Happy Holidays and Happy New Year from everyone at RENCOR Controls. We pass along thanks to our employees, customers and vendors for your past support and look forward to a great 2015!

Flow Control Valve Training Video

Control valve education for New England industrial companies is a primary goal of this blog. We're always keeping an eye out for helpful resources to educate our customers and visitors on control valve operation.

We discovered a great resource of tutorials, courtesy of Columbia Gorge Community College, full of great information that should be shared. The following video is titled "Flow Control Valves" and the instructor is Jim Pytel. He does an excellent job.

ROTEX Solenoid Valves, Actuators & Limit Switches

A 5 minute video of showing the ROTEX line of industrial solenoid valves, pneumatic actuators and limits switches. ROTEX is known for high valve - meaning excellent quality and low cost.

ROTEX manufactures solenoid valves for industrial applications and for valve actuation. They also manufacture a line of high quality rack and pinion actuators (the Infinity Series) and scotch yoke actuators. Finally, their product line is rounded out by a broad line of valve actuation limit switches.

How to Install a Samson 3277 Actuator on a Samson 3241 Globe Control Valve

This is a complete "how-to" for installing the Samson 3277 actuator on top of a Samson 3241 globe control valve.

The Samson types 3271 and 3277 pneumatic actuators contain a rolling diaphragm and internal springs.

Special features

• Low overall height
• Powerful thrust at high response speed
• Low friction
• Various bench ranges by varying the number of springs or their compression
• No special tools required to change the bench range and to reverse the actuator action (also version with hand-wheel)
• Permissible operating temperatures from –50 to +120 °C
• Direct attachment of accessories on additional yoke for
• Type 3277 with concealed travel pick-off

Samson 3241 Globe Control Valve

The control valves consist of a body with trim, bonnet and pneumatic actuator, optionally with metal bellows or insulating extension. The valves may be also equipped with electric, electro-hydraulic, or hand-operated actuators, as well as control accessories and other instrumentation.

The Samson 3730-3 Valve Positioner: Description, Resetting to Factory Default and Performing Auto-Calibration

Samson 3730

The Samson Type 3730-3 is an electro-pneumatic valve positioner with HART® communication for use with linear and quarter-turn industrial valves.

The positioner ensures a predetermined assignment of the valve position to the input signal. It compares the input signal received from a control system to the travel or rotational angle of the control valve and issues a corresponding output signal pressure.

Special Features

• Simple attachment to all common linear and rotary actuators with interface for SAMSON direct attachment, NAMUR rib, valves with rod-type yokes according to IEC 60534-6-1 or to rotary actuators according to VDI/ VDE 3845. 
• Any desired mounting position of the positioner. 
• Simple single-knob, menu-driven operation 
• LCD easy to read in any mounted position due to selectable reading direction. 
• Configurable with a PC over the SSP interface using the TROVIS-VIEW software. 
• Variable, automatic start-up with four different initialization modes. 
• Preset parameters – only values deviating from the standard need to be adjusted. 
• Calibrated travel sensor without gears susceptible to wear. 
• Sub initialization mode (substitution) allows the positioner to be started up in case of emergency whilst the plant is running without the valve moving through the whole travel range. 
• Permanent storage of all parameters in EEPROM (protect- ed against power failure). 
• Two-wire system with small electrical load between 300 and 350 Ω depending on version.
• Adjustable output pressure limitation. 
• Tight-closing function. 
• Continuous monitoring of zero point .
• Integrated temperature sensor and operating hours counter. 
• Two standard programmable position alarms. 
• Self-diagnostics; alarms as condensed state conforming to NAMUR Recommendation NE 107, issued over a fault alarm contact or optional analog position transmitter .
• Integrated EXPERTplus diagnostics (u T 8389 EN) suitable for throttling and on/off valves and with additional partial stroke test for valves in safety-instrumented systems. 

Here is a video that explains how to reset the Samson 3730-3 back to factory default settings and then perform and auto-calibration.

Valve Automation Experience, Capabilities and Facilities

The following video shows some examples of RENCOR Controls valve automation work.

Examples include large automated ball valves, butterfly valves and specialty valves. Actuators include the ROTEX DCS and DCR, Bettis, Morin, and others. Examples of Coker and ball valve refurbishment, and pinch valve automation. Custom brackets and couplings are shown as is custom crating.

RENCOR's modern, well equipped manufacturing space is capable of handing very large automated valves, as well as high quantity production. RENCOR technician's and engineers have decades of experience and can solve the toughest valve automation challenge.

Introduction to the Instrumentation Ball Valve

Instrumentation Ball Valves
(DK-Lok)

Instrumentation ball valves are used in a wide variety of industrial, environmental, pharmaceutical, semiconductor and "clean applications. These valves are designed to handle wild fluctuations in ambient temperatures and operate at high pressures.

Also referred to as "one-piece" instrumentation ball valves, they are an excellent choice for cold ambient conditions down to -65 deg. F as well as handling heated gases and fluids up to 300 deg. F.

What defines the the ball valve as an "instrument ball valve" is the 1 piece ball and stem component. General service, industrial ball valves are designed with a 2 pc. ball and stem arrangement, where the ball "floats" in the process medium and uses the downstream pressure to seat.

Instrumentation ball valves historically were troubled when installed in low ambient temperatures. Cold environments below -50F would cause stem leakage.

Alternative packing materials where developed allowing working temperatures down to -65F but those packing materials were limited on the upper temperature range to 150 deg. F.

Ultimately, new packing was developed to handle -65 F to 300F, which covers a very wide range of application.

Instrument ball valves are available in brass and stainless steel. Their end connections are typically from 1/8" T to 3/4" T (compression tube connections) and from 1/8 NPTF to 1/2" NPTF (pipe sizes ). Many different types of end connections are available.

Instrumentation ball valves are available in the following configurations: 2-way, straight or angle; 3-way switching without any directional requirements; and a 4-way design.

Another Short Demo Video of Hydraulic Manual Override for 1/4 Turn Valves

ROTEX Scotch Yoke Actuator

Another demo of the ROTEX hydraulic manual override. This video demo's the hand pumping of the hydraulic pump which produces air pressure to change the position of a ROTEX DRS.

Hydraulic manual override's give operators the ability to manually reverse the spring position of a large actuator by manually pumping air into the spring cylinder. The hydraulic pump can produce up to 2000 PSI air which is used to compress the spring and reverse actuator position.

A directional hand valve is used to direct flow of the air to the spring cylinder or to vent and the air to and from the actuator, letting the spring decompress. A stainless steel hydraulic oil reservoir and tubing are used for safety and longevity.

Link to ROTEX Hydraulic Manual Override Video.

Tips and Considerations When Applying Control Valves

DeZurik Control Valve

Misapplying or choosing the wrong control valve for an application can have serious consequences on a  plant’s operation and productivity. Here is a list of things to consider when applying control valves.

Control valves are not intended for isolating a process and should not be used as such. They are not intended to provide a bubble tight shutoff.


Choose the proper body, seat and wetted materials for the process being controlled. Consider material compatibility, pressure ratings, and operating temperatures prior to valve selection.

When designing your control loop, put the flow sensor upstream of the control valve. Putting the flow sensor downstream of control valve exposes it to possible bubbles caused by the flashing and turbulence of the flow in the valve cavity.

Watch a Large Scotch Yoke Pneumatic Actuator Operate

I you haven't seen a large scotch yoke actuator operate, the watch the video below of a ROTEX DRS high performance scotch yoke pneumatic actuator mounted on a large ball valve.

The video shows actuator opening valve, closing valve, the valve position indicator, the hydraulic manual override and manual hydraulic pump.  This is a nice visual education for anyone who never saw a large valve and a large actuator operate.

A Few Things to Consider When Choosing Between Pneumatic and Electric Actuators

The choice between a pneumatically or an electrically actuated valve for a process system is predicated on certain application realities. Both have advantages and disadvantages. Generally though, it's the available power source that dictates the approach.


The available power source (compressed air or electricity) is typically the primary criteria for selecting a which type of actuator to use.



Other criteria to consider are:

Peek Inside a Modern Control Valve Manufacturing Facility

SAMSON Controls is world renown for their high quality products, including control valves, self-operated regulators, and positioners. This reputation is earned through complete devotion to quality design and and paying attention to every detail in the manufacturing process.

 

For over 100 years, SAMSON has developed and manufactured control equipment for industrial processes. From rugged self-operated regulators to highly specialized control valves for industrial processes, their broad product range includes valves to meet all requirements. Known primarily for control valves, they manufacture in all sizes, materials and alloys.

The success of the SAMSON brand has in turn grown a worldwide network of skilled and technically competent representatives.

The Inside and Out of Pneumatic Rack and Pinion Actuators

Here is an excellent video that shows the inner construction and major components of a rack and pinion actuator.

While many rack and pinion actuators seem the same, this manufacturer ROTEX, engineers their product to provide the longest possible service life with innovative features such as:

1. V-Seal polymer double lip seal offers the most efficient, dynamic sealing in the industry.
2. Massive bearings with greater surface area allow for higher load capacity. 
3. Monolithic billet pinion provides for incredible strength and durability. 
4. Two part epoxy paint over anodized aluminum body gives superior corrosion protection.

Additionally, ROTEX Controls Inc. warranties the complete actuator for 3 years or 3 million cycles, including all seals. All major components, including body, pinion, bearings, springs, seals, and all hardware are covered for the full term of the warranty, 3 years or 3 million cycles. No other manufacturer warrants their product as well.

An Excellent Control Valve Choice for Any Demanding Application

In a time of rising costs and ever changing technological advances, coupled with increasing regulations and restrictive laws, some valve manufacturers continue to innovate and maintain flawless quality and performance. One such manufacturer is SAMSON Controls.

The SAMSON control valve continues to offer dependability under extreme conditions and the toughest applications.

SAMSON’s modular design provides the user the flexibility of selecting valve components to meet specific applications. Modularity allows each SAMSON valve to be individually applied for optimum performance in any application, included the most demanding or most adverse conditions. Modularity allows the user to save money by minimizing inventory and saves time of installation and maintenance. This all adds up to lower overall cost of ownership.

Samson’s line of control valves is broad and suited for tough and demanding applications such as corrosive media, erosive media, applications with high pressure differentials and extreme process temperatures. Samson valves provide long service life, excellent control and tight sealing. They are often the choice for extreme vacuum applications or where environmentally damaging emissions are possible.

Materials, dimensions and flange configurations are available for industrial standards such as ANSI, DIN, JIS, and ensures that SAMSON products can be used anywhere in the world.

SAMSON’s control valves can be equipped with a wide variety of electric, electro-hydraulic or pneumatic actuators.

Feel fee to contact us for more information on SAMSON Controls.

Need a Valve for Abrasive or Corrosive Slurries?

DeZurik
Urethane
Knifegate
Valve

Need a knife gate valve thats great for corrosive, abrasive or slurry service? Check out a urethane lined knife gate.

Urethane Lined Knife Gate Valves are designed for on-off and throttling applications of abrasive slurry and dry abrasive materials. These valves are ideally suited for applications in mining, chemical and food industries. They are bi-directional and have tight shut-off and can be used for on/off service or for control.

Urethane Lined Knife Gate Valves are available in sizes 2-48" (50-1200mm) with temperature ratings from -40 to 180°F (-40 to 82°C) as standard, with a variety of urethane compounds available on application.

A one-piece, cast-in-place liner that provides bi-directional, drip-tight shutoff to either 150 or 250 psi (1030 or 1720 kPa) CWP are available. All wetted surfaces of the ductile iron body are lined with urethane. These valves are good for dead-end service.

What is a Declutchable Manual Override Gear Operator?

Typical Declutchable
Manual Gear Operator

Declutchable manual gear overrides enable users to manually position their valves to a desired position safely and easily. Gear overrides typically enable 90 degree rotation in either direction and are designed to manually override double acting or spring return actuators.

Designs vary, but most include a self-locking, declutchable worm gear which is designed to provide a secure engagement keeping the valve firmly in position. Declutchable manual gear overrides are usually designed to be “sandwiched” between a pneumatic actuator and quarter-turn valve, allowing the operator to manually operate a pneumatic actuator in case of emergency power or air loss.

Construction normally protects the gears in a completely enclosed, weatherproof and permanently lubricated enclosure. The operation is done via some type of hand wheel. A wide variety of torque outputs are available.

When selecting a declutchable manual gear override consideration must be given to valve torque requirements, weight, size, mounting, operating environment, and criticality of application. An experienced valve application engineer should be consulted prior to selection.

What is A Lined Ball Valve?

Lined Ball Valve

A lined ball valve uses a fluoropolymer or ceramic lining applied to all wetted internal parts of the valve.

Lined valves combine the excellent mechanical properties of metallic bodies with the corrosion resistance of fluorocarbons, such as PFA and PTFE.

Lining the intricately shaped inside surfaces of a valve is certainly an engineering challenge, especially to achieve a uniform thickness and the highest lining quality, without cavities or inclusions.

The special lining process guarantees tight bonding between the lining and the inside of the body. This effectively prevents the lining from shearing off the body in part or being removed completely.

Special options, such as reinforced PTFE bellows seals or adjustable packings, can be accommodated. Bellows seals made of special metals, such as titanium or Hastelloy, are available as options as well.

Lined ball valves are ideally suited for corrosive applications, requiring very reliable performance, tight shutoff, constant torque and no maintenance. Lined ball valves can successfully be applied to a wide range of corrosive applications in industries such as chemical, petro-chemical, pharmaceutical, and pulp and paper.

For more information visit RENCOR Controls.

A One-piece, Forged Steel, Metal Seat Valve for Critical Applications

One-piece, forged steel,
metal seated ball valve

For applications that require high pressure, high temperature and high safety, consider a one-piece, forged steel, metal seated ball valve. Until recently, limitations in the forging process restricted the manufacturing of larger valve bodies, but now 1/2" to 4" valves in ASME Classes 900 to 4500 are available.

These valves offer the following advantages: a one-piece forged design; a streamlined flow path eliminating cavitation and pressure drop; seats with no exposure to the flow stream; a body cavity isolated from solids build up and flow and erosion resistance.

Velan Power Ball Diagram

Forged valves offer greater strength and increased toughness for maximum reliability and safety. They have become the first choice of fossil and nuclear power stations, the nuclear navy and for all severe and critical applications in the chemical and hydrocarbon processing industries.

One particular brand is the Velan Power Ball,  highly advanced, patented, forged, one-piece metal-seated valve designed for high-pressure and high-temperature applications in the power generation and process industries. More information on the Velan Power Ball can be found here.

Because these valves are used in the most critical applications, consultation with application engineers and utilizing factory authorized installers is recommended.

NEMA Classifications for Electric Actuators

Indelac Electric Actuator

Electric actuators, or more specifically, the enclosures for electric actuators, need to be matched to the service in which they will operate. Always consult a qualified valve actuator representative to make sure your electric actuator enclosure meets the service requirements.

The enclosure rating standards are defined by the National Electrical Manufacturers Association (NEMA).

Here are the listings of NEMA Classifications: (you can get from the original document from the NEMA site here.)

Definitions [from NEMA 250-2003]

In Non-Hazardous Locations, the specific enclosure Types, their applications, and the environmental conditions they are designed to protect against, when completely and properly installed, are as follows:

Some Important Valve Terminology

Accessory: Device(s) mounted on an actuator to complement the actuators’ function, such as positioners, solenoids and limit switches.

Actuator: A pneumatic, electric, hydraulically powered “motor” supplying motion to open or close a valve.

Automated Valve: A valve and actuator package capable of responding to a remote pneumatic or electrical signal.

Considerations for Sizing Spring Return Pneumatic Actuators

Pneumatic Actuator
Springs, Piston & Seal 

Sizing direct-acting pneumatic actuators is pretty straightforward. The actuator only has the fixed air supply to energize the actuator. If you have enough actuator torque at a given supply pressure to open and close your valve (plus a safety factor), you're good to go. Spring-return actuators, however, present an additional challenge when sizing.