Solenoid valve reliability in lower power operations

If a valve doesn’t function, your process doesn’t run, and that is money down the drain. Or worse, a spurious trip shuts the method down. Or worst of all, a valve malfunction leads to a dangerous failure. Solenoid valves in oil and gas purposes control the actuators that move massive course of valves, including in emergency shutdown (ESD) methods. The solenoid needs to exhaust air to enable the ESD valve to return to fail-safe mode each time sensors detect a harmful process situation. These valves should be quick-acting, sturdy and, above all, reliable to forestall downtime and the associated losses that occur when a process isn’t working.
And that is much more essential for oil and gasoline operations where there is limited power obtainable, such as distant wellheads or satellite offshore platforms. Here, solenoids face a double reliability problem. First, ตัววัดแรงดันน้ำมัน to operate correctly can’t only cause costly downtime, however a maintenance call to a remote location also takes longer and costs greater than a local repair. Second, to scale back the demand for power, many valve manufacturers resort to compromises that really reduce reliability. This is unhealthy enough for course of valves, however for emergency shutoff valves and other safety instrumented techniques (SIS), it’s unacceptable.
Poppet valves are typically better suited than spool valves for distant areas as a outcome of they’re much less advanced. For low-power purposes, 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 dependable low-power solenoid
Many components can hinder the reliability and efficiency of a solenoid valve. Friction, media flow, sticking of the spool, magnetic forces, remanence of electrical present and materials characteristics are all forces solenoid valve manufacturers have to overcome to construct the most reliable valve.
High spring pressure is essential to offsetting these forces and the friction they trigger. However, in low-power functions, most producers have to compromise spring pressure to permit the valve to shift with minimal power. The reduction in spring drive results in a force-to-friction ratio (FFR) as low as 6, although the widely accepted security degree is an FFR of 10.
Several parts of valve design play into the quantity of friction generated. Optimizing every of those allows a valve to have greater spring pressure while still maintaining a high FFR.
For example, the valve operates by electromagnetism — a current stimulates the valve to open, permitting the media to circulate to the actuator and move the method valve. This media may be air, but it might also be pure gasoline, instrument gas or even liquid. This is particularly true in remote operations that should use whatever media is out there. This means there’s a trade-off between magnetism and corrosion. Valves in which the media comes in contact with the coil should be manufactured from anticorrosive supplies, which have poor magnetic properties. A valve design that isolates the media from the coil — a dry armature — allows using highly magnetized materials. As a end result, there isn’t any residual magnetism after the coil is de-energized, which in turn allows quicker response occasions. This design additionally protects reliability by stopping contaminants in 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 beat the spring power. Integrating the valve and coil into a single housing improves effectivity by preventing power loss, allowing for using a low-power coil, leading to much less energy consumption without diminishing FFR. This built-in coil and housing design additionally reduces heat, preventing spurious journeys or coil burnouts. A dense, thermally efficient (low-heat generating) coil in a housing that acts as a heat sink, designed with no air gap to trap heat across the coil, virtually eliminates coil burnout issues and protects course of availability and safety.
Poppet valves are usually higher suited than spool valves for distant operations. The decreased complexity of poppet valves increases reliability by reducing sticking or friction factors, and decreases the variety of components that can fail. Spool valves typically have massive dynamic seals and heaps of require lubricating grease. Over time, especially if the valves aren’t cycled, the seals stick and the grease hardens, resulting in larger friction that must be overcome. There have been stories of valve failure because of moisture within the instrument media, which thickens the grease.
A direct-acting valve is the only option wherever attainable in low-power environments. Not solely is the design much less complex than an indirect-acting piloted valve, but additionally pilot mechanisms usually have vent ports that can admit moisture and contamination, resulting in corrosion and permitting the valve to stay in the open place even when de-energized. Also, direct-acting solenoids are specifically designed to shift the valves with zero minimum stress requirements.
Note that some bigger actuators require excessive move charges and so a pilot operation is critical. In this case, it is essential to ascertain that each one parts are rated to the same reliability ranking because the solenoid.
Finally, since most remote areas are by definition harsh environments, a solenoid put in there should have sturdy construction and have the ability to stand up to and function at excessive temperatures whereas nonetheless maintaining the identical reliability and security capabilities required in much less harsh environments.
When selecting a solenoid management valve for a distant operation, it’s attainable to discover a valve that does not compromise efficiency and reliability to reduce power demands. Look for a excessive FFR, easy dry armature design, great magnetic and heat conductivity properties and robust building.
Andrew Barko is the sales engineer for the Energy Sector of IMI Precision Engineering, makers of IMI Norgren, IMI Maxseal and IMI Herion brand elements for power operations. He offers cross-functional experience in software engineering and enterprise growth to the oil, fuel, petrochemical and power industries and is certified 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 offers expertise in new business growth and buyer relationship management to the oil, gas, petrochemical and power industries and is certified as a pneumatic specialist by the International Fluid Power Society (IFPS).
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