HPG Range: Direct High-Pressure Gas Actuators

HPG RANGE
DIRECT HIGH-PRESSURE GAS ACTUATORS
Publication F300E
Date of issue 01/07
ROTORK ACTUATORS
HPG RANGE
quality controlled
direct high-pressure gas actuators
In the 50 years since the company was founded,

Rotork has become the standard for excellence in
the field of valve and damper automation for the oil,
gas, power, water and waste treatment industries
around the world.
Rotorks HPG Range of pipeline actuators are

designed to use pipeline gas as the motive power
source. Using our industry recognised and proven
hydraulic scotch yoke quarter-turn actuator as the
valve prime mover, we have experience designing
and supplying direct gas actuators to many end user
specifications. Our actuators are complemented
with a variety of Rotork Fluid System designed and
manufactured high-pressure gas controls. The most
commonly used controls are listed on pages 6 and 7
of this brochure.
As established leaders in actuation technology, we

owe our success to a commitment to quality at every
stage, and at every level, of Rotorks operations.
At the heart of the company is an exceptional
workforce the highly trained, forward thinking
engineers, technicians, and sales support staff who
each play a crucial role in maintaining Rotorks
unrivaled reputation for innovation, reliability and
first class after sale support.
With fluid power factories in Italy, Germany and
the United States, and additional Rotork Centres
of Excellence located around the globe, we are able
to offer creative solutions and design systems for
virtually any application from sub-sea hydraulics to
the most sophisticated and yet simple fluid power
control system.
HPG RANGE
QUARTER-TURN ACTUATORS
Torque Output
Up to 600,000 Nm
(5,300,000 lbf-in)
* Higher torque or thrust
output available upon request.
Manual override is a standard feature of the range.

The design incorporates a separate cylinder for
hydraulic override to ensure complete separation of
high-pressure pipeline gas from the hydraulic fluid.
The use of an independent override cylinder allows
replacement of power cylinder seals without removal
of the actuator from the valve and will even allow
for manual operation while the power cylinder is
disassembled.
The gas control manifold employs poppet style
control valves a reliable design trusted throughout
the industry. They are pilot operated for remote
control. Operation is simple and intuitive.
DESIGN FEATURES
robust and versatile
Every Rotork Fluid System actuator is built to provide long and efficient service with
a minimum of maintenance. The design, engineering and materials used in the construction
ensure optimum performance even in the harshest of environments. Our modular
construction design facilitates stocking by allowing a minimal amount of components to
meet a wide range of valve torque requirements.
Standard Features
Scotch yoke quarter-turn actuators with either symmetrical or canted yoke designs for
optimum sizing of actuator to valve.
Actuators are IP67M/IP68 third party certified and approved for environmental protection.
Actuators are CE and ATEX 94/9/CE third-party certified and approved.
Manual override hand pump for emergency or local operation.
Working pressure up to 105 barg (1500 psig) higher on application.
Dedicated override cylinder.
Chromium plated piston rod and electroless nickel-plated cylinder to provide

enhanced durability of critical sealing surfaces.
Modular and compact gas control manifold.

Local control via lever operated poppet valves on the multi-function manifold.
Remote control via low-pressure or high-pressure solenoids.
Options with either low-pressure or high-pressure control logic design.
Optional Features
Remote shutdown capabilities.

Pressure sensing valves with optional manual reset to monitor pipeline pressure.
Pressure differential valves with optional manual reset to monitor the differential

across the valve.
Linebreak detection safety systems sensing pipeline pressure drop over time.
PED or ASME approved power gas storage tanks to provide power upon loss of main
pipeline pressure other approvals on application.
ESD (emergency shut down) control configurations to suit specific customer
shutdown logic requirements.
Actuator torque limiting devices for the protection of the valve or drive train.
Custom gas filtration.
HIGH-PRESSURE GAS CONTROL SYSTEMS

meeting your operational requirements
A comprehensive range of control systems and schematics have been developed
to meet the requirements of end user direct high-pressure gas applications.
A variety of standard Rotork direct high-pressure gas schematics are listed below.
Please contact our international sales departments for further options.
HIGH-PRESSURE GAS CONTROL SCHEMATICS

SCHEMATIC
DOUBLE
ACTING
QTR.TURN
HYDRAULIC
MANUAL
OVERRIDE
LOCAL/
MANUAL
CONTROL
LOW
PRESSURE
CLOSE
LINEBREAK
2-WAY
ELECTRIC
REMOTE
HPG100
HPG101
HPG102
HPG200
HPG201
Low Pressure Gas Line
HPG202
Hydraulic Fluid Line
LEGEND
Solenoid Connection
High Pressure Gas Line
See these typical schematics on our website www.rotork.com
PARTS LIST FOR HPG200 & HPG201 SCHEMATICS

ITEM QTY.
DESCRIPTION
ITEM QTY.
DESCRIPTION
Rotork Double Acting Actuator

End of Travel Limit Switch Housing (see note)
Poppet DCV (Close)
Poppet DCV (Open)
Solenoid 3/2 NC Valve (Close)
Solenoid 3/2 NC Valve (Open)
Gas Vent Protector Valve
Gas Shuttle Valve
Pilot Gas Pressure Gauge
Supply Gas Pressure Gauge
Pilot Gas Regulator
Pressure Relief
Remote Lockout Valve
Gas Filter (40 Micron)
Gas Dryer
Drain
Gas Storage Tank
Relief Valve
Check Valve
Drain Valve
Low Pressure Sensor
Hydraulic Manual Override With Speed Control
1
2
4a
4b
5a
5b
6
8
9
10
12
1
1
1
1
1
1
1
1
1
1
1
MANUAL OPERATION
Remote Lockout Valve (15) must be in the Manual
Operation position.
Depress hand lever on valve (4a) to CLOSE.
Depress hand lever on valve (4b) to OPEN.
1
1
1
1
1
1
1
1
1
1
1
LOW PRESSURE CLOSE

Pressure sensor valve (23) is normally piloted by an
external source. If the pilot pressure drops below the
setpoint pressure, poppet valve 4a closes the actuator.
The actuator may also be manually operated via the

Hydraulic Override (28).
Notes:
A travel limit switch may be used to de-energise the
solenoid when the actuator reaches the end of travel.
REMOTE OPERATION
Valves are shown de-energised and in the fail position.
Remote Lockout Valve (15) must be OPEN to allow

control pilot gas to the solenoids.
Energise solenoid (5a) to CLOSE.
Energise solenoid (5b) to OPEN.
13
15
16a
16b
16c
20a
20b
20c
20d
23
28
HPG 200
2-way Electric Remote Operation
CUSTOMER
GAS
CONNECTION
16a
16b
16c
5a
5b
15
13
10
12
9
4a
4b
28
1
CUSTOMER
ELECTRICAL
CONNECTION
HPG201
2-way Electric Remote Operation with Low-Pressure Close
CUSTOMER
GAS
CONNECTION
20b
16a
16b
CUSTOMER
PILOT
CONNECTION
16c
20a
20d
20c
23
5a
5b
15
8
13
10
12
9
4a
4b
28
1
2
CUSTOMER
ELECTRICAL
CONNECTION
KEY CONTROL COMPONENTS

safe and reliable
Complimenting the modular design of our highpressure gas systems are the Rotork designed
and manufactured control options ranging from
simple local/remote pilot operated valves to pressure
sensing and linebreak controls.
At the centre of our control systems is our multifunction manifold block. The high-pressure, high-flow
manifold system allows us to configure a wide variety
of control options. Both high and low-pressure
control logic designs are available.
MULTI-FUNCTION MANIFOLD BLOCK
Integral flow control valves for both directions.

Integral gas filter.
Leak free high flow poppet valve design.
Anodised aluminium construction.
Tamper-proof cover (optional).
LINEBREAK SAFETY SYSTEM

Pipeline pressure monitoring device that will signal the
actuator if a set rate of pressure drop is detected.
TORQUE LIMITING DEVICE

Protects the valve from excessive torque loads.
User definable settings.
DIFFERENTIAL PILOT VALVE

Used to prevent opening the actuator when a preset
differential pressure is exceeded across the pipeline valve.
CALIBRATED ORIFICE
Designed for use with the Rotork
Linebreak Safety System and allows
in-house or on-site calibration.
SHUTTLE VALVE
Used as a high-pressure selector valve.
DEHYDRATOR FILTER
For gas conditioning with the filter element
selected to meet operating conditions.
HPG RANGE
Manufacturing Centres
Italy
Rotork Fluid System
Via di Casalino 6
55012 Tassignano - Lucca
Italy
Germany
Rotork Fluid System
Rotork Controls (D) GmbH
Maschweg 51
49324 Melle
United States
Rotork Fluid System
675 Mile Crossing Blvd.
Rochester
New York 14624
Tel: +39 0583 93061

Fax: +39 0583 934612
Email: [email protected]
Tel: +49 (0)5422 9414-0

Fax: +49 (0)5422 9414-10
Tel: +1 585 247 2304

Fax: +1 585 247 2308
Australia
Rotork Fluid System
Factory 1, 9 Malvern Street
Bayswater
Victoria 3153
Canada
Rotork Fluid System
#9, 820 28th Street, NE
Calgary
Alberta T2A 6K1
United States
Rotork Fluid System
9777 West Gulf Bank
Suite15A
Houston, Texas 77040
Tel: +61 (0) 3 9729 8882

Fax: +61 (0) 3 9729 8884
Tel: +1 403 569 9455

Fax: +1 403 569 9414
Tel: +1 713 856 5640

Fax: +1 713 856 8127
Spain
Rotork Fluid System
Larrondogoiko Kalea 2
48180 Larrondo - Loiu
Bizkaia
United Kingdom
Rotork Fluid System
Regina House, Ring Road
Bramley
Leeds LS13 4ET
Singapore
Rotork Fluid System
426 Tagore Industrial Avenue
Singapore
787808
Tel: +34 94 676 6011

Fax: +34 94 676 6018
Tel: +44 (0)113 236 3312

Fax: +44 (0)113 205 7266
Tel: +65 6457 1233

Fax: +65 6457 6011
Centres of Excellence
All Rotork Fluid System actuators are manufactured under a third

party accredited ISO9001:2000 quality assurance programme.
Published and produced in the UK by Rotork Controls Limited.
Rotork recognises all registered trademarks. As we are continually
developing our products, their design is subject to change without
notice. Latest information is available on www.rotork.com

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HPG RANGE

DIRECT HIGH-PRESSURE GAS ACTUATORS

direct high-pressure gas actuators

In the 50 years since the company was founded,

Rotorks HPG Range of pipeline actuators are

As established leaders in actuation technology, we

Manual override is a standard feature of the range.

optimum sizing of actuator to valve.

enhanced durability of critical sealing surfaces.

Modular and compact gas control manifold.

Remote shutdown capabilities.

across the valve.

pipeline pressure other approvals on application.

ESD (emergency shut down) control configurations to suit specific customer

shutdown logic requirements.

HIGH-PRESSURE GAS CONTROL SYSTEMS

HIGH-PRESSURE GAS CONTROL SCHEMATICS

Low Pressure Gas Line

Hydraulic Fluid Line

See these typical schematics on our website www.rotork.com

PARTS LIST FOR HPG200 & HPG201 SCHEMATICS

Rotork Double Acting Actuator

LOW PRESSURE CLOSE

The actuator may also be manually operated via the

Valves are shown de-energised and in the fail position.

Remote Lockout Valve (15) must be OPEN to allow

KEY CONTROL COMPONENTS

MULTI-FUNCTION MANIFOLD BLOCK

Integral flow control valves for both directions.

LINEBREAK SAFETY SYSTEM

TORQUE LIMITING DEVICE

DIFFERENTIAL PILOT VALVE

Tel: +39 0583 93061

Tel: +49 (0)5422 9414-0

Tel: +1 585 247 2304

Tel: +61 (0) 3 9729 8882

Tel: +1 403 569 9455

Tel: +1 713 856 5640

Tel: +34 94 676 6011

Tel: +44 (0)113 236 3312

Tel: +65 6457 1233

All Rotork Fluid System actuators are manufactured under a third

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