Valve Basics & Automation, M t Mustang Aug.

A 25 25, 2008
Tom Jeansonne Emerson, Valve Automation S i Regional Senior R i lS Sales l M Manager

What is a Valve? In order to better understand how basic types of actuators are selected, it might be best to have a quick review of the basic types and functional requirements of typical valves.

What is a Valve? A Valve is a flow interrupting mechanical device, utilizing a body or housing and having a working element element. It has at least one inlet and outlet, and is intended to shut given media. off or control the flow of a g

Terminology - Working Element or Element

The DISC in A Butterfly valve or a BALL in i a ball valve

That part of a valve which acts directly i the in th flow, fl to t control t l the th flow. fl

Two Major Groups of Valve Element Movement

Rotary Types...

Part Turn Multi Turn

Linear Types...

Non Rotating Rotating

Terminology - THRUST and TORQUE

Typically, our industry describes linear force as thrust and rotary force as torque torque.

Basic Types of Linear Valves That Require Thrust

API 6D Gate Globe or Gate Valve Valve Diaphragm Valve

Basic Types of or Part Turn Valves That Require Torque

Ball

Plug

Butterfly

Valve examples

TORQUE:

For the balance of this session we will concentrate one turn valves and torque producing mechanisms.

TORQUE:

The force required to rotate a valves stem. The product of force acting upon a moment arm to produce rotary motion motion.

Valve Torque Requirements

Valve Position/Torque Terminology

Factors Affecting Valve Requirements

Valve flow bore size Valve design Stem size and/or design Working pressures Media characteristics Temperature Fl Flow rate/direction(s) t /di ti ( )

Speed of operation ESD applications Valve condition/alignment Position of valve/damper Dual purpose applications Media build-up D d ti Dead time / cycle l rate t

Valve Size Factor:

Generally, the larger the g the element. valve, the larger

Valve Size Factor:

Reduced Port

Ball bore is smaller than flange bore Surface S f contact area is i smaller th a full than f ll bore

Valve Design or Type The type of valve will usually determine what type motion the stem requires to operate the working element.

Valve Design or Type

Application vs. Design Pressures

Application Pressure: Pressure the valve will be subjected to in real-world applications.

Design Pressure: Manufacturers Manufacturer s Design Pressure (which should be greater or at least equal to the application pressure)

Application Pressure(s)

Pressure Differential:

Upstream Downstream Pressure = Pressure Differential

Application Pressure(s)

Pressure Differential

Upstream Downstream Pressure = Pressure Differential

Typical floating ball valve

One-piece body: bronze, 316 SS, or carbon steel

Blowoutproof stem

Precision-machined ball with TFE Seats

Typical Floating Ball Valve

Basic Types of Rotary Ball Valves...

Floating Ball Valve

Ball is free to move downstream in reaction to pressure

Pressure forces the ball/element into the downstream seat

Typical Floating Ball Valve

Break

T Torque Increasin I ng

End

0 Close

Rotation

90

Ball Valve Typical Trunnion Mounted Ball Valve g Seats with Rotating

Break Seat Rotation

Torque e Increas sing

End

0 0 Close

R t ti Rotation

90 90 Open

Butterfly Valve Torque Typical HP Bfly Valve in Modulating Service y Flow Dynamic

T Torque Negative Pos sitive D Decreasing g Incre easing

Run B k Break

End

0 Close

90 Open

Typical Straight Plug Valve

To orque Negative N Positive De ecreasing Increasing

Break

Run

End

0 Close

Rotation

90 Open

Typical Lubricated Plug Valve

Torque Increa asing

Break

Run

End

0 Close

Rotation

90 Open

MEDIA

A material or collection of materials of which a valve is used to control.

Gas Liquid Solids in suspension Mixture of above (e.g. a slurry)

Flow Rate, Direction - Concerns / Effects Bi-directional, Unidirectional, balanced element or perhaps a triple offset ?

Flow Rate, Direction - Concerns / Effects There's torque seated bfly valves too!

Speed of Operation - Concerns / Effects

Pneumatic / Hydraulic

The output torque or thrust of a pneumatic or hydraulic actuator is not directly affected by speed of operation.

Speed of Operation - Concerns / Effects

Electric

Both Quarterturn and Multi-turn electric actuator outputs may be affected by the speed of operation.

Dead Time (lack of movement)

The length of time a valve and its actuator remains stationary stationary.

Summary as concerns actuator automation affects

Remember, the more information you have h and d understand d t d about b t your application, the more likely the most efficient actuator is selected.

Why Automate?

Definition - Actuator

An Actuator is a device designed to power- operate the closure element of a valve.

Increased Power (Torque or Thrust)

Pi t Picture Courtesy C t of f VMA

Reduced Costs

Pi t Picture Courtesy C t of f VMA

Greater Safety

Pi t Picture Courtesy C t of f VMA

Remote Operation

Pi t Picture Courtesy C t of f VMA

Summary, Why Automate? Increased Power Reduced Costs Greater Safety Remote Operation General G l Overall O ll Improved I d Safety, S f t Service and Efficiency

The Part Turn (1/4) Actuator Product

Torque = What you specify and what you

pay for.
Be B certain t i t to get t what h t you pay for f and d

but do not go overboard (could be more dangerous) dangerous).

Control = An actuator is like a car car,

torque/horsepower are great, but you must be able to control that torque.

Actuator Torque Torque Mechanisms

Actuator Torque

How Much? Where is it Needed?

Actuator Types

Rack & Pinion Scotch Yoke Helical Gear

Force . .Piston or Diaphragm

Operating Pressure
P S Iu A sr r f ta e oc a ne

Force

F=PxA
Where: F = Force in Lbs. Lbs P = Operating Pressure in lbs. per square inch A = Area of Piston in square inches

Torque Force

Moment Arm

Force to Torque Calculation

(in lb)? (in-lb)?

Torque = Force x Radius (or moment arm) T (in-lb) = F (lb) x (in)

Cylinder or Diaphragm & Crank Arm

Operating Pressure, Pneumatic or Hydraulic

A x P = Force +
Moment Arm, I h Inches

T Torque = Force F x Radius R di ( (or moment t arm) ) T (in-lb) = F (lb) x (in)

The Robotarm Story

The torque output from a crank arm mechanism plotted against the torque requirement of most rotary valves can be represented t d graphically hi ll thus: th

Rack & Pinion

Scotch Yoke Torque q Output p

MA
F

0
Min. MA

45 90

Max MA

Fluid/Gas Powered Actuators:

MOMENT TORQUE AREA x PRESSURE x = ARM OUTPUT

Rack & Pinion

Todays Today s Rack & Pinion

Todays Today s Rack & Pinion (Cutaway) Pinion Gear

Two Pistons with Racks

Typical Modern Rack & Pinion

Operating Pressure p.s.i.

Operating Pressure p.s.i.

Inboard Rotation

Then/Or ...

Todays Today s Rack & Pinion

Operating Pressure p.s.i.

Rack & Pinion Mechanism

Torque is generated by pressurizing one side of the actuators piston. In this example the left hand side of the piston is pressurized, pressurized causing the rack to move to the right and the pinion to rotate in an anti-clockwise direction.
Supply Pressure Piston Pinion Gear

Cylinder

Rack

Rack & Pinion Mechanism

Counter-clockwise and clockwise pinion rotation is achieved by pressurizing either the inboard or outboard sides of the pistons. pistons
Counter-Clockwise Clockwise

Supply Pressure Supply Pressure (A li d t (Applied to O Outboard tb d Side Sid of f Pistons) Pi t ) (Applied (A li d to t Inboard I b d Side Sid of f Pistons) Pi t ) Using two piston and racks also provides balanced forces on the pinion and allows for maximum torque generation for a given piston diameter.

Rack & Pinion Mechanism

Spring return actuators are used when a specific valve position (known as the failure position) is required when the actuator supply pressure or control signal is lost. lost Failure positions can be achieve by simply rotating the racks 180 within the actuators body.
Counter-Clockwise Spring Stroke This rack configuration would cause the actuator to fail the valve open (anticlockwise mounting code B) on loss of clockwise, the supply pressure Clockwise Spring Stroke R t ti the Rotating th racks k 180 would ld cause the th actuator to now fail the valve closed (clockwise, mounting code A) on loss of p the pressure

Rack & Pinion Torque Output

Torque is the multiplication of a linear force by the distance of the force from the p point of rotation ( (Moment Arm). ) E.G. Torque = Force x MA.
T = (P x A) x MA
Where: T = Torque F = Force P = Pressure A = Piston Area MA = Moment Arm

MA

Torque Output Double Double-Acting R & P Actuators

In a double-acting rack & pinion actuator, the torque output remains constant throughout the actuator stroke since both the forces generated by the pistons remain constant (assuming a constant supply pressure) and the MA (distance) between the pistons forces and the pinion remains constant.
Torqu ue Output 0 45 Valve Opening Stroke 90 45 Valve Closing Stroke 0

Torque
In a spring-return rack & pinion actuator, the torque output varies throughout the valve stroke.

On the air stroke the torque starts high but linearly decreases as more of the force generated by the piston is used to compress the springs (rather than rotate the pinion).

On the spring stroke the torque starts high but li linearly l decreases d as the th springs i extend t d (re: ( Hooks Law) from their fully compressed position.

Rack & Pinion S.R. Torque Output

Start T Torque

Start

End Standard Rotation 45

End

-5 0

90 95

Rack & Pinion, Typical Materials Of Construction

Body, pistons and end caps = Aluminum, anodized or co-deposition coating Pinion Gear = Aluminum or plated (zinc or ENP) carbon steel Springs = Alloy steel (Coated) Paint = Two part epoxy or anodized Seals Nitrile for standard temperature, -20f to +250f, Best general purpose, good wearage
rate

Low temp Nitrile, -40f to +180f, does not wear as long as above, not the best for
compression p set resistance, , use only y when actual temperature p requires q

Silicone for ultra low temp, -50/60/70 f to +125/150f consult factory, use only when
actual temperature requires, not long wearing, expensive and hard to get

Viton for high temperature, -20f to +300/350f Carboxilated Nitrile, 20-40% more expensive than Nitrile but excellent service life for high
cycle applications

Scotch Yoke

Todays Today s Scotch Yoke

Scotch Yoke Torque Output Opposing Spring Force

Pressure

Piston (Surface Area)

Rack & Pinion

Scotch Yoke Torque q Output p

MA
F

0
Min. MA

45 90

Max MA

The Robotarm Story

The diagram illustrates that the moment arm varies throughout the stroke. By geometric design, the moment arm length at the start and end of the stroke can be found by dividing the moment arm length at the center by the cosine of 45 or .707. By performing this arithmetic, it will be found that the moment arm at the start and end of travel is 1.414 times the moment arm at the center position of travel travel.

Scotch Yoke D.A. Torque Output

A1 A3

MAX MA

A2 Min MA

0o

Rotation
A1 = Pressure Start (Break/Unseating) A2 = Pressure Minimum (Run) ( ) A3 = Pressure End (Full Open)
Actuators & Valves

90o

Scotch Yoke S.R. Torque Output

A1 B1

Unseat
B2

Full Flow Going CW

A2

Seat

Full Flow Going CCW

0o

Rotation

90o

Fail CW: A1 = Pres. Pres Start Start, A2 = Pres Pres. End / B1 = Spr Start, Start B2 = Spr End Fail CCW: A1 = Spr Start, A2 = Spr End / B1 = Pres. Start, B2 = Pres. End
Actuators & Valves

ScotchScotch -Yoke

GC Canted Yoke

45 90

CANTED YOKE

Scotch Yokes Canted

Canted Yoke Swings or twists torque symmetric curve

160000 150000 140000 130000

SPRING END STROKE STROKE IMPROVED

SYMMETRIC YOKE

CANTED YOKE

TORQUE E OUTPUTS

120000 110000 100000 90000 80000 70000 60000 50000 40000

G 5016-32 SR4 G 4014-28 SR1

G 4014-28 SR1

45

DEGREES

90

Bettis BH Helical spline mechanism

The BH piston utilizes multiple h li l splines helical li which hi h engage with ith reciprocal splines in the actuators lower housing. The splines minimize the surface stresses so that wear and fatigue are minimal. All All moving parts of the mechanism are permanently submerged in, and lubricated by the operating fluid.

Products Hydraulic Helical Gear Actuators

turns 90 and is balanced fail-safe safe by means of fail disc springs Linear torque output, very similar to rack and pinion compact td design i

Scotch Yoke & Helical Gear, Typical Materials Of Construction

Body, pistons, yoke and end caps = Cast Ductile Iron or Fabricated Steel Plate Springs = Alloy steel (Coated) Paint = Primer is standard, many other paint systems available Seals
Nitrile for standard temperature temperature, -20f 20f to +250f, +250f Best general purpose, purpose good wearage rate Low temp Nitrile, -40f to +200f, does not wear as long as above, not the best for compression set resistance, use only when actual temperature requires Viton for high temperature, -20f to +350f Carboxilated Nitrile, 20-40% more expensive than Nitrile but excellent service life for high cycle applications Special seal materials available

The Robotarm Story

Using the same piston area, operating pressure, moment arm and assuming g identical efficiencies, the torque q outputs p from the three above-described mechanisms can be plotted graphically thus:

OK, So when Do I Use Which?

The following are general guidelines, THERE ARE MANY VARIABLES. USE RACK AND PINION WHEN
Extreme cold AND CHARPY Requirements Weight is critical (Helical Gear) Unusual dimensional requirements q (Helical ( Gear) ) Constant torque output is an advantage (May actually be cost driven between 25 7,500 LB./In.

OK, So when Do I Use Which?

The following are general guidelines, THERE ARE MANY VARIABLES. USE SCOTCH YOKE
Aluminum not desirable (Helical Gear) Weight is not critical Unusual dimensional requirements (Helical Gear) Variable torque output is an advantage (May be cost driven between 3,000 25,000 and will be availability driven from 35,000 to 6,000,000+ LB./In. High Torque requirement High temperature requirement Remote overrides are required Very High stroke speeds are required (Helical Gear) Hydraulic or high pressure service (Helical Gear)

OK, So when Do I Use Which? RP VS. SY & HG

Common actuator DESIGN or APPLICATION misconceptions

One mechanism has less backlash, hysteresis or dead band than the other One mechanism is best overall One design typically out cycles/performs the other Rack and pinions are a better choice for plug or metal seated ball valves Scotch yokes are a better choice for ball and butterfly valves

Truth is, it all depends on your specific application. There is no such thing as one design that is best for every application.

Closed Loop Systems

Closed Loop p Systems y

There is an increase in the requirements for fail safe - spring p g return type yp valve actuators. The applications are in areas of severe environments. High humidity Salt air Corrosive dust, inks and dyes Wash Downs Etc

Closed Loop Systems

The pumping action of spring return actuators causes the vented side of the pneumatic cylinder to p purge g itself with each stroke. This purging action poses the problem of drawing in contaminates that are potentially harmful to cylinders, springs, and other internal components of the actuator.

Closed Loop Systems As the piston travels the cylinder volume is exhaled and atmosphere inhaled (breathing).

Closed Loop Systems

The closed loop purge system presents a relatively inexpensive, simple solution to the majority j i of f all ll such h applications. li i The closed loop system routes the operating media di b being i exhausted h t df from th the power side id of the cylinder to the vented side of the cylinder. y Maximum pressure on the vented side of the power cylinder is to be 5 to 8 psig.

Closed Loop Systems

Materials for the vent check (relief) valve is generally g y selected from aluminum, brass, or stainless steel to suit specific environmental requirements B i generally Bettis ll selects l stainless i l steel lf for the h components.

Closed Loop p Systems y

QUICK EXHAUST VALVE

VENT CHECK VALVE

Closed Loop p Systems y

VENT CHECK VALVE

QUICK EXHAUST VALVE

Closed Loop p Systems y

VENT CHECK VALVE

QUICK EXHAUST VALVE

G Series and CBA Models on Main Discharge Valves

G Series Se es U Units ts o on Field e d Gat Gathering e g lines es

High Speed Spring Stroke Testing (Note the vapor

cloud c oud and a d ear ea muffs) u s)

Typical Sub Sea Helical Gear Units

G130T52SR3 On 42 ANSI 1500# Torque Seated G130T52 utte y Valves a es Butterfly

Worlds Most Powerful Spring Return Actuator, 1.8 8 M Lb./In. b / Spring Sp g Ending d g with t 3.2 3 M Air Start Sta t

Thank You!

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Color Palette

This slide represents the Emerson color palette

R 150 G 150 B 150

R 15 G 36 B 95

R 225 G 225 B 0

R 225 G 204 B 0

R 153 G 225 B 51

R 0 G 153 B 0

R 224 G 158 B 50

R 225 G 0 B 0

R 71 G 186 B 214

R 0 G 153 B 204

R 204 G 0 B 102

R 153 G 0 B 51

R 102 R 102 G 153 G 0 B 255 B 102

P f Preferred d gradient di t use

The Emerson Color Palette

The Emerson color palette was designed to bring color consistency to various applications from web design to presentations to brochures. brochures It is strongly recommended that the bright and vibrant colors in this palette be used in graphs, text and charts to highlight your PowerPoint presentations, thereby showcasing our world in action. A selection of colors from the palette have been embedded into this template for your use. In order to use the other colors available to you from the palette, please use the following instructions:
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Using the Emerson Color Palette

The extended color palette brings bright, vibrant colors to be used in many ways from highlighting words to making ki exciting iti charts h t and d graphs. h A selection of colors from the palette have been imbedded into this template for your use. In order to use the other colors available to you from the palette please use the following instructions:
Select the word or graphic element you wish to color and select either the Paint can, the Brush, or the A, depending on the item you are coloring, choose More (fill, line, font) colors, click on the tab Custom and enter the correct R G B numbers for the color from the palette on the preceding slide you are creating, click OK.