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Current status and standardization development issues in control valve applications
Control valves play a critical role in industrial automation, but their application is often hindered by several challenges. One of the main issues is the vast variety and complexity of control valve types, specifications, and parameters. These valves are designed to meet different process requirements such as temperature, pressure, and media characteristics. With nearly a thousand different configurations available, selecting, installing, and maintaining control valves becomes a complicated task. This lack of standardization also complicates management and increases operational costs.
Another significant problem is the poor reliability of some control valves. Their performance tends to degrade over time, leading to issues like increased leakage, noise, and reduced repeatability. These problems can cause instability in long-term operations, making it difficult to maintain consistent control quality.
The physical size and weight of control valves also pose challenges. Many valves are bulky and heavy, requiring mechanical equipment for transportation, installation, and maintenance. For example, a DN200 control valve can weigh up to 700 kg, which makes handling inconvenient and costly.
In addition, the flow characteristics of control valves often do not match those of the controlled processes. While valves are manufactured with ideal flow characteristics, real-world conditions can change, causing mismatched behavior and deteriorating control system performance.
Noise from control valves is another concern, especially in industrial environments where it contributes significantly to overall noise pollution. Efforts are being made to reduce this noise through improved design and trim optimization.
Energy consumption is also a growing issue. Control valves, particularly those with pneumatic actuators, consume a lot of energy. As energy resources become scarcer, there is a need for more energy-efficient solutions, such as electric actuators, low-pressure drop designs, and piezoelectric technologies.
Looking ahead, the development of control valves is moving toward intelligence, standardization, miniaturization, rotation, and safety. Intelligent valve positioners enable self-diagnosis, remote communication, and improved control accuracy. Standardization helps ensure compatibility between products from different manufacturers, while miniaturization reduces weight and improves efficiency.
Rotary valves, such as ball and butterfly valves, are gaining popularity due to their compact design, high flow capacity, and good sealing properties. Safety is also becoming a key focus, with enhanced fault detection, reliable operation in hazardous areas, and simplified certification procedures.
Environmental protection is another major trend. Reducing valve noise and leakage is essential to minimize environmental impact. Innovations in packing materials and sealing technologies are being explored to address these issues.
Overall, the evolution of control valves is driven by advances in automation, computer science, and control theory. Fieldbus technology and digital communication are enabling smarter, more reliable control systems. As these developments continue, control valves will play an even more vital role in industrial automation, contributing to more efficient and precise process control.