Selection and sizing of control valves Page2/1

2 Control valve actuators

2.2 Selection of control valve actuators

The selection of an appropriate valve actuator depends on technical and economical factors. Manual
control, external piloting, or internal piloting is possible.
Usually control valves are operated with pneumatic diaphragm actuators, pneumatic piston actuators,
electrical linear actuators and electrical rotary actuators. Electro-hydraulic actuators are used
sometimes.

Actuator type Advantages Disadvantages

Pneumatic Explosion-proof, relatively simple
Relatively insensitive to corroding
environments if control air is used
Unsophisticated design
Use of control gas possible
Interlocking of signals can easily be
achieved
Relatively low costs
High stroking velocities can be achieved
In case of an auxiliary energy failure,
safety position occurs (spring-loaded
design)
Electric Large distance to the source of energy,
easily to compensate
Accessories and parts are standard
supplies
Easy interlocking of signals
High operating and controlling accuracy-
easy to achieve
Large actuating force- easy to achieve
Remote control and monitoring functions
can be implemented easily
Hydraulic High actuating forces
High stroking velocities are possible
In case of an auxiliary energy failure,
safety position occurs (accumulator)
High stability
Distance to the source of energy is limited
(dead time!)
Actuating force for spring-loaded units is
limited
Auxiliary energy must be generated, not
available (costs!)
Auxiliary energy system requires
maintenance
Small systems are normally not
economical
Sensitive to changing process pressure
Larger actuating forces difficult to achieve
Limited stroking velocity
compared to pneumatic or hydraulic
actuators; Explosion-proof difficult
Safety position: in case of an auxiliary
energy failure, additional measures are
required
High maintenance costs
Distance to the source of energy is limited
Transferring actuating power requires
pipes (leakage risks!)
Costly control and operating
Maintenance required

Table 2/1: Advantages and disadvantages of different control valve actuator series

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2.2 Manual actuation

Manual actuation for control valves

If there is no auxiliary energy available, the closure element is moved by means of a trapezoidal
threaded spindle (generally using a hand wheel) to achieve an accurate flow. Larger actuating forces
require transmission by means of gearing.

Figure2/1:
Manual actuation for control valves

A coupling transforms the actuating forces to the valve’s stem. A screw safety device prevents, that
the sealing areas between plug and seat do not abrasive, in case of rotation.
The maximum permitted operating force should not be ignored because operating differential
pressures are limited.
Permitted manual forces for operating industrial valves, according to EN 12570 1.

1
EN 12570: Industriearmaturen; Verfahren für die Auslegung des Betätigungselementes
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2.3 Pneumatic operating actuators

For installation on control valves pneumatic operating actuators is the most popular type in use on/off
valves and control valves. Pneumatic operating actuators are advantageous because they are
explosion proof and have a simple design.

Pneumatic diaphragm actuators

Pneumatic diaphragm actuators are designed as single acting multi-spring actuators, central-spring
actuators or double acting actuators. Pneumatic diaphragm actuators operate by means of a controller
signal, the positioner or another source.
Because of different spring ranges, diaphragm areas and the various accessories cover a very large
application range.

Figure 2/2:
Single-seat control valve with a standard bonnet
and a pneumatic multi-spring diaphragm actuator
FlowTop and FlowAct Series

Advantageous of a pneumatic diaphragm actuator:

Robust and reliable

Temperature resistant to a large extent
Rapid positioning time
In case of an auxiliary energy failure, safety positions react immediately (open/close function).
Operates in intrinsically safe and explosion proof areas (EEx).
Easy maintenance
Simple mechanic construction- inexpensive

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Flexible, pre-formed diaphragms (roll diaphragms) made from reinforced elastomer materials are used
to achieve higher strokes, vast linear actuator characteristics and negligible low friction force. The
diaphragm material dominates the permitted surrounding temperatures. Because of the normally used
Acrylnitril-Butadien-Rubber (NBR), temperatures reach -40°C to 80°C. Below -40°C, the actuators
require diaphragms made from silicon.
Disadvantageous are the limited positioning forces of spring loaded actuators and that the air pipe
distance regarding the energy source is limited. Another disadvantage is the complex construction and
the supply of auxiliary energy.

Single acting actuators

In pneumatic diaphragm actuators, the diaphragm operates in means by pneumatic signals.

A retracting or an extending of the actuator stem occurs, when the diaphragm force is larger than the
installed actuator spring.
The spring returns to its starting position in case of a signal failure (safety position of valves). A huge
advantage of single-acting actuators is the construction-conditioned safety position. The spring force
and the number of springs are defined by the existing additional air pressure.
A central-spring actuator has an adjustable spring (To vary the positioning force and the spring range)
and a double guided actuator stem. The double guided stem makes a reversing of the effective
direction without a reconstructing of the actuator possible. Diaphragm actuators are designed as multi-
spring actuators because of costs and height.

Figure 2/3:
Central-spring actuator
effective direction; stem extended
(Design Flowserve Villach, Series 151 PA 1000)

Upper or lateral manual operations are often attached to operate control valves in case of a pneumatic
signal failure. Upper or lower stroke limitation is adjusted by manual operations.

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Figure 2/4a and 2/4b: Pneumatic multi-spring diaphragm actuator with upper manual operation.
Series: FlowAct

Single acting linear actuators with gear box are also used for rotary valves. In this case a motion
conversion mechanism between the valve and the pneumatic power unit is necessary to convert
between linear and rotary motion.

Figure 2/5:
Butterfly valve with gear box and pneumatic
linear actuator
Valve and gear box design Böhler (BHDT),
actuator Series FlowAct

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Double-acting actuators

Both effective directions require auxiliary energy.

A double acting actuator has no adjustable spring and therefore no constructive safety positioning.

Figure 2/6:
Double-acting diaphragm actuator
(design based on Series FlowAct)

Pneumatic piston actuators

Pneumatic piston actuators are primarily designed for open/close functions. A piston sealing causes
friction- hysteresis occurs. If enough additional air pressure is available, pneumatic piston actuators
(compared to diaphragm actuators) can cope with higher positioning forces. Even if high strokes are
demanded, pneumatic piston actuators are required. If a safety positioning is required, the pneumatic
piston actuators are designed with actuator springs.

Figure 2/7a and 2/7b:

Pneumatic spring cylinder actuator
A: spring action close
B: spring action open
Type: Valtek VL Aluminium actuator

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Figure 2/8:
Pneumatic piston actuator with double pistons, double-acting
(Design Flowserve Villach, Type KO 300-2)

Pneumatic rotary actuators

Pneumatic operating rotary actuators are designed for rotary valves (ball valves, plug cock, butterfly
control valve or rotary plug valve).
In order to operate double-acting piston actuators, pneumatic rotary valves are predominately
designed with an open/close function. If a safety positioning is required, pneumatic rotary actuators
are even designed with an adjustable spring.
The standard interface between valve and actuator, according to DIN ISO 5211.

Typical designs are:

Rock and pinion actuator

The linear motion of the pistons is transferred into pivoting by rock and pinion. The course of
torque is linear.

Scotch yoke type actuator

The linear motion is transferred over an arrangement of levers into rotation. The gear ratio makes
at the beginning and at the end a higher torque possible. This torque is ideal for valves with
distinctive breakaway torque and for valves with a higher closing torque (e.g. ball valve, rotary
plug valve).

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Figure2/9:
Pneumatic rotary actuator
Type NORBRO

Diaphragm actuator with Gear box

Because of its low hysteresis, diaphragm actuators are preferred controlling functions.

Figure 2/10:
Rotary plug valve with
pneumatic diaphragm actuator
Type Valtek MaxFlow

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Energy supply

Pneumatic actuators and the appropriate auxiliary equipment operate only with pneumatic energy
supply. Compressed air is normally used and provided by a compressor. The pressure supply must be
higher than the minimum required pressure of any single equipment.
If a high reliability of the systems (e.g. control loops with safety functions or a continuity of operating
process) is required, an additional auxiliary supply source (besides the auxiliary equipment) is set up.
This essential supply comes from a volume tank. The capacity of volume tanks must be measured
carefully. Operating over a defined period of time must be assured when an energy supply failure
occurs. According to the safety concept, the process must be in good order and condition. In case of
an operating fault, this process must be guaranteed as well.
In order to operate failure-free, most pneumatic additional equipment requires dry instrumental air.
The instrumental air must be free from oil. The pneumatic supply must be free from impurity (e.g.
solids, liquids, vapor or aggressive elements) otherwise the pneumatic equipment is damaged or its
function is affected. Even a total breakdown cannot be excluded.

A dust filter, smaller than 10 μm is required

Free from oil
In order to prevent an icing of the pneumatic equipment, the dew point of the air should stay about
10°C lower than the lowest surrounding temperature.

Quality of the industrial plant air supply, according to: ISO 8573-12 .

2
ISO 8573 Teil 1: Druckluft; Verunreinigungen und Reinheitsklassen
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2.4 Accessories for pneumatic actuators

In order to meet the demands of functioning as a controlling or operating element, the valve and
actuator unit require a device. Accessories influence the auxiliary power of the actuator and signal the
stroke position of the actuator.
Advantageous are actuators and pneumatic additional equipment with standardized connection
possibilities according to IEC 60534-6-13, IEC 60534-6-24 (NAMUR), VDI/VDE 3845 5 or
VDI/VDE 3847 6. An easy construction, without adapter parts for pneumatic additional equipment from
different manufacturers is possible.
It is advantageous to directly construct the positioner, solenoid valve or filter regulator with internal air
ducts. Then, a demounting of pneumatic additional equipment without any additional air or
instrumental air pipes can be guaranteed. Piping and screw connections can be dropped out, high
reliability (because of possible leakage reduction) is assured.

Figure 2/11a, 2/11b and 2/11c:

Pneumatic operated single-seat control valves
A: NAMUR Interface (FlowPro with FlowAct size 700 and Logix 520)
B: VDI/VDE3847 Interface (FlowTop with FlowAct size 252, direct mounted positioner Logix 520 and
direct mounted filter regulator)
C: FlowTop Interface (Flowtop with FlowAct size 252, top mounted hand wheel and Logix 520)

3
IEC 60534-6-1: Stellventile für die Prozessregelung; Montage-Einzelheiten zur Befestigung von Stellungsreglern
an Stellventil-Antriebe; Montage von Stellungsreglern an Hubantriebe
4
IEC 60534-6-2: Stellventile für die Prozessregelung; Montage-Einzelheiten zur Befestigung von Stellungsreglern
an Stellventil-Antriebe; Montage von Stellungsreglern an Schwenkantriebe
5
VDI/VDE 3845: Stellgeräte für strömende Stoffe; Verbindungsstellen zwischen Stellglied, Stellantrieb,
Stellgeräte-Zubehör
6
VDI/VDE 3847: Stellgeräte für strömende Stoffe; Schnittstelle zwischen Stellgerät und Stellungsregler
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The yoke from Flowserve Villach allows a directly setting up of the positioner, solenoid valves and filter
regulators as a compact function unit with internal routing of air flow. A processing alternative would
be an adapter with a standardized interface according to VDI/VDE 3847 and VDI/VDE 3845.

Some designs allow conducting the discharged air of the pneumatic accessories into the spring room
of the actuator. Air ventilation with instrumental air prevents humidity or aggressive surrounding air
from entering the spring room (stroke is working).

Valve positioners

A positioner is used when the position of the plug must be proportional to the instrument signal of the
controller. In case of controlling deviation, the positioner makes fast tracking possible. Stuffing box
friction, forces on the plug or actuator and hysteresis are compensated.

F e d e r s c h lie ß t

M a g n e tv e n t il (a n g e re g t)
A u sg a ng S S P S 2 4 V D C

1 3

Y1
S te llu n g s rü c k m e ld u n g
S o llw e rt W
S te llu n g s re g le r

M S R -L u f t

Figure 2/12:
F ilte r u n d R e d u z ie r sta t io n Pneumatic scheme
of a control valve
o h n e L u f t „Z u “
system

The standardized signal for pneumatic performances averages 0,2 bar (20 kPa) to 1,0 bar (100 kPa).
The standardized pressure supply is defined with 1,4 bar (140 kPa) and a minimal value of 1,3 bar
(130 kPa). Actuators can achieve enormously high pressure levels with a positioner (compared to the
standardized signal). A higher positioning force can be achieved with small diaphragm areas or piston
areas. The control valves can also operate in Split-Range. There are single and double acting
positioners for globe valves and rotary valves.
Most positioners are equipped with inductive or mechanic limit switches, position transmitter (4 to 20
mA), booster relays or gauge.

Pneumatic Positioner (P/P)

The pneumatic positioner is used to operate pneumatic actuators by a pneumatic positioner with an
input signal 0,2 - 1,0 bar (3 – 15 psi) or partitions.
Maximum pressure supply 6 bar

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Analog electro-pneumatic Positioner (I/P)

The electro-pneumatic positioner is used to control pneumatic actuators by a electric positioner or a
control device with an input signal 0/4 - 20 mA or partitions (Split-Range Operating)
User-defined characteristics
intrinsically safe (EEx ia) or explosion proof (EEx d)

Digital electro-pneumatic Positioner (D/P)

Input signal 0/4 - 20 mA or Split Range Operating
Micro-process controlled
Self calibration
Intrinsically safe (EEx ia) or explosion proof (EEx d)

Figure 2/13:
Electro-pneumatic positioner
Type Foxboro/Eckardt SRD 986

Digital Positioner with micro processor

Communicating positioners are used to control actuators through control systems and electrical
controllers supported by HART-communication, FoxCom, Profibus PA or Foundation Fieldbus H1 (FF)

Figure 2/14: Figure 2/15:

Digital positioner Digital positioner
Type Flowserve Logix 3200 IQ Type Flowserve PMV D3

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User-defined characteristics
Status- and diagnostic feedback
Intrinsically safe (EEx ia) or explosion proof (EEx d)

Some manufacturers offer diagnostic possibilities in order to monitor the valve’s condition. Unexpected
failures can be prevented. Diagnostic tests can be done offline or online, without any interruption of
the process. Communicating positioners allow a remote diagnostic.

Pneumatic booster relay

Figure 2/16:
Pneumatic booster relay
Type Valtek Flow Booster

The volume booster is mounted between positioner and actuator in order to increase the additional air
flow for the actuator. Higher positioning speed occurs. Several actuators can work at the same time.
Input- and output signal are equal in pressure.

Position transmitter

A position transmitter is used where a surveillance of the closure member’s position is required. The
position transmitter signalizes the position of the control valve by an analogue electrical signal (4 - 20
mA) or a pneumatic signal (0,2 - 1,0 bar).

Lock- up relay

In case of pressure supply failure, a lock-up relay (safety element) closes the supply line to the
actuator. The actuator remains in its last position. When the supply pressure is restored, the
pneumatic control signal is released to the actuator again.

Solenoid valve

Solenoid valves are used to control pneumatic diaphragm actuators for open/close functions, to
interlock or for safety circuit systems. Direct or indirect controlled 3/2-wege-solenoid valves are used
for most applications.

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The interface between actuator and solenoid valve is standardized: VDI/VDE 38457.

Limit switch

Limit switches are used for limit signals of one or two end positions. Inductive limit switches or micro
switches are applied.

Barrier

Barrier for signal loops divide equipment. In explosive areas mounted equipment is divided from non-
intrinsically safe controllers or other additional equipment.

Filter regulator

In order to protect pneumatic equipment, filter regulators are used to reduce the pressure of plant air
supply.

Figure 2/17:
Filter regulator
Type Foxboro/Eckardt FRS 923

The pneumatic equipment is protected from incorrect high pressure. Solid particles which are larger
than 3 μm or 5 μm and liquids are filtered out. The adjusted secondary pressure and the fluctuating
inlet pressure stay constant.

7
VDI/VDE 3845: Stellgeräte für strömende Stoffe; Verbindungsstellen zwischen Stellglied, Stellantrieb,
Stellgeräte-Zubehör
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2.5 Electrical operating actuators

Electrical operating actuators cope with high operating forces and dynamic forces. Electrical operating
actuators cope where auxiliary energy is plant air supply or at low surrounding temperatures. Electrical
operating actuators are required to dry instrumental air.
The electric actuators are more complex and more expensive than pneumatic actuators. A
disadvantage is that explosion protection can only be guaranteed under extraordinary charges. The
positioning speed is relatively low. The actuators don’t operate appropriate at too high or too low
temperatures and are sensitive to humidity and corrosion.
Electrical operating actuators are not equipped with a safety position. The safety position can only be
applied under extraordinary charges and works only with batteries. A disadvantage is the must of
periodic maintenance and the recharging of the battery. Standard electric gear type actuators are
ideal, when the valve must remain in the last operating position (fail-in-place mode).
For fail-safe action a standby power source (e.g. a relay switch, actuated battery pack and a hand
wheel for manual control) is required.

Electric linear motion actuators

Electric linear motion actuators operate when the auxiliary energy is electrical power and explosion
protection is not required.
Electric linear motion actuators are not very robust and more expensive, compared to electrical rotary
actuators with linear thrust unit.

Figure 2/18:
Electric linear motion actuator
Type Haselhofer

Optional accessories are switches depending on the torque, stroke-dependent limit switches,
potentiometer, electrical positioning feedback, position electronic, break and thermo-elements.

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Electric linear motion actuators are switched off in closing direction. Electric linear motion actuators
depend on the torque and make safe closing possible. The opening direction corresponds to the
valve’s stroke and is limited by a stroke-dependent limit switch.
Electric linear motion actuators only achieve low positioning forces (up to 25 kN). Electrical
engineering is a preferred application field for electric linear motion actuators.

Electrical rotary actuators

Electrical rotary actuators are required to cope with high operating forces and when dynamic forces
occur. Great distances to an energy source are easily to bridge. High control- or operating accuracy, a
remote control and a surveillance function are easily to achieve.
A disadvantage is that an explosion protection can only be guaranteed under extraordinary charges.
The positioning speeds are low and a safety position is normally non-existent. The actuators don’t
operate appropriate at high or low temperatures and are sensitive to humidity and corrosion.

Motion conversion mechanism like the l in ear thrus t u ni t are designed in connection wi th
electrical rotary actuators and to operate control valves or rather open/close valves. The rotation of the
electrical rotary actuator is transferred from a linear thrust unit into an axial stroke movement.
Power plants are a preferred application field for control valves with linear thrust units and electrical
rotary actuators.

Figure 2/19:
Linear thrust unit,
suitable for electrical rotary actuators
Design: Flowserve Villach

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2.6 Electro-hydraulic actuators

Electric-hydraulic linear- or rotary actuators cope with very high positioning force, long strokes and
relatively high positioning speeds. In case of an auxiliary energy failure (pressure accumulator) the
electro-hydraulic actuator design makes a safety position possible.
A disadvantage is that the distance to an energy source is limited, the extensive operating/controlling
and the substantial maintenance. An explosion protection can only be achieved under extraordinary
expense. The actuators aren’t fully functional in every installation position and therefore shouldn’t be
exposed to extremely high or low temperatures. Depending on a certain operation, the proper
hydraulic fluid must be chosen.
In case of an oil pressure failure (failure of a pressure stressed or a pressure generating part or
electrical energy failure), designs with a closed end position accumulator is capable of transforming
the actuator over a hydraulic valve into a closed end position.
The electro-hydraulic actuators are equipped with manual operating possibilities (hand wheel). The
piston (stagnant engine only!) can only be operated with a hand pump.

Figure 2/20:
Elektro-hydraulic actuator in compact design
Type Reineke

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