Ensuring Reliable Valve Operation: The Role of Torque Safety Factors in Actuator Sizing

Pneumatic rack and pinion actuators are pivotal in automating industrial valves, enabling precise control over fluid flow in various processes. When engineers select these actuators for specific valve applications, they must ensure they can deliver sufficient torque to operate the valve under all expected conditions. This requirement leads to incorporating a torque safety factor in the sizing calculations. Understanding why this safety factor is essential involves examining the variables that affect valve torque requirements and the operational reliability of the actuator-valve system.

The Critical Role of Proper Actuator Sizing

Actuator sizing is not merely matching nominal torque values between the actuator and the valve. Valves often experience conditions that can significantly increase the torque required to open or close them. If the actuator cannot provide the necessary torque under these conditions, the valve may fail to operate as intended, leading to process interruptions, safety hazards, or equipment damage. Therefore, engineers must account for various factors influencing torque requirements to ensure reliable and safe valve operation.

Factors Influencing Valve Torque Requirements

Several factors can cause the torque required to operate a valve to exceed the nominal values provided by the manufacturer:

• Friction and Wear: Over time, valves can experience increased friction due to wear, corrosion, or the accumulation of deposits on sealing surfaces. This friction directly translates to higher torque requirements. For instance, sediment buildup in a butterfly valve can make it harder to turn, necessitating more torque from the actuator.
• Temperature Variations: Temperature changes can affect the materials of both the valve and the actuator. Thermal expansion or contraction can alter clearances and increase friction. Additionally, temperature changes can affect the viscosity of the process fluid, making it harder to move the valve.
• Pressure Fluctuations: The differential pressure across a valve influences the torque needed to operate it. Unexpected increases in upstream or downstream pressure can create additional forces that the actuator must overcome. For example, in a ball valve, higher pressure can increase the seating force, thus requiring more torque to unseat the ball.
• Valve Seat Aging: The degradation of valve seats over time can lead to increased torque requirements. Aging seats may harden, lose elasticity, or become damaged, making the valve harder to operate.
• Unanticipated Loads: External factors such as pipeline stresses, misalignment, or mechanical interference can impose additional loads on the valve stem, increasing the torque needed for operation.
• Supply Pressure Variations: Pneumatic actuators rely on a supply of compressed air at a specific pressure. Fluctuations in this supply pressure can reduce the actuator's output torque. For instance, if the air supply drops below the design pressure, the actuator may not produce enough torque to operate the valve.

The Justification for a Torque Safety Factor

Given the many variables that can increase the torque required to operate a valve, engineers incorporate a torque safety factor into the actuator sizing process. This safety factor is a multiplier, usually expressed as a percentage, applied to the nominal valve torque to ensure the actuator can handle the maximum expected torque under all conditions.

The torque safety factor accounts for the following:

• Operational Uncertainties: It compensates for unknown or unpredictable factors that may affect valve torque requirements during the valve's service life.
• Manufacturing Variances: This section considers tolerances and variations in the manufacturing of valves and actuators, which can affect performance.
• Maintenance Practices: It allows for less-than-ideal maintenance conditions, such as valves not being serviced as regularly as required.
• Extreme Conditions: It ensures that the actuator can operate the valve during extreme conditions, such as emergency shutdowns or start-ups, where conditions may not be typical.

By applying a torque safety factor, engineers build a margin of safety that enhances the reliability and longevity of the valve-actuator assembly. This practice helps prevent operational failures, reduces downtime, and maintains safety standards within the industrial facility.

Incorporating a torque safety factor when sizing pneumatic rack and pinion actuators for industrial valves is a critical engineering practice. It accounts for the myriad factors that can increase torque requirements beyond nominal values and ensures that actuators can reliably operate valves under all anticipated conditions. By doing so, engineers safeguard against operational failures, enhance system reliability, and uphold safety in industrial processes.

UNITORQ
2150 Boggs Road
Suite 410
Duluth, GA 30096
https://unitorq.com
Phone: 770-446-7074
Fax: 770-447-1825

Advantages of Stainless Steel Body Pneumatic Rack & Pinion Actuators

Stainless steel body pneumatic rack and pinion actuators have gained significant popularity in various industrial sectors due to their robust construction and reliable performance by combining the toughness of stainless steel with the efficiency of pneumatic operation, these actuators offer several advantages that make them suitable for demanding applications.

One of these actuators' primary advantages is their exceptional resistance to corrosion. Stainless steel protects against corrosion from exposure to harsh chemicals, moisture, and extreme temperatures. This quality makes these actuators ideal for chemical processing, pharmaceuticals, and food and beverage production, where equipment frequently contacts corrosive substances or requires regular washdowns.

Durability represents another significant benefit of these actuators. The stainless steel construction ensures long-term operational reliability, reducing the need for frequent maintenance or replacement. This durability translates into lower operational costs and increased productivity as minimal equipment downtime occurs. In industries where continuous operation remains critical, such as oil and gas or power generation, the reliability of stainless steel actuators becomes an invaluable asset.

These actuators also offer high performance in terms of torque output and speed. The rack and pinion mechanism efficiently converts the linear motion of the pneumatic piston into rotational motion, providing precise control over valve positions. This precision is crucial in applications that require accurate flow control, such as water treatment facilities or chemical dosing systems.

The hygienic properties of stainless steel make these actuators suitable for use in industries with strict sanitary requirements. Equipment in the food and beverage industry must adhere to stringent hygiene standards to prevent contamination. Operators can easily clean stainless steel actuators, which do not harbor bacteria, ensuring compliance with health and safety regulations. Similarly, in pharmaceutical manufacturing, maintaining sterile conditions is essential; stainless steel equipment supports this necessity.

Industries operating in extreme temperatures also benefit from stainless steel body pneumatic rack and pinion actuators. Stainless steel retains its mechanical properties over a wide temperature range, making these actuators suitable for cryogenic applications or high-temperature processes. For example, these actuators maintain consistent performance in power plants or refineries, where temperatures can fluctuate significantly.

Stainless steel body pneumatic rack and pinion actuators offer a combination of corrosion resistance, durability, precision, and safety. Industries that benefit most from these actuators include chemical processing, pharmaceuticals, food and beverage production, oil and gas, water treatment, and power generation. The unique advantages of stainless steel construction make these actuators reliable for applications that demand high performance and resilience in challenging environments. By investing in stainless steel actuators, industries can enhance operational efficiency, ensure compliance with regulatory standards, and achieve long-term cost savings through reduced maintenance and downtime.

UNITORQ

2150 Boggs Road

Suite 410

Duluth, GA 30096

https://unitorq.com

Phone: 770-446-7074

Fax: 770-447-1825

The ISO 9001:2015 Standard: A Pillar of Trust and Quality for UniTorq Actuators and Controls Customers

Achieving ISO 9001:2015 certification is a significant milestone for any organization, and UniTorq Actuators and Controls represents a commitment to delivering the highest standards of quality and reliability. ISO 9001:2015 is the latest version of the ISO 9001 standard, which focuses on quality management systems (QMS). This standard outlines organizations' requirements to consistently provide products and services that meet customer and regulatory requirements.

To achieve ISO 9001:2015 certification, UniTorq Actuators and Controls must establish a quality management system that aligns with the standard's principles. The process begins with a thorough understanding of the organization's context and the needs and expectations of its customers. UniTorq identifies the critical processes in delivering its products and services, ensuring they are well-defined, documented, and controlled.

Leadership plays a crucial role in meeting the ISO 9001:2015 requirements. UniTorq's top management demonstrates a strong commitment to the QMS by setting quality objectives and ensuring that these objectives align with the company's strategic direction. Leadership also ensures that the necessary resources, such as skilled personnel and infrastructure, are available to maintain and improve the QMS.

Risk-based thinking is another critical component of ISO 9001:2015. UniTorq identifies potential risks that could affect the quality of its products and services and takes proactive measures to mitigate these risks. This approach ensures the company remains resilient and adaptable in a dynamic business environment. Moreover, the company focuses on continuous improvement by regularly monitoring and measuring its processes. By analyzing performance data, UniTorq identifies areas for improvement and implements corrective actions to enhance its QMS continually.

Employee involvement and competence are essential in maintaining the QMS's effectiveness. UniTorq ensures that all employees receive appropriate training and understand their roles in achieving quality objectives. The company fosters a culture of quality, where every team member takes responsibility for contributing to the QMS's overall success.

Documented information is another critical requirement of ISO 9001:2015. UniTorq maintains up-to-date records of its processes, procedures, and performance metrics. These records provide evidence of compliance with the standard and serve as a valuable resource for audits and continuous improvement efforts.

By achieving ISO 9001:2015 certification, UniTorq Actuators and Controls demonstrates its commitment to quality and reliability. This certification assures customers that the company operates under a robust QMS consistently delivering high-quality products and services. Customers can trust that UniTorq has implemented rigorous controls to meet their requirements and exceed their expectations.

The ISO 9001:2015 certification gives UniTorq a competitive edge in the market. It signals to customers that the company prioritizes quality in every aspect of its operations, from product design and development to manufacturing and delivery. This commitment to quality enhances customer satisfaction and builds long-term relationships based on trust and confidence.

In summary, achieving ISO 9001:2015 certification requires UniTorq Actuators and Controls to implement a comprehensive QMS emphasizing leadership, risk management, continuous improvement, and employee involvement. This certification assures customers that UniTorq consistently delivers products and services of the highest quality and reliability, reinforcing its position as a trusted partner in the industry.

UniTorq Actuators and Controls
2150 Boggs Road, Suite 410
Duluth, GA 30096
https://unitorq.com
Phone: (770) 446-7074
Fax: (770) 447-1825

Modernizing Fluid Control: Transitioning from Electro-Pneumatic to Digital Valve Positioners

An industrial electro-pneumatic valve positioner is crucial in precisely controlling fluid flow in various industrial processes. Its operation hinges on converting an electrical control signal into a mechanical movement to adjust the position of a valve. This conversion ensures that the valve achieves the desired position accurately and promptly, thereby maintaining the process's efficiency and reliability.

The operation begins with an electrical signal, typically a 4-20 mA current, input from a control system. This electrical signal represents the desired valve position and feeds the electro-pneumatic valve positioner. Inside the positioner, the electrical signal interacts with a coil in a force-balance system, producing a magnetic field proportional to the current. This magnetic field then influences a flapper-nozzle assembly, a core component in the positioner.

The flapper-nozzle system creates a variable air gap between the flapper (a small, movable plate) and the nozzle (an air supply orifice). As the magnetic field alters the position of the flapper, the air gap changes, modulating the backpressure in the nozzle. This backpressure directly affects a relay system that controls the air supply to the valve actuator. 

The actuator, typically a diaphragm or piston, receives the modulated air pressure, converting it into a mechanical force that moves the valve stem. The movement of the valve stem adjusts the position of the valve, thereby controlling the flow of the process fluid. A feedback mechanism, often in the form of a mechanical linkage or a position sensor, constantly monitors the valve's actual position and feeds this information back to the positioner. Suppose there is any discrepancy between the desired position (as indicated by the electrical signal) and the actual position. In that case, the positioner makes the necessary adjustments by altering the air pressure to the actuator until the desired valve position is achieved.

Industrial electro-pneumatic valve positioners are widely applied in various sectors such as oil and gas, chemical processing, water treatment, and power generation. They are instrumental in applications requiring precise fluid flow and pressure control, enabling processes to run efficiently and safely. The positioners enhance process control by ensuring valves respond quickly and accurately to control signals, reducing variability and maintaining the desired setpoints.

In recent years, newer digital valve positioner technology has begun to replace traditional electro-pneumatic valve positioners. Digital positioners offer several advantages, including enhanced accuracy, diagnostics, and communication capabilities. Unlike their electro-pneumatic counterparts, digital positioners use microprocessors to interpret the electrical control signal and adjust the valve position. This allows for more sophisticated control algorithms, which can improve the response time and accuracy of the valve positioning.

Moreover, digital positioners often feature advanced diagnostics that can monitor the health of the valve and actuator system. They can detect issues such as valve stiction, wear, and air leaks, providing maintenance alerts before they lead to process disruptions. Additionally, digital positioners support modern communication protocols like HART, Foundation Fieldbus, and Profibus, enabling seamless integration with plant-wide control and monitoring systems. This connectivity allows operators to access real-time data and make informed decisions to optimize process performance.

Digital valve positioners also offer greater flexibility in configuration and calibration. They can be easily adjusted through software interfaces, allowing quick changes to control parameters without manual intervention. This ease of setup is particularly beneficial in processes that frequently change or require fine-tuning to maintain optimal performance.

In summary, the operation of an industrial electro-pneumatic valve positioner involves converting an electrical control signal into a mechanical movement to adjust valve positions accurately. These devices are essential in various industrial applications requiring precise fluid control. However, the advent of digital positioner technology provides enhanced accuracy, diagnostic capabilities, and communication features, making them a superior choice for modern industrial automation systems.

UniTorq Actuators and Controls
2150 Boggs Road, Suite 410
Duluth, GA 30096
https://unitorq.com
Phone: (770) 446-7074
Fax: (770) 447-1825

The Role of Declutchable Manual Gear Overrides in Industrial Valve Automation

Declutchable Manual Gear Overrides are vital in industrial valve automation, ensuring seamless operations and safety. These devices are essential when the primary automated actuators fail or become unavailable, allowing operators to control valves and maintain process control manually.

Understanding Declutchable Manual Gear Overrides

At the heart of these devices lies their "declutchable" feature. This unique characteristic allows operators to disengage the manual override from the automated system when it is not in use. The significance of this feature cannot be overstated, as it prevents any potential interference between manual and automated operations. This seamless transition between manual and automated modes is crucial for maintaining operational integrity and safety.

Importance Across Various Industries

Declutchable Manual Gear Overrides are indispensable across multiple industries for several key reasons:

1. Backup Operation During Failures: During power outages or actuator failures, these overrides serve as a reliable backup method to operate valves. This capability is crucial for maintaining process control and ensuring safety, as it allows operators to manually control the valves, preventing potential hazards or process disruptions.
2. Facilitating Maintenance and Testing: These overrides enable manual testing and maintenance of valves without the need to dismantle the entire automated system. This feature is particularly valuable as it reduces downtime and maintenance costs while ensuring the continued functionality of the automated system.

Design and Mechanism

The gear mechanism integrated into these overrides is pivotal in their functionality. By multiplying the operator's input force, the mechanism makes it significantly easier to manually move large or high-pressure valves.

Applications in Key Industries

Declutchable Manual Gear Overrides find extensive application in various industries, each of which benefits from their unique capabilities:

1. Oil and Gas Industry: In the oil and gas sector, operations reliability and safety are paramount. These overrides provide a critical manual control option, ensuring processes continue smoothly even during automation failures.
2. Water Treatment: Maintaining precise control over valve positions is essential for efficient and safe water management in water treatment facilities. The manual overrides offer an additional layer of control, contributing to the system's overall reliability.
3. Power Generation: Power generation plants rely heavily on automated systems for efficiency and safety. Declutchable Manual Gear Overrides provide a necessary fallback, ensuring that operations are maintained even during automation issues.
4. Chemical Processing: In chemical processing, precisely controlling valve positions is crucial for maintaining safety and process integrity.

 

Declutchable Manual Gear Overrides are indispensable components in industrial valve automation systems. Their ability to provide manual control during automation failures, facilitate maintenance and testing, and offer precise adjustments makes them essential for ensuring plant reliability, safety, and operational flexibility. 

UniTorq Actuators and Controls
2150 Boggs Road, Suite 410
Duluth, GA 30096
https://unitorq.com
Phone: (770) 446-7074
Fax: (770) 447-1825

The Evolution of Pneumatic and Electric Industrial Valve Actuators: AI, Wireless Communications, and Industrial Digitalization

Over the next five years, the industrial valve actuator market will undergo significant transformations driven by advances in artificial intelligence (AI), wireless communications, and industrial digitalization. These technologies will revolutionize how pneumatic and electric valve actuators operate, enabling enhanced efficiency, reliability, and connectivity in various industrial applications.

Artificial Intelligence Integration

Integrating AI into valve actuators will enable predictive maintenance and intelligent decision-making. AI algorithms can predict potential failures and optimize maintenance schedules by analyzing real-time data from sensors and historical performance records. Thus, they will minimize downtime, reduce maintenance costs, and extend the lifespan of valve actuators. Additionally, AI-powered actuators can self-learn and adapt to changing process conditions, ensuring optimal performance and energy efficiency.

Wireless Communication Advancements

Adopting advanced wireless communication technologies, such as 5G and IoT (Internet of Things), will revolutionize valve actuator connectivity. Wireless communication will enable remote monitoring, control, and diagnostics of valve actuators, eliminating the need for physical site visits, improving operational efficiency, reducing response times, and enhancing safety in hazardous environments. Wireless networks will also facilitate seamless integration with other industrial devices and control systems, enabling real-time data exchange and collaborative decision-making.

Industrial Digitalization

The increasing digitalization of industrial processes will profoundly impact valve actuators. Digital twins, virtual replicas of physical assets, will become more prevalent. These digital models will simulate the behavior of valve actuators under various conditions, enabling predictive maintenance, performance optimization, and virtual commissioning. Cloud-based platforms allow centralized data storage, analysis, and remote access, facilitating data-driven decision-making and cross-functional collaboration.

Cybersecurity Enhancements

As valve actuators become more connected and digitized, cybersecurity will be a critical consideration. Manufacturers will invest in robust security measures, such as encryption, secure communication protocols, and user authentication, to protect valve actuators from cyber threats. Regular security updates and patches will be essential to address evolving vulnerabilities and maintain the integrity of industrial control systems.

Modular and Interoperable Designs

Valve actuator designs will evolve towards modular and interoperable architectures. Modular designs allow easy customization, upgradability, and maintenance, enabling end-users to adapt actuators to specific application requirements. Interoperability will ensure seamless integration with various industrial protocols and control systems, promoting flexibility and reducing integration costs.

Sustainability and Energy Efficiency

Sustainability and energy efficiency will be critical drivers in the development of valve actuators. Manufacturers will focus on designing actuators with reduced power consumption, improved materials, and optimized performance. Advanced control algorithms and energy recovery systems will further enhance energy efficiency. Additionally, adopting eco-friendly materials and manufacturing processes will reduce valve actuators' environmental impact.

The next five years will witness significant advancements in pneumatic and electric industrial valve actuators driven by AI, wireless communications, and industrial digitalization. These technologies will enable predictive maintenance, remote monitoring, and intelligent decision-making, improving efficiency, reliability, and connectivity. As the industry embraces these advancements, valve actuators will become more innovative, secure, and sustainable, revolutionizing how industrial processes are controlled and optimized.

UniTorq Actuators and Controls
2150 Boggs Road, Suite 410
Duluth, GA 30096
https://unitorq.com
Phone: (770) 446-7074
Fax: (770) 447-1825

Electric Valve Actuators: Driving Efficiency Across Industries

In today's fast-paced industrial landscape, the demand for efficient, reliable, and precise control systems is at an all-time high. One key component driving this efficiency is the electric valve actuator. These powerful devices have found their way into various applications, from refining oil and gas to food and beverage processing, revolutionizing industries' operations.

At its core, an electric valve actuator is a device that converts electrical energy into mechanical motion, allowing for the precise control of valves in various industrial processes. The ability to remotely control and monitor valves has proven invaluable in optimizing operations, reducing downtime, and enhancing safety.

In the oil and gas refining industry, electric valve actuators are crucial in managing the complex network of pipelines and valves that transport and process hydrocarbons. The precise control offered by these actuators ensures that the right amount of product is delivered to the correct destination at the right time, minimizing waste and maximizing efficiency. Additionally, remotely monitoring and controlling valves reduces the need for manual intervention, enhancing safety in an industry where the stakes are high.

Power generation is another sector that has embraced the benefits of electric valve actuators. In thermal power plants, electric actuators control the flow of steam, water, and other fluids, ensuring optimal performance and efficiency. Electric actuators are incredibly precise, enabling rapid adjustments to meet varying demands, which results in minimal downtime and maximum output. Furthermore, remotely monitoring and controlling valves reduces the need for manual intervention, enhancing safety in an environment where high temperatures and pressures are the norm.

The chemical manufacturing industry has also seen significant benefits from adopting electric valve actuators. In this sector, precision is paramount, as even slight deviations can have substantial consequences on product quality and safety. Electric actuators provide the level of control needed to maintain strict tolerances, ensuring that chemical reactions proceed as intended. Additionally, remotely monitoring and controlling valves reduces the risk of exposure to hazardous substances, enhancing worker safety.

In the pulp and paper manufacturing industry, electric valve actuators control the flow of pulp, water, and other fluids throughout the production process. These devices provide accurate control that guarantees the appropriate amount of material delivered to the designated area at a suitable time, reducing wastage and boosting productivity. Furthermore, remotely monitoring and controlling valves minimizes manual intervention, enhancing safety in an environment with heavy machinery and high temperatures.

The food and beverage processing industry has benefited significantly from adopting electric valve actuators. In this sector, hygiene and safety are of utmost importance, and electric actuators provide the level of control needed to maintain strict standards. The ability to precisely control the flow of ingredients, water, and other fluids ensures that products are consistently high-quality. In contrast, remotely monitoring and controlling valves reduces the risk of contamination.

Finally, the water treatment industry has embraced the benefits of electric valve actuators in managing the complex network of pipes and valves that transport and treat water. The precise control these devices offer ensures that the right amount of water is delivered to the correct location at the right time, minimizing waste and maximizing efficiency. Additionally, remotely monitoring and controlling valves reduces the need for manual intervention, enhancing safety in an environment where water quality is critical.

In conclusion, electric valve actuators have proven to be a game-changer across various industries. From oil and gas refining to food and beverage processing, these powerful devices drive efficiency, enhance safety, and revolutionize how industries operate. As technology advances, it is clear that electric valve actuators will play an increasingly important role in shaping the industry's future.

UniTorq Actuators and Controls
2150 Boggs Road, Suite 410
Duluth, GA 30096
https://unitorq.com
Phone: (770) 446-7074
Fax: (770) 447-1825