Wuhan Grat Control Valve Co., Ltd.

アプリケーションの背景 冶金産業の熱処理プロセスにおいて、連続焼鈍炉は高品質の冷間圧延鋼帯を製造するための主要な設備です。湖北省の大規模製鉄所は、連続焼鈍ラインの燃焼空気パイプラインにおける精密な流量制御を必要としていました。高頻度調整下, 従来の制御方法は、低精度、応答の遅さ、頻繁な故障, に悩まされていましたが、GRAT Electric Ventilation Butterfly Valveは、高精度で信頼性の高い空気調整ソリューションGRAT 低負荷型電動換気バタフライバルブは、冶金産業における高温、高需要のプロセス制御アプリケーションにおいて、堅牢な適応性と信頼性を実証しています。効率性と耐久性を保証する電動換気バタフライバルブソリューションについては、GRATが新規プロジェクトと設備アップグレードの両方において、信頼できるパートナーです。 . 動作条件 このアプリケーションは、バルブの性能に厳しい課題を課しており、具体的な動作パラメータは以下の通りです:アプリケーション: 連続焼鈍炉の燃焼空気供給パイプライン製品: GRAT 低負荷型電動換気バタフライバルブ媒体: 予熱空気温度: 120℃～300℃（頻繁な変動あり）公称圧力: PN10サイズ: DN200接続: フランジ制御信号: 変調制御、4-20mA動作環境: 工業用ワークショップ設定、高い保護等級と連続運転能力を必要とする設備。 設計寿命: 5年以上 製品の利点と特徴 GRAT Electric Ventilation Butterfly Valveは、焼鈍炉の過酷な環境向けに設計されています: 精密比例制御: 高性能アクチュエータを搭載し、GRAT 低負荷型電動換気バタフライバルブは、冶金産業における高温、高需要のプロセス制御アプリケーションにおいて、堅牢な適応性と信頼性を実証しています。効率性と耐久性を保証する電動換気バタフライバルブソリューションについては、GRATが新規プロジェクトと設備アップグレードの両方において、信頼できるパートナーです。 .炉内雰囲気の変動をGRAT 低負荷型電動換気バタフライバルブは、冶金産業における高温、高需要のプロセス制御アプリケーションにおいて、堅牢な適応性と信頼性を実証しています。効率性と耐久性を保証する電動換気バタフライバルブソリューションについては、GRATが新規プロジェクトと設備アップグレードの両方において、信頼できるパートナーです。 . 優れた耐高温性: SUS304ステンレス鋼で構成されており、300℃でも強度の85％以上を維持しています。 合理化されたディスク設計により、必要なトルクを40％削減し、省エネと摩耗の低減を実現しています。 高い信頼性と長寿命: 内蔵の過負荷保護により、ジャミングによる損傷を防止します。 長期的な高頻度サイクルにおいて、0.01％以下のシール漏れ率を達成しています。 容易な設置とメンテナンス: 標準的なフランジ接続により、迅速な設置が可能です。 モジュール設計により、主要コンポーネントのMTTRは30分未満です。 性能結果 2017年7月の試運転以来、バルブは優れた結果をもたらしています:制御精度の向上: 燃焼空気量の変動は±15％から±6％以内に減少しました。炉内温度差は±5℃以内に低下しました。GRAT 低負荷型電動換気バタフライバルブは、冶金産業における高温、高需要のプロセス制御アプリケーションにおいて、堅牢な適応性と信頼性を実証しています。効率性と耐久性を保証する電動換気バタフライバルブソリューションについては、GRATが新規プロジェクトと設備アップグレードの両方において、信頼できるパートナーです。 バルブは、70ヶ月以上連続して故障なく運転し、25万サイクル以上を蓄積しています。GRAT 低負荷型電動換気バタフライバルブは、冶金産業における高温、高需要のプロセス制御アプリケーションにおいて、堅牢な適応性と信頼性を実証しています。効率性と耐久性を保証する電動換気バタフライバルブソリューションについては、GRATが新規プロジェクトと設備アップグレードの両方において、信頼できるパートナーです。 製品歩留まりは92％から96.5％に増加し、同時にバルブあたりの運用コストを削減しました。卓越した耐久性: 設計寿命を40％超えて運転した後も、バルブは優れた状態を維持し、総ROIを150％以上達成しています。GRAT 低負荷型電動換気バタフライバルブは、冶金産業における高温、高需要のプロセス制御アプリケーションにおいて、堅牢な適応性と信頼性を実証しています。効率性と耐久性を保証する電動換気バタフライバルブソリューションについては、GRATが新規プロジェクトと設備アップグレードの両方において、信頼できるパートナーです。

Application Background In the heat treatment processes of the metallurgical industry, continuous annealing furnaces are core equipment for producing high-quality cold-rolled steel strips. A large steel plant in Hubei needed precise flow control in the combustion air pipeline of its continuous annealing line. Under high-frequency adjustments, Traditional control methods suffered from low precision, slow response, and frequent failures, while GRAT Electric Ventilation Butterfly Valve developed a high-precision, reliable air regulation solution. Operating Conditions This application poses severe challenges to valve performance, with specific operating parameters as follows: Application: Combustion air supply pipeline for continuous annealing furnace Product: GRAT Low-Load Electric Ventilation Butterfly Valve Medium: Preheated Air Temperature: 120°C – 300°C (subject to frequent fluctuations) Nominal Pressure: PN10 Size: DN200 Connection: Flanged Control Signal: Modulating Control, 4-20mA Operating Environment: Industrial workshop setting, requiring equipment with a high protection rating and continuous operation capability. Design Life: ≥ 5 years Product Advantages & Features The GRAT Electric Ventilation Butterfly Valve is engineered for the harsh environments of annealing furnaces: Precise Proportional Control: Features a high-performance actuator with positioning accuracy up to ±0.5%. Maintains furnace atmosphere fluctuations within ±2°C. Excellent High-Temperature Resistance: Constructed from SUS304 stainless steel, retaining over 85% of its strength at 300°C. A streamlined disc design reduces required torque by 40%, saving energy and reducing wear. High Reliability & Long Service Life: Built-in overload protection prevents damage from jamming. Achieves a seal leakage rate below 0.01% for long-term, high-frequency cycling. Easy Installation & Maintenance: Standard flanged connection for quick installation. Modular design ensures MTTR is less than 30 minutes for key components. Performance Results Since commissioning in July 2017, the valve has delivered exceptional results: Improved Control Accuracy: Combustion air volume fluctuation was reduced from ±15% to within ±6%. Furnace zone temperature difference was lowered to within ±5°C. Proven Reliability: The valve has operated continuously without failure for over 70 months, accumulating over 250,000 cycles. Tangible Economic Benefits: Product yield rate increased from 92% to 96.5%, while simultaneously reducing the operating cost per valve. Exceptional Durability: After operating 40% beyond its design life, the valve remains in excellent condition, delivering a total ROI by over 150%. Conclusion: The GRAT Low-Load Electric Ventilation Butterfly Valve demonstrates robust adaptability and reliability in high-temperature, high-demand process control applications within the metallurgical industry. For an Electric Ventilation Butterfly Valve solution that guarantees efficiency and durability, GRAT is your trusted partner for both new projects and equipment upgrades.

Valve Installation direction – a seemingly simple detail that directly impacts sealing performance and service life – is often overlooked in industrial pipeline and equipment maintenance. Especially when space is tight, a common question arises: “If it doesn’t fit vertically, can it be installed horizontally, or even upside down?” The answer isn’t universal; it depends entirely on the valve type and its internal design. Valves That MUST Be Installed in a Specific Direction First, let’s discuss valves that require strict adherence to installation direction, such as solenoid valves and pneumatic diaphragm valves. Incorrect Valve Installation for these types can lead to malfunction or rapid failure. For instance, a common pilot-operated solenoid valve relies on the media pressure differential to drive the valve core. If installed backwards, pressure can block the core, preventing it from opening even when energized. Even if it manages to open, the seal will wear out prematurely due to uneven force. Similarly, an upside-down Valve Installation for a pneumatic diaphragm valve puts constant stress on the diaphragm from gravity, leading to deformation, folding, reduced sealing precision, and a significantly shorter lifespan. Therefore, for these valves, you must follow the media flow direction indicated by the arrow on the valve body; never compromise due to space constraints. Valves with Flexible Installation Directions One category is electric valves – like electric ball valves and electric butterfly valves. These generally allow 360-degree installation in any orientation. Why such flexibility? The key lies in their design: their actuator typically uses a motor with gear transmission, which is unaffected by gravity. Regardless of orientation, power transmission efficiency remains above 95%. Sealing often involves O-rings combined with metal sealing surfaces, where the sealing pressure is controlled by bolt preload and is independent of the installation angle. Therefore, if vertical space is limited, an electric ball valve can be installed horizontally or even inverted in a ceiling plenum without compromising performance, making its Valve Installation highly adaptable. Another common category is pneumatic valves, such as pneumatic ball valves and pneumatic gate valves. They generally permit horizontal installation, but one critical point demands attention – the position of accessories, particularly the filter regulator. This component filters moisture and impurities from the compressed air and regulates pressure. Its bottom usually has a drain port. During Valve Installation, this drain port must face downwards. If it faces up or sideways, condensate cannot drain, accumulating inside the valve body. This leads to air pressure fluctuations, sluggish valve operation, and, more severely, moisture entering the cylinder, causing piston rust and seizure. For a horizontal Valve Installation, adjust the accessory bracket to ensure the drain port is vertically downward, leaving at least 10 cm of space for drainage. Solution for Valve Installation in Tight Spaces Guidelines for Valve Installation Direction When Space is Limited Valve Type Horizontal/Upside-Down Installation Allowed? Core Requirements and Reasons Solenoid Valve Strictly Forbidden Must be installed strictly according to the arrow on the valve body. Reverse installation can prevent the valve core from opening or cause rapid seal wear. Pneumatic Diaphragm Valve Strictly Forbidden Must be installed vertically upright. Inverted installation causes the diaphragm to deform under constant gravity pull, leading to seal failure. Electric Valve Allowed Supports 360° installation in any orientation. Its gear drive and seal design are unaffected by gravity direction. Pneumatic Valve Conditionally Allowed The valve body can be installed horizontally, but you must ensure the filter regulator’s drain port is vertically downward to prevent water accumulation and subsequent failure. Finally, here are two practical tips for any Valve Installation project: First, confirm the valve type to determine if it has orientation restrictions. Second, check accessory requirements, like the orientation of the filter regulator on pneumatic valves. Never assume based on past experience, as this easily leads to operational failures. When facing installation space limitations, consider our newly launched IoT Mini Electric Valve – engineered for compact spaces and high-precision control. This electric actuator features an integrated, compact design, with a volume one-third smaller than comparable torque products, yet it delivers a powerful 50 NM of torque. It supports 360° installation in any orientation, perfectly solving the challenge of insufficient vertical installation space. It supports AC220V or DC24V input, consumes only 10W of power, and fits ball valves up to DN40. Equipped with PWM stepless speed regulation and 0.5% high-precision control, it operates smoothly and adjusts accurately. The built-in brushless motor, integrated OLED Chinese status display, support for various signal feedback, and Modbus communication make it the ideal choice for flexible Valve Installation and reliable control in industrial automation systems. Small size, strong performance, and unrestricted installation orientation – the IoT Mini opens up new possibilities for your space-constrained automation systems. Welcome to learn more about our product details and inquire for custom solutions.

In PTA production plants within the chemical industry, the long-term stable operation of high-temperature and high-pressure steam control valves is crucial for the safety and economy of the entire process system. A PTA plant experienced control valve stem leakage in its steam regulation system. This valve leakage issue resulted not only in energy waste but also posed a threat to production safety. This GRAT case study will systematically analyze the cause of this valve leakage failure and provide a solution, offering a reference for valve selection and maintenance in similar working conditions. Technical Specifications Application: High-Temperature Steam Regulation System, PTA Chemical PlantMedium: Superheated SteamBody Material: WCBConnection Type: FlangedActuator Type: PneumaticOperating Temperature: 385℃Operating Pressure: 4.3MPaCommissioning Date: December 2024Installation Location: Steam Main Line, PTA Plant After approximately six months of continuous operation, significant steam leakage was observed at the valve stem position of this control valve. The rate of valve leakage gradually increased over time, severely impacting production safety and environmental performance. Troubleshooting & Analysis Upon arrival, the GRAT technical support team disassembled the faulty control valve for inspection and identified the following issues: A severe leakage path was present in the stuffing box area. The original PTFE packing showed obvious signs of aging and hardening. Some packing rings were severely worn and had lost their elastic sealing capability. Root Cause Analysis:PTFE packing is prone to hardening and aging in high-temperature environments. Its sealing performance degrades significantly with large temperature fluctuations. The steam temperature in this application reached 385℃, far exceeding the normal service temperature limit for PTFE packing (around 200℃). This caused rapid packing failure, leading directly to the observed steam valve leakage. Key factors influencing potential valve leakage include: Loose gland bolts with insufficient preload (e.g., due to long-term vibration) Worn or scratched valve stem surface (e.g., from solid particles in the medium) Incorrect packing installation methods (e.g., packing ring cuts not staggered) Use of packing material unsuitable for the service conditions (e.g., standard packing in high-temperature applications) Solution & Implementation Based on the specific site conditions, our technical personnel developed a targeted solution to stop the valve leakage: Packing Material Replacement: All original PTFE packing was replaced with flexible graphite packing. This material offers a wide temperature range (-200℃ to +600℃), excellent self-lubrication, and superior thermal stability, making it ideal for preventing high-temperature valve leakage. Optimized Packing Structure: A combination of layered flexible graphite rings and intermediate reinforcing rings was used. This structure ensures reliable sealing performance while enhancing the overall strength of the packing set to combat valve leakage. Standardized Installation Procedure: The packing was installed layer by layer according to standard procedures, ensuring all ring cuts were staggered. A torque wrench was used to tighten the gland bolts evenly to the recommended torque. After replacing the packing and optimizing the installation process, the control valve resumed stable operation. Following 72 hours of continuous monitoring using a portable volatile organic compound detector at multiple points around the gland, the valve stem seal showed zero leakage.

In a burner system, the control valve acts as a precise “conductor,” managing fuel supply and directly impacting combustion efficiency and safety. How does one scientifically select the correct valve for different fuels like natural gas or fuel oil? Senior Engineer Mr. Mo, with over 30 years of hands-on experience, shares his core insights. This article systematically organizes his expertise to help you master burner valve selection. Universal Burner Valve Selection Guide: Master These Six Points for Success Whether the medium is natural gas or fuel oil, a successful burner valve selection process must comprehensively consider the following six core elements, which form the foundation for stable system operation: Valve Body Material & Corrosion Resistance: Select appropriate corrosion-resistant materials such as stainless steel or special alloys based on the operating environment and the corrosiveness of the medium itself, ensuring long-term valve durability. Electrical Protection & Explosion-Proof Rating: In flammable or explosive atmospheres, it is essential to choose valves with electrical components and overall design that comply with onsite explosion-proof standards, minimizing safety risks. Control Accuracy & Flow Characteristics: Choose valves with the appropriate control precision and flow characteristics to achieve accurate and stable air-fuel ratio control. Flow Capacity (Cv Value): The valve’s flow capacity under a specific pressure drop should be slightly greater than the burner’s actual maximum flow requirement, providing a safety margin and avoiding system bottlenecks. Actuation Type & Power Source: Select electric or pneumatic actuation based on site conditions. Electric valves offer precise control and easy wiring; pneumatic valves provide fast action and excellent explosion-proof performance. The required voltage or air supply pressure must be confirmed. Media Pressure & Temperature: The valve’s pressure rating and temperature tolerance must exceed the media’s actual working pressure and temperature, ensuring seal integrity and structural safety. Core Comparison: Natural Gas vs. Fuel Oil Burner Valve Selection While following universal principles, the specific burner valve selection focus must be adjusted for different fuel properties: Selection Factor Natural Gas Control Valve Fuel Oil Control Valve Media Properties Clean, dry, but leakage must be prevented May contain impurities, be viscous, or corrosive Primary Concern Sealing Performance and Response Speed Clog Resistance and Corrosion/Temperature Resistance Material & Sealing Emphasizes high sealing classes to prevent gas leakage Materials must be oil-resistant and corrosion-resistant; some tolerance for impurities is needed Pressure & Temperature Focus on inlet pressure stability Often faces higher operating temperatures and pressures Recommended Product High-sealing Electric Ball Valves, Control Butterfly Valves Electric V-Port Ball Valves (The V-notch shears media, reducing jamming risk) Focus Analysis: Why Electric Actuation is Preferred for Quick Opening Valves For fast shut-off functions at the burner front end, electric valves demonstrate significant advantages over traditional solenoid valves: Higher Reliability: Electric actuators provide high torque, ensuring stable opening and closing cycles that are less susceptible to misoperation from media pressure fluctuations or impurities. Superior Impurity Resistance: Particularly with electric ball valves, the rotational movement of the ball can effectively cut through or displace small particles, offering a degree of “self-cleaning” and avoiding the jamming issues common in direct-acting solenoid valve designs. More Flexible Control: They can receive standard signals from PLC or DCS systems, enabling more complex interlock control strategies. Therefore, for applications demanding high reliability and media adaptability, an electric quick opening valve is the ideal burner valve selection for rapid switching duties. Conclusion Correct burner valve selection is the first step towards efficient and safe burner operation. Our quick opening electric valves are designed for this purpose, featuring 3-second operation, a lifespan exceeding 100,000 cycles, and revolutionary one-step debugging technology. They are key to enhancing your system’s response and safety. To learn how this product can protect your project, please contact us. We specialize in industrial valves, offering a comprehensive product line covering all control and quick opening valve needs for burner systems. If you have specific burner valve selection challenges or project requirements, just contact us for a customized solution from our expert engineers!

With 18 years of deep expertise in industrial chiller units, GRAT guide vane motors have consistently partnered with leading manufacturers in the industry. Renowned for exceptional reliability, our products have earned global customer trust and become the core power component ensuring stable cooling performance. Having undergone over a decade of rigorous market validation, more than 200,000 GRAT guide vane motors have been deployed worldwide. Our motors offer broad compatibility, supporting all types of centrifugal chillers—including single-stage compression, double-stage compression, variable frequency, and magnetic levitation models. They continuously protect the unit’s “heart” (compressor), ensuring trouble-free operation and establishing a stable temperature safety line for industrial processes. Core Patent Technology DDS Switching Debugging: Based on independent patented technology, this feature allows non-specialists to perform rapid calibration, significantly shortening installation and maintenance cycles. PPD Positioning: Precisely compensates for errors and maintains millimeter-level positioning accuracy. Combined with high-quality imported potentiometers, it guarantees long-term operational stability. Protection in Complex Environments Robust Housing: Constructed from aluminum alloy die-casting with an IP68 protection rating. High-Quality Components: Utilizes imported servo units and resin-encapsulated circuit boards. Anti-Interference: Excellent resistance to electromagnetic interference, making it suitable for challenging industrial environments such as those with high humidity and strong radiation. 18 Years of Reputation: The Choice of Global Customers The GRAT guide vane motor is the preferred choice for many world-renowned manufacturers, including: Dunham-Bush (Central Air Conditioning) Johnson Controls Hitachi Ebara Hisense Hitachi Grundfos Pumps CNOOC, Sinopec, CNPC China Shipbuilding Industry Corporation With over 200,000 units deployed, our motors serve critical cooling applications across the electronics, chemical, and pharmaceutical industries worldwide. GRAT remains committed to continuous product optimization through technological innovation. We aim to provide even more stable and efficient guide vane drive solutions for industrial chiller units, partnering with customers to create a new future in refrigeration.

Application Background As an important inorganic chemical pigment, titanium dioxide is widely used in many industrial fields such as coatings, plastics, and papermaking. Its product performance imposes high requirements on the stability and control precision of the production process. In the sulfuric acid method for titanium dioxide production, key processes like acid digestion and hydrolysis place stringent demands on the corrosion resistance, sealing performance, and control accuracy of valves. The GRAT electric hard seal ball valve, with its excellent corrosion resistance and precise regulation capability, provides a reliable fluid control solution for titanium dioxide production. Operating Conditions Model: GRAT Hard Seal Ball Valve Application: Controlling the flow rate and temperature of sulfuric acid during the acid digestion reaction. Medium: Sulfuric Acid Size: DN50 Material: SUS304 Connection Type: Flanged Control Signal: 4-20mA Power Supply: AC220V Design Life: 6 Years Commissioning Date: March 2014 Location: Hubei, China Product Advantages & Features Precise Control, Enhanced EfficiencyOur hard seal ball valve integrates an electric actuation system, enabling remote control and seamless automation compatibility. Utilizing proprietary PPD positioning technology, it achieves ±0.1% positioning accuracy with an adjustable dead zone of 0.3%–3.0%, ensuring high-precision regulation of media flow in diverse industrial applications. Robust Construction, Long-Lasting PerformanceKey components, including the ball and valve seats, are manufactured from specially formulated hard alloys. These materials offer superior hardness and outstanding wear resistance, effectively withstanding erosion from solid particles and fibrous media. As a result, the hard seal ball valve guarantees over 100,000 cycles of trouble-free operation. High-Temperature and High-Pressure ReliabilityEngineered with specially selected materials and reinforced construction, the hard seal ball valve excels in demanding high-temperature and high-pressure environments. Its durable design ensures long-term stability and safe performance, making it a reliable choice for critical pipeline systems. Compact and Cost-Effective DesignThe hard seal ball valve features a space-saving, compact design that simplifies installation and reduces operational footprint. Suitable for a wide range of media—including water, steam, petroleum, and corrosive substances—this valve minimizes maintenance needs and significantly lowers total lifecycle costs. Performance Results Achieved zero failures and zero leakage after continuous operation for 6 years in sulfuric acid, accumulating over 100,000 cycles. Maintained control accuracy within ±0.5%, precisely regulating sulfuric acid flow and temperature in the acid digestion process, ensuring reaction efficiency exceeded 90%. Internal component wear was less than 0.1mm, withstanding erosion and scouring from solid particles (0.5-2mm diameter) in the sedimentation process. Provided stable gas flow control in the calcination process at 800°C high-temperature conditions, ensuring calcined product whiteness remained above 98%. Achieved precise control speed in the hydrolysis process, reducing maintenance costs by 80% and significantly improving production efficiency. The electric hard seal ball valve holds significant application value in the titanium dioxide industry, where its advantages meet the demands of complex working conditions. The special structural design for high-temperature conditions ensures reliable operation, while its anti-clogging and high-temperature protection features enhance service life and production efficiency. The stringent requirements for performance and selection within the titanium dioxide industry also drive continuous optimization of the hard seal ball valve.

.gtr-container-pqr789 { font-family: Verdana, Helvetica, "Times New Roman", Arial, sans-serif; color: #333; line-height: 1.6; padding: 16px; box-sizing: border-box; overflow-x: hidden; } @media (min-width: 768px) { .gtr-container-pqr789 { max-width: 960px; margin: 0 auto; padding: 24px; } } .gtr-container-pqr789 h2 { font-size: 18px; font-weight: bold; margin-top: 24px; margin-bottom: 16px; color: #0056b3; } .gtr-container-pqr789 p { font-size: 14px; margin-bottom: 16px; text-align: left !important; word-break: normal; overflow-wrap: normal; } .gtr-container-pqr789 img { height: auto; } .gtr-container-pqr789 blockquote { margin: 20px 0; padding: 10px 20px; border-left: 4px solid #007bff; color: #555; font-style: italic; background-color: transparent; } .gtr-container-pqr789 ul { margin: 16px 0; padding-left: 20px; } .gtr-container-pqr789 ul li { list-style: none !important; position: relative; margin-bottom: 8px; padding-left: 15px; } .gtr-container-pqr789 ul li::before { content: "•" !important; position: absolute !important; left: 0 !important; color: #007bff; font-weight: bold; font-size: 1.2em; line-height: 1; } .gtr-container-pqr789 ol { margin: 16px 0; padding-left: 25px; counter-reset: list-item; } .gtr-container-pqr789 ol li { list-style: none !important; position: relative; margin-bottom: 8px; padding-left: 20px; } .gtr-container-pqr789 ol li::before { content: counter(list-item) "." !important; position: absolute !important; left: 0 !important; color: #007bff; font-weight: bold; font-size: 1em; text-align: right; width: 18px; } .gtr-container-pqr789 strong { font-weight: bold; } 産業オートメーション制御システムにおいて、電動ボールバルブの信頼性の高い動作は、プロセスの安全性と効率にとって不可欠です。以下のケーススタディでは、配線完了後に開閉しなくなった産業団地のガスパイプラインに設置された電動ボールバルブの最近のトラブルシューティング例を概説します。体系的な検査と専門的な分析を通じて、当社のチームは根本原因を迅速に特定し、効果的な解決策を実装しました。業界の参考として、そのプロセスを以下に共有します。 技術仕様 適用シナリオ: 産業団地ガスパイプライン 目的: 主ガスパイプラインの遮断 媒体: 天然ガス バルブサイズ: DN300 本体材質: WCB 接続タイプ: フランジ 制御信号: スイッチ信号 動作電源: AC220V 設計寿命: 6年 試運転日: 2024年12月 設置場所: 上海 電動ボールバルブと制御盤間のケーブル接続を完了した後、オペレーターはバルブがコマンドに応じて開閉しなくなることを発見しました。この故障により、ガスパイプラインの調整機能が停止し、パーク企業の通常のガス供給に直接影響を与えました。 トラブルシューティングと分析 GRATテクニカルサポートチームが迅速に介入しました。最初の検査で正しい配線が確認され、続いて電気的パラメータの体系的な測定が行われました: 電動アクチュエータ端子で測定された実際の電圧はわずかAC80Vであり、定格AC220V統合計画では、 電力公式P = UI（アクチュエータ電力は1.2kW）によると、電力が一定の場合、電圧の低下は電流の増加につながります。 測定された動作電流は18Aに達しました。この過剰な電流が制御盤の組み込み過電流保護をトリガーし、電動ボールバルブの動作を妨げました。 根本原因分析:著しい電圧降下は、主に電動ボールバルブと制御盤間の600～700メートルの長いケーブル距離が原因でした。このような長距離での電力伝送では、著しい電圧降下により、アクチュエータの正常な起動に必要な電圧を満たすことができませんでした。 線路の電圧降下に影響を与える主な要因には以下が含まれます: 導体材料（例：銅コアケーブルは抵抗率が低く、電圧降下が小さい） 線路長（長さが長いほど電圧降下が増加） 導体断面積（面積が大きいほど抵抗が減少し、電圧降下が減少） 周囲温度（温度が高いほど導体抵抗が増加） この状況は、重要な設計上の考慮事項を浮き彫りにしています。それは、電動ボールバルブの設置における過度の電圧降下を防ぐことであり、特に長距離の場合統合計画では、 解決策と実装 故障の根本原因に対処するため、2つの実行可能な解決策を評価しました: 電圧定格の変更: アクチュエータの動作電圧をAC220VからAC380Vに変更します。AC380Vは安定した電圧と低い電流を提供しますが、このオプションは、現場にAC380V電源がないこと、アクチュエータ交換の高コスト、および潜在的な互換性の問題により除外されました。 制御盤の移設: 現場の担当者との協議の結果、制御盤をボールバルブに近づけて移設し、配線を再設置しました。移設後のテストで確認されたボールバルブは正常な動作を再開し、故障が解決されました。 実装結果:解決策2を決定した後、当社の建設チームは計画を迅速に実行しました。制御盤は電動ボールバルブから約50メートルの位置に再配置されました。新しい電源ケーブルと制御ケーブルが仕様に従って設置されました。変更後のデバッグとテストには以下が含まれます: 精密電圧計でアクチュエータ入力の電圧を測定し、安定したAC215Vであることを確認し、定格要件を完全に満たしました。 クランプメーターで始動電流をチェックし、8.2Aの安定した読み取り値を示し、正常な動作範囲内であることを確認しました。 複数の開閉動作テストを実施し、電動ボールバルブが制御信号に正確かつ確実に応答しました。 72時間の連続監視後、すべてのシステムパラメータが安定したままであり、故障が完全に解消されたことが確認されました。この成功した解決策は、直接的な問題を解決しただけでなく、同様の条件下での電動アクチュエータのレイアウトを計画するための貴重な洞察を提供し、将来のプロジェクト設計の重要な参考資料として役立ちます。 経験のまとめ このケースは、産業オートメーションシステムの設計および設置段階において、電気システムパラメータと機器レイアウトの包括的な評価が不可欠であることを再確認しています。特に以下の点に注意を払う必要があります: 線路の電圧降下による機器の誤動作を防ぐために、電源距離を正確に評価する 。長距離電力伝送シナリオでは、より大きな断面積を考慮して、 ケーブル仕様を科学的に選択する。統合計画では、 電力のマッチング、機器の配置、制御ロジック を考慮するようにする。