Electric steam control valve helps Russian customers solve frequent control system failures

In May 2023, a large chemical enterprise located in Russia was confronted with severe operational challenges regarding its reaction tanks. The medium was the waste heat from a thermal power plant, with a temperature of approximately 250℃ and a pressure of 1.6 MPa. The control valves originally in use frequently malfunctioned, resulting in problems such as burned-out actuators, damaged control modules, and broken reduction gears, which seriously affected the long-term operation of the equipment. Moreover, each shutdown and maintenance operation caused direct economic losses of up to 100,000 RMB. 

The customer raised some issues and requested solutions. Immediately, our company dispatched two engineers to the customer's company in Russia. After the on-site investigation and technical communication by our engineers, we identified that the core problem was that the electric control valve originally selected for the local Russian market could not balance the pressure difference between the inlet and outlet under this working condition. This led to excessive load on the actuator during operation, causing the reduction gear to be overburdened and being damaged several times, as well as damage to the motor and module. Additionally, the particles and impurities in the medium severely eroded the sealing surface of the valve core. 

In response to this harsh working condition, we recommend replacing the electric single-seat regulating valve with an electric sleeve regulating valve that we have independently developed. This valve is specifically designed for high-pressure difference scenarios. The balanced structure of the valve core in the sleeve valve can significantly counteract the unbalanced force generated when steam passes through, reducing the load on the electric actuator and facilitating the long-term stable operation of the regulating valve. After consulting with the users, we made a decisive decision to provide the customers with quotations, transportation plans, and after-sales guidance plans on site. 

Because the electric sleeve regulating valve possesses these advantages:
1). Balanced valve core structure, allowing for large pressure difference
2). Sleeve guiding structure, with a large guiding area
3). Separation design of the sealing surface and the throttling surface
4). Large flow coefficient, strong flow capacity
5). Wide regulating range, precise flow characteristics
6). Low noise, excellent anti-erosion performance
7). Adjustable leakage level, zero leakage for soft seals
8). Flexible configuration of the actuator, energy saving and cost reduction
9). High degree of intelligence, simple wiring
10). Easy maintenance, strong adaptability
11). Various sealing forms, suitable for special working conditions 

Since its commissioning in August 2023:
Operational stability: It has been running continuously for over two years without any faults, far exceeding the 8 months of the local valves in Russia.
Economic benefits: The product price is 20% lower than that of the local brands in Russia, and the spare parts procurement cycle has been shortened from 30 days to 5 days.
Maintenance cost: Due to the use of wear-resistant design, the lifespan of the valve core has been extended by 8 times. 

Customer review: "Not only did it solve our production problems and prevent the high cost of maintenance shutdowns, but it also made us believe in the strength of Chinese manufacturing technology." 

The successful application of this project not only verified SONGO's profound accumulation in the field of high-end and demanding control valves, but also provided a highly valuable reference solution for similar working conditions in the same industry.

Comparison with Electric Single-acting Control Valves