Solenoid valve reliability in lower energy operations

If a valve doesn’t function, your course of doesn’t run, and that’s money down the drain. Or worse, a spurious journey shuts the method down. Or worst of all, a valve malfunction leads to a dangerous failure. Solenoid valves in oil and fuel functions management the actuators that transfer massive course of valves, including in emergency shutdown (ESD) methods. The solenoid must exhaust air to enable the ESD valve to return to fail-safe mode every time sensors detect a dangerous course of situation. These valves should be quick-acting, durable and, above all, dependable to stop downtime and the related losses that occur when a course of isn’t operating.
And this is much more essential for oil and gas operations the place there might be restricted energy obtainable, such as remote wellheads or satellite offshore platforms. Here, solenoids face a double reliability challenge. First, a failure to function accurately can’t solely trigger expensive downtime, however a upkeep call to a distant location additionally takes longer and costs more than a local restore. Second, to scale back the demand for power, many valve producers resort to compromises that really scale back reliability. This is bad sufficient for process valves, however for emergency shutoff valves and other safety instrumented techniques (SIS), it is unacceptable.
Poppet valves are typically higher suited than spool valves for remote places as a end result of they’re much less advanced. For low-power functions, search for a solenoid valve with an FFR of 10 and a design that isolates the media from the coil. (Courtesy of Norgren Inc.)
Choosing a reliable low-power solenoid
Many elements can hinder the reliability and efficiency of a solenoid valve. ตัววัดแรงดันน้ำมัน , media move, sticking of the spool, magnetic forces, remanence of electrical present and material characteristics are all forces solenoid valve manufacturers have to overcome to build the most reliable valve.
High spring drive is key to offsetting these forces and the friction they trigger. However, in low-power functions, most manufacturers should compromise spring force to allow the valve to shift with minimal energy. The discount in spring force ends in a force-to-friction ratio (FFR) as little as 6, though the commonly accepted safety degree is an FFR of 10.
Several parts of valve design play into the amount of friction generated. Optimizing each of these permits a valve to have larger spring drive whereas still sustaining a excessive FFR.
For instance, the valve operates by electromagnetism — a current stimulates the valve to open, permitting the media to circulate to the actuator and move the process valve. This media may be air, but it may also be natural gas, instrument gasoline or even liquid. This is especially true in remote operations that must use no matter media is on the market. This means there’s a trade-off between magnetism and corrosion. Valves during which the media is out there in contact with the coil have to be made of anticorrosive materials, which have poor magnetic properties. A valve design that isolates the media from the coil — a dry armature — allows the use of highly magnetized materials. As a result, there is no residual magnetism after the coil is de-energized, which in turn allows faster response times. This design also protects reliability by preventing contaminants within the media from reaching the inside workings of the valve.
Another factor is the valve housing design. Usually a heavy (high-force) spring requires a high-power coil to overcome the spring energy. Integrating the valve and coil right into a single housing improves effectivity by stopping power loss, allowing for the use of a low-power coil, leading to less energy consumption without diminishing FFR. This integrated coil and housing design additionally reduces warmth, preventing spurious journeys or coil burnouts. A dense, thermally environment friendly (low-heat generating) coil in a housing that acts as a warmth sink, designed with no air gap to lure heat across the coil, nearly eliminates coil burnout issues and protects process availability and security.
Poppet valves are typically higher suited than spool valves for remote operations. The lowered complexity of poppet valves will increase reliability by decreasing sticking or friction points, and reduces the number of components that may fail. Spool valves usually have large dynamic seals and tons of require lubricating grease. Over time, particularly if the valves usually are not cycled, the seals stick and the grease hardens, leading to larger friction that have to be overcome. There have been stories of valve failure due to moisture in the instrument media, which thickens the grease.
A direct-acting valve is the solely option wherever possible in low-power environments. Not only is the design less complicated than an indirect-acting piloted valve, but also pilot mechanisms usually have vent ports that may admit moisture and contamination, leading to corrosion and permitting the valve to stick in the open place even when de-energized. Also, direct-acting solenoids are specifically designed to shift the valves with zero minimum pressure necessities.
Note that some bigger actuators require excessive circulate charges and so a pilot operation is critical. In this case, it is important to ascertain that each one parts are rated to the identical reliability score as the solenoid.
Finally, since most remote locations are by definition harsh environments, a solenoid installed there will must have sturdy construction and be capable of stand up to and function at excessive temperatures while still sustaining the identical reliability and security capabilities required in less harsh environments.
When selecting a solenoid management valve for a distant operation, it’s possible to discover a valve that doesn’t compromise efficiency and reliability to minimize back power calls for. Look for a excessive FFR, easy dry armature design, nice magnetic and warmth conductivity properties and sturdy development.
Andrew Barko is the sales engineer for the Energy Sector of IMI Precision Engineering, makers of IMI Norgren, IMI Maxseal and IMI Herion brand components for energy operations. He offers cross-functional expertise in software engineering and enterprise growth to the oil, gas, petrochemical and energy industries and is licensed as a pneumatic Specialist by the International Fluid Power Society (IFPS).
Collin Skufca is the key account supervisor for the Energy Sector for IMI Precision Engineering. He presents expertise in new enterprise growth and customer relationship management to the oil, gas, petrochemical and power industries and is licensed as a pneumatic specialist by the International Fluid Power Society (IFPS).
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