The Future of Electric Valve Actuators: AI, Wireless Networking, and Digital Twins

Introduction:

As industries continue to embrace digital transformation, electric valve actuators' landscape will significantly advance over the next five years. The rapid evolution of artificial intelligence (AI), wireless networking, and digital twin technologies will revolutionize how electric valve actuators are designed, operated, and maintained. This article explores the potential developments and their impact on various industries.

AI-Powered Predictive Maintenance:

Electric valve actuators will include advanced AI algorithms continuously monitoring and analyzing performance data. These intelligent systems will detect anomalies, predict potential failures, and schedule maintenance activities proactively. AI-driven predictive maintenance will minimize downtime, extend equipment lifespan, and optimize system efficiency. Operators will receive real-time alerts and recommendations, enabling them to make informed decisions and prevent costly disruptions.

Wireless Connectivity and Remote Control:

The proliferation of wireless networking technologies, such as 5G and IoT (Internet of Things), will transform how electric valve actuators are controlled and monitored. Wireless connectivity will enable remote access and control of actuators from anywhere in the world. Operators can adjust valve positions, monitor performance, and receive alerts through mobile devices or centralized control systems. This level of remote accessibility will enhance operational flexibility, reduce response times, and improve overall plant efficiency.

Digital Twin Integration:

Digital twins, virtual replicas of physical assets, will become integral to electric valve actuator management. By creating digital twins of actuators, engineers can simulate various operating scenarios, optimize performance, and predict maintenance requirements. Digital twins will comprehensively understand actuator behavior under different conditions, enabling proactive decision-making and risk mitigation. Integrating digital twins with AI algorithms will further enhance the accuracy and reliability of predictive maintenance strategies.

Self-Diagnosing and Self-Healing Capabilities:

Electric valve actuators of the future will possess self-diagnosing and self-healing capabilities. Embedded sensors and AI algorithms will continuously monitor actuator health, identifying potential issues before they escalate into failures. In minor malfunctions, the actuators can self-correct and adapt their operation to maintain optimal performance. This self-healing capability will reduce the need for manual interventions and minimize downtime, ensuring a more resilient and reliable valve control system.

Cybersecurity Enhancements:

Cybersecurity will be a top priority as electric valve actuators become more connected and digitally integrated. Manufacturers will invest in robust security measures, such as encryption, secure communication protocols, and regular security updates, to protect actuators from cyber threats. Advanced authentication and access control mechanisms will prevent unauthorized access and ensure the integrity of the valve control system. Cybersecurity will be integral to the design and development process, ensuring that electric valve actuators are resilient against evolving cyber risks.

Conclusion:

The next five years will witness a transformative shift in the capabilities and performance of electric valve actuators. The convergence of AI, wireless networking, and digital twin technologies will unlock new possibilities for predictive maintenance, remote control, and self-healing. These advancements will drive operational efficiency, reduce downtime, and enhance plant performance. As industries embrace these technologies, electric valve actuators will become more intelligent, connected, and resilient, paving the way for a new era of intelligent valve control systems.

CTi Controltech
https://cti-ct.com
925-208-4250

Commissioning the ROTORK CK Range Valve Actuators

The Rotork CK actuator range has been designed to meet the needs of diverse actuation applications required by the valve industry and its customers. The modular design concept enables quick product configuration from stock to customer specification with a very short lead time. 

The CK range provides the customer with a range of options to suit all of their actuation requirements. Rotork CK actuators are designed for minimum user interaction. Their primary goal is to provide safe and reliable actuation in harsh environments. 

The modular CK product range offers simple, robust actuators (CK/CKr) suited to harsh environments with the option for two different control packages (Atronik and Centronik) to meet exact site requirements. Atronik offers modest control and feedback for a simple integrated starter solution. Centronik offers advanced control and feedback for more complex site system integration and increased flexibility through remote mounting. 

For questions about all ROTORK products in Northern California and Nevada, contact CTi Controltech.

https://cti-ct.com
925-208-4250

Rotork Electric Valve Actuators on Gas Production Wells Powered by Solar Panels

Solar Powered Rotork Electric Valve Actuators

Engineered for choke and control valve applications, Rotork’s IQTF actuators provide reliable flow control for oil and gas or process operations, capable of achieving accuracy to 0.3% and resolution to 0.1%. A highly accurate absolute position sensor can measure up to 22 output turns independent of electrical power.

Rotork’s customer has ordered IQTF actuators to carry out modulating duties on wellhead rotary non-rising choke valves. Approximately 60 actuators have already been installed to control the flow and pressure of gas and condensate, a mixture of liquid hydrocarbons formed when pressure and temperature decrease as a result of well drilling, at the site near the city of Lufkin. Two IQTF actuators have been installed on each well. More than 30 have also been ordered to hold in the customer’s inventory.

All wells are fully automated to maintain flow and well pressure. To maximize the lifespan of the wells, the customer uses two choke valves on each one to step pressure down from 10,000 psi to 1,200 psi. Shale gas is metered between the wellhead and midstream trunkline where it is transported to domestic supply customers as well as industries including LNG plants and power stations.

The remote location of the wells means a DC power supply using a solar system and battery pack is being used to power the IQTF actuators. This solution was specified as a more reliable option than hydraulic or pneumatic actuation as it avoids potential leakage common in hydraulic actuators. At this location there is also plenty of sun to use as a source while electric actuators use less power than a hydraulic system.

Rotork’s lightweight, compact IQTF actuator provides fast and accurate valve control and can perform up to 1,800 starts per hour, an important factor given the need for a tight well flow threshold to avoid over pressure in the main trunkline. If too much gas is extracted in a short period of time the reservoir can implode or cause ground fractures which water or gas can infiltrate and cause a loss in production. The involvement of Rotork Site Services (RSS), which offered final commission and warranty, and Rotork’s support during initial testing and calibrating was also key in the customer’s decision to choose the company’s products.

IQTF actuators are available with rotary, linear or rising stem valve drive outputs to ISO / MSS standards.

A sealed for life internal lubrication system ensures reliability for the actuators installed on wells at unmanned, remote sites. This system uses oil which can perform in temperatures ranging from -50 to +70 °C (-58 to +158 °F), ideal for the environment in East Texas where temperatures very rarely drop below the lowest point.

For more information about Rotork product in California and Nevada, contact CTi Controltech by calling 925-208-4250 or by visiting https://cti-ct.com.

Reprinted with permission from Rotork.

Electric Actuator for Linear and Quarter Turn Control Valves

Many process control valve installations present the option of selecting either electric or pneumatic actuators as part of the control component train. Pneumatic actuators have been in use for many years, but advances in electric motor design that delivered greater torque and more precise operation have brought electric valve actuators into a prominent market position.

Electric actuators are compact and comparatively self contained, requiring only cable connections and none of the additional devices sometimes needed for a pneumatic installation. There are some points of advantage to consider with electric actuators. Rotork introduced their CVA line of electric actuators almost ten years ago, making it something of a mature product now. Here are some advantageous points about the CVA actuators that likely apply generically as well.

• Setup is accomplished with a Bluetooth enabled device which provides quick calibration of open and closed positions, as well as establishment of valve setup parameters.
• A separately sealed electrical connection compartment keeps motor and mechanical compartment isolated from the environment while electrical connection section cover is removed.
• An on board datalogger records thrust and position data over time for use in asset management and service functions. Data can be downloaded by Bluetooth or transmitted by common protocol to another station.
• Change in setpoint produces a rapid and precise change in valve position with high resolution accuracy and repeatability.
• Actuator can be programmed to move to a preset condition in the event of a loss of electric power. The energy to achieve the failsafe position is stored in the actuator.
• Force balance positioning used in pneumatic valves, with spring force vs. air pressure, has resilience that can result in a change in position of the valve trim in response to a bump in system pressure. Resistance from the gear train on electric drives prevents this movement.
• Static friction of the valve packing and other parts increases the amount of force to intially get the valve moving toward a new position. The additional time required to build air pressure and force to overcome static friction results in delayed valve response, then overshoot of the new setpoint. A combination of a sensor system and the mechanical drive section of an electric actuator eliminates overshoot and delayed response.

Electric actuators can be had in quarter turn and linear versions, with torque ranges suitable for a broad range of process control applications. The datasheet below, from Rotork, provides useful illustrations of the actuator interior, along with additional detail about electric actuators. Share your process control valve requirements and challenges with product application specialists, combining your own process knowledge and experience with their product application expertise to develop the best solutions.

Compact Electric Control Valve Actuators

CML linear valve actuator
Image courtesy of Rotork

Rotork's CMA line of electric valve actuators are intended for use in industrial process control applications where precise response and positioning are key requirements. The variants of linear, rotary and quarter-turn actuators span a wide range of application requirements and support on-board programming and connection via any of several recognized communication protocols.

The compact actuators are available with enclosures rated for several environments, ranging from non-hazardous to hazardous. Low temperature operation to -40 degrees Celsius is provided with the inclusion of a low temperature option.

These are but a small recounting of the useful features incorporated into the product line. More detail is provided in the document included below. For best results, share your valve automation requirements and challenges with process valve automation specialists, combining your own process knowledge and experience with their valve automation expertise to develop effective solutions.

Rotork CMA Compact Electric Valve Actuators from CTi Controltech

Electric Control Valve Actuators

CVQ Electric Valve Actuator
For quarter turn valves
Courtesy Rotork

Many process control valve installations present the option of selecting either electric or pneumatic actuators as part of the control component train. Pneumatic actuators have been in use for many years, but advances in electric motor design that delivered greater torque and more precise operation have brought electric valve actuators into a prominent market position.

Electric actuators are compact and comparatively self contained, requiring only cable connections and none of the additional devices sometimes needed for a pneumatic installation. There are some points of advantage to consider with electric actuators. Rotork introduced their CVA line of electric actuators almost ten years ago, making it something of a mature product now. Here are some advantageous points about the CVA actuators that likely apply generically as well.

• Setup is accomplished with a Bluetooth enabled device which provides quick calibration of open and closed positions, as well as establishment of valve setup parameters.
• A separately sealed electrical connection compartment keeps motor and mechanical compartment isolated from the environment while electrical connection section cover is removed.
• An on board datalogger records thrust and position data over time for use in asset management and service functions. Data can be downloaded by Bluetooth or transmitted by common protocol to another station.
• Change in setpoint produces a rapid and precise change in valve position with high resolution accuracy and repeatability.
• Actuator can be programmed to move to a preset condition in the event of a loss of electric power. The energy to achieve the failsafe position is stored in the actuator.
• Force balance positioning used in pneumatic valves, with spring force vs. air pressure, has resilience that can result in a change in position of the valve trim in response to a bump in system pressure. Resistance from the gear train on electric drives prevents this movement.
• Static friction of the valve packing and other parts increases the amount of force to intially get the valve moving toward a new position. The additional time required to build air pressure and force to overcome static friction results in delayed valve response, then overshoot of the new setpoint. A combination of a sensor system and the mechanical drive section of an electric actuator eliminates overshoot and delayed response.

Electric actuators can be had in quarter turn and linear versions, with torque ranges suitable for a broad range of process control applications. The datasheet below, from Rotork, provides useful illustrations of the actuator interior, along with additional detail about electric actuators. Share your process control valve requirements and challenges with product application specialists, combining your own process knowledge and experience with their product application expertise to develop the best solutions.

Electric Control Valve Actuators for Industrial Process Applications from CTi Controltech

Electric Valve Actuator - Inner Workings

IQ3 Electric Actuator
Rotork

Rotork's IQ3 electric actuator is one of the most advanced and full featured valve actuators available today. The IQ3 incorporates many innovative features which expand its functionality, making it an advantageous choice for many industrial applications. In just the latest generation, a number of new features have been incorporated (from Rotork website).

• New intuitive user interface
• Advanced dual stacked display with configurable datalogger functionality
• Toughened glass screen plus optional environmental shield
• Setting tool with secured Bluetooth® connection
• High reliability, solid-state controls (multi-turn variants)
• Reduced internal wiring and connections
• Simplified torque sensor (multi-turn variants)
• Simple and robust absolute position sensor with high reliability and accuracy
• New thrust base design (multi-turn variants)
• Separable gearbox/thrust base across the range (multi-turn variants)
• Advanced real-time status reporting

The video below provides a display of the parts assembly of an IQ3 actuator. The mechanically inclined should find it interesting. You can get more detail on the IQ3 series of actuators for every application from a product specialist. Share your valve and actuator challenges with experts and get the best available solutions.

Why Do We Debate Air vs. Electric Powered Valve Actuators?

Industrial Process Control Valve
Courtesy Rotork

Which is better, air or electric? We're talking about valve actuators here. Just for perspective on how original this article might turn out to be, I commanded my friendly Google search engine to look for "air vs. electric actuators". Google always finds something, no matter what you ask, giving the humble user an impression that the big "G" has all the answers....and they truly may. Don't misunderstand me. I am a big Google fan. Someday I might even pay for something that they provide me. Anyway, I was humbled by the avalanche of search returns on my the subject, 17,200,000 articles. That's a large number, even for a Google search. Many of the articles related to industrial machinery automation, not valves. Changing my search to "electric vs pneumatic valve actuator" shaved the returns down to 236K, a more manageable volume.
Dutifully reading the highest ranked articles and following threads in forums, I started to wonder why, like figurative gladiators, we pit these two valve actuator motive power sources against one another. There is not a single winner in this case. One is not universally better, more advantageous, than the other. Both methodologies have instances where they can be used to best advantage. A good recommendation is to not be too influenced by the past, by what your own industrial process control experience may have been. The manufacturers of these products are continuously modifying designs and releasing products with newer technologies and better performance that may eliminate some shortcomings of the past.

Your best course of action is to consider the following:

• What is the expected useful life of the process? Short term, long term, permanent?
• Will existing air supply and piping system accommodate the anticipated additional pneumatic valve load, if that type actuator seems otherwise advantageous?
• Are there sufficient maintenance and technical resources in place to keep either system in top operating condition and successfully deal with operational and repair issues that will arise? Does the current maintenance staff have sufficient knowledge and training to perform needed tasks?
• Are there rated hazardous zones where valves will be located?
• What needs to happen to valve position if motive power (air pressure or electricity) fails?
• What valve positioning requirements are associated with proper control of the process?
• What interfaces with any existing control systems, if any, need to be accomplished?

Carefully consider these points, add several of you own. Consult with knowledgeable sales engineers that specialize in valve automation. Combine experience and knowledge from a number of sources and a good solution will materialize. 

Rotork Skilmatic Valve Actuators Enhance Performance and Safety

Electro-Hydraulic Valve Actuator
Courtesy Rotork

Incorporating levels of performance and safety into industrial fluid handling systems presents ever increasing challenges to those designing, owning, and operating those systems. Rotork Fluid Systems developed the Skilmatic line of valve actuators to provide the positioning performance, operational safety, and data connectivity needed for best-in-class implementation of industrial process control valves.

The Skilmatic range of self-contained electro-hydraulic actuators combine the precision of hydraulic control, the simplicity of electrical operation, and the reliability of mechanical fail-safe action into a single integrated product. In addition to general purpose, flameproof, and modulating versions of the actuators, Rotork offers intelligent versions of the product that deliver improved control and monitoring functions:

• Datalogger recording of events, trends, alarms.
• Bluetooth connectivity for data download and upload between actuator and Rotork’s InSight2 software.
• Semi-automatic position limit calibration.
• Partial stroke operation.
• Improved position control for modulating operations.
• Valve flow characterization for modulating control with various valve attributes, such as equal %, linear, and more.
• Manual override detection.
• Alarm output relays with selectable function.
• Internal temperature sensor.

The actuators are available in a myriad of configurations to suit every application. A wide range of standard arrangements are offered, along with custom versions configurable to provide a specific solution demanded for a special application. A deeper profile and description of the product line, principals of operation, and operational benefits is available from a product specialist, who can also assist with selecting and configuring the right unit for your project or application.

Intelligent Valve Control for Part-Turn Valves

ICT 3rd Generation

The introduction of this new electric valve actuator brings the advanced functionality and asset management capabilities of intelligent technology to the direct-drive operation of part-turn valves.

Valve maintenance requirements can be identified and anticipated, eliminating unplanned interruptions to the process or over-cautious planned maintenance outages. The actuator's powerful datalogger provides comprehensive data capture for planned maintenance and troubleshooting. Data includes valve torque profiles, operational start profiles, vibration and temperature trend logs and an event log. Specific asset management information includes running time, average torque and number of starts. Service or maintenance alarms are selectable from configurable menus including open and close torque levels, total starts and vibration levels.

IQT 3rd Generation Electric Part-Turn Aactuator from CTi Controltech

For more information contact:

CTi Controltech
22 Beta Ct.
San Ramon, CA 94583
Phone: 925-208-4250
Fax: 925-208-4251
Email: contactus@cti-ct.com

www.cti-ct.com

ROTORK IQ Electric Actuator Overview

Here is a quick overview of one of the most popular, and universally specified, electric actuators - the ROTORK IQ Series.

The IQ electric actuator features include ROTORK's unique double-sealed enclosure, ‘non-intrusive' infra-red commissioning, data-logging, predictive maintenance, Bluetooth® communications interface and absolute encoder.

The IQ functionality and reliability is available for valves of virtually every size and description, including multi-turn (rotary), quarter-turn, isolating and modulating, with watertight and hazardous area approvals to all internationally recognized standards.

Excellent Control Valve Actuator White Paper from Rotork

Here is a white paper from electric actuator manufacturer Rotork pointing out the benefits of electric actuators over pneumatic.

Electric control valve actuators provide excellent performance and are ideal for oil and gas wells in remote production fields. Instrument air supply systems are costly and require significant energy to run. If mains power isn’t available, an instrument air supply isn’t practical, especially when only a few control valves are in use at a location. Solar powered DC electric actuators are ideal for such an application.

Control Valve Actuators: Their Impact on Control and Variability from ctict

Electrically Actuated Ball Valve Operation with Limit Switches

This video demonstrates the operation a small (Worcester) motor operated ball valve also known as an “MOV”. Also known as an “electric actuator”, motor operators come in a wide variety of sizes and styles. Some electric actuators are intended for quarter-turn valves (such as ball and butterfly valves), while others are designed to operate linear valves (such as gate and globe valves).

The MOV / electric actuator consists of an electric motor with the gearbox assembly which rotates the shaft of the valve. Most MOVs operate at 120, 240 or 480 volt, single or three phase. Basic features include adjustable limit switches to limit valve travel and to notify valve status, directional settings, analog inputs to allow for precise control, analog outputs to provide a feedback signal and digital communications. MOV enclosures can be either NEMA 4, NEMA 4X and NEMA 7 and are available in a wide range of torque outputs to match the valve it is operating.

Electrically Actuated Control Valves for Data Center HVAC Chillers

3-way chilled water valve
with electric actuator
for data center.

A data center chiller is a cooling system used to remove the heat generated by computer hardware and storage devices, and transfers that heat to another place where it can be used for some other process. Chillers are used in the data centers heating, ventilating and air-conditioning (HVAC) systems. Large scale HVAC chillers are used to provide accurate and reliable cooling. These chillers work around the clock to keep ambient temperatures optimized for data center operation. Because of the considerable heat generated by so many servers operating in such close proximity to one another, accurate and reliable temperature and humidity control is critical. If there is a failure, building temperatures would rise quickly and possibly ruin equipment and lose data.

A main component of the cooling system is the chilled water 3-way control valve used to throttle the chilled water to the building’s heat exchangers. It is essential that these control valves control accurately and perform reliably. Also, and in the event of a power failure, they must be programmable to move to a predetermined valve position.

I many data center HVAC applications, electric actuators are the preferred means to actuate the control valves. Their reliability, tightness of control, and failure-mode programmability are key reasons why chiller OEMs and data center building engineers choose electric actuators.

Electric Actuator for Fuel Oil Control Valve

Control Valve Actuator

In a Power Station burning both low-sulphur fuel oil and natural gas, an electric control valve actuator was installed on an outdoor fuel oil control valve application. The existing 6” ball valves which utilized a pneumatic I/P positioner and spring diaphragm pneumatic actuator wasn’t performing well. A decision was made to use a ROTORK CVA electric control valve actuator because it provides extremely precise control-valve operation with repeatability and resolution performance at less than 0.1% of full scale.

Because the valve operates outdoors, and modulates frequently to control the flow of fuel oil held in storage tanks to the fuel oil pumps, its a difficult application to get precise control. The built-in Bluetooth communications makes it easy to set up, calibrate and monitor performance.

The valve failure mode is also very important, in both loses-of-signal and loss-of-power. The specified ROTORK Actuators use a charged super capacitor and the built-in programming of the actuator control to assure proper “fail-to” in any event.

Torque and Limit Switch Considerations When Applying Electric Valve Acuators

When selecting an electric actuator for industrial valves, an understanding of the valve torque requirements, both at start of travel, and end of travel, is critical for proper operation and optimal service life. Additionally, the ability to accurately set, or limit, disk travel is required.

Many of today's industrial electric valve actuators provide easy setting or programming of travel and torque sensing.

This short video provides a brief visual understanding of the reasons why valve torque and travel limits are important.

An Industrial Electric Actuator Designed to Keep the Water and Dust Out

The Rotork IQ3 electric actuator includes a double o-ring seal to keep the internal parts sealed away from water and dust should the electrical conduit seals fail.

The Rotork IQ3 also includes these advanced features:

• New intuitive user interface
• Advanced dual stacked display with configurable datalogger functionality
• Toughened glass screen plus optional environmental shield
• Setting tool with secured Bluetooth® connection
• High reliability, solid-state controls
• Reduced internal wiring and connections
• Simplified torque sensor
• Simple and robust absolute position sensor with high reliability and accuracy
• New thrust base design
• Separable gearbox/thrust base across the range
• Advanced real-time status reporting

Watch this video to see the how the IQ3 double o-ring seal keeps out water and dust.