旋转电动阀控制有助于可口可乐企业的环境改善

Rotork CVA电气控制阀致动技术正在帮助CCE提高其韦克菲尔德生产工厂的效率并降低能源成本。Rotork能够提供CVA执行器，这些执行器可帮助工厂减少其环境影响，而削减成本。

在过去的五年中，CCE在欧洲最大的软饮料生产工厂的韦克菲尔德（Wakefield）现场投资了超过1亿英镑，这是一项长期计划的一部分，强调了其对本地制造业的承诺和新技术的发展。自从能源监测系统上安装并采取行动以来，该公司自2009年以来就已经使韦克菲尔德的电力降低了13％。

该计划的重要部分是节省为传统气动控制阀致动的提供和维护空气供应的持续成本。这是通过引入Rotork CVA控制阀执行器来执行调节和故障安全阀职责的引入。

在引入CVA之前，电动执行器的调节性能不能符合气动控制阀的性能。CVA执行器通过可编程的失败位置选项引入了连续的，可重复的调制电控。在行业标准4-20 MA控制信号或数字网络上运行，分辨率，可重复性和磁滞性能的全尺度为<0.1％，为最苛刻的应用提供了适用性。

机械特征包括旋转式良好的双密封外壳，该外壳永久保护内部电气组件免受操作氛围的影响。IP68尘埃紧密，水密和暂时的潜水外壳对于CVA范围内的所有型号，包括具有危险区域批准的所有型号。由于损失主电源，内置的超级电容器使执行器可以将阀门移至所需的位置，可编程为开放，关闭，任何中间位置或停留位置。

CVA actuators utilise Rotork’s innovative and well established ‘non-intrusive’ communication technology for actuator programming and adjustment. Actuator set-up and configuration is performed using a Bluetooth® enabled PDA or PC running Rotork Enlight software. Every CVA incorporates an onboard data logger, enabling operational data such as valve torque profiles, dwell times, actuator events and statistics to be downloaded for detailed investigation and diagnosis. After analysis, any required configuration changes can be uploaded into to the actuator.

Digital control network options include HART, Modbus and Profibus protocols, facilitating enhanced installed economy as well as giving the CVA the increased ability to dovetail into existing asset management systems. The all-electric design, which can be specified for single-phase AC or DC supplies, also simplifies the process of retrofitting actuators onto existing valves, which has been performed at Wakefield by Rotork Site Services.

A recent example is on the production line where the adoption of Rotork CVA technology for a demanding valve duty has considerably reduced the cost of energy consumption when compared with traditional pneumatic actuation with no loss of performance.

Andy Reynolds, Automation Engineer at the Wakefield plant, takes up the story:

“我们正在寻找一种用于气动控制阀的替代方法，以便尽可能多地消除该区域中压缩空气的需求并降低成本。根据3英寸控制阀的平均空气使用率为2m3/hr，每平方英尺0.05英镑，运行成本为每年870英镑。CVA执行器平均使用10瓦以0.15英镑/kW的价格使用，同一时期的费用为13英镑。这表示每年节省每年857英镑，因为该数字没有考虑到系统中的任何泄漏。

“Up to now, electrically actuated valves could not respond fast enough to maintain good pressure control in the bottle filling machine. Rotork were confident that their CVA actuator would not only give a similar performance to our existing valve, but would also be cheaper to run. Their confidence was so high they offered us an actuator on a sale or return basis if it did not meet expectations in any way.

“To prove this, the performance of the existing pneumatic control valve on the main product feed into the filling machine was first monitored and recorded. Using an adaptor made at Rotork’s facility in Leeds, the CVA actuator was then fitted to the same valve and connected to the existing 4-20 mA control signal from the PLC.

“在24-7的操作中运行和监视CVA执行器1个月后，比较了两个执行器的结果。这些图清楚地表明，在生产模式下，CVA的性能同样好，甚至比气动执行器更好。但是，在CIP（清洁）清洁模式时，CVA的性能比气动更好。这是因为当设定点较低时，CVA执行器不会像气动执行器那样超过设定点，并且在CIP模式下电路中的反向压力较高。”

韦克菲尔德的安装

The CVA installed at Wakefield is on the inlet of the bottle filling machine, similar to the one shown below.

Basically there are two operation modes and the CVA plays an important part in both.

Product Mode

• 产品（该系统中的可口可乐）以4 bar的控制压力泵入油箱（称为碗）
• The tank is only filled to approximately 50% with product; the remaining 50% is compressed air
• The compressed air pressure above the product must be no greater or lower than 4 bar at all times
• The product is then discharged into the bottles in a controlled system (filling system)
• 如果储罐中的压力高于4杆，则会产生过度填充瓶子和瓶爆炸（称为Fobbing）的风险。如果压力太低，则瓶子填充不足

CVA控制PID控制系统中的这种压力，设定点为4 bar。这不仅节省了功耗和改善的控制，而且还可以降低压缩空气消耗。

CIP (Clean In Place) Mode

• 每72小时，必须使用热苛性溶液对产品罐进行彻底清洁；这个过程是完全自动化的
• During the CIP mode the tank (bowl) is 100% filled with hot caustic solution at 72°C
• 由于储罐完全饱满
• If the pressure is increased then damage to the filling valve can occur
• CVA控制PID控制系统中的这种压力，设定点为1.5 bar。如上所述，CVA的性能比气动执行器好得多，因为CVA不会超出设定点

Commenting on the work at Wakefield, Rotork UK Site Services Sales Manager said: “We were asked by CCE to improve the production operation, which has been successfully achieved with the added benefit of a reduced reliance on costly instrument air. We are looking forward to the future with this household name company and the opportunity to introduce our innovative products throughout their global operations.”