Basics of industrial valve actuation and automation, including actuators, brackets, couplings limit switches and solenoid valve.

1. AUTOMATION OVERVIEW
EMCISA Training
November 4 -6 2013

2. STANDARDS
V - VDI/VDE 3845
I - I.S.0. 5210/5211
N - NAMUR
V
V
I
TOP MOUNTING
PAD
N
N
BOTTOM
MOUNTING PAD
SOLENOID
MOUNTING PAD
N
N
Standards
 I.S.O. 9000 Series.
 I.S.O. 5210 / 5211 Valve Automation
Standards.
 N.A.M.U.R. Actuation Standards.
 V.D.I. / V.D.E. Accessory Standards.

3. Pneumatic Actuators are
offered in several different
Designs

4. Advantages:
 Simplistic Design.
 Rugged.
 Torque curve
mirrors the Valve
characteristics.
 Inexpensive for
torque output.

5. Advantage:
 Low cost.
 Long History.
Disadvantage:
 Does not comply
with International
Standards.
 Torque curve is
opposite of Valve
characteristics.

6. Advantages:
 Low Cost
Disadvantages:
 Not suited for safe
spring return design
 Uneven O-Ring wear
 Does not comply with
International
Standards

7. Advantages:
 Sold for control.
Disadvantages:
 Large Envelope
 Heavy
 Unbalanced
Mounting
 Does not comply
with International
Standards

8. Advantages:
 Compact Design.
 Evenly Balanced.
 Light Weight.
 Complies with
International
Standards.
 Ease of adapting
Accessories.

9. Typical On/Off Automated
1
3 2
4 5
6
7
Valve Package
Valve Cost = 30% of total package
Automation Cost = 70% of total package
# Item Cost as % of
Total Package
2”
Advantages
Hytork
Typical
Valve Dist.
1 Switch 14% Equal or
Greater
Equal or Lesser
2 Bracket 1% Equal or
Greater
Equal or Lesser
3 Conduit 1% Greater Lesser
4 Solenoid 13% Equal or
Greater
Equal or Lesser
5 Actuator 23% Greater Lesser
6 Main Bracket &
Coupling
9% Equal or Lesser Equal or
Greater
7 Valve 30% Equal or Lesser Equal or
Greater
Item Cost as % of
Total Package
Advantages
Hytork
Typical
Valve Dist.
Labor & Handling 9% Equal Equal
Speed of response N/A Equal or Lesser Equal or
Greater
Automated Valve Package Breakout

10. Typical 1/4-Turn
Modulating
Control Valve Package
Approx. Cost of 3” “V”- notch 1/4-turn
= $3000.00
Typical Conventional
Modulating
Globe Valve Package
Approx. Cost of 3” Globe
= $4000.00
Automated Valve Package Breakout

11. End of travel indicating Limit Switches
Used to indicate the final
position of a valve.
 Local indication uses a
visual indicator.
 Remote indication uses
electrical switches.
Is used as a controller for
additional equipment or as a
junction house to I/O.

12. Types of Solenoid Valves
 Three Way (Spring return Actuators)
Normally Closed Construction -exhausts pressure when solenoid is de-energized,
applies pressure when energized.
Normally Open Construction -applies pressure when solenoid is de-energized,
exhausts pressure when energized.
Universal Construction -for normally closed or normally open operation.
 Four Way (Double Acting Actuators)
 Single Solenoid -valve shifts when solenoid is energized, returns to normal position
when de-energized.
 Dual Solenoid -valve shifts when one solenoid is energized, returns when the other
is energized. May be energized momentarily or continuously.

14. COIL DE-ENERGIZED COIL ENERGIZED
AS THE SPRINGS MOVE THE PISTONS TOWARDS EACH OTHER A
PARTIAL VACUUM IS CREATED IN THE SPRING CHAMBERS.
THE EXHAUSTING AIR FROM BETWEEN THE PISTONS IS FORCED
INTO THE APRING CHAMBERS PREVENTING THE ATMOSPHERIC
AIR ENTERING THE ACTUATOR
PISTONS MOVING TOGETHER UNDER SPRING FORCE
PISTONS PUSHED APART BY THE AIR
PRESSURE FORCING AIR FROM THE
SPRING CHAMBERS TO EXHAUST TO
ATMOSPHERE.

15. TRAVEL
STOPS
3°
7°
3°
7°
96°
90°
76°
OVERTRAVEL
ADJUSTMENT
0°
TRAVEL
OVERTRAVEL
PINION
ROTATION

16. Speed Control

17. Automated Valve Failure
• Valve Leaks-By.
• Actuator not stroking properly.
• Valve will not change position.
• No Limit Switch Indication.

18. Valve Leaks
• Is the Solenoid Functional ?
• Test the Coil.
• Test the spool valve in the solenoid.
• Is the Actuator Traveling 90º ?
• Adjust the travel stops.
– Improperly adjusted travel stops or no
travel stops will cause valve seat failure.

19. Actuator not cycling full Stroke
• Air blow-by at the pinion.
– Caused by actuator to valve misalignment.
– Caused by high cycle fatigue.
• Air bleeding through the solenoid exhaust port.
– Piston “O”-Ring failure.
• Build up of valve corrosion.
– Slow down in cycle time.
– Eventual stroke travel limitation.
• On spring return (Fail Position)
– Broken or Fatigued Springs.

20. Actuator does not Stroke
• Insufficient air supply
Check supply pressure with gauge
• Actuator mounted incorrect on valve
Remove actuator from valve, check that both are in the
same position before mounting.
• Control components not working
Replace faulty component.
• Required torque greater than sizing torque
Resize actuator

21. Actuator strokes too slow
• Control components too small Cv
Install larger components
• Insufficient volume to actuator
Increase size of supply lines
• Clogged breathers, filters or exhaust port silencers
Check and clean, or replace
• Incorrect speed control settings
Adjust speed controls

22. Actuator strokes too fast
• Control components too large Cv
Install speed controls
• Too much torque
Lower the supply pressure
• No speed control components
Install speed controls

23. Actuator strokes jerky
• Insufficient volume supply
Increase supply
• Insufficient torque
Increase supply pressure
Check actuator sizing
Actuator may need overhaul
• Defective valve
Consult valve manufacturer’s documentation

24. No Limit Switch Indication
• Enclosure is full of water.
• Corrosion on the contacts.
• Cams have vibrated of setting.
• Broken Wire.