Advanced Actuation & Automation Processes in Gas Lines

Precision and safety are critical in the oil and gas industry. Automation using flow control valve actuators optimizes efficiency, modulates the flow of gas or liquid, increases safety for operators and decreases maintenance and operating costs over time. The automation industry has recognized that the function of actuators has moved beyond just opening and closing valves to providing key diagnostic and operational data via Bluetooth interfaces from sensors that measure pressure, torque and vibration. The types of actuators needed are dependent on a variety of factors.

Types of Valves

The types of valves controlled by the actuators determine the actuator used. The actuator must be matched to the following characteristics of the valves:

• Function

• Movement

• Position

The frequency that the valves are used varies with the function of the valves. Those that open up or close off the flow completely for maintenance or safety reasons are used less frequently than those that continually modulate the flow of gas or liquid. Similarly, the movement of the valves varies with the type of valve, requiring actuation. Controls for ball valves require a swivel movement provided by a quarter-turn actuator, while a multi-turn actuator would enable the many turns required to open or close a valve.

Precision is key in oil and gas transmission and electric actuators can provide superior positioning accuracy. Position accuracy is important for control valves that modulate the flow during the various stages. From the initial flow of crude oil and natural gas to storage and transportation, then finally to the refining and distribution process, the valves modulate not only the flow rate and pressure through the various pipe diameters but the rate that the oil or gas is fed into the various processes along the way.

Processes

The more processes involved, the more actuators are needed to manage the complexity of the system. We recommend you work closely with your electric actuator manufacturer to help configure a solution that is right for your needs. Sensor technology has expanded the use of flow control valve actuators to allow for monitoring in real-time and integration into IIoT (Industrial Internet of Things). Much like the smart electronics being used in factories and homes, the controls for ball valves have embraced smart technology to deliver improved flow control. Integration with supervisory control systems enables next-generation processes such as asset management on a plant-wide scale and optimized maintenance control and scheduling. Integrated operations combined with wireless communication provide operational information at a faster rate, allowing more processes to be managed with fewer resources but with increased accuracy, efficiency and response time.

Selecting the Right Automation Solutions for Valves

Create a customized solution for your valve automation today. Whether you’re looking to update your current equipment or installing a brand-new valve that requires automation, compare these essential components for valve actuation and other automation solutions designed to streamline your process and improve your overall efficiency.

Linear Vs. Rotary Actuators

One of the most important factors in selecting the right automation is choosing between linear and rotary actuators. Linear actuators operate with pinch, gate and globe valves to create an efficient automated valve operation. Each of these options require movement in a straight line, so a linear actuator manipulates the valve in this pattern.

A rotary actuator works with different types of motor operated valves. These actuators produce more traditional rotational movements. Choose a rotary actuator if you need automation for your plug, ball or butterfly valves.

Comparing Power Sources

Once you’ve selected the ideal actuator movement, your controllers and positioners require a specific power source. Whether you’ve chosen linear or rotary actuators, select one of these reliable sources of power:

• Electric

• Hydraulic

• Pneumatic

Electric is a popular option for custom linear actuators. It allows you to control your actuator with precision, requires a cost-effective maintenance schedule and is flexible enough to be used for a variety of industrial valves. However, heavy-duty valves require stronger electric motors, pneumatic power or hydraulic pressure for proper use.

Selecting Accessories

Finally, your valve actuator requires a series of accessories for precision performance. Pneumatic actuators in particular require solenoid valves, positioners and limit switches for safe and effective operation.

Solenoid valves are used as a pilot valve for your heavy duty linear actuator and other pneumatic rotary actuator designs. These control devices control the air pressure through either manual manipulation or electrical signal. When connected with the latest computer software, your solenoid valve will automatically adjust the pressure and timing of your pneumatic actuator for precision control of your valve.

A positioner is essential for throttling your air flow. Be sure your pneumatic positioner allows you the level of control and maximum air flow you need to operate your valve and accurately adjust the flow rate as necessary.

Finally, a limit switch is necessary for accurate control of your valve. Similar to an electrical actuator, a pneumatic actuator requires a limit switch to signal when you’ve reached the appropriate rotational point on your valve.

Automate Your Valves Today

Discover how you can select the ideal automation solution using the proper flow control valve actuators in order to achieve precision results and improve your industrial performance. Discuss your options with a respected flow control automation engineer and select the actuator that controls your valves and produces proven results today.

Control Valves Work on Precision Timing and Repeatability

Valve actuators are one of the most important parts of any mechanical system. In industries that rely on accuracy and streamlined processes, you can’t afford to have a control valve that malfunctions. When the flow of fluids or gases within your mechanical system is unreliable, it costs you more in reduced quality, equipment repairs and even down time when vales or actuators fail to function. So what makes one industrial actuator superior to another? Whether you’re processing gasoline or filtering wastewater, it’s imperative to invest in reliable technology for your control loop. Reduce Risk Through Improved Timing

Regardless of what fluid you are dealing with, it’s imperative that you be able to accurately control the flow rate and regulate the variables that determine mechanical efficiencies and service consistency. A faulty actuator may not manage the ratio of the fluids with the precision you require, so you need to ensure you’re achieving top-notch process control for valves. Valve timing is one of the most important yet often overlooked functions to look out for. Why? The timing function controls the following outcomes:

• Set point controls the valve lift event

• Ratio of various fluids allowed into your tanks

• Overload and overheating probability is minimized

All of these functions are dependent upon your control valve actuators’ ability to achieve accurate timing at each and every valve lift event.

Why Repeatability Matters     

When a scientist achieves a particular outcome in the process of an experiment, it is all but worthless if that outcome cannot be replicated. The same is true of actuators for valves. If a globe valve only produces results intermittently, your process will suffer. Time is of the essence in an industrial environment, so you should seek globe valves with precision metrics down to the millisecond. Valves with a high repeatability rate won’t be compromised by continual operation throughout the day—whether it’s constant or varying. Any valve with a limited duty cycle,  is prone to overheating that can cause errors and delays.

Choosing the Right Globe Valve Actuator

Some globe valve actuators are higher quality than others. There are also several types to choose from—pneumatic, hydraulic, electric, and spring. No matter what kind your line of work requires, investing in an actuator manufactured with quality is worth investing in. The quality of your mechanical systems depends upon a reliable flow through fluid gateways. Find an actuator for globe valves that produces reliable repeatability and precision timing for optimal results and minimal downtime in your fluid management process.

Partner with a supplier who can provide you with all of the valve and actuator parts that your control loop requires. Process control for valves is one of the most important aspects for your plant’s productivity. This is not an area you can skimp on without sacrificing quality.