Features and benefits of modern

actuators
and effects on plant operations

SIPOS Aktorik is a manufacturer of electric actuators

The main focus of the corporate activities is:

Design and development, manufacturing and sales of electric actuators;

Conceptual design and realisation of solutions for water and power applications;
Development of tailor-made customer solutions;
Worldwide sales and service.

Company history
Arising from Siemens, SIPOS Aktorik can look back at more than 100 years
experience in design, production and sales of electric actuators.
October 1999 the Siemens actuator division was outsourced to a newly founded
company SIPOS Aktorik GmbH.

SIEMENS
SIPOS Aktorik took over all obligations and rights arising from the Siemens
actuator business, also the spare part supply for former Siemens actuator
series.

SIPOS Aktorik - Products

Markets

Water & waste water plants

Conventional power plants

Desalination

District cooling

Pipelines

Nuclear power plants

Pump stations

Sales & Service worldwide

SIPOS Aktorik
Germany
Tel. +49 (0)9187-9227-0
Fax +49 (0)9187-9227-5111
E-mail
6

info@sipos.de
sales@sipos.de

Actuators in a power and water treatment plants

Valve maker

Control system

Actuators influence plant performance

Actuators automate safety relevant valves
Actuators automate control valves (turbine control, damper control)
Actuators influence process reliability
Actuators need cabling and system requirements
Actuators influence the wear of valves

What is expected from an actuator

Mechanically robust, long lifetime (lubrification, wear, corrosion, operation time)
Robustness against mechanical influences (temperature, shock)
Easy to install and commission (faults may result from wrong installation)
High accuracy (precise control of processes)
Robustness against electrical influences (overvoltage, undervoltage, EMC)
High availability (7/24) (spares availability, repair time, replacement time)

Modern actuators: evolution from mechanics to electronics

SIPOS 3

SIPOS 3 MC

SIPOS 5 Flash

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SIPOS 5 integrated frequency converter

Conventional actuator

800 parts
12

SIPOS 5

100 parts

SIPOS 5 Flash differences to conventional

actuators
No mechanical end switches

No mechanical torque switches

No reversing contactors
No tripping delay, no overtorque in any condition

Variable speed drive, full motorprotection (overvoltage,

temperature)
Modular design (3 gearbox sizes, 8 motor sizes, 5 electronics
sizes cover the full range)
Softwarefunctions can be activated when needed (e.g.
positioner, process controller, external speed control,)

Elevators operated by a conventional actuator

On the way up

Fast stop
on the 15th floor

Lastfall
stop Free
funLobby
on the
way down

SIPOS 5 Flash characteristics

Speed reduction in the end positions
go easy on the valve
Driving a valve at full speed into or out
of its end position can cause

seat damage,
additional maintenance costs,
plant downtime.
The SIPOS 5 Flash with its integrated
frequency controller automatically

reduces the motor speed

controls the torque
gentle operation reduces wear

Modular design
Control PCB

Power PCB

Asynchronous motor

Plug connection

Signaling gear or encoder

Hand crank /-wheel
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Gearbox

Speed changing standard functions

Standard speed control
The output speed can be adjusted at any time
in 7 steps in the chosen speed range.

Customize whats needed - when its needed !

Adjust the valve operating time to process necessities

SIPOS 5 Flash the main thing to remember

Change speed at any time!

Robustness in mechanical design

Power train features

Control head with integrated
frequency converter defining
speed and torque of motor

3 phase motor

Fixed connection between

motor and wormshaft

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Worm shaft

low tolerance hard-hard

toothing,

Worm wheel

Worm wheel &

output shaft,
are one piece

Mechanical design of SIPOS 5

One stage, low tolerance
worm gear box, self locking

Motor direct connected to

worm shaft

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Longlife bearings and seals

Minimum of parts
Casing of Aluminium Alloy

3 ph Universal motor
Simple manual operation
O ring seals

SIPOS 5 Flash things to remember

Loads according EN60068-2-6 up to 5g acceleration tolerated
High tech aluminium alloy casing
Hard hard toothing
Minimum of mechanical parts
Temperature range -20C to 60C (+80C optional)
Recommended spares (500 installed actuators):
2 electronics heads
3 signalling gearboxes
2 handwheels

High accuracy

High accuracy by software features

Positioner

with adaptive dead band

Rise Time:

parameter for fine-tuning of acceleration and deceleration

Variable Speed: reduction of kinetic energy before reaching new setpoints

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Positioner Adaption of deadband in case of bad signals

EMC toughness

Upward adaption

Downward adaption

Minimizing switching cycles

caused by disturbances

Minimizing deadzone
minimizing control deviation

control loop remains stable

Rise time 0.1s

time

Travel time approx. 3 s

No speed reduction when
approaching to setpoint

Setpoint / actual value [%]

Setpoint / actual value [%]

Influence of actuator parameter Rise time

Rise time 2s
time

A higher rise time helps to adjust the actual value to

the setpoint.
However overshooting may occur.

Without
Speed reduction

time

Travel time ca. 3s

Rise time 0.1s

Setpoint / actual value [%]

Setpoint / actual value [%]

Influence of Speed Reduction

With speed reduction

time

No overshooting due to speed reduction,

even with very low rise times.
Speed reduction is SIPOS 5 Flash standard.
A DC-break can additionally be activated

Topic:
Voltage fluctuations

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Source of Voltage fluctuations

Cable length
Electrical grounding inappropriate
Disturbances from generators and pumps
Switching of loads
Transformators

Plant start and rundown procedures

The electric grid in a powerplant is worse than outside

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Voltage Fluctuations and challenges for electric actuation

Plant Operators

want the valve to be operable in case of over- and undervoltage

do not want to have overtorque on the valve

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Voltage Fluctuations and challenges for electric actuation

Why is this a challenge?

31

Voltage fluctuations affect motor operation / performance

In case of undervoltage a conventional actuator could not be able to operate the
valve

To compensate this actuators are sized to certain undervoltage conditions

This means in times of nominal voltage the actuator motor can produce
an overtorque that can damage the valve.
Then again the valve has to be oversized to compensate

The sizing issue overtorque

When sizing conventional actuators to work with nominal torque at -20%
undervoltage

it causes an overtorque with a factor of 1.56 at nominal voltage

it causes an overtorque with a factor of 2.25 at 20% overvoltage
in case of switch-off failure.

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Voltage fluctuations handling with SIPOS 5

SIPOS 5 actuators feature

integrated frequency converter

intelligent electronics
Advantages concerning power supply:
Voltage fluctuations of
up to -30% and + 20% are tolerated
and do not lead to system failure.

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Reliability
The maximum output torque for SIPOS 5 actuators is
always the defined preset torque
at -30% undervoltage
at Nominal voltage
at +20% overvoltage

from 40 Hz to 70 Hz

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Overtorque in a modern SIPOS 5 actuator:

Conventional actuator

SIPOS 5 actuator
N/A; speed reduction in
end positions
N/A
Tripping torque is the
stall torque of the motor at
selected speed and torque
N/A
The motor sees no
under- or overvoltage due to
frequency converter

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What is expected from an actuator

SIPOS 5 solution
Mechanically robust, long lifetime

Reduction of mechanical parts,

Use of premium materials

Robustness against mechanical influences

Easy to install and commission

User Interface clear and understandable

Easy mechanical mounting

High accuracy
Robustness against electrical influences

High availability

Premium materials, small tolerances,

smart software solutions
Integrated frequency converter, motor
protection
Modular structure, spares concept,

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Sales and Service Partner for GCC

Managing Director: Mr. Ahmed Sobhi

P.O. Box 32950,
Abu Dhabi UAE
Tel. + 971 2 4470902

37

SIPOS 5
HiMod

Applications with very high requirements

Control valves
Boiler start-up valves
Dampers
Turbine regulation
Injector valves
Feedwater pump control

and other applications with high accuracy and dynamic requirements!

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SIPOS new TOP Product:

HiMod Precision in continuous duty
The new electric actuator SIPOS 5 HiMod was
developed to operate in conditions where the
highest quality of control is an absolute prerequisite.

Key features:

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Precision:
max. 0.1% to 0.2% tolerance
Continuous duty:
Meets Class D requirements of EN 15714-2
Reliable and robust: 5 year guarantee on motor and gear components
Double-sealed:
Protection in tough environments
Easy non intrusive commissioning without tools
Comprehensive software functions: Essential actuation for 'smart' solutions

Continuous duty
Standard SIPOS 5 Flash HiMod feature:
Class D continuous modulation according
to EN 15714-2 (Ed. Oct. 2009)
For continuous modulating duty, one start consists of
at least revolution,
with a load of at least 30% of the rated torque

SIPOS 5 HiMod has been tested concerning this modulation class,

considering the most critical ambient conditions
60C / 140F ambient temperature; (80C / 176F with separate mounting ).

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Continuous duty EN 15714-2

SIPOS HiMod:
3600
1800
1200
starts per hour

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SIPOS Selected references in MENA

SIPOS has supplied many standard and modulating actuators to
power and desalination plants.
Here a few:

Power and Desalination Plant Jebel Ali L,

Tripolis West
power plant,
Ataka
power plant,
Shoubra El Kheima power plant,
Ras Djinet
power plant,
Skikda
power plant,
Khoms
power plant,
Rabigh
power plant,
Al Hunnay
Water Distribution,

UAE
Libya
Egypt
Egypt
Algeria
Algeria
Libya
KSA
KSA

SIPOS References in MENA

SIPOS has supplied standard and modulating actuators for various district
cooling plants, e.g.:

Yas Island
Zayed Military City
Al Raha Beach 2
Al Raha Beach 4
Ajman 2
Sheikh Zayed Road
Al Rigga
Dubai Metro
Mohammed Bin Zayed City
Spinneys
ARAMCO