Different types of actuators Advantages & Disadvantages Selection of Actuator Sizing of Actuator Performance Tests on Actuators Force / Torque Demanded by valves S.Rammohan, CRE, Fluid Control Research Institute

1. VALVE ACTUATOR A powered valve operator used to open or close a valve, energized manually or by pneumatic, electric or hydraulic power source. BASIC FUNCTIONS Provide enough thrust/ torque to operate the valve Hold the valve check / plug / butterfly / ball in required position Operate the sanitary valves through its full travel at rated speed Provide fail safe mode in the event of power failure Prevent excessive forces under unfavorable conditions. Actuator Linear Manual Lever Hand wheel Gear box Rotary Electric Pneumatic Motor Solenoid Diaphragm Piston Cam,Vane Fail safe Fire safe Hydraulic

2. PNEUMATIC ACTUATOR Uses compressed air as the source of energy Actuator o/p force proportional to air pressure Capacity decided by Operation time Force demanded Size of piping required to deliver air Diaphragm Piston Cam

3. Actuator types - operation • As air pressure increases, the valve opening can becomes larger or smaller • Air-to-open (normally closed, fail close): as the air P increases, the valve opening gets larger • Air-to-close (normally open, fail open): as the air P increases, the valve opening gets smaller

4. PNEUMATIC ACTUATOR ADVANTAGES Compressed air economical and convenient for use Self locking can be achieved by a spring At elevated temperature assist valve operation Exhaust air can be vented to atmosphere DIS ADVANTAGES No hammer blow to unseat the valve Limitation for holding at required position Material of construction is vulnerable for heat Manual provision create high lock in force while bewitching Susceptible to seizure due to corrosion & dirt Air consumption very high

5. ELECTRIC ACTUATORS Comprises an electric motor and a gear arrangement Electrical limit switches Torque sensor Self locking features- Threaded spindle and nut . Thread of the lead screw should be self locking Manual Operation- Normally Provided with hand wheel lever operated clutch Duty cycle Motor will be heated when put in operation Isolation - Valve operation Few times a day Regulating - Valve operation 30 - 60 starts/hr Modulating - Valve operation 600 - 1800 /hr

6. ELECTRIC ACTUATORS ADVANTAGES High rotational speed so high kinetic energy Good positioning accuracy - Reduction gearing Easy interfacing with computers No dirt or moisture Operate instantaneously over great distances Complete system can be tested w/o moving valve position Sequencing of valve operation is easy DIS ADVANTAGES Vulnerability to high temperature Vulnerability to moisture Precludes mechanical means of storing energy in the event of power failure

7. Hydraulic Actuators Used for high torque / thrust applications Different mechanisms employed Rack and pinion Piston and cylinder Hydraulic motor Rotary piston Similar to pneumatic actuation Needs energy source - Hydraulic power pack Torque output depend on fluid pressure Greater flexibility of energy source Widely used with the following Large sliding gate valves Pen-stock valves Large globe valves

8. Hydraulic Actuators Advantages Very high operating torque suitable for large sized valves Fail safe operation is easy - Hydraulic pressure stored In compressible - easy for hydraulic lock Good positional accuracy Hydraulic system is compact Disadvantages Piping pressure drop limits distance of hydraulic control Hydraulic system is costly No kinetic energy for hammer blow unseating High thermal expansion rate - thermal insulation required Close machining tolerances -susceptible to malfunction

9. Diaphragm Actuator A piece of Fabric reinforced elastomer sandwiched between casing connected to a linear shaft Double acting or with spring return Air pressures up to 4 bar only Fast response to signal changes Stroke limited to 150 - 200 mm Widely used with control valves

10. Piston Actuator A cylinder and a piston with an O ring Double acting or with spring return Air pressure up to 10 bar Different mechanisms to convert linear motion to rotary motion

11. Rack & Pinion Single or Double piston Integral rack drivers the pinion Available for 90 or 180° rotation Torque output is constant Suitable for plug valves

12. Cam Double piston by a spacer with a cam and shaft between them Rotational style determined by cam profile Mechanical stop are not required Torque varies with profile

13. SELECTION OF VALVE ACTUATOR 1. 2. 3. 4. 5. Calculation of force requirement Selection of Power source Selection of mechanism Sizing of actuator & components Selection of accessories.

14. Actuator Selection Chart 1. Calculation of force requirement 2. Selection of Power source 3. Selection of mechanism 4. Sizing of actuator & components 5. Selection of accessories. Sl.No. 1 2 3 4 5 6 7 8 9 10 11 12 13 Parameter Valve size and Type Pressure Drop Operating Condition Flow medium Sealing Fire safety Fail safe Operation Operating Temperature Cyclic Speed & rate Stem Orientation Aging Response Time Type of Control 1 2 3 4 5

20. Actuator Selection Chart 1. Calculation of force requirement 2. Selection of Power source 3. Selection of mechanism 4. Sizing of actuator & components 5. Selection of accessories. Sl.No. 1 2 3 4 5 6 7 8 9 10 11 12 13 Parameter Valve size and Type Pressure Drop Operating Condition Flow medium Sealing Fire safety Fail safe Operation Operating Temperature Cyclic Speed & rate Stem Orientation Aging Response Time Type of Control 1 

15. Actuator Selection Parameters to be considered while selection 1. Valve Type and size The torque / force requirement of the valve 2. Pressure Drop Torque / axial force - function DP 3. Services & operating condition Whether On/Off, Regulating, Modulating duty Regulating duty - based on Break away torque For part turn, actuator should counter balance the force due to unbalance

16. Actuator Selection 4. Flow medium Lubrication property of operating fluid Whether fluid is slurry or contain solid particles Erode the sealing surfaces Wear and tear depends on the operating fluid Actuator output decreases with time which needs additional capacity for actuator 5. Sealing - Bi directional Force depends on flow past the valve disc. 50% in case of BFV if seat is placed down stream Less force if the flow is from bottom of disc

17. Actuator Selection 6. Fire safety Fire safety needs additional metal seat Requirement is 50 - 100 % more normal torque 7. Fail safe operation Automatic fail safe operation - more energy to be stored Needs additional torque / force 8. Operating temperature Provided with metallic bearing higher temperature Higher friction coefficient for elevated temperature Cryogenic application needs more torque due to higher friction of plastic seat & bearing

18. Actuator Selection 9. Cyclic speed & rate Fast cyclic speed needs special actuators Large diaphragm,solenoid valves and large size tubing, quick exhaust valves Pneumatic actuation is preferred 10. Stem orientation Plays a major role in deciding the force requirement in gate valves Stem other than vertical prone to seat leakage and falling of the stem

19. Actuator Selection 11. Aging and un accounted factors Normally 25 - 40% margin is provided 20. Response Time Major factor in deciding type of actuation Fast response Pneumatic actuators are preferred Hydraulic & Electric actuators - sluggish response 13. Type of Control Positional accuracy ON / OFF or control application Especially in the case of Part turn valves

21. SIZING OF VALVE ACTUATOR Valve thrust = Port area * Differential pressure or torque * Valve factor * Stuffing box friction * pressure effect on stem a) Valve type b) Valve size c) Maximum differential pressure d) Minimum pneumatic / hydraulic pressure (for Pneumatic/hydraulic system only) e) Valve stem diameter

22. SIZING OF VALVE ACTUATOR Valve factor – Cage type or double guided stem – ON/OFF or throttling ( control) – Seating is metal to metal or soft seat ( with soft seat material) – Liquid or gas with operating temperature – Whether fail safe Stuffing box friction – Stem diameter – Stuffing element used – Maximum operating pressure

23. SIZING OF VALVE ACTUATOR Pressure effect on stem – Stem diameter – Maximum differential pressure For fail safe system whether with spring or not : if spring type a) Valve stroke b) Actuator thrust w/o spring c) Spring factor Spring wire diameter Spring diameter Length of spring

24. SIZING OF VALVE ACTUATOR Accumulator type a) Valve thrust at beginning & end of stroke b) Supply air pressure c) Mode of closure for air failure d) Volume of actuator e) No. of strokes required after air failure

25. Actuator sizing procedure Diaphragm --spring return Diaphragm--Scotch Yoke Torque Design Torque 0 Valve Torque Valve opening 90

26. CASE STUDY Actuators for a Filter bed of a water treatment plant

27. Selection of actuator Duty Bidirectional sealing Fire safety Fail safe Cyclic speed & rate Stem orientation Aging & related factors Response Continuous N.A N.A N.A Continuous N.A N.A N.A Continuous N.A N.A N.A Continuous N.A N.A N.A Vertical NEW Medium Vertical NEW Medium Vertical NEW Medium Vertical NEW Medium

28. Sizing of Actuator Valve type Valve size Operating pressure Operating temperature Shut off pressure Pressure drop-operation Operating condition Flow medium Torque / Force required Actuator Torque/ force Gate 12" 1.5 bar Ambient 1.5 bar Nil ON/OFF Water Gate 12" 1.5 bar Ambient 1.5 bar Nil ON/OFF Water Butterfly 12" 1.5 bar Ambient 1.5 bar 0.1 bar ON/OFF Water Gate 12" 1.5 bar Ambient 1.5 bar Nil ON/OFF Water

29. Testing of Actuators

30. Standards related to testing of Actuators • ANSI/AWWA/C 504 Soft seated butterfly valves • ANSI/AWWA/C 540 Power actuating devices for valves • BS 4151 Method of evaluation of pneumatic positions • ISA S 26 Dynamic response testing • IS 9334 Specification of electric motor actuators • CEGB 569701 Electric actuators - Multi turn • IEEE 382 Qualification of actuators for nuclear power plants • IS 8935 Specification of electric solenoid actuators

31. Performance Evaluation of Actuators Type tests for pneumatic actuators - BS 4151 A.1. Accuracy test a. Linearity: b. Hysteresis : A.2. Dead zone test A.3. Supply pressure variation A.4. Vibration test A.5. Drift test A.6. Accelerated life test A.7. Gain A.8. Hunting A.9. Dynamic response test A.10. Hydro-static test A.11. Endurance test A.12. Torque test c. Repeat-ability

32. Routine tests for actuators a) Accuracy test (A.1) b) Supply variation test (A.3) c) Hydro-static test (A.10)

33. CYLINDER ACTUATOR Standard AWWA C 540 Type test • Endurance test No of cycles 5000 One stroke -One cycle Two stroke ( Open-Close-Open) OFF time 10 min. maximum Pressure reach the rated at the end of stroke • Hydro-static test 3 times rated pressure before and after the endurance test

34. CYLINDER ACTUATOR Standard AWWA C 540 Performance test Maximum no load driver pressure Maximum no load driver pressure Quarter turn actuators Torque test Torque applied - Twice the rated Endurance test No. of cycles - Depend on torque Full rated torque at seating 30% of rate during rest of stroke 7 psi for pneumatic 15 psi for hydraulic

35. ELECTRIC MOTOR ACTUATOR Standard :AWWA C 540 Power supply variation Input voltage Frequency Current consumed Performance test Actual stroke time 90 - 110 % of rated Torque switch to limit output torque by 120% of seating torque Limit switch to limit travel by 110% of rated

36. ELECTRIC MOTOR ACTUATOR Standard :AWWA C 540 Endurance test No of cycles One stroke One cycle OFF time Seating Torque Running Torque 5000 30sec. Two stroke ( Open - Close - Open) 10 min. maximum Rated Torque ( 10% at the ends) 30% rated torque ( 10 -90% of stroke)

37. ELECTRIC MOTOR ACTUATOR Standard : CEGB 569701 Working check Wiring for continuity & correctness Correct phase rotation of motor Pressurization Gear box to be filled with oil at 1 bar for 15 minutes Insulation resistance Motor winding & transformer primary with dc voltage High voltage test As per Bs 4999 part 60 Torque characteristics As per Bs 4999 part 32 Max. operating time for specified torque Ambient temperature of 20 40 and 70 degree C

38. ELECTRIC MOTOR ACTUATOR Standard : CEGB 569701 Power supply variation Input voltage 80 % rated - at max torque switch setting Running with 75% rated voltage for 2 minutes Torque switch setting Torque switch to max. setting and design torque applied on the actuator sleeve Increase till torque switch operates Repeat this with minimum torque settings Consecutive starts Over heating test As per Bs 4999 part 60

39. ELECTRIC MOTOR ACTUATOR Standard : CEGB 569701 Stall torque test Torque switch setting overridden and torque applied on the actuator sleeve increase till motor stalls at 100 % & 75 % rated voltage Humidity Test 70 deg. And 95 % RH for 18 hours then 50 for 24 hours repeated for 28 days Endurance Test 500000 revolutions with 24 rpm Cycling period 4 min. 33 % torque during 95 % of travel 95 % rated torque at 5 % of travel After each 500 cycles manual check of operation

40. ELECTRIC MOTOR ACTUATOR Standard : IS 9334 Life test Mounted on the valve Operated for 500 operations Check the performance Response time test Response time verified at rated voltage & Frequency Variation in supply voltage Test Supply voltage varied by 6 % No change in performance Variation in Frequency Frequency varied by 3 %

41. ELECTRIC MOTOR ACTUATOR Standard : IS 9334 Tests for motor AS per IS 325 Insulation resistance High voltage test Full load voltage, current, power input & slip Temperature rise test Tests for limit switches Endurance test No of cycles depends on the breaking current Function properly after endurance Tests on output shaft Tested for an axial force equivalent to rated torque Tests on Terminal boxes Damp heat cycling test

42. ELECTRIC MOTOR ACTUATOR Standard : IS 9334 Tests on Terminal boxes IS 2147 Damp heat cycling test IS 9000 part 5/ section 1 Upper temperature 55 C No. of cycles 6

43. Pneumatic Position-er Testing Standard BS 4151 Static Behavior Average departure from Linearity Hysteresis Repeat ability 3 psi - 9 psi for full stroke 9 psi - 15 psi for full stroke 3 psi - 15 psi for full stroke Dead zone Forward path : Largest change in input signal without a detectable change in valve position Feed back path : Largest change in stem position without causing a feed back

44. Pneumatic Position-er Testing CONSTANCY Standard BS 4151 Pressure supply variation 10% of normal value Accuracy test Temperature variation -20, 0, 20, 40°C Accuracy test Mounting position 10° from vertical (4 dir.) Accuracy test Vibration Shaker table - resonance search 5 - 150 Hz Displacement 0.05” 1 - 10 Hz Acceleration 0.5g 10 150 Hz Frequency rate one octave in two minutes To be conducted 4 and 14 psi input pressure

45. Pneumatic Position-er Testing Standard BS 4151 STABILITY Drift 14 psi input pressure for 168 hours Each 24 hours, position for 3 & 15 psi to be measured Accelerated life test Sine wave input with mid point at 9 psi and peak to pack of 6 psi (6 - 12 psi) Frequency of 10 cycles per minute 15000 cycles of operation Position corresponding to 3 & 15 psi to be checked before and after the test

46. DYNAMIC RESPONSE TESTING Standard ISA S 26 Two types of input a) Sine wave - Mid point at arithmetic mean of actual input Peak to peak - 10% of actual input Signal frequency 0.001 - 20 Hz Minimum 20 points in 3 decade Amplitude of input and output signal Phase relationship of i/p and o/p signal At initial frequency, o/p is same as steady state value with same input and no phase difference At maximum frequency,o/p is 10% of same signal at steady state or the phase lag is more than 300° Input signal Amplitude 1db from 0.001 - 20 Hz

47. DYNAMIC RESPONSE TESTING Standard ISA S 26

48. DYNAMIC RESPONSE TESTING Standard ISA S 26 Phase shift <5° Drift <5% of full span in 4 hours Procedure Blank Run Actual Testing Static Calibration Out put Magnitude Plot - Semi log - Signal freq. Vs Gain Phase Plot - Semi log - Signal Freq. Vs Phase lag b)Step input Input 10% step or 90% step of mean Output Magnitude Plot - Time Vs input signal Time Vs output signal