In the modern power industry, safe production and equipment management have always been core concerns. With the continuous expansion of power equipment and the increasing complexity of systems, effectively ensuring the safety and reliability of power equipment operations has become a pressing issue for the industry. Against this backdrop, valve interlocks have become increasingly widely used as a safety control measure. This article will systematically explore the current status of valve interlock applications in the power industry, its mechanisms of operation, typical application scenarios, and future development trends from multiple perspectives.
1. Basic Concepts of Valve Interlocks
A valve interlock, is a safety control system for equipment operation implemented through mechanical, electronic, or hydraulic means. Its core function is to ensure that operators strictly follow the prescribed operating sequence when operating valves, thereby preventing equipment accidents or safety hazards caused by incorrect operation. Valve interlocks are typically implemented using the following methods:
Mechanical interlocks: Physically interlock valves are connected using locking pins, chains, or mechanical levers, ensuring that one valve must be operated before another.
Electronic interlocks: Utilizing sensors, relays, and control systems, they implement logical control of electrical signals to ensure the correct operating sequence. Hydraulic or pneumatic interlocking: Controls valve operation through hydraulic or pneumatic systems and is commonly used in applications involving high pressure, high temperature, or hazardous media.
In the power industry, valve interlocking is not only used for traditional valve control but is also often integrated into automated control systems to form intelligent operation and management solutions.
2. The Power Industry's Need for Valve Safety Control
The power industry involves power generation, transmission, distribution, and auxiliary systems, encompassing a wide variety of equipment types, including steam turbines, boilers, gas turbines, cooling water systems, substations, and high-pressure pipeline systems. The following characteristics make valve operation safety a key concern:
High-pressure and high-temperature environments: Steam pipelines in thermal power plants can reach pressures of tens of MPa and temperatures exceeding 500°C. Improper operation can cause explosions or serious equipment damage.
Complex media: Power plant pipelines may contain a variety of media, including steam, gas, water, and chemicals. Misoperation can easily lead to cross-contamination or leakage.
Complex system linkages: Various equipment in the power system is tightly interconnected, and misoperation of a single valve can cause cascading failures throughout the entire system. Strict safety regulations: The power industry has strict operating procedures and safety standards. Any operational error may violate legal liability or industry standards.
For these reasons, the use of valve interlocks in the power industry is not only a means of improving operational safety, but also a crucial tool for companies to comply with regulations and improve management.
3. Typical Application Scenarios of Valve Interlocks in the Power Industry
3.1 Boiler System Valve Interlocks
Boilers are the core equipment of thermal power plants, and their operation involves high-temperature, high-pressure steam and water circulation systems. In boiler systems, valve interlocks are primarily used in the following ways:
Feedwater Valve and Blowdown Valve Interlocks: Before operating the blowdown valve, the feedwater valve must be closed to prevent high-pressure steam backflow and water hammer.
Combustion Air Valve and Fuel Valve Interlocks: Ensure that the fuel supply is adequately supplied with air to prevent incomplete combustion or deflagration.
Safety Valve Interlocks: Through mechanical or electronic interlocks, automatic protection against overpressure conditions is provided to prevent operator error that could cause the safety valve to close prematurely.
Valve interlocks ensure that boiler operators strictly follow operating procedures when operating valves, significantly reducing the risk of accidents. 3.2 Cooling Water System Applications
Power units generate significant amounts of heat during operation, which needs to be dissipated through the cooling water system. Cooling water systems involve numerous valves, including pump inlet and outlet valves, bypass valves, and diverter valves. Valve interlocks in such systems can achieve:
Sequential control of pump start and stop sequences: The inlet valve must be opened before starting the pump, and the outlet valve must be closed before shutting down the pump to prevent water hammer and dry running.
System maintenance safety: During maintenance on pipelines or heat exchangers, interlocks ensure that relevant valves are closed to prevent water from accidentally entering the maintenance area.
3.3 Gas Turbines and Gas Pipelines
In gas turbines or gas-fired power plants, the sequence of valve operation is crucial to safety. Valve interlocks can ensure:
Proper gas supply and exhaust sequencing: The exhaust valve must be opened before the gas valve is closed to prevent gas accumulation and explosion.
Pressure regulating valve interlocks: In high-pressure gas systems, interlocks ensure that pressure valves operate in the designed sequence to prevent sudden pressure increases. 3.4 Applications in High-Voltage Transmission and Distribution Equipment
Although primarily electrical equipment, power substations or high-voltage distribution systems also contain gas-insulated circuit breakers (GIS) and high-voltage valves, such as SF6 gas control valves. Valve interlocks in these types of equipment include:
Circuit breaker operation interlocks: When operating high-voltage switches or gas valves, the interlock sequence is ensured to comply with safety regulations, preventing equipment breakdown or accidents caused by incorrect operation.
Gas replenishment and discharge sequence control: When operating gas valves, interlocks control the order of filling, exhausting, and pressure relief to ensure safe operation.
3.5 Automation Power Plant Control System Integration
Modern power plants generally use a DCS (Distributed Control System) or SCADA system for centralized control. Valve interlocks are used in automation systems for the following applications:
Logic control integration: Mechanical or electrical interlock signals are connected to the DCS system to enable remote monitoring and sequence control of valve operations.
Alarm and protection linkage: If an operation sequence error occurs, the system will immediately issue an alarm or automatically take protective measures to prevent the accident from escalating. Historical Recording and Operation Audit: The interlock system records valve operation sequences, providing data support for safety audits and accident tracing.
4. Advantages of Valve Interlock in the Power Industry
Improved Safety: The most obvious advantage is preventing operational errors, ensuring the safety of personnel and equipment.
Reduced Maintenance Costs: Correct operation sequences reduce valve and pipeline damage, reducing maintenance frequency and costs.
Improved Automation: Integrating valve operations into automated system management reduces manual intervention and improves system reliability.
Compliance with Regulations and Standards: Complies with power industry safety operation standards and national regulations, reducing enterprise safety management risks.
Digital Management: The interlock system provides operation records, abnormality alarms, and maintenance reminders, facilitating digital management.
5. Conclusion
In summary, valve interlocks are used in multiple key areas of the power industry, including boiler systems, cooling water systems, gas turbines, high-voltage distribution equipment, and automated control systems. They not only ensure operational safety but also serve as a crucial tool for improving equipment reliability and optimizing management processes. With the advancement of intelligent and digital systems, the application of valve interlocks will become more widespread and efficient, providing solid technical support for safe production and equipment management in the power industry.
For power companies, selecting the right valve interlock system not only reduces operational risks but also improves overall safety management and drives smart power plant construction to higher standards.
Nudango's valve interlock system effectively ensures safe valve operation in boilers, cooling water systems, gas turbines, and high-voltage distribution equipment. This system utilizes multiple mechanical, electrical, and hydraulic interlocks to ensure that operating procedures adhere to safety regulations, preventing equipment failures or accidents caused by misoperation, thereby improving operational efficiency and management.
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