Control valve actuators

Selecting control valve actuators

The selection of an appropriate valve actuator depends on technical and economical factors.
Manual control, external piloting, or internal piloting are possible. Usually control valves are
operated with pneumatic diaphragm actuators, pneumatic piston actuators, electrical linear
actuators, electrical rotary actuators or sometimes with electro-hydraulic actuators.
Actuator
type

Pros

Cons

-Distance to the source of energy is

limited (dead time problems)
-Actuating force of spring-loaded
units is limited
-Auxiliary energy must be generated
and made available (cost implications)
-Auxiliary energy system requires
considerable maintenance
-Small systems are normally not
economical
-Sensitive to changing process
pressure
-Larger actuating forces difficult to
-Large distance to the source of energy is
achieve
no problem
-Limited stroking velocity
-Accessories and parts are standard
-Explosion-proofing costlier in
supplies Easy interlocking of signals
comparison to pneumatic or hydraulic
Electric
-High regulation and control accuracy can
actuators
be realised easily
-Reaching of safe position in case of
-Large actuating force easy to achieve
auxiliary energy outages must be
-Remote control and monitoring functions
ensured by additional measures
can be implemented easily
-High maintenance costs
-Distance to the source of energy is
-High actuating forces
limited
-High stroking velocities are possible
-Tubing is required for transmission
-Outages of the auxiliary energy do not of the actuating power, implying
Hydraulic
prevent reaching of safe position
additional leakage risks
(accumulator)
-Costly control
-High stability
-Considerable maintenance
requirements
-Explosion-proofing relatively simple
-Relatively insensitive to corroding
environments if control air is used
-Unsophisticated design
-Use of control gas possible
Pneumatic -Logic interlocking of signals can be
realised easily Relatively low-cost
-High stroking velocities can be realised
-Fail safe - Outages of the auxiliary
energy do not prevent reaching of safe
position (spring-loaded actuator)

Table 2/1: Pros and cons of different valve actuator types

Selection of the actuator type is determined by the specific requirements of the particular
plant, in the first instance.

Manual actuation

Manual actuators for control valves

Manual actuators are useful where the flow through the valve must be very precisely, but no
auxiliary energy supply is provided or automatic control is not required.
The closure element is moved by means of a trapezoidal threaded spindle, generally using a
hand wheel. Larger actuating forces necessitate graduated transmission by means of gearing.

Figure 2/1: Manual actuator for control valves

Pneumatically operated actuators

For installation on control valves pneumatically operated actuators are the most popular type
in use. A benefit is the simplicity of design. This actuators are explosionproof.
Pneumatic diaphragm actuators
Pneumatically operated diaphragm actuators are using low pressure air supply from
controller, positioner or other source. The frictional forces and thus the hysteresis are
negligibly low. Molded diaphragms are used to provide linear characteristic and high travels.
An important benefit of the spring diaphragm actuators is their ability to fail safe (to close
or open the valve on air or signal failure). The fail safe direction depends on the safety
requirements. If the fail in place mode is desired spring-diaphragm or other pneumatic
actuators have to use block up valves. Usually there is a central spring design or a multi
spring design. Direct acting function is given when increasing air pressure extends actuator
stem. When the function is reverse acting increasing air pressure retracts actuator stem.

Figure 2/2: Single seat control valve with normal bonet and pneumatic diaphragm multispring actuator Series FoxTop and FoxAct
For the examination of the actuator force and of the stroking time of pneumatic multi-springand central-spring actuators will besides the spring range as well as data about the strokes,
diaphragm area, dead volume and stroke volume required. Also the maximum air supply
pressure has to be taken into consideration. Pneumatic diaphragm actuators with diaphragm
made out of NBR can be used from -40C up to 80C. Beneath -40C it have the actuators be
equipped with diaphragm made out of silicon.
For special applications the pneumatic actuators are made of stainless steel.
New designs of jokes are suitable for directly attachable valve positioners and solenoid
valves with internal air supply for air extends stem.

Figure 2/3a and 2/3b: Pneumatic diaphragm multi-spring actuator and a top mounted
handwheel Series FoxAct
The pneumatically operated actuators can be additionally equipped with a top-mounted or
side-mounted manual actuator. Top-mounted or side-mounted handwheel are used with either
direct acting or reverse acting actuators for manually operation, adjustable travel stop or to
override the control signal to give the operator the option to override the control system.
Pneumatic piston actuators
Pneumatically operated piston actuators are using high pressure plant air, often eliminating
the need for supply pressure regulator. When the pressure of the supply air is high enough,
the actuator forces are higher than with diaphragm actuators. Springless double acting
designs give maximum force in both directions.
The friction of piston actuators is higher than of diaphragm actuators. It probably will
increase with use because of O-ring and guide surface wear. Maintenance is required more
often for this type of actuators.

Figure 2/4: Pneumatically operated piston actuator

Mostly this actuators are used for On/Off operation. For the demand of a safety position this
actuators are fitted with a spring or separated cylinder to store air pressure, kept there by a
pressure actuated lockup valve.
Pneumatic rotary actuators
Rotary actuators are used to operate valves with rotary closure members such as rotary plug
valves, ball valves, plug valves or butterfly valves.
Diaphragm actuators
With rolling diaphragm good for high strokes Fail safe with spring Usually used for control
service
Rock and pinion actuator
Recommended for on/off applications because of the backlash
Scotch yoke type actuator
The force varies through the stroke

Accessories for pneumatic actuators

Accessories comprise the devices needed for the valve and actuator unit to fulfil its function
as a controlling or regulating element. As a rule they are items of equipment which influence
the auxiliary power of the actuator and signal the stroke position of the actuator.
Valve positioners
A positioner is used to ensure a position of the plug proportional to the instrument signal
from the controller and to increase actuator thrust or stiffness. Factors as stuffing box friction,
forces on the plug or actuator hysteresis are compensated. The positioner is also necessary for
split-range applications. There are versions for single acting or double acting actuators.
Usually attachment kits for linear actuators according to NAMUR, direct mounting without
tubing, or rotary actuators according to VDI/VDE 3845 are available.
The different types of valve positioners are:
Pneumatic positioners (input signal 0,2 to 1,0 bar)
Electro pneumatic positioners Analog (input signal 0/4 to 20 mA)
Digital (input signal 0/4 to 20 mA)
Intelligent with communication (via HART, FoxCom, Foundation Fieldbus H1 or Profibus
PA) Explosion-protection EEx ia according to CENELEC or instrinsic safety according to
FM or CSA Explosion-protection EEx d or explosion proof according to FM or CSA

Figure 2/5: Electro-pneumatic positioner Type Foxboro/Eckardt SRD 9863

Figure 2/6: Digital positioner Type PMV D3

Most of the positioners can be fitted with inductive limit switches, micro-switches, position
transmitter (4 to 20 mA), booster relays or gauges.
Booster relay
The pneumatic booster is increasing the air volume of pneumatic signals. The result is a fast
system response. The input and output signals are equal. This unit is mounted between the
positioner and the actuator.
Block up relay
The block-up relay is a safety element which closes the supply line to the actuator in case of
failure of the supply pressure. The actuator remains in the position last assumed. When the
supply pressure is restored, the pneumatic control signal is released once again to the
actuator.
Solenoid valves
Solenoid valves are used to control pneumatic actuators for on/off function or for interlocking
and safety circuit systems.
The interface between actuator and auxiliary equipment is standardised in the VDI/VDE
38451.

Figure 2/7: Pneumatic diaphragm actuator with direct mounted digital positioner and solenoid
valve; Internal air supply Type Foxact with Foxboro/Eckardt SRD 991 and Seitz CP 0632
CPU oH
Position response
Position Transmitter

Position transmitters are used to convert the valve stem position into a pneumatic signal 0,2
to 1 bar or standard electrical signal 4 to 20 mA.
Limit switches

Limit switches (micro switches or inductive) are used to signal one or two end positions for
signal lights, electric relays or alarms.

Figure 2/8: Inductive limit switch Type Foxboro/Eckardt SGE 985

Filter regulator

Filter regulators are used to reduce the pressure of the plant air supply in order to protect the
control equipment. They also remove dust particles and water content.

Figure 2/9: Filter regulator Type FoxBoro/Eckardt FRS 923

Electrical operated actuators

Control valves with electrical linear or rotary actuators are used when the auxiliary energy is
electrical power.
The electric actuators are more complex and more expensive than pneumatic actuators. They
offer advantages where no air supply source is available, where low ambient temperatures
could freeze condensed water in pneumatic supply lines or where unusually large stem forces
are needed. The electrically operated actuators have an handwheel for manual operation as
standard fittings. When the valve must remain in the last travel position (fail-in-place mode)
the standard electric gear type actuators are ideal. Normally the actuator is equipped with an
electronic positioner, and a position feedback device.
For fail-safe action a standby power source, such as a relay switch actuated battery pack, is
necessary. A disadvantage is the must of periodic maintenance and recharging of the battery.
Electrical linear motion actuator
The linear actuators are mainly designed for operating control or shut-off valves with a linear
stroke and operating forces up to 25 kN. The actuators are adjustable to the required valve
stroke and force. Optional accessories are additional limit switches, position feedback,
positioner and a heating resistor.

Figure 2/10: Electrical linear actuator Type Haselhofer

Electric rotary actuator
The electric rotary actuators is composed of a motorised gear train and screw assembly which
drives the valve stem. The actuator is equipped with an electronic positioner, and a position
feedback device. Control valves with thrust units and electric multi-turn actuators are
generally implemented in centralised heating plants and power stations.
Linear thrust unit
For attachment of electric multi-turn actuators you need a linear thrust unit to transpose the
torque of the actuator into an axial force.
Linear thrust units of Schmidt Armaturen is a robust, closed design. Thermal expansion of the
valve stem is compensated by spring elements in the thrust unit.

Figure 2/11: Linear thrust unit design Schmidt Armaturen

Electro-hydraulic actuators
Electro-hydraulic actuators require electrical power to the motor and an electrical input signal
from the controller. This actuators are ideal for isolated location where pneumatic supply
pressure is not available but where precise control of valve plug position is needed. They
offer the advantage that they can be placed remotely from an instrument.
They are expensive in relation to a pneumatic diaphragm actuated valve.
The essence of the design requires a constant source of pressure, which means a constant use
of electric power to pump the hydraulic power fluid.
High performance actuators are working with very high pressure-This actuators normally
require a external hydraulic source. This hydraulic source can be used for a number of
actuators.