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Why are actuators important and are they making your

life easier?

Hua Aun Tan

September 16th, 2020

Outline

• Actuator fundamentals/considerations

• Types of actuation

• Electrification

• Connected smart diagnostics

• Valve actuation examples

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Actuator Fundamentals

What is an Actuator?

• An actuator provides motive force to a valve to all a valve to stroke open or

closed.

Actuator Considerations

• What Valve are you mounting this to?

– Linear or Rotary

– Mounting

• What do you want the actuator to do?

– Control or Isolation

– Fail action – Open/Close/Last/Manual Override

– Stroke Speed

• What are the constraints of actuation?

– Motive Force – Air/Hydraulic/Electric/Power Gas

– Size and Weight

– Cost

– Environmental Impact

Designed for Automation?

Mounting on difficult valves

Isolation valve for underground oil/water separator

Custom Actuation Retrofits - Haney Main No.2 Valve Chamber Upgrades

Before After

Actuator Considerations

• What Valve are you mounting this to?

– Linear or Rotary

– Mounting

• What do you want the actuator to do?

– Control or Isolation

– Fail action – Open/Close/Last/Manual Override

– Stroke Speed

• What are the constraints of actuation?

– Motive Force – Air/Hydraulic/Electric/Power Gas

– Size and Weight

– Cost

– Environmental Impact

Actuator – No Fail Action

Double-acting actuators require pneumatic force in both

directions to drive a change in valve position.

Valve Opening Stroke Valve Closing Stroke

Actuator – Fail Action

Spring-return actuators provide true reliable

mechanical fail safe positioning

Valve Opening Stroke Valve Closing Stroke

• Other forms of motive force for

failure:

– Accumulator

– Volume tank

– Battery Backup/UPS

– Super Capacitors

Actuator Considerations

• What Valve are you mounting this to?

– Linear or Rotary

– Mounting

• What do you want the actuator to do?

– Control or Isolation

– Fail action – Open/Close/Last/Manual Override

– Stroke Speed

• What are the constraints of actuation?

– Motive Force – Air/Hydraulic/Electric/Power Gas

– Size and Weight

– Cost

– Environmental Impact

Space Constraints

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Types of Actuation

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Pressure loaded actuators

• Pneumatic

• Gas powered

• Hydraulic

• Water powered

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Rotary Rack & Pinion Actuators

• Constant torque through stroke (Double Acting)

• Compact and lightweight

• Simple and easy to maintain

• Economical choice

• Medium cycle on/off applications

• Typically pneumatic only

T= F x d

F

Torque

Rotation0 90

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Scotch-Yoke Actuators

• Increased torque at start and end

• Robust design

• Well suited for butterfly and ball valves

• Typically used for larger valve sizes

• Can be designed for most pressure sources

T= F x dTorque

Rotation0 90

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Scotch Yoke – Modular & Scalable

Power Module Drive Module Spring Module

G130T52

SR3

•

in Qatar

•

spring end

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Scotch Yoke – Morin Water Hydraulic (WH)

Standard Options utilizing SS base material allow for water powered actuators up to 160 psi

• Due to construction of actuator utilizing SS components, Morin S and B-WH designs allow for water as the power source vs. air or gas.

• Seals are modified to include a T Seal on the piston and lip seals on the piston rods

• Often there is a reliable source of water pressure vs. air pressure: waste water treatment, offshore fire water systems, fire protection.

• Water facilities in warm climates often use water pressure to save air compression costs

Hydraulic Actuators

• Much higher pressure than air

• Much smaller bore

• Require hydraulic power supply (or hand pump)

• Potential for leaks

• Much high torque or thrust output

• Reliable

Bettis PressureGuard – Emergency Shutdown System

Pump to Open, Pilot to Close

Bettis PressureMatic Pilot

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Electrification – Electric Actuators

Electric Actuators – Basic Attributes

• Sizes range from 100 in.lbs to in

excess of 1,000,000 in.lbs

• Rotary and linear applications

• DC, 1PH or 3PH AC power supply

• Fail safe Battery, UPS, Spring,

Electro-Hydraulic

• Lower installation costs

• Ideal for applications where air

supply is not available or practical

• Small envelope for larger valves

• Powerful diagnostics available

Different types of Electric Actuators

Fisher easy-Drive Baumann SV-1 Bettis EM

Bettis RTSKeystone EPI 2

Bettis XTE3000

Bettis M2CP

Bettis EHO

General Electric Actuators

Motor Gears

Electric Motor Manual Override

Handwheel

Position Sensing

Torque Sensing

Drive nut Collar

Rotary/Linear Operation

Linear/Multi-Turn Drive Sleeve

Bronze Stem nut

Stem tube / cover

• Recommended – Use stem covers for linear actuators

• Protects drive sleeve from dirt and water ingress.

• Protects operators from rising stem

Gear Train – Worm Gear

• Self-locking

• Fail last

• Cold rolled steel on

aluminum bronze

• Ability to replace

drive nut from above

• ¼ Turn or multi-turn

Gear Train – Spur Gears

• Back Drivable

• Electric brake or fail indeterminate

• Gears can be plastic

• ¼ Turn or 180 degree rotation

Gear Train – Other Types

Planetary / Differential Gear

Rack and pinion drive

Linear Ball Screw Gear

Auxiliary Gears

Worm Gear

Bevel Gear

Spur Gear

Electrification – Fail Safe Electric

Spring Return – Torsion Spring

• Spur gear actuator

• Electric brake & release

• ¼ Turn

• Limited to 3” to 4” valve

• Discrete & Analogue control

Spring Return – Belleville Springs

• Linear or ¼ Turn

– Linear 5620 lb.f (up to 4“ stroke)

– ¼ Turn up to 17,700 in.lb (18“+ butterfly)

• 0.2% control accuracy with modulating option

• Adjustable speed

• Up to SIL3 & PST (partial stroke testing)

• Non-intrusive Bluetooth

• Data logging

• HART & Modbus RTU

Spring Return – Belleville Springs

Base CM03 Actuator

Motor

Active Brake

Eddy Current Brake

Shaft Output

Linear Ball Screw Gear

Rack and pinion drive

Adjustable Mech. Endstop

Spring Assembly

Planetary / Differential Gear

Worm Gear

(Self-locking)

Spring Return – Belleville Springs

Electrification – Electro-Hydraulic

The Evolution of Electro-Hydraulics

Stand-alone

Bolt-on

Integrated

Spring Return – Electro-Hydraulic

Control Enclosure

Motor

Hydraulic Manifold

Hand Pump

Reservoir

Sight Level Gauge Local Display and Operation

G Series Hydraulic Spring Return Actuator

Circuit Breaker/ Disconnect

Electrification – Control

Control Types

• Use switches, printed circuit boards

and wires

• Configuration is ‘hard wired’

• To set limits you must open the

electrical compartment (‘intrusive’)

• Uses microprocessors on printed

circuit boards

• Configuration is programmed

• Limits set without opening electrical

compartment (‘non-intrusive’)

Electro-Mechanical Digital

Benefits of Electro-Mechanical

• Modular controls package

• Non-integral and integral starters

• Controls are located in large, hinged controls compartment

• Same controls package for multi-turn and quarter-turn

• Ease of troubleshooting

Bettis M2CP - Electro-Mechanical Actuator

• M2CP Design has been in production since 1986

• All the components are modular (removed individually or on the

backplane)

• Options are available on various boards

• Units are easily field serviceable and a robust design

• Preferred Electric for most Pipeline Companies in NA

• Multiple Supply Voltages DC, 1Ø, 3Ø

• Various motor sizes from 1/16 HP to 8 HP

• On / Off and Modulating (1,200 starts per hour)

Legacy Brews Actuator

Benefits of Digital

• Digital and non-intrusive commissioning and configuration

• Digitally stored configurations

• Configurable alerts alarms

• LCD configurable Display

• More protocols for communication

• Smart capabilities

Bettis XTE3000

• Features:– Intelligent and versatile actuator with a wide range of

torque and speed for on/off & control

– Non-intrusive setup via local interface, Bluetooth, or DCMlink

• Range:– Multi-turn torque up 1,440 Nm (1,062 ft lbs)

– Quarter-turn torque up to 63,000 Nm (46,466 ft lbs)

– Couple to available external gears to extend upper limits of torque and thrust

• Certifications:– FM, FM-C, ATEX, IECEx, NEPSI, CU-TR, INMETRO, CCOE,

KOSHA

– IP68, NEMA 4, 4X, 6

– AWWA (Q2 FY20)

• Protocols:– Modbus, HART, FOUNDATION Fieldbus, PROFIBUS,

LonWorks™

XTE3000

Bettis XTE

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Smart Capabilities - Access to data

• Actuators can be connected via

wireless mesh

• Configuration, Monitoring and

Diagnostics can be done remotely

• Saves on personnel time and

provides realtime access to data

Benefit of Smart Capabilities

Configure

Monitor

Diagnose

Smart Capabilities - Configure

• Unified user interface for

electric actuators

• Easy to use configuration and

calibration

• Central location to save, copy,

import/export and store

configurations, profiles and

diagnostic data.

• Communicates via multiple

networking protocols

Smart Capabilities - Monitor

• Real time and remote

monitoring

• Monitor dashboard gives users

quick access to asset health

and status

• Up to 53 Alarms can be

reported on the dashboard in

easy to see colour

• Live Trending of Critical

Parameters

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Status & fault indication options:

Remote Indication Features

• OPEN Limit• CLOSE Limit• OPENING• CLOSING• MOVING• LOW BATTERY• S/S in LOCAL• S/S in STOP• S/S in REMOTE• OPEN Torque Trip• CLOSE Torque Trip• OVER TORQUE – Either Direction• Communication Failure• Local ESD

• VALVE STALL• VALVE MOVED MANUALLY• LOST POWER• MOTOR OVERLOAD• LOST PHASE• OPEN Inhibit Signal Present• CLOSE Inhibit Signal Present• LOCAL ‘ESD’ Signal Present• ‘ESD’ ACTIVE• LOST ANALOG Signal• ACTUATOR FAIL• EFM (Electronics Fault Monitor)• Initialization Failure• Normal Operation

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Diagnostics

• Alarm Log

• Torque Profile

• Torque Archive

• Operation Log

– Motor Starts

– Number of

Strokes

– Motor Run Time

• Hardware Diagnostics

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Benefit: Predict & Act on Failures Before They Occur

INSTRUMENT ALERT

Time

Healt

h

FAILURE BEGINS

Failure Condition Acceleration

FAILURE

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Benefit: Predict & Act on Failures Before They Occur

Earlier Identification = Incremental Value

INSTRUMENT ALERT

Time

Healt

h

FAILURE BEGINS

Predictive Maintenance Approach

• Time-Series Analysis

• Online (In-Situ) Diagnostics

• Analytics

FAILURE

Traditional Maintenance Approaches

• Vibration

• Acoustics

• Process Variables

• Offline Diagnostics

• Preventive Maintenance

Cost of Repair

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Cost Savings Through Predictive Maintenance

Maintenance ImpactPredictiveMaintenanceBushings Thrust PadBack Thrust Washer

$X

PreventativeMaintenanceBushings Thrust PadFront Thrust WasherFront Impeller Wear RingBack Impeller Wear RingBack Thrust WasherImpeller RepairShaft.25 Torque Ring.1 Casing.2 Containment Shell

$5X

ReactiveMaintenanceBushings Thrust PadFront Thrust WasherFront Impeller Wear RingBack Impeller Wear RingBack Thrust WasherImpeller RepairShaftTorque RingCasingContainment Shell

$15X

Operations Impact

Lost ProductionRework

$40X

COST

Operations ImpactRange: 1x to 160x Cost of Pump Source: Olin Chemical Corp.

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Summary

• Always consider your valve type when looking for a new actuator

• Then consider your required functionality and limitations

• There are many options available in the market specific to your needs.

• Finally consider your plant and processes as a whole as there are lots of new

technologies that can increase the efficiency and effectiveness of your

maintenance and operations.

join the conversation

Contact Me

Hua Aun Tan – Technical Specialist

Phone

(778) 835-7164

Email

Tan.huaaun@spartancontrols.com

24/7 Support

+1 (877) 276-6404