Ensure Long-term Performance of Electric Ball Control Valves

Electric ball control valves are essential in various industries due to their outstanding control capabilities and versatility. They efficiently manage the switching or connection of pipeline media and can be adapted for regulating applications. However, their unique structure and operating environment make electric actuators vulnerable to damage from environmental factors or internal pipeline conditions, impacting the valve's lifespan. Proper maintenance is crucial to extend the lifespan of electric ball control valves, boost operational efficiency, minimize downtime, and reduce replacement costs.

Storage Requirements for Electric Ball Control Valves

The storage conditions of electric ball control valves directly affect their lifespan and performance. To ensure that the valves remain in good condition during long-term storage, the following storage requirements should be adhered to:

Environmental Conditions: Electric ball control valves should be stored in a dry, well-ventilated indoor environment. Fluctuations in humidity and temperature can lead to material aging and corrosion.

Sealing: During storage, the valve's openings should be sealed with plastic caps to prevent dust and foreign objects from entering the valve body, which could cause wear or damage.

Regular Inspection: Electric ball control valves that are stored for extended periods should be inspected regularly. Internal debris should be removed, and anti-rust oil should be applied to the machined surfaces to prevent rust and jamming.

Installation and On-Site Inspection

Proper installation and regular on-site inspections are crucial for ensuring the normal operation of electric ball control valves:

Installation Inspection: After installing the electric ball control valve, check the on-site equipment to ensure all installation procedures are complete. Inspect flanges and supports for bolts to ensure threads are intact and there are no looseness issues.

Handwheel and Fastening Nuts: Tighten any loose fastening nuts on the handwheel promptly to prevent wear at connection points or loss of the handwheel and nameplate. If the handwheel is lost, do not use an adjustable wrench as a substitute; replace it as soon as possible.

Packing Gland: Ensure that the packing gland is not misaligned and has no pre-tightening gaps to maintain sealing performance.

Protective Cover: For valves exposed to rain, snow, dust, sand, and other environmental contaminants, install a protective cover to prevent damage to the valve stem.

Scale and Accessories: Ensure that the scale on the electric ball control valve remains intact, accurate, and clear. Check that seals, caps, pneumatic accessories, and insulation jackets are complete and free from dents or cracks.

Actuator Requirements and Troubleshooting

The actuator of an electric ball control valve must be capable of limiting torque (axial force) and rotation angle. Once the electric actuator's specifications are determined, the control torque is also set. Under normal operating conditions, the motor should not overload. However, the following conditions may cause overloading:

Low Power Supply Voltage: This can prevent the motor from providing the required torque, causing it to stop.

Incorrect Torque Limit Settings: If the torque limit is set too high, it can cause sustained excessive torque, leading to motor stoppage.

Intermittent Use: Excessive heat accumulation may exceed the motor's allowable temperature rise.

Torque Limiting Mechanism Circuit Failure: This can result in excessive torque.

High Ambient Temperature: This reduces the motor’s thermal capacity. Ambient temperature should be maintained between -25°C and 70°C.

Fault Handling: If a fault occurs with the electric ball control valve, avoid disassembling it yourself to prevent accidents. Fault resolution should be carried out by professional technicians. Generally, avoid striking the electric ball control valve or placing objects on it to prevent damage.

Use in Special Environments

In specific environmental conditions, such as unstable current, corrosive environments, flammable or explosive settings, special media, or prolonged lack of maintenance, explosion-proof electric ball control valves should be chosen. Due to the complexity of the electric actuator, avoid self-disassembly in case of failure to prevent accidents. Generally, the electric ball control valve should not be struck or have objects placed on it.

Maintenance and Care Considerations

Maintenance Frequency: Develop a regular maintenance plan based on actual usage. This includes checking all components of the electric ball control valve to ensure normal operation.

Cleaning and Maintenance: Regularly clean the external parts of the electric ball control valve to maintain the valve and actuator in good condition and prevent dirt accumulation.

Lubrication: Lubricate moving parts as needed to reduce wear and extend lifespan.

Electric ball control valves are core components in modern industrial automation process control, and their reliability and efficiency directly impact the stable operation of the entire system. Through proper storage, precise installation, regular inspections, and meticulous maintenance, the lifespan of electric ball control valves can be effectively extended, and their operational performance can be enhanced. Understanding and addressing potential faults, especially in special environments, are crucial for ensuring long-term reliable operation. Implementing these maintenance measures not only reduces downtime and repair costs but also ensures the equipment performs excellently in critical operations, ultimately boosting production efficiency and reducing operational costs.