Jamesbury™ Quadra-Powr™ Spring Diaphragm Quarter Turn Actuators for Use in Both Modulating Control and On-Off Service

Valves provide pressure reduction and flow control through piping systems and are critical to industries that form the backbone of the modern world. The valve actuator is crucial for valve operation. Actuators are powered devices that move valves between open and closed states. The valves can open or close depending on the movement it receives from an actuator; this motion is responsible for controlling the flow and pressure within an industrial system or process.

Jamesbury™ Quadra-Powr™ spring diaphragm QPX series quarter turn actuators are applicable for modulating control and on-off service. These actuators offer an exceptionally long cycle life and are well-suited to operate almost any type of rotary valve. The QPX actuator provides smooth and efficient quarter-turn valve operation and safe and reliable operation even when minimal supply pressure is available.

Exclusively developed for quarter-turn valve service, Quadra-Powr™ X spring-diaphragm actuators provide safe and reliable operation even when minimal supply pressures are available. Yet they can operate at pressures as high as 7 bar (100 psi).

These units operate by air, gas, water, oil, or other supply media compatible with the actuator's ductile iron/carbon steel casing and the Buna-N diaphragm reinforced with polyamide fabric. This unique spring-diaphragm actuator for rotary valves provides safe, smooth, and reliable valve actuation at minimal pressures and up to 100 psi (6.9 BAR). Quadra-Powr X torque outputs range from 15 to 796 Nm (11 to 587 ft-lbs), depending on actuator selection and available supply pressure.

Jamesbury™ Quadra-Powr™ Features:

• Rolling diaphragm for minimum friction
• Low friction bearings – factory lubricated for lifetime
• Field reversible for spring to open or close simply by flipping actuator over
• Safety contained springs prevent hazards of inadvertent ejection during maintenance
• Corrosion resistant – two layer epoxy and polyurethane paint with stainless steel fasteners
• Adjustable stops for both open and closed positions
• Wide input pressure range – up to 7 bar (100 psi)

For more information, contact Mead O'Brien. Call (800) 874-9655 or visit https://meadobrien.com.

Pneumatic Valve Actuators

Actuated valve with pneumatic
scotch yoke actuator (Metso Neles)

Pneumatic valve actuators are used in extreme conditions in many industries such as oil and gas, chemical, water and wastewater, bulk storage, pulp & paper, and power generation. These devices are used in a multitude of valve control processes for regulation (or cessation) of flow, and / or controlling pressure and level.  Due to their reliability and simplicity, pneumatic actuators are one of the most popular types of actuators used in industry today.

Pneumatic valve actuators work by conversion of air pressure into motion. The device applies a force of air to a diaphragm, rotary vane, or piston that is attached to the actuator shaft, which is then mechanically connected to the stem of the valve or damper. Depending on the type, pneumatic actuators produce either linear or rotary motion. 

ACTUATOR ACTION - SPRING RETURN OR DOUBLE ACTING

Spring Return — Pneumatic actuators with spring return design have air supplied from one side. The spring on the opposite side is responsible for the motion. With this design, air compression moves the opens or shuts the valves while the spring is responsible for the opposite motion. 

Diaphragm actuator
(Metso Neles)

Double Acting  — Double acting actuators have air fed on both sides of a piston. The pressure on one side is higher as compared to the other that results in the required in movement. Air is used to open and close the valves.  

PNEUMATIC ACTUATOR DESIGNS

Diaphragm Actuators — Diaphragm actuators work by applying pressure to a thin membrane or diaphragm.  

Piston Actuators — Piston actuators apply compress air to a piston that is within a cylinder. Air is fed into a chamber that moves the piston in one direction. The piston moves in the opposite direction when air pressure is removed (spring assisted) or directed to the other side (double acting). 

Rack and Pinion — Rack and pinion actuators produce rotation by applying pressure to pistons with gears that turn a pinion gear. Rack and pinion actuators can be spring return or double acting. They are valued because of their compact size and versatility.

Rack and pinion actuator
(Metso Jamesbury)

Scotch Yoke — A scotch-yoke actuator contains a piston, yoke, connecting shaft, and rotary pin. They can be direct acting or spring return. They are capable of providing very high torque outputs and are generally used on larger valves. Scotch yoke actuators can be powered by air or process gas.

Rotary Vane —Vane actuators use a mechanical vane, connected to a shaft, that separates a circular shaped body in two "clamshell" halves. The vane moves in response to the differential pressure inside the actuator body, turning the shaft clockwise or counter-clockwise in response to the pressure differential. External springs units are available for spring return models.

Scotch yoke actuator (Metso Neles)

BENEFITS OF PNEUMATIC ACTUATORS

The use of compressed air (typically found in all industrial facilities) as the power source is the prime advantage for the use of pneumatic actuators. Additionally, pneumatic actuators have an advantage in suitability for different environments and can be used in extremes temperatures. They are preferred over electrical actuators in explosive, flammable and other hazardous areas because they do not require electricity (a possible ignition source) to operate. They do not create electrical fields or electrical noise since there is no electrical motor. Pneumatic valve actuators are faster opening and closing compared to their electric counterparts. Finally, they are low cost, lightweight, durable, require little maintenance (depending on quality) and there are a myriad of positioning controls, speed controls, and communications devices available for tailoring the actuator to the application.

DRAWBACKS OF PNEUMATIC ACTUATORS

While compressed air is the main reason for using pneumatic actuators, it can also be considered a drawback. For instance, pneumatic actuators can perform poorly when the air supply source is located at a distance, resulting in lag and slow response. Another drawback of pneumatic actuators is the additional cost for the compressed air system due to the requirement of dust filters and moisture removing dryers. These are required to ensure clean air is fed into the system.

APPLYING PNEUMATIC ACTUATORS

There are many aspects to the proper, safe, and efficient application of pneumatic actuators to valves and dampers. The sizing the power (torque) output being paramount. All valves and dampers have unique torque requirements. You must consider a threshold force for opening (breakaway), as the valve continues to move to its open or closed position, and then for seating. Matching the actuators to the valve type, and operating conditions is critical. Published torque curves must be reviewed and understood. Too little torque and the valve will not respond. Too much torque increases cost and can damage the valve. Spring return adds to this complexity. Considering all this, it is strongly suggested you always discuss any valve actuation requirement with an experience applications expert. They will ensure the proper, safe, and cost effective mating of pneumatic actuator to valve or damper.

Industrial Valve Actuator Basics

Electric actuator (Limitorque)

Actuators are devices which supply the force and motion to open and close valves. They can be manually, pneumatically, hydraulically, or electrically operated. In common industrial usage, the term actuator generally refers to a device which employs a non-human power source and can respond to a controlling signal. Handles and wheels, technically manual actuators, are not usually referred to as actuators. They do not provide the automation component characteristic of powered units.

The primary function of a valve actuator is to set and hold the valve position in response to a process control signal. Actuator operation is related to the valve on which it is installed, not the process regulated by the valve. Thus a general purpose actuator may be used across a broad range of applications.

Pneumatic actuator (Metso Neles)

In a control loop, the controller has an input signal parameter, registered from the process, and compares it to a desired setpoint parameter. The controller adjusts its output to eliminate the difference between the process setpoint and process measured condition. The output signal then drives some control element, in this case the actuator, so that the error between setpoint and actual conditions is reduced. The output signal from the controller serves as the input signal to the actuator, resulting in a repositioning of the valve trim to increase or decrease the fluid flow through the valve.

An actuator must provide sufficient force to open and close its companion valve. The size or power of the actuator must match the operating and torque requirements of the companion valve. After an evaluation is done for the specific application, it may be found that other things must be accommodated by the actuator, such as dynamic fluid properties of the process or the seating and unseating properties of the valve. It is important that each specific application be evaluated to develop a carefully matched valve and actuator for the process.

Hydraulic and electric actuators are readily available in multi-turn and quarter-turn configurations. Pneumatic actuators are generally one of two types applied to quarter-turn valves: scotch-yoke and rack and pinion. A third type of pneumatic actuator, the vane actuator, is also available.

For converting input power into torque, electric actuators use motors and gear boxes while pneumatic actuators use air cylinders. Depending on torque and force required by the valve, the motor horsepower, gearing, and size of pneumatic cylinder may change.

Linear pneumatic actuator (Neles)

There are almost countless valve actuator variants available in the industrial marketplace. Many are tailored for very narrow application ranges, while others are more generally applied. Special designs can offer more complex operating characteristics. Ultimately, when applying actuators to any type of device, consultation with an application specialist is recommended to help establish and attain proper performance, safety and cost goals, as well as evaluation and matching of the proper actuator to the valve operation requirements. Share your fluid process control requirements with a specialist in valve automation, combining your own process knowledge and experience with their product application expertise to develop effective solutions.

Understanding Industrial Valve Actuators

Automated Pneumatic
Ball Valve (Jamesbury)

Valves are essential to industries which constitute the backbone of the modern world. The prevalence of valves in engineering, mechanics, and science demands that each individual valve performs to a certain standard. Just as the valve itself is a key component of a larger system, the valve actuator is as important to the valve as the valve is to the industry in which it functions. Actuators are powered mechanisms that position valves between open and closed states; the actuators are controllable either by manual control or as part of an automated control loop, where the actuator responds to a remote control signal. Depending on the valve and actuator combination, valves of different types can be closed, fully open, or somewhere in-between. Current actuation technology allows for remote indication of valve position, as well as other diagnostic and operational information. Regardless of its source of power, be it electric, hydraulic, pneumatic, or another, all actuators produce either linear or rotary motion under the command of a control source.

Thanks to actuators, multiple valves can be controlled in a process system in a coordinated fashion; imagine if, in a large industrial environment, engineers had to physically adjust every valve via a hand wheel or lever! While that manual arrangement may create jobs, it is, unfortunately, completely impractical from a logistical and economic perspective. Actuators enable automation to be applied to valve operation.

Pneumatic actuator
(Jamesbury Quadra-Powr) 

Pneumatic actuators utilize air pressure as the motive force which changes the position of a valve. Pressurized-liquid reliant devices are known as hydraulic actuators. Electric actuators, either motor driven or solenoid operated, rely on electric power to drive the valve trim into position. With controllers constantly monitoring a process, evaluating inputs, changes in valve position can be remotely controlled to provide the needed response to maintain the desired process condition.

Manual operation and regulation of valves is becoming less prevalent as automation continues to gain traction throughout every industry. Valve actuators serve as the interface between the control intelligence and the physical movement of the valve. The timeliness and automation advantages of the valve actuators also serve as an immense help in risk mitigation, where, as long as the system is functioning correctly, critical calamities in either environmental conditions or to a facility can be pre-empted and quickly prevented. Generally speaking, manual actuators rely on hand operation of levers, gears, or wheels, but valves which are frequently changed (or which exist in remote areas) benefit from an automatic actuator with an external power source for a myriad of practical reasons, most pressingly being located in an area mostly impractical for manual operation or complicated by hazardous conditions.

Electric Actuator
(Limitorque)

Thanks to their versatility and stratified uses, actuators serve as industrial keystones to, arguably, one of the most important control elements of industries around the world. Just as industries are the backbones of societies, valves are key building blocks to industrial processes, with actuators as an invaluable device ensuring both safe and precise operation.

Using a Valve Monitor for Tank Fill Control

Tank fill application using a StoneL Axiom
Expeditor to throttle flow.

Fill tanks and hoppers rapidly and accurately using the StoneL Axiom Expeditor valve monitor on a pneumatically operated valve.

You can set the Axiom Expeditor to partially close the valve to reduce flow as the full level approaches. You get fast, economical “topping off” of every batch with a single valve sized for high flow rates, which may be throttled back at the end of the fill cycle.

Simple operation and control system integration

• Full open and closed cycling is performed by energizing and de-energizing the discrete 24 VDC output (DO) from the control system.
• A preset intermediate position may be achieved by maintaining power from the discrete output (DO) and switching on the analog output (AO) at a preset level between 4 and 20 mA.
• Intermediate control is achieved by maintaining power from the discrete output (DO) and energizing the control system’s analog output (AO). By changing the AO signal, the Axiom control output will toggle the solenoids to the desired position within ±4% of full scale.
• The valve/actuator operates to the fail-safe position whenever the discrete output (DO) is de-energized.

Schematic for tank fill application showing control inputs/outputs.

Watch this short video illustrating how the tank fill feature works.

For more information on valve monitoring and control visit this link or call Mead O'Brien at (800) 892-2769.

BIST (Built-in-Self-Test) Features for Electronic Valve Actuators

Electric actuator (Limittorque)

Abstract

The development and implementation of safety related devices in plant systems is crucial for dependable operation, not to mention peace of mind. Safety and safe operation were once only high priorities for installations that involve hazardous environments. Expensive certification testing was, and still is, paramount to meeting the hazards of such environments, but a new level of plant-wide integrity is emerging — that of Safety Integrity Level (SIL) and SIS. SIL is a safety rating that can be derived by analyzing a system to determine the risk of a failure occurring and the severity of its consequences. Safety Instrumented Systems (SIS) are systems containing instrumentation or controls installed for the purpose of preventing or mitigating a failure either by emergency shut down (ESD) or diverting the hazard. New or replacement equipment must have the ability to be introduced into plant systems without jeopardizing either the SIL of the operation or negatively impacting the SIS.

Read the entire white paper below.

For more information visit this link or contact:

Mead O'Brien
www.meadobrien.com

(800) 892-2769

BIST (Built-in-Self-Test) Features for Electronic Valve Actuators from Mead O'Brien, Inc.

Flowserve Limitorque Actuators: General Safety Precautions and Practices

Limitorque multi-turn actuator.

The following are general guidelines for safely operating Limitorque actuators. This post is intended to supplement Flowserve / Limitorque's ongoing efforts to provide information on the safe and proper use of electric valve actuators on industrial globe, gate, ball, butterfly and plug valves.  It is critically important to always refer to the installation & maintenance manual before applying, installing and servicing Limitorque actuators. If unsure about any of the recommended safety or installation procedures, contact a factory authorized technician before going any further.

More than 1 million Limitorque actuators have been installed around the world, and some have been in operation for more than 50 years. The ruggedness and reliability of Limitorque electric actuators are among the primary reasons that customers continue to select Limitorque products.

Actuators requiring 90° of rotation to operate are necessary for quarter-turn valves such as ball, butterfly, plug and dampers, and rotary control valves. These types of Limitorque electric actuators are available for operations such as open-close, modulating, network and rotary service.

Multi-turn actuators are required to operate various types of rising stem valves such as gate, slide-gates, globe, check and linear control valves. These types of Limitorque electric actuators are available for operations such as open-close, modulating, network and linear service.

General Safety Precautions

1. Warning: Read the Installation and Maintenance Manual carefully and completely before attempting to install, operate, or troubleshoot the Limitorque actuator.
2. Warning: Be aware of electrical hazards. Turn off incoming power before working on the actuator and before opening the switch compartment.
3. Warning: Potential HIGH PRESSURE vessel — be aware of high-pressure hazards associated with the attached valve or other actuated device when installing or performing maintenance on the actuator. Do not remove the actuator mounting bolts from the valve or actuated device unless the valve or device stem is secured or there is no pressure in the line.
4. Warning: For maintenance and/or disassembly of the actuator while installed on the valve, ensure that the actuator is not under thrust or torque load. If the valve must be left in service, the valve stem must be locked in such a way as to prevent any movement of the valve stem.
5. Warning: Do not attempt to remove the spring cartridge cap, housing cover, or stem nut locknut from the actuator while the valve or actuated device is under load.
6. Warning: Do not manually operate the actuator with devices other than the installed handwheel and declutch lever. Using force beyond the ratings of the actuator and/or using additive force devices such as cheater bars, wheel wrenches, pipe wrenches, or other devices on the actuator handwheel or declutch lever may cause serious personal injury and/or damage to the actuator and valve.
7. Warning: Do not exceed any design limitations or make modifications to this equipment without first consulting Limitorque.
8. Warning: Actuators equipped with electrical devices (motors, controls) requiring field wiring must be wired and checked for proper operation by a qualified tradesman.
9. Warning: Use of the product must be suspended any time it fails to operate properly.
10. Caution: Do not use oversized motor overload heaters. Instead, look for the cause of the overload.
11. Caution: Do not operate the valve under motor operation without first setting or checking the limit switch setting and motor direction.
12. Caution: Do not force the declutch lever into the motor operation position. The lever returns to this position automatically when the motor is energized.
13. Caution: Do not depress the declutch lever during motor operation to stop valve travel.
14. Caution: Do not use replacement parts that are not genuine Flowserve Limitorque parts, as serious personal injury and/or damage to the actuator and valve may result.
15. Caution: Do not lift actuator/gearbox or actuator/valve combinations with only the eye bolts in the SMB actuator. These eye bolts are designed for lifting the SMB actuator only.

General Safety Practices

The following check points should be performed to maintain safe operation of the actuator:

1. Eye bolts in SMB and SB actuators are designed for lifting only the actuator and not associated gearboxes or valves.
2. Mount the actuator with the motor in a horizontal plane, if possible.
3. Keep the switch compartment clean and dry.
4. Keep the valve stem clean and lubricated.
5. Set up a periodic operating schedule for infrequently used valves.
6. Verify all actuator wiring is in accordance with the applicable wiring diagram.
7. Carefully check for correct motor rotation direction. If the valve closes when open button is pushed, the motor leads may have to be reversed.
8. Verify the stem nut is secured tightly by the locknut and that the top thread of the locknut is crimped or staked in two places.
9. Use a protective stem cover. Check valve stem travel and clearance before mounting covers on rising stem valves.

Mead O'Brien Authorized
Blue Ribbon Limitorque Parts & Service

For more information, or if you need field support with any Limitorque actuator, parts, or service, contact one of the following Mead O'Brien offices: 

www.meadobrien.com

Mead O’Brien, Inc.
10800 Midwest Industrial Blvd
St. Louis, Missouri 63132
(314) 423-5161

Mead O’Brien, Inc.
1429 Atlantic
North Kansas City, MO 64116
(816) 471-3993

Mead O’Brien, Inc.
16 South Main Street
PO Box 1086
Calvert City, Kentucky 42029-1086
(270) 395-7330

Mead O’Brien, Inc.
824 West Elgin
Broken Arrow, Oklahoma 74012
(918) 251-1588

The Rack and Pinion Style Pneumatic Valve Actuator

Rack & Pinion Actuator
(courtesy of Flowserve Automax)

Three primary kinds of valve actuators are commonly used: pneumatic, hydraulic, and electric.

Pneumatic actuators can be further categorized as scotch yoke design, vane design, and the subject of this post - rack and pinion actuators.

Rack and pinion actuators provide a rotational movement designed to open and close quarter-turn valves such as ball, butterfly, or plug valves and also for operating industrial or commercial dampers.

The rotational movement of a rack and pinion actuator is accomplished via linear motion and two gears. A circular gear, referred to a “pinion” engages the teeth of a linear gear “bar” referred to as the “rack”.

Pneumatic actuators use pistons that are attached to the rack. As air or spring power is applied the to pistons, the rack is “pushed” inward or “pulled” outward. This linear movement is transferred to the rotary pinion gear (in both directions) providing bi-directional rotation.

Visual of rack and pinion
(courtesy of Wikipedia)

Rack and pinion actuators pistons can be pressurized with air, gas, or oil to provide the linear the movement that spins the pinion gear. To rotate the pinion gear in the opposite direction, the air, gas, or oil must be redirected to the other sides of the piston, or use coil springs as the energy source for rotation. Rack and pinion actuators using springs are referred to as "spring-return actuators". Actuators that rely on opposite side pressurization of the rack are referred to as "direct acting".

Most actuators are designed for 100-degree travel with clockwise and counterclockwise travel adjustment for open and closed positions. World standard ISO mounting pad are commonly available to provide ease and flexibility in direct valve installation.

NAMUR mounting dimensions on actuator pneumatic port connections and on actuator accessory holes and drive shaft are also common design features to make adding pilot valves and accessories more convenient.

Fully automated valve with rack
and pinion actuator, solenoid, and
limit switch.

Pneumatic pneumatic rack and pinion actuators are compact and save space. They are reliable, durable and provide a good life cycle. There are many brands of rack and pinion actuators on the market, all with subtle differences in piston seals, shaft seals, spring design and body designs.

For more information on any pneumatic or electric valve automation project, contact:

Mead O’Brien, Inc.
www.meadobrien.com
10800 Midwest Industrial Blvd
St. Louis, Missouri 63132
Phone (314) 423-5161
Toll Free (800) 874-9655
Fax (314) 423-5707
Email: meadstl@meadobrien.com