旋转electric valve control contributes to Coca-Cola Enterprises’ environmental improvements

旋转CVA electric control valve actuation technology is helping CCE to increase efficiency and reduce energy costs at its Wakefield production plant. Rotork was able to provide CVA actuators which help the plant reduce their environmental impact in addition to cutting costs.

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。

Prior to the introduction of the CVA, the modulating performance of electric actuators could not match the performance of pneumatic control valves. CVA actuators have introduced continuous, repeatable modulating electrical control with a programmable fail-to-position option. Operating on an industry standard 4-20 mA control signal or digital network, the resolution, repeatability and hysteresis performance is quoted at <0.1% of full scale, offering suitability for the most demanding applications.

Mechanical features include Rotork’s well-proven double-sealed enclosure, which permanently protects internal electrical components from the effects of the operating atmosphere. The IP68 dust-tight, watertight and temporarily submersible enclosure is universal to all models in the CVA range, including those with hazardous area approvals. On loss of mains power, built-in super-capacitors allow the actuator to move the valve to a desired position, programmable as open, close, any intermediate position or stayput.

CVA执行器利用Rotork的创新且建立了良好的“非侵入性”通信技术来执行编程和调整。执行器的设置和配置是使用启用蓝牙®PDA或PC运行Rotork Enlight软件执行的。每个CVA都包含一个机上数据记录仪，可以下载诸如阀扭矩轮廓，停留时间，执行器事件和统计数据等操作数据，以进行详细的调查和诊断。分析后，任何必需的配置更改都可以上传到执行器中。

数字控制网络选项包括HART，MODBUS和PROFIBUS协议，促进增强的安装经济，并为CVA提供了增加对现有资产管理系统的增强能力。可以为单相AC或DC供应指定的全电动设计也简化了将执行器改造到现有阀上的过程，该阀已通过Rotork Site Services在Wakefield执行。

最近的一个例子是生产线上，与传统的气动驱动相比，旋转式CVA技术用于苛刻的阀门责任，降低了能源消耗的成本，而不会损失性能。

韦克菲尔德工厂的自动化工程师安迪·雷诺兹（Andy Reynolds）接管了这个故事：

“We were looking for an alternative to pneumatic control valves in order to remove the need for compressed air as much as possible in the area and reduce costs. Based on average air usage of 2m3/hr for a 3” control valve at £0.05 per m3, the running cost would be £870 per annum. The CVA actuator, using an average of 10 watts at £0.15/kW, would cost £13 for the same period. This represents a minimum saving of £857 per annum per valve, as this figure does not take into consideration any leaks in the system.

“到目前为止，电动阀门无法迅速响应，无法在瓶装机中保持良好的压力控制。Rotork充满信心，他们的CVA执行器不仅会与我们现有的阀门提供类似的性能，而且还会更便宜。他们的信心很高，如果不以任何方式达到期望，他们为我们提供了一名执行者。

“为了证明这一点，首先监视并记录了主产品饲料中现有的气动控制阀的性能。然后，使用在利兹的Rotork设施中制造的适配器，然后将CVA执行器安装到同一阀门，并连接到PLC现有的4-20 MA控制信号。

“After running and monitoring the CVA actuator in a 24-7 operation for 1 month, the results from the two actuators were compared. The graphs clearly show that in production mode the CVA performs equally well, if not better than the pneumatic actuator. However, when in CIP (Clean In Place) cleaning mode, the performance of the CVA is much better than the pneumatic. This is because the CVA actuator does not overshoot the set point like the pneumatic actuator does when the set point is lower and back pressure in the circuit is higher when in CIP mode.”

The Installation at Wakefield

安装在韦克菲尔德的CVA位于瓶装机的入口上，类似于下面所示。

基本上有两种操作模式，CVA在两者中都起着重要作用。

产品模式

• The product (diet Coca Cola in this system) is pumped into the tank (referred to as bowl) at a controlled pressure of 4 bar
• 该水箱仅填充到大约50％的产品中；其余50％是压缩空气
• 产品上方的压缩气压始终不得大或低于4 bar
• 然后将产品排放到受控系统中的瓶子（填充系统）中
• If the pressure in the tank is above 4 bar it creates a risk of over-filling the bottles and bottle explosion (known as fobbing). If the pressure is too low the bottles are under-filled

The CVA controls this pressure in a PID controlled system, the set point being 4 bar. This not only saves on power consumption and improved control but also lowers the compressed air consumption.

CIP（清洁）模式

• 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
• 在CIP模式下，储罐（碗）100％在72°C下充满了热苛性溶液
• 由于储罐完全饱满
• 如果压力增加，则可能会损坏填充阀
• The CVA controls this pressure in a PID controlled system, the set point being 1.5 bar. As stated above, the performance of the CVA is much better than the pneumatic actuator as the CVA does not overshoot the set point

Rotork UK网站服务销售经理在评论Wakefield的工作时说：“ CCE要求我们改善生产运营，这是成功实现的，这是由于降低了对昂贵的仪器空气的依赖而获得的额外好处。我们期待着这家家喻户晓的公司的未来，并有机会在整个全球运营中介绍我们的创新产品。”