、BS5150标准中，同样未给出阀杆最小直径的数据，设计时，必须对阀杆直径进行设计计算，其计算公式如下：式中K——阀杆设计计算系数，其中DN300～DN500，K取0.70～0.75；DN600～DNl00。K取0.60～0.65； 　　Q——阀杆开启时的轴向力(N)； 　　[σL]——铸铁(HT250)许用拉应力，[σL]取35.28MPa； 　　其中Q采用简易计算公式，且因QG(闸板组件的重量)数值小，不予计算。式中QMF——密封面达到必需比压时的作用力(N)； 　　QMJ——密封面介质静压作用力(N)； 　　d——通径，d=DN(mm)； 　　bm——阀体密封面宽度(mm)； 　　qmf——必需密封比压(MPa)； 　　P——介质压力，设计时，P取1.6MPa。 　　DN300～DN1000阀杆最小直径的气动管路截止阀设计计算数据见表4。

 　　3 设计验证——型式试验 　　DN300～DN1000英标铸铁闸阀样机，通过了马来西亚国家质量权威机构SiRiM的型式试验，对设计进行了验证，型式试验严格按照英国国家标准BS5163：1986进行。型式试验的试验项目有：外观检验、尺寸检验、材料理化试验、壳体强度试验、密封试验、最大功能扭矩试验、最小强度扭矩试验、清洁度检验、涂层和标志检验。 　　这里着重介绍壳体强度试验、密封试验，最大功能扭矩试验、最小强度扭矩试验。

 　　3.1 壳体强度试验 　　壳体强度试验，试验介质压力2.4MPa，保持试验压力最短持续时间1h,不得有肉眼可见渗漏。

 　　3.2 密封试验 　　密封试验，试验介质压力1.76MPa，保持试验压力最短持续时间15min，不得有肉眼可见渗漏，即在阀体的密封面上，15min内不能有任何肉眼可见的渗漏，包括挂在密封面上小水珠。 　　需要再次强调的是：设计的阀体必须有足够的强度和刚度，密封试验时，壳体的变形必须控制在0.001DN范围之内，否则将很难通过密封试验。

 　　3.3 最大功能扭矩试验 　　最大功能扭矩试验，中央空调专用阀是指闸阀在无介质压力和有介质压力的情况下，在开、关的全过程中，任一瞬间其最大的扭矩都不能超过表5规定的扭矩。

　　3.4 最小强度扭矩试验 　　最小强度扭矩试验，是对PN1.6MPaDN300～DNlO00英标铸铁闸阀设计的验证，其试验步骤： 　3.4.1 全开、全关试验 　　用最大功能试验扭矩对阀门进行全开、全关操作试验，并做好全开、全关位置的记号，同时记录全开、全关过程中阀杆的转动圈数。 　　3.4.2阀处于全关位置的最小强度扭矩试验 　　阀处于全关位置后，再在阀杆的四方头上，顺着关紧的方向(顺时针方向)，逐渐施加最大功能试验扭矩3倍的扭矩，即最小强度试验扭矩，见表6；以验证阀体、阀盖、闸板、阀杆、阀杆螺母、填料函等主要零件及中法兰螺栓的强度是否达到BS5163：1986标准的要求。 　　3.4.3阀处于全开位置的最小强度扭矩试验 　　阀处于全开位置后，再在阀杆的四方头上，顺着开启的方向(逆时针方向)，逐渐施加最大功能试验扭矩3倍的扭矩，即最小强度试验扭矩，见表6；以验证阀体、阀盖、闸板、阀杆、阀杆螺母、填料函等主要零件及中法兰螺栓的强度是否达到BS5163：1986标准的要求。 　　3.4.4密封试验 　　重新用最大功能试验扭矩使阀处于全关位置，再次氧气专用阀 铜阀门进行密封试验，试验介质压力1.76MPa,保持试验压力最短持续时间15min不得有任何肉眼可见的渗漏，以确认阀是否产生变形；设计是否达到BS5163：1986标准的要求。 　　3.4.5全开、全关试验 　　再次用最大功能试验扭矩对阀进行全开、全关操作试验，并核对全开、全关的位置是否与3.4.1试验时全开、全关的位置是否相符；再次记录全开、全关过程中阀杆的转动圈数，核对是否与3.4.1试验时阀杆的转动圈数是否相同，以确认阀杆、阀杆螺母的强度、刚度是否满足BS5163：1986标准的要求。

 　　3.5零件检验 　　拆开零件，检验阀体、阀盖、闸板、阀杆、阀杆螺母、填料函等零件及中法兰的螺柱、螺母是否完好，以确认阀体、阀盖、闸板、阀杆、阀杆螺母、填料函等主要零件及中法兰螺栓的设计是否满足BS5163：1986标准的要求。

 　　4结束语 　　经设计验证——型式试验，确认BS5163、BS51501.6MPaDN300～DNl000英标铸铁闸阀的设计满足了BS5163：1986标准的要求，投入了批量生产，并大批量出口马来西亚、新加坡。通过设计，深切感到BS5163标准的型式试验方法——最小强度扭矩试验是十分科学的，应该在阀门行业中推广，这是企业进行阀门新产品设计验证的好办法；深切感到阀门行业应该规范各类阀门的最大功能试验扭矩，即规范各类阀门的启闭力矩，这是时代发展、社会进步对阀门进行人性化设计提出的新要求

“ 1.6MPaDN300 ~ DN1000 British standard cast iron gate valve design knowledge ”是由中国闸阀网提供的阀门行业新闻，译文仅供参考。另外，中国闸阀网还提供相关产品搜索： 电动闸阀、 手动闸阀、 气动闸阀、 楔式闸阀、 刀形闸阀（刀闸阀）等。

译文：
          1 Overview BS5163, BS51501.6MPaDN300 ~ DNl000 British standard cast iron gate valve, in the United Kingdom, Singapore, Malaysia and the Middle East, some countries water supply pipes and industrial pipes are widely used, and their structural features, see: open-gear transmission gate shown in Figure 1; closed gear transmission gate shown in Figure 2. This article focuses on the 1.6MPaDN300 ~ 1000 British standard wall iron gate valve, valve cover thickness, gate thickness, stem diameter design calculation and design verification - type testing. 2 Design 2.1 Calculation of the Thickness body BS5163, BS5150 standard does not give a push in the smallest shell thickness data, the design must be designed on the valve body wall thickness calculation. Design, the body cavity of the section in the shape of the approximate oval, Figure 3, the wall thickness S'B1 design and calculation, is oval thickness calculation formula is the formula: the formula K - Body wall thickness of approximately elliptical cross section factor, which DN300 ~ DN500, K take 1.13, DN600 ~ DNl000, K take 1.07; P - medium pressure, design, P take 1.6MPa; a - elliptical cross section similar to the long axis (mm); [ΣL] - cast iron (HT250) allowable tensile stress, [σL] take 35.28MPa; C - corrosion allowance, C obtained 5 (mm). DN300 ~ DN1000 minimum thickness body design results in Table 1. Design found that the design of valve body wall thickness, in addition to considering body strength, it should consider the stiffness of body, that body should be the body cavity of the deformation (refer to 1.6MPa under media pressure) control in 0.001DN range, otherwise, the body will not be achieved due to deformation and sealing. Settlement body stiffness of Figure 1, the body of the external cavity design ribs, and the external body and the body of the end stiffener flange connected to achieve the increase in body rigidity, if necessary range designed wall thickness, which increased approximately elliptical cross section in the body part of the wall cavity. Design wall thickness of 2.2 valve cover Design, wall thickness S'B2 valve cover design calculations are usually not directly take body wall thickness of the wall thickness of 0.95 as the valve cover. DN300 ~ DN1000 valve cover minimum wall thickness data in Table 2; valve cover design of ribs shown in Figure 1. 2.3 Calculation of the Thickness gate BS5163, BS5150 standards, the same minimum thickness gate did not give data, design, wall thickness S'B3 gate must be designed calculation, the formula is as follows: type in d - diameter (mm); P - medium pressure, design, P take 1.6MPa; [ΣW] - cast iron (HT250) allowable bending stress, [σW] take 56.84MPa; C - corrosion allowance, C take 3 (mm). DN300 ~ DN1000 the design of ram minimum thickness results in Table 3. 2.4 Design and calculation of stem diameter BS5163, BS5150 standards and are not given in the smallest stem diameter data, design, stem diameter, the design must be calculated on the basis the following formula: the formula K - coefficient of stem design and calculation, which DN300 ~ DN500, K take 0.70 ~ 0.75; DN600 ~ DNl00. Take 0.60 to 0.65 K; Q - when the axial force open the valve stem (N); [ΣL] - cast iron (HT250) allowable tensile stress, [σL] take 35.28MPa; Using a simple formula in which Q, and because of QG (ram component weight) value is small, not be counted. Type of QMF - sealing surface to achieve the necessary pressure when compared with the force (N); QMJ - Medium Static sealing surface force (N); d - diameter, d = DN (mm); bm - Seal Surface Width (mm); qmf - need to seal than the pressure (MPa); P - medium pressure, design, P take 1.6MPa. Minimum diameter of DN300 ~ DN1000 stem design calculations in table 4. 3 Design Verification - Type Test DN300 ~ DN1000 British standard cast iron gate valve prototype, by the Malaysian authority SiRiM quality type test, the design is verified, type test in strict accordance with British Standard BS5163: 1986 for. Pilot project type: appearance inspection, dimensionalGate Valves inspection, material physics and chemistry test, shell strength test, seal test, the maximum torque test function, the minimum torque strength testing, cleanliness testing, coating and marking tests. Here focuses on the shell strength test, seal test, the maximum torque test function, the minimum torque strength test. 3.1 Shell strength test Shell strength test, test medium pressure 2.4MPa, the pressure to keep the shortest trial duration 1h, may not have visible leakage. 3.2 Sealing test Seal test, test medium pressure 1.76MPa, the shortest duration to maintain test pressure 15min, there is no visible leakage, that is, the valve sealing surface, 15min can not carry any visible leakage, including the hanging in the seal surface Little drops of water. Need to re-emphasize: the design of the body must have sufficient strength and rigidity, seal test, the shell deformation must be controlled within the 0.001DN, it will be difficult through the sealing test. Maximum torque 3.3 Functional Test Maximum torque function tests, is the gate without media pressure and media pressure situations, opening and closing of the whole process, any moment of its maximum torque can not exceed the torque requirement in table 5. 3.4 Minimum Strength of torque test Minimum torque strength test, is PN1.6MPaDN300 ~ DNlO00 British standard cast iron gate valve design verification, the test steps: 3.4.1 Responding to fully test Function tests with maximum torque of the valve to fully open, fully closed operational testing, and make fully open, fully closed position of the mark while recording fully open, fully closed the valve stem during rotation number. 3.4.2 valve in the fully closed position of the minimum strength of torque test Valve in the fully closed position, then the valve stem of the four head off along the tight direction (clockwise direction), and gradually impose the maximum function tests 3 times the torque of torque, that is the minimum strength test torque, see Table 6 ; to Check Valvesverify that the valve body, valve cover, gate and stem and stem nut, stuffing and other main parts and whether the strength in the flange bolts to BS5163: 1986 standard. 3.4.3 valve in fully open position of the minimum strength of torque test Valve in the fully open position, then the head of the Quartet in the stem, along the opening direction (counterclockwise), and gradually impose the maximum function tests 3 times the torque of torque, that is the minimum strength test torque, see Table 6 ; to verify that the valve body, valve cover, gate, stem, stem nut, stuffing and other major components and the strength of flange bolts are to BS5163: 1986 standard. 3.4.4 Sealing test Function test re-using the maximum torque the valve in the fully closed again to seal test, test medium pressure 1.76MPa,Ball Valves continued to maintain the shortest time of 15min test pressure without any visible leak, to confirm whether the valve distortion; design is to BS5163: 1986 standard. 3.4.5 fully open, fully closed test Function test again with the greatest torque on the valve fully open, fully closed operational testing and verification is fully open and fully closed position with the 3.4.1 test whether the fully open, fully closed position are matched; another record open, the whole off the valve stem during rotation number, check whether the 3.4.1 test whether the stem of the same rotation number, to confirm the stem nut strength, stiffness meets BS5163: 1986 standard. 3.5 Part Inspection Disassemble parts, test valve, valveButterfly Valves cover, gate, stem, stem nut, stuffing and other parts and the flange of the stud, nut is intact, to confirm the valve body, valve cover, gate, stem , stem nut, stuffing and other main parts and whether the design of the flange bolts to meet BS5163: 1986 standard. 4 Conclusion The design verification - type test, to confirm BS5163, BS51501.6MPaDN300 ~ DNl000 British standard cast iron gate valve designed to meet BS5163: 1986 standards, into the mass production Plug Valvesand large quantities are exported to Malaysia and Singapore. By design, the pattern of deeply felt BS5163 standard test methods - the minimum torque strength test is very scientific, it should be in the valve industry in the promotion, which is an enterprise valve design verification of new products a good way; deeply felt the valve industry various types of valves should regulate the maximum torque function test, which regulate various types of valves opening and closing moments of the times, development, social progress for humanity on the valve design a new demand

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2010-07-29 06:55

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