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ROTEX Controls USA: Valve Automation 101

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

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ROTEX Controls USA: Valve Automation 101

  1. 1. AUTOMATION OVERVIEW EMCISA Training November 4 -6 2013
  2. 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. 3. Pneumatic Actuators are offered in several different Designs
  4. 4. Advantages:  Simplistic Design.  Rugged.  Torque curve mirrors the Valve characteristics.  Inexpensive for torque output.
  5. 5. Advantage:  Low cost.  Long History. Disadvantage:  Does not comply with International Standards.  Torque curve is opposite of Valve characteristics.
  6. 6. Advantages:  Low Cost Disadvantages:  Not suited for safe spring return design  Uneven O-Ring wear  Does not comply with International Standards
  7. 7. Advantages:  Sold for control. Disadvantages:  Large Envelope  Heavy  Unbalanced Mounting  Does not comply with International Standards
  8. 8. Advantages:  Compact Design.  Evenly Balanced.  Light Weight.  Complies with International Standards.  Ease of adapting Accessories.
  9. 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. 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. 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. 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.
  13. 13. 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.
  14. 14. TRAVEL STOPS 3° 7° 3° 7° 96° 90° 76° OVERTRAVEL ADJUSTMENT 0° TRAVEL OVERTRAVEL PINION ROTATION
  15. 15. Speed Control
  16. 16. Automated Valve Failure • Valve Leaks-By. • Actuator not stroking properly. • Valve will not change position. • No Limit Switch Indication.
  17. 17. 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.
  18. 18. 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.
  19. 19. 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
  20. 20. 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
  21. 21. 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
  22. 22. 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
  23. 23. No Limit Switch Indication • Enclosure is full of water. • Corrosion on the contacts. • Cams have vibrated of setting. • Broken Wire.

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