Wuhan Grat Control Valve Co., Ltd.

응용 배경 야금 산업의 열처리 공정에서 연속 어닐링로(annealing furnace)는 고품질 냉간 압연 강판을 생산하는 핵심 장비입니다. 후베이의 한 대형 제철소는 연속 어닐링 라인의 연소 공기 파이프라인에서 정밀한 유량 제어가 필요했습니다.고주파 조정 하에서, 기존 제어 방식은 낮은 정밀도, 느린 응답 속도, 잦은 고장으로 어려움을 겪었으며, GRAT Electric Ventilation Butterfly Valve는 고정밀, 신뢰할 수 있는 공기 조절 솔루션GRAT 저부하 전기 환기 버터플라이 밸브는 야금 산업 내 고온, 고수요 공정 제어 응용 분야에서 강력한 적응성과 신뢰성을 보여줍니다. 효율성과 내구성을 보장하는 전기 환기 버터플라이 밸브 솔루션을 위해 GRAT는 신규 프로젝트와 장비 업그레이드 모두에 대해 신뢰할 수 있는 파트너입니다. 작동 조건 이 응용 분야는 밸브 성능에 심각한 문제를 제기하며, 구체적인 작동 매개변수는 다음과 같습니다: 응용 분야: 연속 어닐링로의 연소 공기 공급 파이프라인 제품: GRAT 저부하 전기 환기 버터플라이 밸브 매체: 예열 공기 온도: 120°C – 300°C (빈번한 변동에 따라) 공칭 압력: PN10 크기: DN200 연결: 플랜지 제어 신호: 변조 제어, 4-20mA 작동 환경: 산업 작업장 설정, 높은 보호 등급 및 지속적인 작동 능력이 필요합니다. 설계 수명: ≥ 5년 제품 장점 및 특징 GRAT Electric Ventilation Butterfly Valve는 어닐링로의 가혹한 환경을 위해 설계되었습니다: 정밀 비례 제어: 다음과 같은 고성능 액추에이터를 특징으로 합니다. 위치 정확도는 ±0.5%까지GRAT 저부하 전기 환기 버터플라이 밸브는 야금 산업 내 고온, 고수요 공정 제어 응용 분야에서 강력한 적응성과 신뢰성을 보여줍니다. 효율성과 내구성을 보장하는 전기 환기 버터플라이 밸브 솔루션을 위해 GRAT는 신규 프로젝트와 장비 업그레이드 모두에 대해 신뢰할 수 있는 파트너입니다. 로 분위기 변동을 유지합니다. ±2°C 이내GRAT 저부하 전기 환기 버터플라이 밸브는 야금 산업 내 고온, 고수요 공정 제어 응용 분야에서 강력한 적응성과 신뢰성을 보여줍니다. 효율성과 내구성을 보장하는 전기 환기 버터플라이 밸브 솔루션을 위해 GRAT는 신규 프로젝트와 장비 업그레이드 모두에 대해 신뢰할 수 있는 파트너입니다. 우수한 고온 저항: 다음으로 구성되었습니다. SUS304 스테인리스 스틸, 유지 강도의 85% 이상 300°C에서. 유선형 디스크 디자인 필요한 토크를 40% 줄입니다, 에너지 절약 및 마모 감소. 높은 신뢰성 및 긴 수명: 내장 과부하 보호 잼으로 인한 손상을 방지합니다. 다음과 같은 결과를 얻습니다. 0.01% 미만의 씰 누출률 장기간의 고주파 사이클링을 위해. 쉬운 설치 및 유지보수: 표준 플랜지 연결 빠른 설치를 위해. 모듈식 설계는 다음을 보장합니다. MTTR은 핵심 구성 요소의 경우 30분 미만입니다.성능 결과 2017년 7월 시운전 이후, 밸브는 탁월한 결과를 제공했습니다:향상된 제어 정확도: 연소 공기량 변동은 ±15%에서 ±6% 이내로 감소했습니다. 로 구역 온도 차이는 ±5°C 이내로 낮아졌습니다.GRAT 저부하 전기 환기 버터플라이 밸브는 야금 산업 내 고온, 고수요 공정 제어 응용 분야에서 강력한 적응성과 신뢰성을 보여줍니다. 효율성과 내구성을 보장하는 전기 환기 버터플라이 밸브 솔루션을 위해 GRAT는 신규 프로젝트와 장비 업그레이드 모두에 대해 신뢰할 수 있는 파트너입니다. 밸브는 70개월 이상 고장 없이 지속적으로 작동, 누적 250,000회 이상의 사이클.GRAT 저부하 전기 환기 버터플라이 밸브는 야금 산업 내 고온, 고수요 공정 제어 응용 분야에서 강력한 적응성과 신뢰성을 보여줍니다. 효율성과 내구성을 보장하는 전기 환기 버터플라이 밸브 솔루션을 위해 GRAT는 신규 프로젝트와 장비 업그레이드 모두에 대해 신뢰할 수 있는 파트너입니다. 제품 수율이 92%에서 96.5%로 증가, 동시에 밸브당 운영 비용을 절감했습니다.탁월한 내구성: 작동 후 설계 수명을 40% 초과, 밸브는 여전히 훌륭한 상태를 유지하며 총 ROI를 150% 이상 제공합니다.GRAT 저부하 전기 환기 버터플라이 밸브는 야금 산업 내 고온, 고수요 공정 제어 응용 분야에서 강력한 적응성과 신뢰성을 보여줍니다. 효율성과 내구성을 보장하는 전기 환기 버터플라이 밸브 솔루션을 위해 GRAT는 신규 프로젝트와 장비 업그레이드 모두에 대해 신뢰할 수 있는 파트너입니다.

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; } 산업 자동화 제어 시스템에서 전기 볼 밸브의 안정적인 작동은 공정 안전과 효율성에 매우 중요합니다. 다음 사례 연구는 배선 완료 후 산업 단지 가스 파이프라인에 설치된 전기 볼 밸브가 열리거나 닫히지 않은 최근의 문제 해결 사례를 간략하게 설명합니다. 체계적인 검사 및 전문적인 분석을 통해 당사 팀은 근본 원인을 신속하게 파악하고 효과적인 솔루션을 구현했습니다. 업계 참고용으로 아래에 해당 과정을 공유합니다. 기술 사양 적용 시나리오: 산업 단지 가스 파이프라인 목적: 주 가스 파이프라인 차단 매체: 천연 가스 밸브 크기: DN300 본체 재질: WCB 연결 유형: 플랜지 제어 신호: 스위치 신호 작동 전원: AC220V 설계 수명: 6년 시운전 날짜: 2024년 12월 설치 위치: 상하이 전기 볼 밸브와 제어 캐비닛 사이의 케이블 연결을 완료한 후, 작업자는 밸브가 명령에 따라 열리거나 닫히지 않는다는 것을 발견했습니다. 이 고장으로 인해 가스 파이프라인의 조절 기능이 비활성화되어, 단지 내 기업의 정상적인 가스 공급에 직접적인 영향을 미쳤습니다.문제 해결 및 분석GRAT 기술 지원팀이 즉시 개입했습니다. 초기 검사에서 올바른 배선이 확인되었으며, 그 다음으로 전기적 매개변수의 체계적인 측정이 이루어졌습니다.전기 액추에이터 단자에서 측정된 실제 전압은 단지 AC80V로, 정격 AC220V보다 현저히 낮았습니다.전력 공식 P = UI (액추에이터 전력은 1.2kW)에 따르면, 전력이 일정할 때 전압 감소는 전류 증가로 이어집니다. 측정된 작동 전류는 18A에 도달했습니다. 이 과도한 전류는 제어 캐비닛의 내장 과전류 보호 기능을 트리거하여 전기 볼 밸브의 작동을 방지했습니다. 근본 원인 분석: 심각한 전압 강하는 주로 전기 볼 밸브와 제어 캐비닛 사이의 긴 케이블 거리(600~700미터) 때문이었습니다. 전력 전송을 위해 이처럼 긴 거리를 사용하면 상당한 전압 강하로 인해 정상적인 액추에이터 시동에 필요한 전압을 충족할 수 없게 됩니다.선로 전압 강하에 영향을 미치는 주요 요인은 다음과 같습니다.도체 재료 (예: 구리 코어 케이블은 저항률이 낮고 전압 강하가 작음)선로 길이 (길이가 길수록 전압 강하 증가) 주변 온도 (온도가 높을수록 도체 저항 증가)이 상황은 특히 장거리에서 전기 볼 밸브 설치 시 과도한 전압 강하를 방지하는 중요한 설계 고려 사항을 강조합니다.솔루션 및 구현 고장 근본 원인을 해결하기 위해 두 가지 실행 가능한 솔루션을 평가했습니다.전압 정격 변경: 액추에이터 작동 전압을 AC220V에서 AC380V로 수정합니다. AC380V는 안정적인 전압과 낮은 전류를 제공하지만, 현장에 AC380V 전원이 없고, 액추에이터 교체 비용이 높으며, 잠재적인 호환성 문제가 있어 이 옵션은 제외되었습니다.제어 캐비닛 재배치: 현장 직원과의 논의 후, 제어 캐비닛을 볼 밸브에 더 가깝게 이동하고 배선을 다시 설치했습니다. 재배치 후 테스트에서 볼 밸브가 정상 작동을 재개하여 고장이 해결되었음을 확인했습니다. 구현 결과:솔루션 2를 결정한 후, 당사 시공팀은 계획을 신속하게 실행했습니다. 제어 캐비닛은 전기 볼 밸브에서 약 50미터 떨어진 곳으로 재배치되었습니다. 새로운 전원 및 제어 케이블이 사양에 따라 설치되었습니다. 수정 후 디버깅 및 테스트에는 다음이 포함되었습니다.정밀 전압계로 액추에이터 입력에서 전압을 측정하여 안정적인 AC215V를 확인하여 정격 요구 사항을 완전히 충족했습니다.클램프 미터로 시동 전류를 확인하여 정상 작동 범위 내에서 안정적인 8.2A의 판독값을 표시했습니다. 전기 볼 밸브가 제어 신호에 정확하고 안정적으로 응답하는 여러 열림/닫힘 작동 테스트를 수행했습니다. 72시간 연속 모니터링 후 모든 시스템 매개변수가 안정적으로 유지되어 고장이 완전히 제거되었음을 확인했습니다. 이 성공적인 해결은 즉각적인 문제를 해결했을 뿐만 아니라 유사한 조건에서 전기 액추에이터의 레이아웃을 계획하는 데 귀중한 통찰력을 제공하여 향후 프로젝트 설계를 위한 핵심 참고 자료 역할을 했습니다.경험 요약 이 사례는 산업 자동화 시스템의 설계 및 설치 단계에서 전기 시스템 매개변수 및 장비 레이아웃에 대한 포괄적인 평가가 필수적임을 다시 한 번 강조합니다. 특히 다음 사항에 주의를 기울여야 합니다.선로 전압 강하로 인한 장비 오작동을 방지하기 위해 전원 공급 거리를 정확하게 평가합니다. 장거리 전력 전송 시나리오를 고려하여 더 큰 단면적을 고려하여 케이블 사양을 과학적으로 선택합니다.전력 매칭, 장비 배치 및 제어 로직을 고려한 통합 계획을 보장합니다. 전기 볼 밸브 시스템의 전압 강하를 효과적으로 관리하는 것은 안정성에 매우 중요합니다. GRAT는 전문적인 기술 서비스와 엄격한 고장 분석을 제공하여 산업 시스템의 안전, 안정성 및 효율성을 보장하는 신뢰할 수 있는 제어 밸브 솔루션을 제공하기 위해 최선을 다하고 있습니다. 다양한 분야의 고객으로부터 문의 및 협력을 환영합니다.