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INDUSTRY LEADING FLOW CONTROL NEWS FROM THE WORLD OF ROTORK

Rotork Contract NewsRotork provides electric solutionsat the Botlek Tank Terminal

Rotork Product NewsThe Rotork ManPower range:Manually energised solutionfor fail-safe valve actuators

Rotork launches 3rd generation IQ range ofintelligent non-intrusiveelectric valve actuatorsFull story on page 4

NEW ROTORK CMA RANGE ACTUATORPage 14CMA actuator increases the scope of Rotorks advanced electric control valve technology

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INDUSTRY LEADING FLOW CONTROLNEWS FROM THE WORLD OF ROTORK

A Botlek engineer uses the wireless hand-held setting tool on a Rotork Skilmatic SI valveactuator, Botlek Tank Terminal (BTT) Rotterdam.Full story Page 3.

If you would like to receive future editions ofmagazine electronically then please email:

[email protected]

For every person who opts to receive the magazineelectronically, Rotork will donate the cost to printtheir copy of the magazineto its chosen charity, WaterAid.

COVER STORY

Rotork launches 3rd

generation IQ rangeof intelligent non-intrusive electric valveactuators...................................................................... 4-6

COMPANY NEWSRotork Group company news from aroundthe world.................................................................. 8, 19

APPOINTMENTS New Rotork Directors appointed.................................. 9

CONTRACT NEWSRotork Group contract news from around

the world......................................................... 3, 7, 10-12PRODUCT NEWS

Rotork Group product news from aroundthe world................................................................. 13-18

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Construction of the 70 million first phaseof the terminal began in April 2010 and wascompleted within budget and on time by thePolish company Polimex-Mostostal S.A. BTThas 34 storage tanks, providing a combinedstorage capacity of 200,000 cubic metres, ofwhich 130,000 cubic metres is earmarked forclean fuels and the rest is for edible oils andbiodiesel. The state-of-the-art terminal hasdeepwater berths including a 420 metre jettythat can simultaneously accommodate twoseagoing vessels and two barges, operating24 hours-a-day.

Over 250 Rotork IQ Pro multi-turn and quarter-turn intelligent electric actuators have beeninstalled to operate the valves that control theroutine movement of liquids throughout the site.A further 55 Rotork Skilmatic SI self-containedelectro-hydraulic actuators have been installedin strategic areas on valves that provide fail-safeEmergency Shutdown (ESD) protection frompotential accidents and spillages. All the Rotorkactuators are monitored and controlled on fullyredundant Rotork Pakscan digital bus loops,linked by three Pakscan P3 master stations to thesites central SCADA system.

The Skilmatic SI actuators are equipped withintegral circuitry designed to receive a separatelyhardwired discrete ESD alarm signal that willoverride any other input and move the actuatorto the pre-determined safe position, even in theevent of electrical power failure. These actuatorsare situated on the inlet and outlet ports ofthe storage tanks and on the marine and truck

Rotork provides electricsolutions at the Botlek

Tank Terminal

The recently opened Botlek TankTerminal (BTT) at Rotterdam relies onRotorks latest electric valve actuationtechnologies for automated flowcontrol and vital safety related dutiesassociated with the import, export and

storage of a varied range of liquid bulk products.

loading bays. They are key components in theSafety Instrumented System (SIS) that operateswith dedicated level and flow sensors andESD logic solvers to provide the sites Safety

Instrumented Function (SIF).

BTT General Manager Charles Smissaert pointedout that the Rotork Skilmatic electro-hydraulicsolution for ESD protection at the site had beenselected as a more robust and reliable alternativeto air operated actuators, which also requiremore maintenance.

All Rotork actuators at BTT feature ATEXexplosionproof certification and IP68 double-sealed watertight enclosures designed forharsh and exposed environments. They alsoshare Rotorks IQ Pro non-intrusive setting,

commissioning and data communicationtechnologies, enabling actuator configurationand Data logger files to be transferred from thefield to the office for diagnostics, analysis andstorage. In combination with Rotork IQ-Insightsoftware, this data can help to maximise plantutilisation by identifying potential valve wearproblems and facilitating predictive maintenance.

The punctual completion of the tank farm wasassisted by the nearby presence of Rotork BVsfully equipped workshop, which provided thefacilities to motorise all the valves, encompassinggate and butterfly designs in sizes up to 16

inches, before shipping them to site as complete,factory tested packages. Rotork also assistedwith installation and commissioning and willcontinue to provide local support for all theinstalled actuators.

Aerial view of the Botlek Tank Terminal.

Rotork Skilmatic SI electro-hydraulic fail-safe valve actuators on the loading jetty.

Rotork IQ Pro and Skilmatic SI valve actuators in a tank manifold area.

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Rotork is proud to announce theintroduction of the 3 rd generation ofits flagship IQ range of intelligentnon-intrusive heavy duty electricvalve actuators.

Benefitting from over 50 years of practicaloperating experience throughout the worldand continuous feedback from all of Rotorksvalve actuation markets, the IQ3 nowintroduces new levels of functionality andasset management abilities combined withfurther refinements to a well-proven andrugged mechanical design. The 3 rd generationintelligent electric actuator strengthens thepedigree of a product that has led the wayin actuation technology since its firstappearance in the early 1990s.

The large wide viewing angle indicationwindow is the focus of attention for non-intrusive two way wireless communication andmulti-functional indication, encompassing user-friendly menus for setting-up, configurationand commissioning, local position indication,valve and actuator status, asset managementand diagnostic operating information.

An LCD segment display provides positional andwarning icon information, whilst actuator setup andoperating menus along with detailed diagnostic andoperational data screens are clearly displayed in dotmatrix format. Four selectable Home-screens providea quick view of operational status and processinformation in real-time without having to navigateto the diagnostic screens. The four selectable screensinclude: Position with text status, Torque (analoguescale) & Position, Torque (numerical scale) & Positionand Demand & Position.

Diagnostic graphics present a window into the process, showing the valve torque and usage profiles alongwith service logs, facilitating real time analysis directlyat the actuator.

The new hand-held setting tool uses an infrared signalto check that both items (actuator and setting tool)are Rotork devices before pairing them together usingBluetooth wireless technology. The security enabledby this technology is further enhanced by the ability toenable or disable the Bluetooth link as the method offurther communication.

Advanced IQ data logging and communication

capabilities have been increased in response to the endusers desire to access more data, both in the field and in the control room.

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Rotork launches 3rd generation IQrange of intelligent non-intrusive

electric valve actuators

IQ3 actuators are available as three-phase,

single-phase and DC variants.

Wireless two-way communicationusing the non-intrusive hand held

setting tool is a secure way of programming the actuator andaccessing asset management data.

COVER STORY

Continued on page 6

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1 Rugged and reliable operation using simpleworm and wheel drive train, proven in over fiftyyears of reliable operation on every continent.

2 Valve position maintained even if theactuator is removed. Separable thrust basesremain in position on the valve across the range.

3 Non-intrusive, wireless communication; actuator can be securely set up, updated andinterrogated whilst permanently protected fromthe ambient environment.

4 Absolute position measurement at alltimes with or without power through use of theRotork absolute encoder.

5 Quick and easy commissioning andconfiguration. Detailed screens provide flexible ,at-a-glance views of plant status and remainfunctional even at very low temperatures.

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6 Improved environmental sealingincreasing reliability through padlockablelocal/remote selector switch, operating internalswitches without penetrating shafts whichwould require individual sealing.

7 Enhanced reliability. IP68 watertight andtemporarily submersible enclosure with Rotorks

legendary double-sealed terminal compartment.8 Actuators suitable for three-phase,single-phase or DC motors. Isolating,regulating and modulating duty versions.

9 Reliable emergency manual operation via direct drive or geared handwheel, bothwith lost motion hammerblow effect. Includespadlockable hand/auto clutch for safe operationif the motor is running.

IQ3 actuators now feature anabsolute encoder as standard.

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Using the setting tool withBluetooth wireless technologythe data from the actuatorscan be transferred to a PC foranalysis using freely available

Rotork Insight2 diagnosticsoftware. Valve maintenancerequirements can be identifiedand anticipated, eliminatingunplanned interruptions to theprocess or over-cautious plannedmaintenance outages.

A patented absolute encoderwith built-in redundancy and selfchecking mechanically tracks valvepositions even if the actuatoris manually operated when thepower is off. No power is required

for the actuator to reliably andaccurately measure position.Using the latest technology andfollowing several years of testing,the IQ absolute encoder hasonly four moving parts and canmeasure up to 8,000 output turns.Local LCD and remote contactindication is maintained and fullconfiguration of the actuatorsettings during a power outage isenabled by the standard battery.

Mechanical improvements includenew handwheel assemblies, newnon-intrusive local control switchesand optimised corrosion protectionby material and coating selection.

Thrust bases have been re-engineered as separatecomponents on all models inthe IQ range, enabling actuatorsto be removed from the valvewithout altering the valveposition. The IP68 watertightand temporarily submersibledouble-sealed enclosure isuniversal to all actuators, includingthose with explosion-proofcertification, ensuring long termreliable performance in the most

challenging environments. Rotork3 rd generation IQ3 multi-turnactuators are designed for valvesof all types, sizes and description,either by direct attachment orin combination with secondarygearboxes.

A full description canbe viewed anddownloaded from:www. iqactuator .com

Rotork Insight2 software streamlines actuator set-up and facilitatesasset management.

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The IQ3s new smooth rim handwheel design.Rotorks legendary double-sealed terminal compartment.

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Rotork retrofit improves valveactuation efficiency atAmsterdam water treatment plantRotork modulatingelectric valve actuatorshave been installed inan efficiency upgrade

project at a large watertreatment works servingthe Dutch capital city of

Amsterdam.

The modern and highly automatedplant at Vogelenzang, ownedby Waternet, has a daily watertreatment capacity of 180,000cubic metres. The treatmentregime comprises pre-screening,carbon filtration, ozone injection

and sand filtration. Waternetis the only water company inthe Netherlands to cover theentire water cycle, from thetreatment of waste water and

provision of drinking water tocleaning and maintaining levelsof surface water. These services

are performed on behalf of theRegional Public Water Authority Amstel, Gooi and Vecht and theCity of Amsterdam.

Reliability problems had arisenwith the electric actuators onthe carbon filtration plant atVogelenzang, which were failingto cope with the modulatingvalve duties required for efficientfiltering and backwashingoperations. Rotorks solution hasbeen to remove the old actuators,

install IQTM Pro quarter-turnmodulating actuators directly ontothe affected butterfly valves andconnect to the existing power andcontrol cabling. This work has

been performed by Rotork SiteServices, Rotorks specialist divisionfor retrofitting, site maintenance

and repair activities.The site wiring interface withthe old actuators was by meansof plug-and-socket connections.In order to retain these, Rotorkengineered a separate plug-and-socket housing, locallysited by each new actuator andconnected to the actuator terminalcompartment. This has speededup installation and enabled thenew actuators to be retrofittedwith minimal modification to

site wiring.On completion of the project, atotal of 120 Rotork IQTM 1000actuators have been installed

on DN350 and DN400 butterflyvalves. Rotork has also beenawarded a ten-year maintenance

contract for the actuators,involving tri-annual inspectionsand functional testing.

All Rotork IQ actuators incorporatestandard features designed forincreased functionality, optimumplant utilisation and improvedlong term asset management. Forexample, an integral data loggerstores historical operating data,including the sequence of valvetorque profiles. This informationcan be downloaded and analysed

with Rotorks PC-based IQ-Insightsoftware to establish predictivemaintenance schedules or identifypotential problems.

An engineer uses the wireless hand-held setting tool to download datalogger files from one of the RotorkIQTM actuators at Vogelenzang for

storage in the asset management programme.

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COMPANYNEWS

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Elsewhere valve operation in remote locationsprovides more applications for Fairchildproducts. For example, on plunger lift and gatestations the natural gas industry, gas and watervalve control is required in the absence ofconventional power sources. The solution hasbeen provided by the use of the Fairchild ModelMP2400 Precision M/P Converter in conjunctionwith a 12-24 Volt solar powered supply.

Rotork Fairchild can be contacted viathe Rotork website or via email at:[email protected]

Rotork Fairchild - The firstcompany in the new RotorkInstruments divisionThe Rotork Instruments division hasbeen created to provide services and

products in the wider flow controlmarket and in particular productsassociated with flow and pressurecontrol, diagnostics and informationgathering technology.

Rotork Fairchild, a market leading manufacturerof precision pneumatic controls and powertransmission products, is the first memberof the Rotork Instruments division. From itsheadquarters in Winston-Salem, North CarolinaUSA, Fairchild produces a comprehensive rangeof pneumatic regulators, boosters, relays andtransducers, as well as speed and positioncontrol transmissions, designed to performcritical duties with precision and reliability.

The products are used for original equipmentand capital project applications as well asin maintenance, repair and operations in awide range of industries including oil & gas,automation, pulp & paper, chemicals andpharmaceuticals.

The company serves the global market

through its state-of-the-art engineering,design and assembly facility in North Carolina,well established sourcing relationships anddistribution centres in China, India and Brazil,supported by a network of 125 internationaldistributors.

In addition to the expansion of its global salesreach, a key element of Fairchilds growth planis the development of innovative new productsto gain market share and address new markets.Fairchild is well regarded as an industryleader in the provision of custom-engineeredsolutions to meet customers developing needs.

Continued focus on product development isaimed at future expansion in areas includingthe medical industry, as illustrated by a recenthyperbaric chamber application.

PPR Series - Pneumatic pressureregulators

These devices provide highlyaccurate control of output pressure.They are able to handle fluctuatingsupply pressure, vibration andtemperature variations.

EPT Series - Electro-pneumatictransducers

Products in this range generate apneumatic output, proportionalto the voltage or current of anelectrical input. Products includehigh accuracy, high performanceand explosion-proof variants.

PVB Series - Pneumatic volumeboosters

These products are used to convertlow flow pneumatic signals to highflow outputs. They are accurate andfast acting, available in a number ofspecific variants.

PR Series - Pneumatic relays

This extensive line of products isused to transform pneumatic signals,performing mathematical operationson one or more inputs.

In this example, the aim is to maintain thetightly controlled flow and pressure of anoxygen-enriched atmosphere into and out ofthe chamber, which is used for patient injuryand therapy treatment. The overall system mustbe fast, accurate and versatile.

The solution is to use the Fairchild ModelT7800 Transducer to provide accurate pressurecontrol to the means of inflation. The Model4500 Volume Booster can also be incorporatedinto the system to dramatically boost the airflow and provide a faster response in order to

minimise the cycle time.

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Pamela Bingham, Rotork Group Business Development Director.

As Director of Rotork SiteServices, Philip Burness isresponsible for Rotorksworldwide after-sales andengineering projects business.

Philip brings to his new positionover thirty years experiencein process industry service andmaintenance activities, mostrecently as the Service Directorfor a leading internationalmanufacturer of instrumentationand control systems.

His previous experience includesinstrument and control design,implementation and maintenance

responsibilities in the chemical,plastics and power generationindustries.

As Rotork Site Services Director,Philip will work with Rotorksworldwide sales and servicecompany network to continuethe growth of after sales support,engineering projects and life ofplant services.

In this important role he replaces

Grant Wood, who has beenappointed Managing Director ofRotork Controls, Rotorks electricvalve actuation division.

Philip Burness - Rotork Site Services Director

Pamela Bingham joins Rotork asGroup Business DevelopmentDirector, a new position, createdin line with Rotorks strategyfor the further development ofnew business, new customers,acquisitions and externalrelationships.

Pamela has held directorial positions in theengineering industry for the past seven years,working in legal, commercial and businessdevelopment roles. She joins Rotork fromDavid Brown Gear Systems Limited, where

she was a senior executive on the LeadershipTeam. She qualified as a solicitor in Scotlandtwenty years ago, having achieved anhonours degree in law and a postgraduatediploma in legal practise from the Universityof Edinburgh. She re-qualified as an Englishlawyer in 1996.

Pamela has built her career from a strongbackground in legal roles to one whereshe has taken on broader executive andstrategic responsibilities, focusing on thedevelopment and implementation ofstrategies for business growth throughorganic growth and acquisition.

Working in legal and directorial positions incompanies serving industries that includeoil and gas, utilities, railways, mining,defence, water and renewable energy, theseduties have provided in-depth experienceof competitive global markets includingemerging and developing economies.

Speaking about her new appointment,Pamela said: I am delighted to be joiningRotork to assist in the execution of its longterm strategy of expanding into the widerflow control market, which will undoubtedly

provide further opportunities for growth .

Pamela Bingham - Group Business Development Director

New Rotork Directors appointed

Andrew Withers has beenappointed Technical Directorfor Rotork Controls, the electricvalve actuation division ofthe global Rotork flow controlengineering group. In his new

position he will be responsiblefor new product developmentsand research functionsinvolving all of Rotorks electricactuator product lines.

Andrew will be taking over fromGraham Ogden who, as RotorkGroup Research and DevelopmentDirector, will now focus ondevelopments encompassing allof the Rotork Group divisions Controls, Fluid Systems, Gearsand Instruments as well asdirecting specific strategic groupprogrammes.

Andrew joined Rotork in 2002as a Graduate Electronics Design

Engineer following the awardof a First Class Honours Degreein Electronic Engineering at theUniversity of Manchester Instituteof Science and Technology.

Andrew Withers - Rotork ControlsTechnical Director

His work has been closely involvedwith major product developmentsembracing Rotorks intelligentIQ electric actuators, the SI/EHelectro-hydraulic actuator rangesand the innovative CVA electriccontrol valve actuator.

Promoted to Senior Engineerin 2009, he became Electronics

Design Manager in 2011, wherehe has played a major part in theintroduction of the 3 rd generationflagship Rotork IQ range ofintelligent electric valve actuators.

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Rotork electric modulating actuatorshave been installed in an upgrade at theRWE npower Fawley Power Station in

southern England.

Built in the late 1960s, the oil-fired station iscapable of supplying the National Grid with1,000 megawatts of power to balance supplyand demand at times of peak usage. It is

therefore essential that the station can respondto the National Grid demands with speed andflexibility. The Rotork actuators have replacedobsolete hydraulic actuators and power packsthat were requiring increased levels of costly andtime consuming maintenance and presentingongoing issues involving the use of hydraulicoils. These included high operating pressuresand the potential for safety and environmentalissues associated with leaks. The power packsalso required continuous electrical power tomaintain hydraulic pressure. By comparison,the Rotork actuators only use electricity whenthey are operating and do not require routinemaintenance.

The upgrade project was awarded to ExeecoActuation Projects and Service (APS), a companythat specialises in power station maintenanceand upgrade services. APS responsibilitiesencompassed the removal of old equipment,installation of new actuators, wiring into newlocal junction boxes, commissioning and producttraining for staff at the station. The retrofittingbegan on the stations Unit 1 during the 2009outage period with the installation of RotorkType LA linear stroke actuators on reheat andsuper heater dampers and electric feed pump

Actuation upgrade improves powerstation combustion efficiency

Andrew Millard (right) Control & Instrument Engineer at Fawley Power Station pictured with Mike Dale fromEXEECO APS (left) by the Rotork Type SM-6000 actuator.

Rotork has been awarded the newframework agreement for the supply ofvalve actuators to United Utilities, theUKs largest listed water company.

Serving a population of seven million, UnitedUtilities operates 184 reservoirs, more than700 water and sewage treatment plants and170,000 kilometres of pipework and sewers inan area bounded by the English Midlands, theIrish Sea, the Scottish Borders, the Pennines andthe Peak District.

After a period with another electric actuatormanufacturer the move to Rotork follows therevision of the United Utilities specification forvalve actuators to include an IP68 watertightand temporarily submersible enclosure, double-sealing and non-intrusive actuator configurationand limit switch setting.

These requirements, which are recognisedby United Utilities as essential for long termenvironmental resistance, reliable performanceand low maintenance, are standard design

features of Rotorks IQ and IQT intelligent electricvalve actuator ranges.

In addition to contributing to efficient plantoperation, they also help to reduce the overallcost of ownership.

In the photograph, Adele Green, United UtilitiesCategory Buyer (Supply Chain & Commercial Asset Management & Performance Services)is pictured with Laurence Kettle, RotorkFrameworks & Contracts Manager, following thesigning of the new agreement.

Commenting on the award, Laurence said:

Rotork is looking forward to the successfulimplementation of this new opportunityto serve United Utilities and its business

partners.

Rotork wins United Utilitiesframework agreement

speed regulators. This was followed by theinstallation of Rotork Type SM-6000 lever armactuators on ID (induced draft) and FD (forceddraft) fan discharge dampers. Upon completionof the project, a total of sixteen Type LA andfour Type SM-6000 actuators have now beeninstalled on Units 1 and 3.

The Rotork Type LA actuators deliver a self-lockinglinear stroke output of up to 610 mm (24 inches) atthe rate of up to 2,000 starts per hour.

Rotork Type SM-6000 actuators deliver a self-locking rotational output ranging from 90 to 313for continuous, unrestricted modulating duties.

Both types are specifically designed for thehigh temperatures, challenging environmentsand arduous duty cycles associated with powerstation operations. At Fawley the actuatorsare operated by the stations existing EmersonOvation DCS system utilising 4-20 mA signalsfor position demand and feedback.

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Adele Green, United Utilities Category Buyerwith Laurence Kettle, Rotork Frameworks &Contracts Manager.

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An offshore platform in the North Sea

that is the first of its type to serve a power generating wind farm is hometo fifty Rotork IQT Pro intelligentelectric valve actuators.

The Borwin Alpha platform is the first offshoreinstallation designed to convert AC power intohigh voltage direct current (HVDC) for onwardtransmission. Built and designed by the HeeremaFabrication Group on behalf of ABB, the facilitycan transfer a power of 400 MW at a bipolarvoltage of 150 kV. The converted current iscarried by a 200 kilometre cable for onshoreconnection to the European power grid.

The BARD Offshore 1 wind farm that is servedby the Borwin Alpha platform is situated 100kilometres northwest of the German island ofBorkum. Eighty wind turbines will be installedwhen the farm is completed in 2012.

The 200 kilometre cable connection to themainland is the longest in the world for anoffshore wind farm, as well as the first to utiliseHVDC transmission.

The majority of the Rotork IQT Pro actuatorsare controlling the operation of butterfly valvesin applications on the cooling system for thepower conversion plant and the fuel systemsfor emergency generators. Some of the valvesare installed within the platform superstructurewhilst others are outside and exposed to

Rotork supports innovative offshorewind farm technology

The Borwin Alpha platform topsides being lowered into position during installation.

the harsh North Sea environment. Reliableoperation is enhanced by the double-sealedactuator enclosure design, combined withnon-intrusive commissioning and data transfertechnologies that permanently eliminate theneed to remove any covers once the actuatorsare wired-up. Rotork IQT Pro actuators alsoincorporate increased functionality features

as standard for improved long term assetmanagement. For example, an integraldata logger stores historical operating data,including the sequence of valve torque profiles.This information can be downloaded andanalysed with Rotorks PC-based IQ-Insightsoftware to establish predictive maintenanceschedules or identify potential problems.

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Rotork Fluid Systems has supplied the specialised hydraulic actuator packagefor a second subsea safety isolationvalve (SSIV) installation on the sameoffshore gas gathering project off thecoast of Egypt.

The single acting, spring-return rack and pinionactuator, model number GSR-2-490-110F/CX,will operate a 16 inch ANSI Class 900 ball valveinstalled on the 11 kilometre export pipeline fromthe Seth Platform. This pipeline connectsto the Tuna Platform export pipeline endmanifold for onward transport to the shore viathe TNW2 Platform.

The new actuator will operate an SSIV installedat a depth of 84 metres near to the SethPlatform, which, together with a check valveinstalled upstream of the ball valve, will preventany gas backflow in the event of a pipeline or

riser rupture in the proximity of the platform.A dedicated electro-hydraulic umbilical fromthe platform will control the actuator, whilst anintegral valve manifold system on the actuatoritself will enable local diver operation.

Rotork actuates subsea safetyvalve installations

In addition, an actuator and gearbox declutch

mechanism completes the provision of totalvalve control under all operating conditions, incombination with an ROV (Remotely Operatedunderwater Vehicle) interface.

The installation is very similar to the Rotorkactuated SSIV package that was previouslysupplied for the 24 inch export pipeline fromthe Tuna Platform in the same gas field. Bothinstallations are equipped for pipeline piggingoperations and fitted with superstructures forprotection against accidental impacts and toprevent any interference with fishing activities.

Rotork has 20 years extensive experience of thedesign and manufacture of actuators for subseainstallations. The company has successfullycompleted hyperbaric testing of its subseaproducts at simulated depths of 2,500 metres.

This Rotork subsea hydraulic valve actuator packageis the second to be supplied for SSIV duty at the

same Egyptian gas field.

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The application demands unrestrictedmodulation of a three-way valve to controlthe pre-heated temperature of fuel gas forelectricity generating turbines.

The Rotork CVA actuators have been installedon seven skid-mounted units supplied to RiyadhPP11, a power plant project serving the capitalcity of Saudi Arabia. Manufactured by PetrogasGas Systems in The Netherlands, the units heatthe gas on its way to the turbines by passing itthrough a chamber that is surrounded by an oilbath that is heated to a temperature of 185 C.

A CVA actuator controls the position of athree-way valve on the inlet side of each unitto ensure that the process does not overheat.Operating from a 4-20 mA control signal, the

actuator moves the valve to control the heatoutput. Precise and responsive valve positionalcontrol, with repeatability and resolution at lessthan 0.1%, makes an important contributionto the overall high efficiency of the pre-heatingperformance.

Seven ATEX certified explosionproof CVQquarter-turn actuators have been supplied tooperate 200 mm (8 inch) Class 300 valves.The double-sealed CVA design also providespermanent environmental protection to IP68,with non-intrusive setting and commissioningtechnology. An integral data-logger facilitatesvalve diagnostics with predictive maintenancecapabilities for efficient long term assetmanagement.

Rotork CVA specified forflow control duty on gas

turbine pre-heater plants

Failsafe CVA valve control assists efficient mineral gradingThe MEP TBS Hydrosizer is used in the miningand mineral process industries throughoutthe world to separate materials, removecontaminants and beneficiate mineral particles

that are generally less than 5 mm in size.Applications include coal preparation, thepreparation of high-grade sand for concreteproducts, glass making or foundry use,the removal of silica from iron ore and theseparation of a range of minerals such as zirconfrom sand, plus many others.

The TBS Hydrosizer process utilises an upwardcurrent of water to create a hindered settlingclassifier in which material within a narrow sizeband can be held in a state of teeter. Smalleror lighter particles entering the classifier aredisplaced to the overflow, where they can

be collected, whilst larger or heavier particlesmigrate to the bottom and are dischargedthrough spigot valves, fitted in the bottom ofthe TBS Hydrosizer.

A well defined separation is achieved bymaintaining a constant flow of upward currentwater, even though the level and nature ofthe mineral content in the water can causethe density to fluctuate. The constant flow ofmaterial is achieved by means of a 4-20 mAsignal from a hydrostatic density probe withinthe Hydrosizer Tank, which is used to controlthe CVA actuator operation. The CVA adjusts

the position of a valve, allowing material todischarge at a rate that is determined by thehydrostatic head. With resolution, repeatabilityand hysteresis performance quoted at lessthan 0.1% of full scale, the swift response

and positional accuracy delivered by the CVAactuator enhances the efficiency of the process.In addition, integral super capacitors enablefail-safe operation of the CVA to close the valve

on loss of mains power or loss of control signalto prevent any damage or contamination of theproduct.

The all-electric CVA actuator is economicalto install and easy to set-up using Rotorksnon-intrusive Bluetooth communicationtechnologies. A data logger in the actuatorstores operating data in historical order thatcan be downloaded and diagnosed in orderto monitor the condition of the valve and planfor any perceived maintenance requirement inadvance, without interruption to productionroutines. The CVAs rugged construction and

double-sealed IP68 watertight enclosure isdesigned to withstand the harsh and exposedenvironments often encountered in the miningand mineral industries.

Rotorks innovative CVA electricactuator has been specified forcritical valve control duty on hightemperature gas turbine pre-heater equipment supplied to the

power generation industry.

A completed CVA actuator installation on one of the pre-heater skids at the Petrogas Gas Systems factory.

Rotork CVA electric control valveactuators have been specified forcritical flow control duties on heavyduty mineral processing machinerymanufactured by Mineral EngineeringProcesses Limited (MEP).

A Rotork CVA actuator installed on a TBSHydrosizer, operated by the control signal from theadjacent density probe. TBS Hydrosizer two-stage lignite removal installation.

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Providing a maximum rated thrustof 5,000 lbsf (22,241 N) and alinear stroke length of up to 4.5inches (115 mm), the CVL-5000retains all the features andbenefits of the established RotorkCVA range, providing highlyaccurate control valve automationcombined with advanced,non-intrusive calibration, valvediagnostics and the simplicity andeconomy of electric operation.

CVA actuators deliver continuous,repeatable modulating controlwith a programmable fail toposition option. Operating onan industry standard 4-20 mA

control signal or digital bus, theresolution, repeatability and

hysteresis performanceis quoted at

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The new Rotork CMA (Compact Modulating Actuator) provides all-electric control valve operation.

1 Encoder TechnologyThe CMA utilises absolute encoder technologywhere a unique digital code corresponds to theangular position (CMQ), stroke length (CML)or rotary (CMR) position of the actuator.

To achieve high resolution, the position sensorlocation eliminates any backlash effect in the

gearing. The sensor is a 12-bit rotary magneticencoder, fitted at the output gear stages,removing any internal backlash effect that mayexist in the drive train.

2 User InterfaceTwo relays can be programmed to closeupon reaching a desired position or anyother available fault condition among theprogrammable options.

3 DC Brushless MotorThe CMA uses a high efficiency, continuous

rated, brushless DC motor. This allowsmaintenance-free operation even withcontinuous unrestricted modulation duty.

4 Hand DriveA hand drive mechanism is provided asstandard for all CMA actuators to allowmanual operation of the valve. Pressing downon the hand-knob shaft allows it to engagea gear in the upper section of the drive train.Releasing causes the spring to disengage

the gear.

5 GeartrainThe simple yet durable high efficiency spurgear drive is lubricated for life. It has provenhigh reliability.

The CML and CMQ standard build is capableof resisting any back drive from the load, upto 125% of the rated thrust or torque ofthe actuator.

6 Output DriveThe CMQ and CMR base conforms to MSS SP-

101 or ISO 5211. CML may be adapted to suitindividual valves.

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The gas is delivered to oil tanks that convertit to hydraulic pressure. The pressurisedhydraulic oil is used to drive Rotorks industryproven scotch yoke and linear actuators. Usingpressurised oil as the driving fluid providespowerful and smooth actuator control andisolates the cylinder from the pipeline gas.This prevents contaminants from entering thehydraulic cylinder, eliminating corrosion and sealdeterioration and extending actuator life.

The range has undergone an importantupgrade, including streamlined manufacturingand product improvements. As a result GOactuators are now lighter, more compact andincorporate advanced changes to functionalspecifications.

The compact, modular gas control manifoldsemploy poppet style control valves a reliabledesign trusted throughout the pipeline industry and are available in fail-safe versions. Standardgas control systems are complemented by arange of Rotork designed optional equipmentand functions including Line Break, LowPressure Close and High differential Inhibit.Operation is simple and intuitive.

The design, engineering and materials used inconstruction ensure optimum performance ineven the harshest of environments. The modulardesign facilitates stocking by allowing a minimalnumber of components to meet a wide range ofvalve torque and duty requirements.

Gas-over-oil actuators upgraded

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Rotork GO Range gas-over-oil range pipeline actuators aredesigned to use pipeline gas as the motive power source.

Features: GO tanks isolate the hydraulic cylinders from contaminants, preventing internal

corrosion and extending actuator life.

Modular and compact integrated multi-function manifold design reduces fittingsand potential leakages.

Quarter-turn or linear output.

Adjustable stroke time for smooth and precise valve operation.

Line break, high differential open inhibit and low pressure close control options forpipeline protection.

Torque limiting devices for valve and drive train protection.

Manual pump for emergency or local operation.

Environmental protection certified to IP66M/67M.

Hazardous area approvals to international standards. Working pressure range 10 105 barg (145 1,520 psig).

Ambient temperature range -46 C (-50 F) to 60 C (140 F).

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The Rotork ManPower range greatly reducesinstallation time and expense since no external

electrical, hydraulic or pneumatic power supplyis required.

Suitable for a wide range of ball, butterflyand plug valves, the scotch-yoke actuatorsare equipped with a compact,self-contained manuallyoperated hydraulic powerpack. A hydraulic handpump on the power pack isused to operate the actuator andcompress the fail-safe spring, holdingthe valve in the desired open or closed positionuntil a fail-safe signal is received, at which point

the spring will immediately drive the valve tothe safe position.

Fail-safe operation of ManPower units canbe triggered by electrical signals, high or lowpressure pilots or fire sensors, enabling thesuccessful fulfilment of many ESD (EmergencyShutdowns) and pressure related protectionduties in the oil, gas, petrochemical andpipeline industries.

Rotork ManPower actuators are availablewith output torques up to 45,000 Nm, with

Manually energised solutionfor fail-safe valve actuators

ManPower modules designedfor two versions of Rotork

scotch-yoke actuators.

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Many such applications involve undergroundinstallations and the fully sealed IP68watertight construction of the W100 isdesigned with this in mind.

The stainless steel input shaft operates alloysteel bevel gears within an O-ring sealed castiron gear case secured with stainless steel boltsand fastenings.

Two versions of the gearbox are available.The first can be attached to any gearbox thathas an ISO F10 or MSS FA10 input flange,whilst the second is specifically designed foruse with Rotork AB and IW range quarter-turngearboxes.

With a rated torque output of 152 Nm(1,345 lbf.in), W100 gearboxes are suitable

for an ambient temperature range of-40 C to +120 C.

Rotork gearboxes provide 90o shaft direction change

explosionproof and watertight certificationto international standards. A wide range of

options includes local position indication,integral limit switches, speed control, highspeed operation, local electrical controls,manual reset and corrosion resistant trims.

Where space is restricted the ManPowerhydraulic module can be located separatelyfrom the valve. Standard units are suitablefor a temperature range from -23 C to+60 C and equipped with built-intemperature compensation.

Rotork Fluid Systems has introduced aninnovative range of manually energised

spring-return actuators to provide aneconomical solution for fail-safe valvesthat are infrequently operated.

The W100 multi-turn bevel gearboxhas been introduced by Rotork Gearsfor applications where the input toa gearbox needs to change directionby 90 degrees to allow manual ormotorised operation .

Features: Stainless steel 316 input shaft

& fasteners. Cast iron housing.

W100 Multi-turn 1:1 manual

bevel gearbox for 90 shaftdirection changing.

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The new 242 Series manualquarter-turn gear operatorsfrom Rotork Gears benefit fromthe latest design technologiesto provide optimum robustnessand durability with minimalnon-structural mass andreduced overall size.

Suitable for the operation ofball, butterfly and plug valves orother quarter-turn devices in mostgeneral industrial applications, all

242 Series manual gear operatorsfeature a sturdy cast iron IP67watertight enclosure, a ductile ironwormwheel, PTFE thrust washersand adjustable end stop screws.

A range of five sizes is availableto accept valve stem diameters ofup to 70 mm (or 58 mm square

section) and deliver an outputtorque range of up to 2,100 Nm. Built with standard ISO basedimensions between F05 and F25,simple and rugged 242 Series gearoperators are ideally suited for lowtorque manual applications.

Options include stainless steelinput shafts and fasteners, Namurand Westlock mountings, an IP68temporarily submersible enclosureand a padlock kit.

This rendered CAD image of the242 has been selected by Siemensfor the Solid Edge ST5 designsoftware splashscreen and willappear in rotation whenever usersaround the world start using SolidEdge ST5.

Robust and compact manual gear operators for quarter-turn valves

Rotork Gears has developed the innovativeDual Speed Input Reducer (DSIR) for

speeding up the manual operation of valvesand valve gearboxes by reducing the totalnumber of input turns required.

To achieve this, the DSIR has two gearing ratios.Switching between the ratios is simply a matterof pushing or pulling on the input shaft. Thehigh 4.25:1 ratio gearing is used for the portionof the valve stroke where the torque requirementis high, which is usually at the beginning and theend of the stroke. In mid-travel the valve torquegenerally drops considerably and therefore thelow 1:1 ratio gearing can be used to reduce the

number of input turns required. This can providea 70% reduction in the number of turns requiredand the operating time.

Manufactured from cast iron with carbon andalloy steel shafts and gearing, the rugged DSIR

is designed for arduous operation in an ambienttemperature range of -40 C to +120 C. Thestandard enclosure specification is watertight toIP67, with IP68 optionally available.

Other options include output machining formounting directly to a valve, flexible driveextensions and a padlockable facility. It is alsopossible to lock the gearbox drive in either of thetwo gearing ratios.

Rotork DSIR gearbox speeds up manual valve operation

The 242 Series gearbox range.

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It is now two years since themanufacture of electric and fluid poweractuators and valve gearboxes startedat the brand new Rotork factory at

Jigani, as reported in Rotalk 33.

In the intervening time, the Rotork factory atChennai, which first began manufacturing Rotorkactuators over twenty-five years ago, has beenthe subject of a recently completed multi-millionpound investment programme.

The result is a second state-of-the-artmanufacturing plant for Rotork products in India,housed in an ultra-modern 3,600 square metrebuilding with features including energy savinglighting, a rainwater recycling system and astaff gym.

In addition to manufacturing new products,the facility is now a Centre of Excellence forRotork Fluid Systems, providing control systempackaging for new actuators together with sparesand maintenance services tailored to meet therequirements of local industries.

Second new production plant opens inIndia home to the Rotork Innovation

Design and Engineering Centre

Exterior and interior views of the new Rotork Chennai facility.

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The new Chennai plant, which wasopened by Rotork Chief ExecutivePeter France in November 2011, isalso home to the Rotork InnovationDesign and Engineering Centre (RIDEC),the worldwide focus for researchand development for all of Rotorksproduct ranges. Here, a dedicatedstaff of engineers work with Rotorksglobal organisation to co-ordinate andfacilitate innovation and new productdevelopment.

19Receive future editions of electronically by emailing [email protected]

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UK Rotork plctel +44 (0)1225 733200fax +44 (0)1225 333467email [email protected]

USA

Rotork Controls Inc.tel +1 (585) 247 2304fax +1 (585) 247 2308email [email protected]


Rotalk is published and printed byRotork Controls Ltd. in the UK.

For more information on ROTALK articles and features contact ROTORK Bath: +44 (0)1225 733200 email: [email protected]

www. rotork .com

For the latest news followRotork on twitter @rotork

More applications available on Rotork.comThe Customer Portal on the Rotorkwebsite provides secure access to a

programme of user-friendly interactiveareas including:

E-Learning

The latest addition to Rotorks line up of trainingtools is a series of E-Learning modules aimed atanyone who has requirement to commission anduse Rotork actuators and associated equipmentin the field. The modules consist of interactivelearning solutions that will take around 30minutes to complete and are equally useful asa refresher course for those who deal with theequipment infrequently.

The range comprises: Introduction to IQ Actuators Introduction to IQT Actuators Introduction to CVA Actuators Pakscan Loop Configuration IQ Insight Diagnostic Software Introduction to Rotork Process

Control Actuators

Software for IQ and CVA actuators: IQ Insight and IQ Pocket Insight Diagnostics CVA Enlight and CVA Pocket Enlight

Diagnostics IQ Pro Language Modules CVA Commissioning Report Pakscan Long Term Datalogger Viewer

Sizing Guide

The guide enables the correct type and size ofelectric actuator to be selected for all valve typesand sizes, taking into account power supply,enclosure specification (hazardous/non-hazardous)and mechanical interfaces. Version 3.0 nowincludes handwheel-gearbox combination sizingfor all types and sizes of manually operatedvalves, ensuring efficient valve operation at userspecified handwheel rim-pull values.

For both electric actuator and handwheelsizing, the selected combination details providecomprehensive information for specification,enquiry or quotation. In addition, 30 corporateand instructional videos are available for viewingor downloading from the portal as well as a

comprehensive demonstration of the Pakscandigital bus control system.

Software Downloads

Rotork has a comprehensive range of softwaredownloads to support its intelligent actuationproducts.

To access the Customer Portal, go to rotork.comand click the Login link in the top right-handcorner of the screen. If you dont yet have anaccount you can sign up by clicking the Click hereto register for an account link on the Login page.

Upcoming exhibitionsWEFTEC 1st - 3rd October 2012

WEFTEC is the largest conference of its kindin North America and offers water quality

professionals from around the world withthe best water quality education and trainingavailable today. The 85th annual WEFTEC is inNew Orleans, Louisiana this year.

Come and visit us in Hall C/D, booth 2334.For more information visit www.weftec.org

ADIPEC 11th - 14th November 2012

The 15th Abu Dhabi International PetroleumExhibition and Conference (ADIPEC) takes placeat the Abu Dhabi National Exhibition Centre

(ADNEC). ADIPEC is supported by Abu DhabiNational Oil Company (ADNOC) and the UAEsMinistry of Energy and hosts over 1,500 exhibitions and attracts more than 45,000 attendees.

Come and visit us at stand 4022. For more information visit www.adipec.com

VALVE WORLD EXPO 27th - 29th November 2012

Valve Word Expo, the 8th Biennial ValveWorld Conference & Exhibition will be held inDsseldorf, Germany for the second time. This

calendar highlight already has 371 exhibitorsfrom 34 countries registered for the event.Leading experts will present papers and hostworkshops on key flow control topics

Come and visit us in Hall 03, stand E53. For moreinformation visit www.valveworldexpo.com

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