Solenoid valve reliability in lower energy operations

If a valve doesn’t operate, your process doesn’t run, and that’s money down the drain. Or worse, a spurious trip shuts the method down. Or worst of all, a valve malfunction results in a harmful failure. Solenoid valves in oil and fuel functions control the actuators that transfer large process valves, together with in emergency shutdown (ESD) systems. The solenoid must exhaust air to allow the ESD valve to return to fail-safe mode whenever sensors detect a harmful course of scenario. These valves have to be quick-acting, sturdy and, above all, reliable to stop downtime and the associated losses that occur when a process isn’t operating.
And this is much more important for oil and gas operations the place there’s limited power available, similar to remote wellheads or satellite offshore platforms. Here, solenoids face a double reliability problem. First, a failure to operate appropriately cannot solely trigger pricey downtime, however a upkeep name to a distant location also takes longer and costs more than an area repair. Second, to scale back the demand for energy, many valve producers resort to compromises that actually reduce reliability. This is bad enough for course of valves, but for emergency shutoff valves and other security instrumented systems (SIS), it’s unacceptable.
Poppet valves are typically higher suited than spool valves for remote places as a outcome of they’re much less complex. For low-power purposes, look 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 dependable low-power solenoid
Many factors can hinder the reliability and performance of a solenoid valve. Friction, media move, sticking of the spool, magnetic forces, remanence of electrical present and materials characteristics are all forces solenoid valve producers have to overcome to construct the most reliable valve.
High spring force is essential to offsetting these forces and the friction they trigger. However, in low-power applications, most producers should compromise spring pressure to allow the valve to shift with minimal power. The reduction in spring force leads to a force-to-friction ratio (FFR) as low as 6, though the widely accepted safety level is an FFR of 10.
Several components of valve design play into the quantity of friction generated. Optimizing each of these permits a valve to have greater spring force whereas still sustaining a high FFR.
For example, the valve operates by electromagnetism — a present stimulates the valve to open, permitting the media to move to the actuator and transfer the process valve. This media could also be air, but it may also be natural gas, instrument gas and even liquid. This is especially true in remote operations that must use no matter media is out there. This means there is a trade-off between magnetism and corrosion. Valves during which the media comes in contact with the coil must be manufactured from anticorrosive materials, which have poor magnetic properties. A valve design that isolates the media from the coil — a dry armature — permits using extremely magnetized material. As a end result, there is not a residual magnetism after the coil is de-energized, which in flip allows quicker response times. This design additionally protects reliability by preventing contaminants in the media from reaching the internal workings of the valve.
Another factor is the valve housing design. Usually a heavy (high-force) spring requires a high-power coil to beat the spring strength. Integrating the valve and coil into a single housing improves efficiency by preventing vitality loss, permitting for the use of a low-power coil, leading to less energy consumption with out diminishing FFR. This built-in coil and housing design also reduces warmth, preventing spurious trips or coil burnouts. A dense, thermally environment friendly (low-heat generating) coil in a housing that acts as a heat sink, designed with no air gap to entice warmth across the coil, virtually eliminates coil burnout concerns and protects course of availability and safety.
Poppet valves are generally higher suited than spool valves for distant operations. The decreased complexity of poppet valves will increase reliability by reducing sticking or friction factors, and reduces the number of parts that can fail. Spool valves typically have massive dynamic seals and lots of require lubricating grease. Over time, especially if the valves aren’t cycled, the seals stick and the grease hardens, leading to higher friction that must be overcome. There have been reports of valve failure due to moisture within the instrument media, which thickens the grease.
A direct-acting valve is the solely option wherever attainable in low-power environments. Not only is the design much less complicated than an indirect-acting piloted valve, but additionally pilot mechanisms usually have vent ports that can admit moisture and contamination, leading to corrosion and permitting the valve to stick within the open position even when de-energized. Also, direct-acting solenoids are particularly designed to shift the valves with zero minimal pressure necessities.
Note that some bigger actuators require excessive circulate rates and so a pilot operation is critical. In this case, it is necessary to confirm 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 need to have sturdy building and be capable of withstand and operate at excessive temperatures while nonetheless sustaining the same reliability and safety capabilities required in much less harsh environments.
When selecting a solenoid management valve for a remote operation, it’s attainable to discover a valve that doesn’t compromise performance and reliability to reduce energy calls for. Look for a excessive FFR, easy dry armature design, great magnetic and warmth conductivity properties and sturdy construction.
เกจวัดแรงดันco2 is the sales engineer for the Energy Sector of IMI Precision Engineering, makers of IMI Norgren, IMI Maxseal and IMI Herion brand elements for vitality operations. He presents cross-functional experience in application engineering and business improvement to the oil, gasoline, petrochemical and energy industries and is licensed as a pneumatic Specialist by the International Fluid Power Society (IFPS).
Collin Skufca is the key account manager for the Energy Sector for IMI Precision Engineering. He presents experience in new enterprise improvement and customer relationship management to the oil, gasoline, petrochemical and power industries and is licensed as a pneumatic specialist by the International Fluid Power Society (IFPS).

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