VRCs Presentation by Luca Testa 2015

A leading company in marine engineering

The remote control of the valves is a key feature in the automation of complex projects such as ships and offshore plants. Valves operation is the way of control for most of the processes vital to the operation onboard. Navalimpianti can supply the widest range of marine valve remote control system, hydraulically or electro-hydraulically operated, from the smallest to the largest valve diameters, complete with ballast and fluids level monitoring equipments, draught gauging and heeling systems for a full control of ship trim and list.

Valve Remote Control Systems

Navalimpianti know how vital is the VRC’s performance, for the safe and economical operation of modern fleets. A leading company in marine engineering, since 1971, Navalimpianti started developing and testing a patented concept of hydraulic actuator especially designed for marine applications. The experience, resulting from the manufacturing and installation of more than 100,000 valve actuators, is today realized in the state of the art of our ultimate solutions.

Experience-driven solutions

Marine Valve Remote Control Systems And Components Overview

•Linear actuators

• Rotary actuators

• Micro Power Packs

• Control Systems

RAM : Linear actuators, hydraulically operated, symmetrical chambers, suitable for the application on globe or small gate valves; Force up to 129,000 N on four available sizes, double or single acting type.  Special custom type for gate valves on request.

TORK : True rack and pinion quarter turn actuators, hydraulically operated, symmetrical  oil chambers, suitable for the application on butterfly and ball valves; torque up to 10,500 Nm on five available sizes, double or single acting type

Actuators

All the actuators share a modular design concept to be easily configured according with the required valve functions like Double acting, Single acting (either with gas or mechanical spring operation),Fail Open/Fail Close, Submersible conversion kit, Fixed or portable Hand pumps, quick connection couplings, emergency controls, hydro-lock function

• Robust compact units operating at pressure up to 160 bar. Piston and shaft made of Stainless Steel

• Valve top plate design includes double shaft penetration seal and intermediate chamber complete with an inspection plug; the design prevent the pollution of the process fluids and the contamination of the hydraulic circuits. Also it allows to promptly detect any unwanted shaft leakage.

• Symmetrical volumes of open / close cylinders chambers means no variation of the hydraulic oil level in the power pack, thus reducing oil contamination from air moisture.

• Fully integrated, marine grade, switchbox and electrical components certified IP68 (at 50 mt depth for 48 hours).

• Hydraulic interfaces designed for easy mounting of accessories (double non-return valve, bypass valve and much more) that can be flanged directly to the actuator without additional pipe works and fittings.

• The modular design of the actuator is such that the same can be easily transformed from a simple to double effect, or submerged, with few and simple interventions.

RAM – Hydraulic Linear Actuators

• Accurate rack and pinion design for long life and high efficiency operation, without maintenance.

• Precision sliding rings made of acetylic resin that offer higher toughness, stiffness and low friction/ wear properties); Absence of metal to metal friction between piston and cylinder increases the mechanical efficiency.

• Rack and pinion made of high tensile carbon steel, for reliable operation at any frequency of use; No rust can lock this robust mechanical interface.

• Cylinders bodies can be disassembled, to expose the piston lip seal and the sliding ring, with

the actuator remaining on the valve; Only four stainless steel screws needs to be removed to allow a maintenance check on place, also after year of operation in the most adverse environmental conditions.

• Robust compact units operating at pressure up to 160 bar. Design is made intrinsically tolerant to presence of suspended solids in the hydraulic fluid to achieve an increased reliability as well as and to reduce commissioning time.

• Symmetrical volumes of open / close cylinders chambers means no variation of the hydraulic oil level in the power pack, thus reducing oil contamination from air moisture.

• Fully integrated, marine grade, switchbox and electrical components certified IP68 (at 50 mt depth for 48 hours).

• Hydraulic interfaces designed for easy mounting of accessories (double non-return valve, bypass valve and much more) that can be flanged directly to the actuator without additional pipe works and fittings.

• The modular design of the actuator is such that the same can be easily transformed from a simple to double effect, or submerged, with few and simple interventions.

TORK – Hydraulic Rotary Actuators

Navalimpianti valves remote control system is present since 1971 on hundredths of traditionally operated ships of any size and type.Navalimpianti VRC is a traditional hydraulic system, including solenoid valve racks, hydraulic power pack and actuators, oriented mainly to piping connection, suitable to be controlled by a traditional control desk or connected to I/O cabinets for control via an IMCS.Hydraulic power pack is fully automated and all the valves can be throttled, as for standard Navalimpianti operation philosophy.VRC systems are complete of all installation accessories, portable pumps, emergency operation fittings. Control panel can be console type, wall or recessed mounting panel, with engraved mimic diagram for easier operability.Navalimpianti VRC standard type is suitable for tankers, chemical and product carriers application.Navalimpianti hydraulic position indicating units NHI06 for the control of the actual position of valves, either submerged or not, permit the installation of the equipments in sheltered area, allowing easier maintenance and avoiding any electrical installation in Hazardous Area.

Hydraulic VRCS

• Off-shore standard hydraulic power pack for heavy duty 24/24h / 365/365d operation.

• Solenoid valve racks for sheltered or deck areas in EX(d) or EX(i) versions.

• Actuators for dry / sheltered / unsheltered / sub-merged installation.

• Full range of on –off / throttling controlling devices and accessories for emergency operations.

Hydraulic VRCS

The electro-hydraulic micro power pack has been designed to be directly coupled to each type of Tork/Ram actuator (or by a short length of pipes allowing local split installation for operation of submerged valves). MHPP has been designed to optimize dimensions, weight and number of components. The MHPP unit contains the electric motor, the oil reservoir, the hydraulic pump with relevant accessories and the electric / electronic control section including local valve position signals (Led type). The Micro-hydraulic Power Pack protection class is IP68. Delivered filled with hydraulic oil, the MHPP can be installed in any position simply adjusting the inlet oil tank plug. MHPP built in input/output switchbox can be connected hardwire and/or serial bus to any control system.

Micro Hydraulic Power Pack MHPP

Valves remote control systems for cruise ships

A micro hydraulic power pack (MHPP) directly coupled and factory assembled with any RAM or TORK makes the electro-hydraulic actuators. Therefore control connections are only of electrical type. The system architecture allows the most flexible control solutions. The system intelligence can be distributed to the actuator level or to a given number of local cabinets. The electro-hydraulic actuators have a built in input/output switchbox allowing any type of control system configuration from serial connection, to local loops or stellar with different level of redundancies. According to the project specification the control layout can be designed to comply with the most complex application requirements.

WINners : The Electro-Hydraulic System

WINners™ E is a widely diffused intelligent distributed valve remote control system developed and installed by Navalimpianti since 1995. Together with TORK™ and RAM™ actuators, it permits to realise electro hydraulically operated valve remote control systems suitable for application anytime the direct hydraulic control of valves is to be preferred.

Valves remote control systems for cruise and off-shore

WINners Valves remote control systems for cruise ships

• WINners is a computer oriented distributed system with self powered actuators; it permits to realize a WINners LON network connected to Navim Scalink workstations or to an IMCS limiting the wiring. E-Tork LT and E-Ram actuator further reduces the cost of installation in way of the WINners control cabinets that minimize the general cable runs.One single WCC can collect and drive up to 45 neighbor E-Tork LT and E-Ram with full local control capability for maintenance.

• WINners system provide full control of valves actuators in local mode of operation, last called valve position or safety action is maintained / performed also in case of IMCS shut down. WINners serial data link includes, for each single actuator and valve, a “status information” to IMCS; this can be managed (on mimic diagrams or in alarm pages) to increase the operator confidence and safety of operation.

• WINners standard, maintenance, local, emergency control hierarchy assures a “marine maneuver-ability “ in any circumstances:

• from the IMCS supervisor or control room desk;• from a mimic diagram secondary station overriding the supervisor;• from the local units.

• For each valve are provided: • electrical overriding action (Local/Remote operation) with open-close-throttle

capability (also in case of failure of the electronic section);• on place, operating the actuator by means of the portable or fixed hydraulic hand

pump.

To next WINners Control Cabinet

E-Ram linear actuators for globe valves

WINners Control Cabinet (WCC)No practical limit on the number of units

that can be installed

E-Tork LT rotating actuators for butterfly & ball valves

WINners Control Cabinet available models:

• WC1 – Up to 15 valves• WC2 – Up to 30 valves• WC3 – Up to 45 valves

MIMICDiagram

Panel(optional)Overriding

thesupervisor

NAVIMGateway Unit

MODBUS standard interface to third party supervisor(Other communication protocols available on request)

NAVIM Scalink control room console: • Valve Remote Control• Level & Draught Gauging & Monitoring• Pump and main lines measures• Other auxiliaries

High noise immunity field data link up to 2 km length

EX(d) explosion proof version for Hazardous Areas – also in Split version

WINners Key Features:• Local / Remote control mode & Open / Close controls (for each

single valve) permit easy local operation;• Different Open / Close operating time can be factory set on

WINners Cards (WC);• WINners Control Cabinet can accommodate any combination of

E-Tork LT & E-Ram actuators

LON network Serial Data Link

WINners control units are not simply interface cabinets, they actively control the valves depending on them

without supervisor intervention

E-Split for submerged operation

Tank

PipingPenetration

s

WINners for Cruise

• Actuators are connected only to the electrical cables; no oil leakage, no expensive installation, flushing and commissioning of hydraulic lines. ( In the Winners configuration only one multicore cable is required for power and control signals of each single actuator.  Cables can run on existing cable-ways, are unnecessary independent cable-ways.

• No ship space is wasted for hydraulic power pack and solenoid valve units; dedicated rooms are thus available for payload or accommodation.

• No sources of noise, no water hammer noise on hydraulic lines; the MHPP units are very silent and can be installed very close to accommodation and passenger cabins.

• Essential layout; the complete system (equipment + installation) is less expensive than the traditional hydraulic system.

• Explosion proof version are available for Hazardous Area installation.

• Splitting of the Electro-hydraulic units allows the actuators to action valves in submerged tanks powered by their MHPP installed on dry space near to the hydraulic pipes tank’s penetration.

Valves remote control systems for Cruise Ships

WINners Control Cabinet (WCC)

E-Tork LT / E-Ram actuator and valve

E-Tork LT / E-Ram actuator and Rule valve

Gateway (MODBUS protocol)

Navim Scalink Workstation (As main or as emergency backup)

Winners system

Third Party Supervisor

WINners Serial Data link

WCC to E-Tork LT / E-Ram electrically operated actuators cables (1 single for each actuator control+signal)

Connections

• Each main vertical zone is independent: The valve control system survives for Rule Safety valves at compartment level; cross linking WCC units may increase availability in case of fire;

• Above the bulkhead deck it is installed the control panels relevant only to Rule safety valves;

• The distributed Winners Control Cabinets permit to optimize cabling to valve actuators;

• Multi level operability is guaranteed at Supervisor level and:• Directly on place, valve actuator mechanically or hydraulically

operated by portable pump;• At WCC level operating on the WC cards• From automation system or Navim Scalink Workstation

Hard wired mimic diagram (on request)

WINners Mimic Diagrams hardwired connections

Key features of Navalimpianti WINners system:

Bulkhead Deck

Main Vert. Z No5 Main Vert. Z No4 Main Vert. Z No3 Main Vert. Z No2 Main Vert. Z No2

WINners for Cruise

• Service and Spare Parts• Customers training• Systems upgrading• Systems performance evaluation• Maintenance and repairs• Systems refitting

Worldwide Organization

more than 100,000 valve

actuators installed onboardOceanwide References

www.navim.com

More than 15.000 plants supplied all over the world in 40 years