Background
The gas transmission scenario in Shanghai Industrial Park is complex. The traditional layout of supporting controls for electric ball valves is unreasonable, which is prone to failures, affects operation and maintenance efficiency, and fails to meet the precise on-off requirements of gas pipelines. To address these issues, GRAT electric actuators have been introduced. As the core driving component of electric ball valves, this product overcomes the drawbacks of traditional control layouts, undertakes valve opening/closing control and stable power output, and ensures stable and efficient automated operation and maintenance of gas pipelines.
Key challenge
- Wiring Adaptation: After cable connection in accordance with standard drawings, the electric ball valve cannot be normally activated or closed via the control box, leaving the equipment inoperable.
- Production Impact: The fault directly disrupts normal gas pipeline scheduling. Prolonged unresolved issues will halt production for enterprises in the park and cause economic losses.
Operation Condition
Product Name: Electric Ball Valve
Application: Main gas pipeline on/off control
Medium: Natural gas
Nominal Diameter: DN300
Material: WCB
Connection Type: Flanged
Control Signal: Standard on-off (dry contact)
Operating Voltage: AC 220V
Design Service Life: 6 years
Commissioning Date: December 2024
Location: Shanghai
Solution & Implementation
- Solution 1: Adjust the actuator operating voltage from the original AC 220V to AC 380V. Although this scheme stabilizes voltage and reduces operating current, no AC 380V power supply is available on-site. Additionally, actuator replacement incurs high costs and carries equipment compatibility risks; thus, this solution was rejected.
- Solution 2: Relocate the control box. Following full communication and coordination with on-site personnel, the control box was moved to an area near the electric ball valve, with standardized rewiring to shorten cable transmission distance, fundamentally resolving voltage drop issues. After commissioning and power-on testing, the electric ball valve achieved normal startup and shutdown, with the fault completely eliminated.
Performance Result
- Equipment Operation: After control box relocation, the electric ball valve starts and stops normally, electrical parameters meet standards, and it stably performs main gas pipeline on-off functions, ensuring reliable gas pipeline scheduling.
- Lessons Learned: During the installation and commissioning of industrial equipment, a comprehensive evaluation of the electrical system is required, with key focus on voltage drop, equipment layout and other critical factors, to rationally plan equipment parameters and installation positions. In after-sales troubleshooting, a rigorous attitude shall be maintained to identify root causes through professional testing, and select optimal solutions based on on-site conditions, effectively ensuring stable industrial production and minimizing economic losses caused by equipment failures.
Call to Action
If your industrial park or gas transmission project faces similar electric ball valve faults, voltage drop or inefficient operation, contact us promptly. Our professional team will provide tailored on-site inspection and solutions, leveraging GRAT electric actuators’ reliability and on-site experience to avoid production interruptions and losses.