Training On Different Types Of

Actuators

By
-KIRAN. NANJAIAH
-C & I
• Definition :
A valve actuator is the mechanism for opening and
closing a valve. Manually operated valves require
someone in attendance to adjust them using a direct
or geared mechanism attached to the valve stem.

A Pneumatic actuator is a transducer that converts

energy (typically from compressed air) into motion
Operates by a combination of force from the air and an
opposing spring force. The actuator positions the
control valve by transmitting its motion through the
stem
• The most common final control element in
the process control industries is the control
valve. The control valve manipulates a flowing
fluid, such as gas, steam, water, or chemical
compounds, to compensate for the load
disturbance and keep the regulated process
variable as close as possible to the desired set point
 CONTROL VALVE USE

• Control valves are valves used to control conditions such as flow

pressure, temperature, and liquid level by fully or partially opening or
closing in response to signals received from controllers that compare a
"setpoint" to a "process variable" whose value is provided by sensors that
monitor changes in such conditions. Control Valve is also termed as the
Final Control Element.
• The opening or closing of control valves is usually done automatically by
electrical, hydraulic or pneumatic Actuators. Positioners are used to
control the opening or closing of the actuator based on electric, or
pneumatic signals. These control signals, traditionally based on 3-15psi
(0.2-1.0bar), more common now are 4-20mA Signals
 Types of Pneumatic valves

• Globe Valves
• Gate Valves
• Plug valves
• Check valves
• Needle Valves
• Ball Valves
• Butterfly Valve
Pneumatic Actuators

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• Air to Close: An increase in air pressure to
the actuator is required to cause the actuator
to close. This is another way of saying , the
valve fail open or Normally Open.

• Air to Open: An increase in air pressure to

the actuator is required to cause the actuator
to open. This is another way of saying , the
valve fail Close or Normally Close.
 Control Valve ACTION
• Action: Control valves operated through pneumatic actuators can be
either (i) air to open, or (ii) air to close. They are designed such that if
the air supply fails, the control valve will be either fully open, or fully
closed, depending upon the safety requirement of the process. For
example, if the valve is used to control steam or fuel flow, the valve
should be shut off completely in case of air failure. On the other hand,
if the valve is handling cooling water to a reactor, the flow should be
maximum in case of emergency. The schematic arrangements of these
two actions are shown in Fig. 2. Valve A are air to close type,
indicating, if the air fails, the valve will be fully open. Opposite is the
case for valve B.
Pneumatic Actuators

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• Direct Acting: A direct acting actuator is one in which
the actuator stem extends with an increase in diaphragm
pressure. A direct acting valve is one with a push down
to close plug and seat orientation. A direct acting
Positioner or a direct acting Controller outputs an
increase in signal in response to an increase in set point.

• Reverse Acting: A reverse acting actuator is one in

which the actuator stem retracts with an increase in
diaphragm pressure. A reverse acting valve is one with a
push down to open plug and seat orientation. A Reverse
acting Positioner or a reverse acting Controller outputs
an decrease in signal in response to an increase in set
point.
Which way do
each of these
actuators fail?
DIRECT ACTING ACTUATOR
REVERSE ACTING ACTUATOR
 Number of Plugs
• Control valves can also be characterized in terms of the number of
plugs present, as single-seated valve and double-seated valve. The
difference in construction between a single seated and double-seated
valve are illustrated in Fig. a & b
 Single Seated Valve
• Only one plug is present in the control valve, so it is single seated
valve. The advantage of this type of valve is that, it can be fully closed
and flow variation from 0 to 100% can be achieved. But looking at its
construction, due to the pressure drop across the orifice a large upward
force is present in the orifice area, and as a result, the force required to
move the valve against this upward thrust is also large. Thus this type
of valves is more suitable for small flow rates.
 Double Seated Valve
• On the other hand, there are two plugs in a double-seated valve; flow
moves upward in one orifice area, and downward in the other orifice.
The resultant upward or downward thrust is almost zero. As a result,
the force required to move a double-seated valve is comparatively
much less.

• But the double-seated valve suffers from one disadvantage. The flow
cannot be shut off completely, because of the differential temperature
expansion of the stem and the valve seat. If one plug is tightly closed,
there is usually a small gap between the other plug and its seat. Thus,
single-seated valves are recommended for when the valves are
required to be shut off completely. But there are many processes,
where the valve used is not expected to operate near shut off position.
For this condition, double-seated valves are recommended.
 GLOBE VALVE

SINGLE SEATED DOUBLE SEATED 19

 VALVE CHARACERISTIC

Characteristic Curves :
The inherent flow characteristic of a control valve is the relationship
between the flow and the lift of the plug at constant pressure drop.

Linear :
Flow is directly proportional to valve lift.

Equal % :
Flow changes by a constant percentage of its instantaneous value for
each unit of valve lift.

Quick Opening :
Flow increases rapidly with initial travel reaching near its maximum at a
low lift.

Modified Parabolic :
Provides fine throttling action at low valve lift and approximately a linear
characteristic for upper portions of travel.
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 ACTUATOR ACCESSORIES

• Positioner
• Position feedback transmitter
• Air Filter Regulator
• Air lock Relay
• Volume Booster
• Limit switches
• Needle valve for Instrument
Air Isolation
 Valve Components

Controls the movements

of the disc. Handwheel
Support element Yoke bushing
connection Yoke
between bonnet
Compresses or stem nut
and handwheel.
packing.. Gland
Gland Flange/
The location for
Packing
packing to be
Seal between the stuffing
box andStuffing
stem. Box
Follower
Upper part of valve. Bonnet
Transfer motion
Provides of between
a seal Handwheelthe to
stem
Backseat
placed.
Directs
Support flow,
for, and
yoke the disc.
and bonnet. Keeps pressure off
attachment
actuator, component
handwheel, Attached to disc
whenby: Gasket
Split Joint
to system
etc..
Body to bonnet seal. Body Threaded
packing valve is open.

Stem
Gland Flange is a
one piece unit used Wedge/Disc
One piece
Pins/cotter
to compress keys.
packing.
The area where
disc/wedge
Follower closes
consists Seat
of
ontwo
theseparate
valve body Component part of the valve that
pieces. opens or closes against the seat to
to stop or reduce
Bolted or threaded. start or stop flow.
flow.
 VALVE POSITIONER

Pneumatic control valves can be equipped

with a valve positioner, a type of
mechanical or digital feedback controller
that senses the actual stem position,
compares it to the desired position, and
adjusts the air pressure to the valve
accordingly.
Improves valve response time
Can be used to characterize valve response
The volume of air output from pneumatic
controllers or I/P converters may not be
sufficient to position the valve
 What is VALVE POSITIONER ?

A device used to position a valve with regard to a signal.

The positioner compares the input signal with mechanical

feedback link from the actuator. It then produces the force
necessary to move the actuator output until the mechanical
output position feedback corresponds with the pneumatic
signal value.

The Positioners can also be used to modify the action of

the valve ( reverse Acting Positioner) , alter the stroke or
controller input signal ( Split range Positioner), increase
the pressure to the valve actuator ( amplifying Positioner) ,
or alter the control valve flow Characteristic
( Characterized Positioner).
 VALVE POSITIONER
Flapper Nozzle: A pneumatic control system
operates with air. The signal is transmitted in form of
variable air pressure (often in the range 3-15 psi, i.e. 0.2
to 1.0 bar) that initiates the control action. One of the
basic building blocks of a pneumatic control system is
the flapper nozzle amplifier. It converts very small
displacement signal (in order of microns) to variation of
air pressure. The basic construction of a flapper nozzle
amplifier is shown in Fig.1. Constant air pressure
(20psi) is supplied to one end of the pipeline. There is an
orifice at this end. At the other end of the pipe there is a
nozzle and a flapper. The gap between the nozzle and
the flapper is set by the input signal. As the flapper
moves closer to the nozzle, there will be less airflow
through the nozzle and the air pressure inside the pipe
will increase. On the other hand, if the flapper moves
further away from the nozzle, the air pressure decreases.
At the extreme, if the nozzle is open (flapper is far off),
the output pressure will be equal to the atmospheric
pressure. If the nozzle is blocks, the output pressure will
be equal to the supply pressure. A pressure measuring
device in the pipeline can effectively show the pressure
variation.
VALVE POSITIONER
 POSITION FEEDBACK TRANSMITTER

• A device that is mechanically

connected to the valve stem
and will generate and
transmit either a pneumatic
or electrical signal that
represents the valve stem
Position.
 POSITION FEEDBACK TRANSMITTER

• position transmitters provide

true position feedback for
monitoring or control uses.
• Presently the smart positioner
having in-built feature for
measurement of the valve
position with retransmission
output in 4 to 20 ma signal
 AIR FILTER REGULATOR
• Pneumatic pressure controls fall in the category of pressure
reducing valves, commonly referred to as air line regulators. It
is also essential, once a system pressure has been selected to
perform a task, that air be supplied at constant pressure to the
actuator, regardless of variations in flow and upstream
pressure. Thus, it is important to add to a pneumatic system a
pressure regulator that:
• • supplies air at constant pressure regardless of flow variation
or upstream pressure,
• helps operate the system more economically by minimizing
the amount of pressurized air that is wasted. (This happens
when the system operates at pressures higher than needed for
the job),
• helps promote safety by operating the actuator at reduced
pressure,
• extends component life because operating at higher-than-
recommended pressures increases wear rate and reduces
equipment life,
• produces readily controlled variable air pressures where
needed, and
• increases operating efficiency
 AIR LOCK RELAY
• Air Lock Relay is highly effective in holding the air in lock
condition, when there is supply failure in the process
pneumatic line, thereby keeping the control valve in stay-put
condition. The design is very compact and offers flexibility
for panel mounting as well as mounting on control valves.

• Description:
• The instrument is spring-loaded and in the normal operating
condition, an equilibrium is established between the signal
pressure and spring force, any offset caused by the reduction in
signal pressure will make the inlet valve close due to the spring
force. This closed condition will continue until the signal pressure
is re-established to the original level. The soft seated design
ensures a bubble-tight shut-off on signal failure. The nylon
reinforced diaphragm and the specially selected internal
components are designed for years of trouble free performance
and easy servicing.
 VOLUME BOOSTER
volume booster products are pneumatic devices
used for amplifying pneumatic control signals
and enhancing control of final control elements
with faster movement.
i.e.
Convert low volume control air signal to a
proportionally higher volume air pressure which
is applied to an actuator to position the valve
 LIMIT SWITCHES
Limit switch preventing the travel of an object in a
mechanism past some predetermined point, mechanically
operated by the motion of the object itself.
In control valve it may or may not be used for indication
of the valve open and close status in remote DCS.

Generally it is used in on/off type valves for getting the

status of valve
Limit switches are used in a variety of applications and
environments because of their ruggedness, ease of
installation, and reliability of operation. They can
determine the presence or absence, passing, positioning,
and end of travel of an object. They were first used to
define the limit of travel of an object; hence the name
"Limit Switch".
Valve Limit
Switches
The convention at
Palo Verde:
Red light = Valve
open
Green light =
valve shut
Both lights lit =
valve intermediate
position

Limit switches are

Valve Limit
Switches
The convention at
Palo Verde:
Red light = Valve
open
Green light =
valve shut
Both lights lit =
valve intermediate
position

Limit switches are

 Working Principles
(Rotary Pneumatic Actuators)
• Rotary actuators are used to convert potential
pneumatic energy into mechanical energy.
• Rotary actuators produce torque
• Commonly called air motors
• In most cases rotary actuators are not chosen
for their efficiencies, but for their power,
speed and torque.
 Single Acting Actuator
• The spring return actuator or Single acting
Actuator is the actuator that used spring
force to place the valve position in close or
open position. We only need to pressurize
on one side only to operate the valve
 ROTARY ACTUATOR- DOUBLE ACTING
Working principle of the Double-acting actuator
•When the air supply pressure enters the middle chamber
between two cylinder pistons from the air port (2), it will
separate the two pistons and make them move toward both ends
of the cylinder, air in the air chamber be discharged from the air
port (4) and the rack of two pistons simultaneously drive (gears
of )the output shaft in counter clockwise rotation. On the
contrary, when the air supply enters the air chambers on both
ends, it will make two pistons move toward the middle of the
cylinder, where the air is discharged from the air port (2) and
make the rack of two pistons simultaneously drive (gears of )the
output shaft in clockwise rotation. (If the piston is fixed in the
opposite direction, the output shaft will be in opposite rotation.)
 Double acting pneumatic valve with 2/5 way double coil
solenoid valve working principle,
• Double electric control solenoid valve on both sides by electromagnetic coil
electricity and without electricity to control the valve opening and closing,
when one coil power -loosing, another coil without electricity can keep valve
core at the current position, and this current position is called a memory
function of the valve.
• 1 hole: Air source inlet hole, 5KG
• 2 hole: Connect with pneumatic valve 2 hole
• 4 hole: Connect with pneumatic valve 4 hole
• 3 hole, 5 hole: Corresponding to 2 hole, 4 hole exhaust.
 Double acting pneumatic valve with 2/5 way double coil
solenoid valve working principle,
• When solenoid valve A coil get electricity, 2 hole inlet air, 4 hole exhaust. Pneumatic
valve actuator counter clockwise rotation, valve open. When A coil power off, B coil
without electricity, pneumatic valve is still keep the current position. A coil just need
get once electricity and open the valve Coil with low power consumption.
• When solenoid valve B coil get electricity, 4 hole inlet, 2 hole exhaust. Pneumatic
valve actuator anticlockwise rotation, valve closed. When B coil power off, A coil
without electricity, pneumatic valve still keep the current position, B coil just need get
once electricity, valve closed, the coil with low power consumption.
• If A coil and B coil get electricity at the same time, the valve not working, remain in
place.
Double acting pneumatic valve with 2/5 way double coil
solenoid valve working principle,

•
 Double Acting Pneumatic
Actuator (Power Cylinder )
 Pneumatic Actuators

Pneumatic actuators as illustrated in the image below provide for

automatic or semiautomatic valve operation. These actuators translate
an air signal into valve stem motion by air pressure acting on a
diaphragm or piston connected to the stem. Pneumatic actuators are
used in throttle valves for open-close positioning where fast action is
required. When air pressure closes the valve and spring action opens
the valve, the actuator is termed direct acting.
When air pressure opens the valve and spring action closes the valve,
the actuator is termed reverse acting. Duplex actuators have air
supplied to both sides of the diaphragm. The differential pressure
across the diaphragm positions the valve stem. Automatic operation is
provided when the air signals are automatically controlled by circuitry.
Semi-automatic operation is provided by manual switches in the
circuitry to the air control valves
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Arrangement of a Typical Air Supply for Pneumatic
Actuators
HP Bypass
ELECTRICAL OPERATED ACTUATOR
Electric motors permit manual, semi-automatic, and automatic
operation of the valve. Motors are used mostly for open-close
functions, although they are adaptable to positioning the valve to any
point opening as illustrated in the image below. The motor is usually
a, reversible, high speed type connected through a gear train to reduce
the motor speed and thereby increase the torque at the stem. Direction
of motor rotation determines direction of disk motion.
The electrical actuation can be semi-automatic, as when the motor is
started by a control system. A handwheel, which can be engaged to
the gear train, provides for manual operating of the valve. Limit
switches are normally provided to stop the motor automatically at full
open and full closed valve positions. Limit switches are operated
either physically by position of the valve or torsionally by torque of
the motor.

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ELECTRICAL OPERATED GEAR BOX

47
HP BYPASS CV
LP Bypass
LP Bypass
 HYDRAULIC VALVES
• Hydraulic Actuators, as used in industrial process control,
employ hydraulic pressure to drive an output member.
These are used where high speed and large forces are
required. The fluid used in hydraulic actuator is highly
incompressible so that pressure applied can be transmitted
instantaneously to the member attached to it.

51
 Principle Used in Hydraulic Actuator
System
• Pascal’s Law :
• Pressure applied to a confined fluid at any point is transmitted
undiminished and equally throughout the fluid in all directions and acts
upon every part of the confining vessel at right angles to its interior
surfaces.
• Amplification of Force :
• Since pressure P applied on an area A gives rise to a force F, given as,
F = P×A
• Thus, if a force is applied over a small area to cause a pressure P in a
confined fluid, the force generated on a larger area can be made many
times larger than the applied force that crated the pressure. This
principle is used in various hydraulic devices to such hydraulic press to
generate very high forces.

52
 Components of Hydraulic Actuation
Systems
• Hydraulic Fluid :
Hydraulic fluid must be essentially non-compressible to be able to
transmit power instantaneously from one part of the system to another.
At the same time, it should lubricate the moving parts to reduce friction
loss and cool the components so that the heat generated does not lead to
fire hazards. It also helps in removing the contaminants to filter.

• Reservoir :
It holds the hydraulic fluid to be circulated and allows air entrapped in
the fluid to escape. This is an important feature as the bulk modulus of
the oil, which determines the stiffness of hydraulic system, deteriorates
considerably in the presence of entrapped air bubbles. It also helps in
dissipating heat.

53
 Components of Hydraulic Actuation
Systems
• Filter :
The hydraulic fluid is kept clean in the system with the help of filters and
strainers. It removes minute particles from the fluid, which can cause
blocking of the orifices of servo-valves or cause jamming of spools.
• Hydrostatic or Positive Displacement Pumps :
These pumps deliver a given amount of fluid for each cycle of motion, that
is, stroke or revolution. Their output in terms of the volume flow rate is
solely dependent on the speed of the prime-mover and is independent of
outlet pressure notwithstanding leakage. These pumps are generally rated by
their volume flow rate output at a given drive speed and by their maximum
operating pressure capability which is specified based on factors of safety
and operating life considerations. In theory, a pump delivers an amount of
fluid equal to its displacement each cycle or revolution. In reality, the actual
output is reduced because of internal leakage or slippage which increases
with operating pressure.
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 Single Acting Cylinder
• Single Acting Cylinder: It has only one fluid chamber and exerts
force in only one direction. When mounted vertically, they often
retract by the force of gravity on the load. Ram type cylinders are
used in elevators, hydraulic jacks and hoists.

55
 Double Acting Cylinder
• Double-Acting Cylinder: The double-acting cylinder is operated
by hydraulic fluid in both directions and is capable of a power
stroke either way. In single rod double-acting cylinder there are
unequal areas exposed to pressure during the forward and return
movements due to the cross-sectional area of the rod. The
extending stroke is slower, but capable of exerting a greater force
than when the piston and rod are being retracted.

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