Motorized ball valve

If you are looking for a reliablemotorized ball valve, then you are probably faced with a lot of information. Many manufacturers promise heavenly automation conditions, but in practice there are nuances that are often kept silent. For example, the importance of proper actuator selection and valve compatibility is often overlooked, or the operating environment is not taken into account. I will try to share my experience, or rather, the experience of our company Shandong Linyao Intelligent Agriculture Technology LLC, which is engaged in the development and implementation of automated process control systems in agriculture. We often encounter situations where beautiful technical specifications do not always correspond to real needs.

Drive selection: a key factor in reliability

The first thing you need to understand is that there is no universal drive. Choiceelectric actuator for ball valveis a separate task that requires careful analysis. There is no need to save money here, because the reliability of the drive directly affects the uninterrupted operation of the entire system. In our work, we often come across a situation where they choose the cheapest drive, and then complain about its frequent breakdowns and the need to replace it.

It is important to consider several parameters: torque, operating temperature range, degree of protection against moisture and dust (IP rating), and type of control (DC or AC). And, of course, it is necessary to correctly calculate the required torque based on the characteristics of the valve, medium pressure and flow resistance. Incorrect calculation can lead to overload of the drive and its failure.

For example, we had a case where an actuator with insufficient torque was selected for a large diameter valve. As a result, the drive quickly overheated and failed, requiring expensive repairs and equipment downtime. It is better to immediately slightly overestimate the required torque than to deal with the consequences later.

Types of electric drives: pros and cons

There are several types of electric drives that can be used to controlmotorized ball valves. The most common are gear drives and direct drives. Gear drives provide more torque, but are more complex in design and require regular maintenance. Direct drive drives are simpler in design, but have less torque. The choice between these types depends on the specific application requirements.

We often recommend that customers use encoders for feedback to ensure accurate valve positioning and avoid accidental shutoff of flow. The encoder allows the actuator to monitor the current position of the valve and adjust its operation if necessary.

Another important aspect is the drive control system. It can be simple (with manual control) or complex (with automatic control via Modbus or Profibus protocol). With automatic control, the valve can be integrated into the process control system, thereby optimizing the operation of the entire system.

Difficulties in operation and typical problems

Even with proper selection and installationmotorized ball valveProblems may arise during operation. The most common problems are valve sticking, actuator failure, and seal leaks. Causes of valve sticking may include contamination, corrosion, or improper adjustment. Drive failure is often associated with overload, overheating or moisture ingress. Seal leaks can be caused by wear or improper installation.

In our practice, there are often cases when the valve gets stuck due to foreign objects getting into the flow. For example, in an irrigation system, debris and leaves can cause the valve to become stuck in the closed position. To prevent such situations, it is recommended to use filters and grids.

Regular maintenance is the key to long and reliable operationelectrically actuated ball valves. Maintenance should include cleaning the valve and actuator, lubricating bearings, checking seals, and checking electrical function. We offer our clients comprehensive services for the maintenance and repair of automated process control systems.

Power problems and surge protection

Don't forget about power issues. Unstable voltage or overvoltage can cause drive failure. To protect against such situations, it is recommended to use surge protectors and voltage stabilizers. It is important to correctly select the rated voltage of the drive in accordance with the characteristics of the electrical network. In rural areas, where power surges are common, this is especially true.

We recommend using an uninterruptible power supply (UPS) to ensure continued system operation in the event of a power outage. This avoids data loss and prevents unauthorized shutdown of the valve.

You should also take into account the requirements for grounding and lightning protection during installationmotorized ball valves. Failure to do so may result in electric shock and equipment damage.

Application experience in agricultural systems

In the agricultural sectormotorized ball valvesused to automatically control the supply of water, fertilizers and pesticides. They allow you to optimize the use of resources and increase productivity. We implemented such systems in fields for grain, vegetable and fruit crops. This works especially effectively in drip irrigation and microirrigation systems.

For example, in one of the apple fields we installed an automatic control system for the supply of water and fertilizers based on data from soil moisture and pH sensors. This made it possible to reduce water consumption by 20% and increase apple yields by 15%. Management was carried out through the SCADA system, which made it possible to quickly monitor the operation of all valves and adjust resource supply parameters.

In the future, it is planned to introduce machine learning systems to optimize workmotorized ball valvesbased on big data analysis. This will make it possible to more accurately predict plant resource needs and automate the process of managing technological processes.

Integration with process control systems

Integrationelectrically actuated ball valveswith process control systems (APCS) allows you to create a comprehensive automated control system. Such a system allows you to centrally control the operation of all valves, obtain data on the condition of the equipment and quickly respond to emergency situations. This is especially important in large agricultural complexes where many different systems need to be coordinated.

When integrating with a process control system, it is necessary to use standard data exchange protocols, such as Modbus, Profibus or Ethernet/IP. This ensures compatibility of the valves with various control systems. We develop our own software modules for integrationmotorized ball valveswith automated process control systems, which allows you to use their functionality as efficiently as possible.

For example, we have developed modules for automatically adjusting water pressure and flow based on data from pressure and flow sensors. This allows you to maintain optimal conditions for plant growth and prevent over- or under-moistening of the soil.