Limitorque Making Valve Control Easier Electric Actuator .

LimitorqueMaking Valve Control Easier Electric Actuator TechnologiesDesign ApproachesPresenters:Earnest CareyManager,Flowserve Limitorque Product Managementecarey@flowserve.comDavid MontgomerySMB & L120 Actuator Product Managerdamontgomery@flowserve.com1LimitorqueMaking Valve Control Easier Electric & Electronic ActuatorsSite ConsiderationsApplication Issues High ambient temperatures Particulate-laden atmosphere Shock and vibration2

LimitorqueMaking Valve Control Easier Electric ActuatorsDesign Approaches Electro-Mechanical ActuationL120 Electric ActuatorsSMB Electric Actuator3LimitorqueMaking Valve Control Easier Electric ActuatorsDesign Approaches Electronic, Non-intrusive ActuationMX Actuator4

LimitorqueMaking Valve Control Easier Electro-Mechanical Actuators Multi-turn output Double reduction gear set(Motor set & Worm set) Wide range of output speedsdue to motor and gearingcombinations Electro-mechanical torquecontrol Electro-mechanical positioncontrol Broad range of thrust and torqueratingsSMB Actuator5LimitorqueMaking Valve Control Easier Electro-Mechanical ActuatorsEnvironmental Considerations Weatherproof Hazardous – explosion-proof, dust ignition proofFactory Mutual & CSA certifications to:Class I - Groups C & D - Divisions 1Class II, Groups E, F, G - Division 1Vibration Ability to withstand severe shock and vibrationProven by independent tests, such as those for nuclear and USNavy installations6

LimitorqueMaking Valve Control Easier Electro-Mechanical ActuatorsTemperature Suitable for line temperatures over 1,000o F Spring compensation option for stem growthor high speed Viton seals Teflon wiring High temperature lubricants7LimitorqueMaking Valve Control Easier Electro-Mechanical ActuatorsElectrical / Mechanical Features Cast iron or ductile iron gear housings Locking gearing Hammerblow effectLost motion at the drive sleeve overcomes sticking valves byapplying a “hammer blow” effect to the stem nut/valve steminterface Handwheel Operation Position Control (Limit Switch) Torque Control (Torque Switch) Position Indication – 0-10v or 4-20mA output8

LimitorqueMaking Valve Control Easier Electro-Mechanical ActuatorControlsNo Controls Unit – reversing starter mounted remotelyfrom the actuatorIntegral Reversing Controls – reversing starter mountedinside the actuator control compartment Electrical and mechanical options available¾ Torque trending from torque switch output¾ Valve disc position feedback¾ On-actuator position indication9LimitorqueMaking Valve Control Easier Electro-Mechanical ActuatorsPosition Control Switch(Geared Limit Switch) Gear driven- reliable operation- 100% repeatable position control. In step at all timeswhether in manual or motor operation Infinite Set Positions from Full Open to Full Close 16 Electrical Contacts, 300v rated, to provide:- position control of the valve disc-to-seat interface- sequencing interface for related processes- valve position indication (open, closed, mid-travel)10

LimitorqueMaking Valve Control Easier Electro-Mechanical ActuatorsTorque Control Switch(Torque Switch) Provides torque control in open and close directions Adjustable to allow for changes in torque requirements dueto valve seat wear or changes in operational requirements Provides Overload ProtectionTorque output limited to prevent excessive torque output Tight Valve Closure / Torque Seating Electrical contacts rated to 300v11LimitorqueMaking Valve Control Easier Electro-Mechanical ActuatorsMotor DesignsA wide range of motor options to meet variedinstallation requirements AC Motors1 phase, 1-60-115v & 230v3 phase, 3-60-208v to 575v DC Motors125v or 250vMotor design options include extended duty and/or extendeddynamic torque12

LimitorqueMaking Valve Control Easier Electro-Mechanical ActuatorsSummary Electro-Mechanical actuators are most often applied where:– the actuator controls are remotely located– the service conditions are the most severe Viton seals, lubricant, and wiring providing protection againsthigh ambient temperatures Rugged design with proven long-term dependability13LimitorqueMaking Valve Control Easier Electronic Non-IntrusiveActuation14

LimitorqueMaking Valve Control Easier Electronic ActuationSmart, Non-intrusiveNo.Description1Three phase motor2Motor gear attachment3Plug-in connectors4Termination chamber5Terminal connectionblock6Gear set7Thrust base8Control chamber9Local control switches10Multi-lingual display11Absolute encoder12Cast aluminum housing13Declutch lever14Handwheel15LimitorqueMaking Valve Control Easier Electronic ActuatorsPosition Sensing, Encoders Non-intrusive actuators typically useencoders to sense valve positionTwo basic types of encoders –incremental and absoluteIncremental encoders count turns ofdrive sleeve digitally, but require someauxiliary power supply to maintain thisinformation if main power is removedAbsolute encoders countincrementally, but since they areabsolute, can maintain position whenpower is isolated without auxiliarypower supply16

LimitorqueMaking Valve Control Easier Electronic ActuatorsTorque SensingMX Torque sensing is electronic technology A microprocessor calculates output torque from motorspeed, and voltage and temperature fluctuations. Theadvantage is there are no moving parts that are subjectto environmental conditions.Torque limit may be set from 40–100% of rating in 1%increments.A boost circuit is included to prevent torque trip duringinitial valve unseating and in cold climates.This torque boost feature can also be User configured tosupply the maximum amount of torque the unit iscapable of producing for aging or severe service valves.A “Jammed Valve Protection” feature, with automaticretry sequence, is included to de-energize the motor if theoutput torque requirement exceeds boost torque.17LimitorqueMaking Valve Control Easier Electronic ActuatorsVibration and Seismic TestsTest LevelsMXVibration LevelsSeismic LevelsDrop TestIEC68-2-6;5-200-5 HZsw eeps @0.75g in 3axes; 2-352 Hz @1.0g in 35.0g from3.5-35 HZin 3 axesASTMD3332-88,method A18

LimitorqueMaking Valve Control Easier Electronic Actuators - Diagnostics FDA Frequency Domain Analysis, & captures torque, position , orspeed values @ regular time intervals when the actuator is inmotorized operation.The data collected is then calculated w/ a FFT (Fast FourierTransform), which converts & stores the data as frequency.Frequency is used to determine a variation from normal operationwhich may indicate a premature component failureWhen compared w/ a baseline plot, collected @ EOL, a trend couldindicate a valve or actuator 1011712559667381513744290220715 Good Drivetrain0.008Bad drivetrain0.008MANF PROCESS ERROR OR EXCESSIVE W EARUnacceptable variations in worm shaft lead angle0.0070.006Fundamental freq, 1st & 2nd 04.700 .0 B.I.S.T. features – redundant capabilities – ifone of 18 optical devices fails (9 pairs),encoder can switch to another optical paireddevice and continue safe operation (up to50% failure)An alarm will be noted that a “HardwareFailure” has occurred and should be resolved.Continued safe operation of the actuator ispermissible until a second paired device fails.7 102.5109.9117.2124.5 19LimitorqueMaking Valve Control Easier Electronic ActuatorsDiagnosticsThe MX now offers Bluetooth technologyas optional, up to 10 meters. When usedwith Flowserve Limitorque’s Windows CEbased graphical interface Dashboard,diagnostic information can be transferredeasily to a PDA, lap top computer or cellphone. In addition, new firmware can beuploaded and actuator configurationstransferred from one device to any numberof subsequent actuators.Standard low power wireless communication pathto the actuator enables monitoring andconfiguration of the unit via a Bluetoothequipped PC, PDA, Cell Phone, etc WITHOUThaving to stand directly in front of the controlhead. FHSS (Frequency Hopping SpreadSpectrum) allows a reliable communication linkeven in a “noisy” environment & 128 bit dataencryption can be enabled to protect the privacyof the link. MX Dashboard configuration /diagnostics tools can use the Bluetooth link as ameans for communicating with the actuator.Visible Blue LED in the controls LCD windowsignifies an active Bluetooth link to the actuatoris established.20

LimitorqueMaking Valve Control Easier Electronic ActuatorsNetworksModbus Interconnectivity options provideflexibility for interfacing with variouscustomer control systems by utilizingproven and accepted open systems basedcommunication architectures.Network Options:Master Station IIFoundation Fieldbus H1Profibus DP-V1Profibus PAModbusDeviceNetFDT/DTM21LimitorqueMaking Valve Control Easier Electronic ActuatorsNetworks Modbus Increase in transmission rate up to 115.2 kbps Dual network boards for component/line redundancy Foundation Fieldbus PID functionality w/ adaptive self tuning algorithm FDT/DTM22

LimitorqueMaking Valve Control Easier Electronic ActuatorsNetworks Profibus DP Profibus DP/V2 will provide slave-to-slave communications usingbroadcast communication via "publisher" / "subscriber" method, aswell as synchronization of all networked MXs to a system time witha deviation of less than a millisecond. This will enhance diagnosticreporting of faults, as well as the chronological sequencing of events. Profisafe will provide communication to “Safety Hosts” whilesupporting up to SIL 3. RedCom will provide a channel for redundant communications Dual boards w/ independent connections for component/lineredundancy FDT/DTM23LimitorqueMaking Valve Control Easier Electronic ActuatorsNetworksFDT/DTM TechnologyDevice Type Manager (DTM) files that can be integrated in to anyField Device Tool (FDT) frame application that is coupled to anasset management suite. This allows protocol independentnetworking with instrument user interface in a standard softwareenvironment. The DTM is a software component that encapsulates all devicespecific data, as well as provides functions for accessing deviceparameters, configuring and operating the devices, anddiagnosing problems. It can be developed from GSD/DD files.24

LimitorqueMaking Valve Control Easier Electronic ActuatorsNetworksFDT/DTM TechnologyDevice Type Manager (DTM) files that can be integrated in to any FieldDevice Tool (FDT) frame application that is coupled to an assetmanagement suite. This allows protocol independent networking withinstrument user interface in a standard software environment. The FDT frame application defines a set of interfaces between thehosting application and the DTMs. The application will contain thecommunication component (ComDTM) to interface the host systemwith the specific fieldbus communication (e.g., HART, PROFIBUS,FOUNDATION fieldbus, etc.). The FDT container initiates the DTMand enables interaction between the host and field device.25Making Valve Control Easier LimitorqueElectric & Electronic Actuators – Coker User Installations (partial listing)CompanyActuator BrandMotivaSMB - NCUSonoco PhillipMXShellL120 BICChevronSMB - NCUExxonL120 BICLyondell - CitgoL120 BICChevronL120/MXPemex - MexicoMXLyondellL120 BICValeroL120 BICCVR EnergySMB / L120Conoco PhillipsL120 BICPetrobras – BrazilL120 / MX w/ DDCENAP – ChileMXMotivaL120 BICValeroL120 BICNCRASMB / L120BP / AmocoL120 BICPemex - MexicoL120 BICHovensa,L120/UEC26

LimitorqueMaking Valve Control Easier Electronic ActuatorsSummary Preferred for applicationsrequiring:- integrally mounted controls- network capabilities- advanced data acquisition27

SMB Electric Actuator L120 Electric Actuators 4 . MX Actuator. 5 Limitorque Making Valve Control Easier Electro-Mechanical Actuators Multi-turn output Double reduction gear set (Motor set & Worm set) Wide range of output speeds due to motor and gearing combinations Electro-mechanical torque control