How to maintain electric valves in harsh environments
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As an important part of modern industrial automation control systems, electric valves not only play the role of opening and closing pipelines or regulating flow, but are also directly related to the safety of the entire process. However, in harsh environments such as high temperature, severe cold, high humidity, dust, and corrosive gases, the normal operation of electric valves faces huge challenges. Scientific maintenance strategies are the key to ensuring long-term stable operation in these environments.
In harsh environments, the performance of electric valves often changes due to external factors. For example, high humidity and salt spray can easily cause corrosion of internal components of electric actuators, especially metal parts such as control boards and motor terminals. If there are no effective protection measures, these corrosions will cause signal interference, slow operation and even failure. High temperatures will cause the internal lubricating oil to deteriorate or evaporate, aggravating the wear of the gear system; while low temperatures may cause the metal structure to shrink and the sealing material to harden, affecting the opening and closing accuracy. In addition, dust, sediment and other particles will also enter the seal or transmission device after long-term accumulation, increasing the risk of jamming. Therefore, understanding and predicting environmental risks is the first step in maintenance work.
Regular surface cleaning is a basic measure to prevent equipment deterioration
In areas with strong winds, humid air, and corrosive gases, the electric valve housing is prone to accumulation of pollutants. Once these substances penetrate into the gaps, they will accelerate metal corrosion and coating peeling off. To avoid such problems, the valve surface must be cleaned and maintained regularly. It is recommended to use a clean soft cloth and neutral detergent for wiping. Avoid using acidic and alkaline solutions or high-pressure water guns. These methods may damage the surface protective layer or bring water inside. After cleaning, the shell should be checked immediately for coating peeling, rust spots, cracks, etc., and anti-corrosion materials should be reapplied in a timely manner according to the situation to block the corrosion chain from the source.
The Tightness Of The Cable Interface Determines The Reliability Of The Valve Electrical System
In environments with frequent rain or high humidity, the cable interface of the electric valve can easily become a fault prone point. If the cable sheath is damaged, the sealing ring is aged, or the compression piece is loose, moisture may penetrate along the cable into the actuator, causing problems such as circuit short circuit and signal loss. Therefore, during maintenance, it is important to check whether all cable entries are tightly closed. If necessary, the waterproof gland should be pressed tightly and special waterproof glue should be used to seal the remaining gaps.
The Status Of The Lubrication System Is Directly Related To The Stability Of The Internal Transmission System
The transmission mechanisms in electric valves, such as worm gears, planetary gears or ball screws, all rely on lubricants to reduce friction and delay wear. In a high-temperature environment, the grease may dilute and evaporate, greatly reducing the lubrication performance; while under low-temperature conditions, the grease may thicken, causing slow movement or even blockage. Therefore, it is necessary to select the appropriate type of grease according to the equipment operating environment and check the lubrication status regularly. When it is found that the lubricating layer has become black, thinned or has particles, it should be replaced immediately and the old oil residue should be thoroughly cleaned to prevent reactions caused by mixing old and new oil. At the same time, be careful not to over-lubricate to prevent excess grease from flowing into the motor and causing new malfunctions.
Strengthen Lightning Protection And Anti-electromagnetic Interference Design
Outdoors or in areas with frequent thunderstorms, external electrical shocks such as lightning strikes, electrostatic discharges, and electromagnetic interference pose a great threat to electric valves. A single lightning strike can cause core components such as the control board and frequency conversion module to be burned. Therefore, electrical protection must be paid attention to in daily maintenance. First of all, you should ensure that the electric valve body and its control cabinet are well grounded, and the ground resistance meets industry standards; secondly, it is recommended to install a surge protector (SPD) or isolation transformer at the incoming and outgoing lines to absorb instantaneous voltage fluctuations. In addition, shielded cables should be used to transmit signals to prevent external electromagnetic fields from interfering with signal stability. Maintenance personnel should also strictly implement anti-static operating specifications when operating to avoid inadvertent release of static electricity.
