With the advancement of large-scale foreign technology, a wide range of new equipment and standalone machines have emerged. The development of valve-related technologies has been marked by scale, high parameters, and high-performance automation, aligning with the control systems of these large-scale units. Over the past two decades, the control methods for valves in foreign countries have also seen significant progress. In addition to traditional manual, motorized, electric, pneumatic, and hydraulic controls, there is an increasing variety of electro-hydraulic, gas-liquid linked, and automated valves, with continuous innovation and expansion on the horizon.
For example, in the oil refining industry, some of the largest refineries process up to 36.4 million tons annually (such as in the Caribbean), while others reach 30 million tons per year (like in Venezuela). There are nearly 30 refineries with a capacity of 20 million tons per year. The largest refinery units can process up to 24 million tons per year, catalytic cracking units up to 8.24 million tons, and hydrocracking units up to 3.2 million tons. As the size of these facilities grows, so do the valves, leading to a shift toward more advanced and automated control systems.
In recent years, long-distance pipeline systems have developed rapidly due to their low cost—only about one-third of railway transport—and their durability, as they are buried underground and less prone to damage. Additionally, pipeline construction is faster and requires less investment. This has led to a sharp increase in demand for long-distance pipeline valves. For power generation, the largest thermal units can reach up to 130,000 kW, while single-axis thermal plants go up to 1.2 million kW, and the largest nuclear power unit reaches 1.3 million kW.
The valves used in these systems have grown significantly in size. For instance, the largest slab gate valves can reach 1620mm and 2000mm in diameter, butterfly valves up to 9750mm, and ball valves up to 3050mm. Some drive valves weigh as much as 184 tons, and water gate valves can be as large as 2750mm with pressures reaching 9MPa.
The economic benefits of large-scale equipment include increased production efficiency, reduced infrastructure investment, and lower raw material consumption. Compared to a 1 million-ton annual refining unit, a 5 million-ton facility reduces investment per ton by 50%. A 6 million-ton refinery, compared to two 3 million-ton units, requires only 69% of the investment, 53% of steel, 54% of floor space, and 75% of production costs, while labor productivity increases by 170%.
As automation levels rise, many foreign petrochemical companies now use direct digital control for their main processes, with some implementing computerized hierarchical control. Chemical industries like synthetic ammonia, urea, synthetic fiber, rubber, and plastics often use patrol detection and alarm systems, with some achieving partial automation.
Today, large-scale power generation units over 200,000 kW are typically computer-controlled. Nuclear power plants are also managed via computers, and many countries use computer systems for long-distance pipeline control, often equipped with microwave communication. Control rooms now require only two or three personnel, who can monitor the entire system through TV screens.
With the continuous improvement of equipment, processes, and performance, the range of valves available abroad has expanded greatly. New types of valves such as emergency shut-off valves, quick-opening valves, fire dampers, static-resistant valves, temperature-reducing pressure-reducing valves, butterfly check valves, pressure relief valves, vacuum jacket valves, water-cooled or air-cooled valves, safety gate valves, and safety shut-off valves have all gained popularity. Among standard valves, ball valves, butterfly valves, and slab gate valves have experienced the fastest growth over the past 20 years.
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