Valve Actuation News from Rotork 22 www.rotork.com www.rotork.com The best takes a quarter-turn for the better IQT brings intelligent, non-intrusive reliability to direct quarter-turn valve actuation See page 3 and enclosed leaflet Plus: ‘Fluid System News’ The best takes a quarter-turn for the better IQT brings intelligent, non-intrusive reliability to direct quarter-turn valve actuation See page 3 and enclosed leaflet Plus: ‘Fluid System News’
Transcript
Valve Actuation News from Rotork
22
www.rotork.comwww.rotork.com
The best takes aquarter-turn for the betterIQT brings intelligent, non-intrusivereliability to direct quarter-turn valveactuationSee page 3 and enclosed leafletPlus:‘Fluid System News’
The best takes aquarter-turn for the betterIQT brings intelligent, non-intrusivereliability to direct quarter-turn valveactuationSee page 3 and enclosed leafletPlus:‘Fluid System News’
Rotalk - Issue 22 2
For further information on Rotalk articles and features contact Katrina Swinson at Rotork Bath . . . . ➔
Above: Rotork’s new factory in Malaysia on theofficial opening day.
Left: Part of the Rotork production line;actuators ready for packing andshipment.
Below: Rotork Operations Director GeorgeMalcolm describes actuator test rigoperation to Rod Brooks, businessadvisor in Malaysia, and – on the left –Bruce Cleghorn and Dato’ Salamon BinSalamat.
Rotork opens new factoriesin Italy and Malaysia
ActuationNews
Increased business success and newproducts have generated the demand formore manufacturing capacity, resulting in theopening of new Rotork factories in Italy andMalaysia.
Fluid System, Italy
Rotork in MalaysiaIn April Rotork opened a new factory in Malaysia to meet thedemand from world-wide markets for reliable, low cost multi-turnelectric valve actuators.Situated at Shah Alam, close to Kuala Lumpur, themanufacturing plant and offices, which employ mainly locallyrecruited staff, were officially opened by Bruce Cleghorn, theBritish High Commissioner in Malaysia, and Dato’ Salamon BinSalamat, the Mayor of Shah Alam.Rotork’s new Fluid System factory at Lucca – a four fold
expansion on the old plant – opened in June.
The occasion was marked with a celebration reception for customersand suppliers, featuring factory tours, an exhibition of Rotork productsand helicopter trips for an aerial view of the plant and beautiful Luccasurroundings.
Combined with our established Fluid System plant in RochesterUSA, the new Lucca factory gives Rotork the world’s largestcapacity for heavy duty fluid power actuator production.
For a full Fluid Sytem update, see the enclosed‘Fluid System News’ special edition.
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Cover Story: IQT completesthe Rotork intelligent valveactuator family
For a decade, Rotork has led the world in intelligent, non-intrusive electric valve actuation technologies. Now in itssecond generation, Rotork’s market-leading IQ multi-turnactuator delivers unrivalled levels of reliability, user-friendliness and installed cost economies in thousands ofinstallations throughout the world, running on 3-phase,single phase or DC power supplies.
With the launch of the IQT, Rotorkbrings these proven benefits to thedirect actuation of quarter-turn valvesrequiring up to 2000Nm.
remote control systems, offeringmore benefits with significantinstalled cost savings. Rotork’sdedicated Pakscan system iscapable of controlling up to 240 fielddevices on a single loop, usingRotork’s In-Vision SCADA softwareto provide full monitoring and control
The IQT embodies legendary Rotorkfeatures – permanent double-sealing, infra-red ‘non-intrusive’commissioning and communication,on-board data logger, rationalised‘system on a chip’ technology,comprehensive control andindication flexibility – with specialiseddirect drive elements designed forcompact, efficient and economicquarter-turn valve operation.Now, virtually all the valve types inany plant can benefit from theinherent advantages of direct driveRotork IQ intelligence. Secure, non-intrusive and intrinsically safecommissioning – with or withoutmains power connected – is just thebeginning. IrDA communication
Advanced motortechnologyThe IQT will operate from3-phase, single-phase or DCelectrical supplies, and will alwaysrun in the correct directionirrespective of supply type andconnection.
ATEX approvedAll IQT actuators incorporate adouble-sealed, permanentlywatertight enclosure conformingto IP68, 7 metres / 72 hours(NEMA 4, 4X and 6). Hazardousarea actuators are fully approvedto the latest ATEX standards.
Speed controlRotork’s proven quarter-turnmotor control technology – nowintegrated with IQ ‘system on achip’ – enables the IQT outputspeed to be non-intrusivelyadjusted over a 4:1 range withoutaffecting the torque output.
Drive couplingsThe easily removable drive bushfacilitates convenient adaptation tovirtually any valve stem. IQT basedesign and drive couplingscomply with either ISO 5211 orMSS SP-101.
IQTF (full turn) optionThe IQTF extends all theadvantages of the IQT to non-thrust applications requiring upto 20 full turns.
Now – for all valve types – compact, direct drive Rotork intelligentactuation has arrived.
provides fast, standardised dataexchange. Actuator settings can beanalysed, reset and even transferredto other units. The data loggerstores the operational log inhistorical order, including a record ofvalve torque profiles that can bedownloaded for predictive valvemaintenance.Rotork’s dedicated IQ-Insight PCsoftware facilitates all interrogation,analysis and re-programmingactivities, either in the field by directconnection to a laptop, or using aPDA running IQ Pocket-Insight toupload from the actuator anddownload later to a PC.IQ technology interfaces seamlesslywith all popular digital two-wire
of complex installations by means ofhighly flexible graphic displays andoverviews, running on a standardPC. Alternatively, IQ and IQTactuators offer connectivity with allmajor open fieldbus systems,including DeviceNet, Profibus andFoundation Fieldbus.
The contract involved twenty-fourball valves on a total of 200kilometres of 400mm chilled waterrunning tunnel cooling pipeworkinstalled in the two main tunnels,which removes the huge quantitiesof heat generated by the trains thatpass through and undergroundplant rooms. Situated at the mid-point and two cross-over points ateach end of the tunnels, the valvesare used to configure the flow ofwater through the appropriate tunnelsections to suit prevailing operatingconditions.Originally, all but four of the valveswere manually operated, but thesteady increase in the number oftrains using the tunnel has dictatedthe need to automate all of them.This will ensure that the tunnelcooling can be efficiently switchedbetween the appropriate loops formaximum efficiency and economy.For this to happen, the valves needto be remotely operated, using theEurotunnel central control room andSCADA system, saving the timeconsuming exercise of despatchingoperators to the diverse locationswhenever valves need to be openedor closed at frequencies of up toonce a week. Eurotunnel’s chosensolution was to equip the valveswith a Rotork IQ electric actuatorand Pakscan two-wire controlpackage that would link directly intothe Modbus protocol of the tunnel’sexisting PLC data highway.Rotork Retrofit’s initial challengeinvolved the design of suitablycompact adaptation to ensure thatthe actuators would be out ofharm’s way from passing trains. Allthe valves are in elevated locations,on the tunnel side, with various valvestem orientations, including inverted.Retrofit designers overcame theconstraints of these spacerestrictions by utilising a combinationof Rotork Gears worm and bevelgear operators with IQ20 intelligentelectric actuators.The task of installation had to beprogrammed into a very restrictedtime frame, allowing the work to beperformed only at set times at nighton Saturdays and Sundays. Inaddition, access was only possibleby means of Eurotunnelmaintenance transport, which woulddeliver and collect the Retrofitengineers at strict, predeterminedtimes. Therefore, as Rotork Lead
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Engineer John White explains: “itwas crucial to ensure that all theequipment to do the job was onboard; there was no scope to goback and pick up any forgottenparts. It was equally important toensure that the job was finished bythe time we were to be collected inorder to keep the project onschedule.”Specialised hydraulic lifting gear wasbrought in to hoist the actuator/gearoperator packages onto the valves,often using the Eurotunnelmaintenance train as a liftingplatform. In this way, working inclose co-operation with Eurotunnelstaff and the cabling contractor, itwas possible, on average, tocomplete one actuator installationduring each night of working.At each of the three locations, aRotork Pakscan IIS sequencermaster station was installed to linkthe retrofitted actuators to the maindata highway, enabling valvemonitoring and control to beperformed at the central controlroom. In addition, a Rotork TouchScreen Interface panel has beeninstalled at each site, providing aback-up facility by which theactuators can be operated locally,using Rotork In-Vision software.In-Vision also has a data loggingfacility that records every actuatorcommand and action, creating anevent-by-event database ofhistorical operating information.This information can be useddiagnostically to preparepreventative maintenance schedulesand avoid unplanned interruptions.
Rotork retrofit project runs likethe Eurotunnel timetable(On time and to schedule!)The contract to automate valves inside the Channel Tunnelpresented Rotork Retrofit with an unprecedented list of challenges toovercome, not only relating to the size and physical locations of thevalves themselves, but also due to the very restricted timescalesavailable to carry out the work.
The cooling system in the Channel Tunnel has a totalheat rejection capability of 50 megawatts, theequivalent of the output from a small power station.This enables the ambient temperature in the tunnel tobe maintained at between 25 and 30°C at all times.Eurotunnel’s Shuttle railway engines are the mostpowerful in the world, equipped with 12 or 17megawatt motors to pull their 3000 ton trains throughthe tunnel.Up to twelve passenger and freight Shuttle trainspass through the tunnel each hour, in addition tomany Eurostar and freight through-trains en-route tonumerous UK and mainland European destinations.
Peter Bithell, Eurotunnel’s M & E ProjectManager, has been pleased by the overallperformance of all the participants in theretrofit project. He says “Generally the taskhas gone very smoothly, bearing in mind theenormous amount of organisation, planningand co-operation that was essential forpractical and safety reasons.“Meticulous attention to every detail,ensuring that equipment and staff were inthe right place at the right time, enabled theentire project to be successfully completedwith no unexpected incidents. With theactuators installed we are now able to beginour programme of pre-planning valveconfigurations, which will further improveeconomy and efficiency in the future.”
Did you know?
Rotork has been associated with Eurotunnel fromthe time it was first built. Pictured here is one ofthe 300 Rotork AQ valve actuators installed on thetunnels’ fire mains.
For further information on Rotalk articles and features contact Katrina Swinson at Rotork Bath . . . . ➔
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Rotork Fluid System has won theorder for heavy duty hydraulicactuators and control panels onthe Statoil Kristin productionplatform New Development projectin the Norwegian North Sea.The order, awarded within the termsof Statoil’s framework agreement,encompasses 74 Rotork LH rangelinear hydraulic spring returnactuators to operate Petrovalvesgate valves in sizes from 50mm (2”)Class 1500 to 300mm (12”) Class600, and Control Seal rising stem
Rotork Valvekits is the firstspecialist valve mounting kitmanufacturer to develop andintroduce a bespoke CADsoftware programme to optimisedesign, production and deliveryfor virtually all of its range of kits.QuicKits covers all popular rangesof quarter-turn valves, gearboxes,and the principal electric andpneumatic actuatormanufacturers. The compilation ofover fifteen years of mounting kitexpertise, QuicKits encompassesnearly 15,000 designpermutations.Manufactured to ISO5211, DIN3337 or customised dimensions,Rotork Valvekits’ mounting kitsoffer open or closed designs,fabricated or cast in a range ofmaterials and fitted with square,
QuicKits valve mounting kit serviceis another first for Rotork Valvekits
ContractNews
Top left: Eurotunnel’s Peter Bithell andRotork’s Mike Howard test the operationof the Rotork Pakscan masterstation andTouch Screen Interface situated at thecentre point of the tunnel, 70 metresbelow the English Channel seabed, 19kilometres from the UK coastline.
Top right: Rotork Retrofit engineersinstalling the gearbox on one of thevertically installed Channel Tunnel valves.
Above: A completed valve gearbox andIQ20 actuator installation.
keyed, hexagonal or ‘double-D’couplings. The service is adaptableto volume or one-off orders and canbe provided on a next day basis. Inaddition to optimising selection andspeeding delivery, the new softwarealso facilitates the production ofengineering drawings and email-able electronic files.
Rotork Valvekits’ managing directorMartin Hunt enthuses: “OurQuicKits software is an excitingdevelopment for this market, offeringcustomers the benefit of fifteenyears’ unrivalled expertise at thetouch of a button. By investing insuch innovation we confidentlyexpect that we will continue toprovide the most efficient and bestvalue mounting kit service available.” Rotork QuicKits CAD screens, showing the engineering drawing, exploded
ball valves in sizes from 50mm (2”)Class 300 to 150mm (6”) Class600. Each actuator will be suppliedwith a Rotork designed local controlpanel, for direct connection to theplatform’s hydraulic ring main.The compact and lightweight designof Rotork’s linear actuators, some ofwhich are pictured here at the newFluid System production plant inItaly, made an important contributionto winning this order, which wasawarded by Statoil’s engineeringcontractor Aker Kvaerner.
In addition, to comply with thestringent contract specification,each actuator is chemically cleanedand flushed internally aftermanufacture to safeguardcommissioning activities andenhance long-term reliability.Rotork believes that it is the onlymanufacturer of heavy duty fluidpower actuators to have investedin a dedicated in-house chemicalcleaning plant to offer theseadditional safeguards.
The order, which includes a largenumber of ATEX approvedflameproof actuators, was awardedto Rotork’s agent in Sweden, AlnabValves Instruments, for a newstorage tank farm and associatedpipework at the Nynas plant inNynasham, near Stockholm Theproject, known as the ‘NynasMaster Plan’, also involves linkingnew and existing valves to aProfibus-based SCADA systemdesigned by Siemens, which isbeing introduced to operate the site.During negotiations, Rotork andAlnab worked very closely withNynas, their consultants PIC andSiemens to provide detailedtechnical support. This included theprovision of an IQ actuator fitted
ContractNews
Technical support wins Rotork orderfor synthetic oil plant expansion
with the Rotork Profibus card thatwas supplied to Siemens to ensurefull operational connectivity with theirSCADA system and facilitatecommissioning activities. Theseefforts contributed to the successfulaward of the order in the face offierce competition from Europeanactuator manufacturers.Three sizes of Rotork IQ intelligentactuators are being supplied tooperate Velan gate valves in sizesfrom 150mm (6”) to 350mm (14”).The valves are being fitted to theactuators and tested at Alnab’sGothenburg factory, whilst Alnab willalso provide commissioning, serviceand support to the end user,delivering a simplified contractualroute for the project.
Rotork Gearshas successfullycompleted a fast-trackcontract to design andsupply 22 specialisedsub-sea valve gearoperators for the ShellExploration Penguins(Phase 1) project in theNorth Sea.Designated SSW (Sub SeaWorm), the gear operators willoperate a range of ball valves atdepths down to 190 metresapproximately 150 kilometres fromthe Shetland Islands. In order tomeet the strict demands of thecontract, Rotork Gears successfullydesigned, manufactured andpressure tested all 22 units within aten-week timescale.SSW gear operators embodyspecialised design features to
Rotork Gears wins Shellcontract with new sub-sea gearboxes
Rotork will supply more than sevenhundred IQ range intelligent electricactuators to valvemakers in China,Holland, Italy and the USA. Themajority will be fitted with RotorkGears IW quarter-turn gearboxesfor the operation of pipeline ballvalves and plug valves. Sixtyactuators are special IQMmodulating versions for theoperation of pressure controlvalves.When completed in 2005, the40inch diameter buried pipeline willhave the capacity to carry 12 billioncubic metres of gas a year. Todate, 505 billion cubic metres ofreserves have been discovered atTarim, enough to maintain a steadysupply for an estimated 30 years.
Valve actuation contractfor China’s largest gaspipeline project to dateRotork has been selected to supply valve actuatorsthroughout the largest and most significant gas industrydistribution project ever planned in China. The $25 billionWest to East Natural Gas Pipeline will extend for 4000kilometres, from Lunnan in Xinjiang through nineprovinces to Shanghai, carrying gas from the Tarim Basinfields to the Yangtze Delta.
The pipeline is designed with thirty-five process stations and 138 blockstations, facilitating thedevelopment of municipal andbranch pipeline networks in thefuture.The orders for the West to EastNatural Gas Pipeline – awarded toRotork’s Beijing Company – extendthe company’s success with oil andgas industry distribution projects inChina. In 2001 Rotork wasawarded the valve actuationcontract for the Lan-Chen-Yupipeline, which is the largest oilproduction pipeline in China, whilstin the 1990’s Rotork was awarded90% of all valve actuation orders inChina for major natural gas pipelineand network renewal projects.
Rotork has won an order for more than 300 IQ intelligentelectric actuators with Profibus connectivity, for installationat a synthetic oil production plant in Sweden.
withstand the harsh challenges ofthe operating environment. Theseinclude pressure compensation,high integrity sealing, Super Duplexinput shafts and seal housings andhigh visibility indication, together withdirect and remote ROV dockingfacilities.For more information contact RotorkGears on 0113 205 7276 or [email protected].
For further information on Rotalk articles and features contact Katrina Swinson at Rotork Bath . . . . ➔
Left to right: Riamo Lindfors, Nynas procurement manager, RobertNordin from PIC and Alnab’s Rolf Arvidsson with some of the newlyinstalled IQ actuators.
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When Rotork Gears companyExeeco were asked by UnitedUtilities to solve a ‘dry bedding’sand filter problem at watertreatment works serving the northwest of England, they were ableto submit an ideal solution usingRotork Skilmatic actuators.The problem was recognised afterseveral power failures had led to‘dry bedding’ in filter beds, causedby delayed closing of outlet valves,jeopardising the quality of the waterreaching the reservoirs. It wasdecided that the process needed todetect a power failure in order to putthe treatment plant inlet and outletvalves on ‘standby’ until the back-up generators cut in.On some of the pumping stationsan uninterrupted power supply(UPS) was the obvious solution, but
Skilmatic actuators provide solution to‘dry bedding’ at water treatment plants
this was deemed to be too costlyand require too much maintenanceto be seen as the universal solution.However, these drawbacks couldbe overcome using Rotork Skilmaticfailsafe electric actuators.The Skilmatic actuator is a totallyself-contained failsafe electro-hydraulic design capable ofcontinuous modulation duty andfailsafe action on loss of signal orpower supply.On power failure the Skilmaticactuator is programmed toautomatically go into standby modefor a predetermined time, afterwhich, if the back-up generator hasnot started, it prevents the filter fromrunning dry by closing the outletvalve be means of its integral springreturn mechanism. This successfulsolution saves the expense of
“Rotork Exeeco provided an excellent technicaland economical solution that addressed all ourconcerns, we were delighted with the supportwe received throughout the contract….”Carl Tetlow, United Utilities Project Manager.
installing separate pneumaticsystems or back-up batteries.Carl Tetlow, United Utilities ProjectEngineer explained: “ Weapproached Rotork Exeeco as ouractuation specialists to design aspecific solution for this problem.Their specialist knowledge ofactuators and applications providedus with an excellent technical andeconomical solution that addressedall our concerns. We weredelighted with the support wereceived throughout the contract
and would have no hesitation inconsidering this product to extendthe scope to other treatment plantsin the North West.”Rotork Exeeco Sales Director IanElliott adds: “ We were pleased withour solution to this project as it hasavoided the customer incurring thelarge expense of installing UPS orbattery back-up systems, whichwere the customary failsafe systemsuntil we devised our simple buteffective alternative.”.
Pictured at the UK premises of theWeir Valve Group in Huddersfield,these Rotork Skilmatic SL413 linearactuators are being supplied to anLPG (liquid petroleum gas) plant atVizag on the east coast of India.Fourteen of the ATEX certifiedfailsafe actuators were ordered tooperate globe valves on new plantbeing built by Engineers India Ltd ofNew Delhi.Designed for modulating or twoposition valve duties, SkilmaticSL413 flameproof actuatorscombine the benefits andeconomies of electrical operationand control with failsafe securitywithin Zone 1 hazardous areas.
SkilmaticATEXactuatorsfor LPGplant
Carl Tetlow and Ian Elliott with the Skilmatic SHQ416 quarter-turn actuatorinstalled at Watergrove WTW in Manchester.
Now, the integrity of this muchadmired Suffolk scenery is beingfurther protected by its inclusion inan advanced river levelmanagement automation project
Dedham Lock and Mill, the subject of the masterly JohnConstable oil painting, has seen relatively few changes in the180 years that have passed since the celebrated British landscapeartist was inspired to capture it on canvas.
undertaken by the UK EnvironmentAgency in the Anglian region. Theproject – initiated in the late 1990’s –is improving flood protectionthroughout Norfolk, Suffolk and
New and refurbished Rotorkelectric valve actuators are beingused throughout a major upgradeproject at one of Severn TrentWater’s largest water treatmentworks.Opened originally in the early1900’s, Bamford WTW takes waterfrom the Derwent, Howden andLadybower reservoirs in the PeakDistrict to supply Derbyshire,Leicestershire and Nottinghamshireat a rate of up to 197megalitres/day.The £5 million project for treatmentmodifications, undertaken byNorwest Holst Construction Ltd,involves the refurbishment of inletworks, rapid gravity filters and limeplant, together with the installation ofnew washwater recovery plant,instrumentation and analysers.As an integral part of this work,Rotork’s specialist Retrofitdepartment has installed new IQelectric actuators on existing valvesand refurbished sixty existing Rotorkactuators on the site, as well asproviding a commissioning serviceon the new Rotork AQ actuatorsthat were supplied on new SaintGobain valves.Rotork Retrofit Site ServicesManager Mike Dale explains: “Ourability to refurbish our customers’existing actuators as well assupplying new illustrates how a
Severn Trent Water treatment upgrade demonstrates RotorkRetrofit options
flexible approach can save moneywithout compromising quality orreliability. Refurbished actuators arebrought up to as new condition andusually carry the same warranties asnew equipment.”A significant area of Rotork activityinvolves the refurbishment of 28rapid gravity filters, including 16 thatare the first in the UK to beequipped with LP block filtrationsystems, supplied by Tetra. Newactuators on filter inlet and outletpenstocks, together with backwash,diverter and air scour valves, linkedto a new Boulting Groupsupervisory PLC system, willincrease the automaticbackwashing cycle from 24 to 36hours, improving filter utilisation andreducing the amount of washwaterrequired. Rotork actuators are alsoinstalled on new lamella separatorplant that will filter the washwaterbefore it is returned to the treatmentworks. This in turn will reduce theloading on the rapid gravity filterbeds, further improving utilisationand efficiency.Rotork Retrofit was awarded thevalve actuation contract at Bamfordunder the terms of the frameworkagreement with Severn Trent Water.Rotork’s framework is now in itssecond period of agreement,following the expiry of the originalfive year agreement.
“Our ability to refurbish existing actuators as wellas supplying new illustrates how a flexibleapproach can save money without compromisingquality or reliability.”
Norwest Holst M & E Supervisor Kevin Roddenby inspects a Rotork IQ actuatorinstalled on a Bamford filter inlet penstock and (right) downloads operating datafrom IQ and AQ actuators installed on backwash and air scour valves.
For further information on Rotalk articles and features contact Katrina Swinson at Rotork Bath . . . . ➔
Rotork’s performance throughouta challenging valve actuationretrofit project on the GasBooster Station at the giantCorus Scunthorpe Steel Workshas been praised by the projectmanager.The Rotork Retrofit contract involvedchanging twelve large electricactuators on 36 inch and 48 inchgate valves and installing a newactuator on a previously handoperated Emergency Shut Down(ESD) valve. The work was requiredfollowing the reclassification of theGas Booster plant as a Zone 2hazardous area by Corus’s ownATEX team under the directives ofthe latest legislation.The plant makes Mixed EnhancedGas (MEG) by boosting and mixingcoke oven gas with blast furnaceand natural gases at a rate of up to30,000 cu.metres/hour, providing aneconomical main energy source forthe weekly production of over70,000 tons of steel sections, plateand rod at Scunthorpe. Since theoperation of the entire steelworks isdependent upon the Gas Boosterplant, it was essential to complete allthe on-site retrofit activities within avery restricted window of pre-determined outages over a two-week period.Within this span of time, thenormally open valves had to beclosed, old actuators removed andnew ATEX certified Rotork IQelectric actuators fitted, wired up,commissioned and linked to a new
“The programme worked particularlywell; we are pleased with the way thatRotork worked with us at every stage ofthe contract….” – George Mounsey,Corus project manager.
centralised control room situatedoutside of the ATEX classified area.At the same time, the manuallyoperated ESD valve was partlydismantled and fitted with Rotorkdesigned adaptation assembly anda new IQ actuator.George Mounsey, a Senior ProjectEngineer in the Corus NorthernEngineering Services Projects &Technology Department in chargeof the project takes up the story:“The importance of this projectdemanded good planning, carefulmanagement, close co-operationand attention to detail. Teams fromCorus and Rotork worked togetheras a joint venture, Corus arrangingoutages, facilitating access,providing craning and supportingRotork’s activities around the valves,all of which are in elevatedinstallations.“Rotork ensured that the newactuators were expeditedspecifically to meet the Corustimescale and delivered punctuallyto their field engineers. Theprogramme worked particularlywell; we are pleased with the waythat Rotork worked with us at everystage of the contract to meet theextremely restricted installation andcommissioning period.“As a result, the booster stationwas returned to operation on time,with the stations main control valvesin a fully compliant ATEX Zone 2area condition, without anydisruption to the operation of thesteelworks.”
Rotorkin Control
Essex by automating manuallyoperated sluice gates in rivers andbypass channels and linking themby telemetry to centralised controlrooms.Automation involves equipping thesites with Rotork electric actuatorsthat operate automatically inresponse to control signals fromupstream level sensors. At some ofthe most remote sites there is nomains electricity supply available topower the automation plant.At these locations the problem isovercome by the installation ofRotork actuators with d.c. motors,operated and controlled byinnovative battery-poweredpackages that are kept charged bywind generators and/or solarpanels. Situated on the River Stourbetween Colchester and Ipswich,the sluice at Dedham Mill is thelatest site to be modernised, using aRotork IQ range intelligent actuatorconnected to a Millronics ultrasoniclevel sensor and controller.According to Environment Agency
M & E Flood Defence Engineer IvanNicholls: “The Rotork actuators areintroducing the ability to raise orlower the sluice gates in smallstages at frequent intervals, reactingwith accuracy to changing riverconditions. Previously, manualoperation offered only a crude andinfrequent adjustment – usually fullyopening or closing the gates –which doesn’t necessarily suitprevailing or subsequent riverconditions. Automation is improvingour ability to prevent flooding andalso enables us to monitor overallriver conditions throughout the areaat the Environment Agency’scentralised telemetry control rooms.”
One of the completed Rotork IQactuated sluices at Dedham Mill.
Corus’s George Mounsey with the ATEX certified Rotork IQ actuators installed on a48” gate valve (above) and the Emergency Shut Down (ESD) valve (right) at theScunthorpe gas booster plant.
Rotork has introduced a significant expansion of its market leading valveactuation activities at Houston for the benefit of customers in Texas,Louisiana, Oklahoma, Arkansas and Mississippi.The key to the service expansion was the opening in December 2002 ofa new Rotork sales, service and workshop facility in Houston, where anincreased number of staff are available to take care of every aspect ofcustomer service, from quotation through delivery to after sales andwarranty activity. The new premises incorporate offices, engineering andtraining facilities and a large, fully equipped workshop, supported by astrategic inventory of electric and fluid power actuators for fast deliveries.Workshop activities include valve adaptation, actuator mounting,actuator packaging and testing.The entire facility has been designed to enhance Rotork’s direct salesservices to local valvemakers and OEMs and to deliver a proactivespecification writing and products approval service for Gulf Coast basedengineers, contractors and end users.
Rotork expands valveactuation services for Gulf Coast customers
In April 2003 the new Houstonfacility was the venue for acombined Rotork Latin Americantraining seminar, attended byseventeen delegates from Mexico,Brazil, Colombia, Ecuador, Peru,Chile, Argentina and Trinidad.The five day programme, whichincluded seminars on Skilmatic
Houston venue for LatinAmerican Training Seminar
and Jordan products, wasuniversally praised as a totalsuccess and a motivational boostfor all involved parties.The seminar also further reinforcesthe strategy that had been agreedearlier in the year to combine thestrengths of Rotork and Jordan inthe Latin American marketplace.
Thirty-two GO actuators are alsobeing supplied to Cooper Cameronfor a large gas pipeline project in theMiddle East to operate mostly 56”pipeline ball valves, pressure rated atANSI Class 600.
Line Break abilityThese GO actuators are equippedwith Line Break control abilities, whichconstantly monitor the pipelinepressure and trigger the actuator toshut the valve in the event of anunexplained pressure drop, avertingthe risk of uncontrolled gas leaks.
Fluid System’s gas over oildesign wins pipelineactuation orders in India…Rotork Fluid System’s new gas-over-oil GO range actuators arebeing supplied for natural gaspipeline network extension project inIndia.Fifteen actuators in three sizes havebeen ordered by valvemaker AudcoIndia Ltd at Chennai for theoperation of 24”, 12” and 8” Class600 trunnion mounted ball valves.The valves will be installed on a new64km section of pipeline runningfrom Paguthan to Baroda, with ashort branch line from Sherkitowards Godra, in Gujarat State,north west India. Ambienttemperatures in the area regularly
get as high as 45°C, which,combined with high levels ofhumidity, creates a challengingenvironment for the actuators andtheir control equipment. This isovercome by the careful selection ofmaterials and finishes combinedwith rigorous attention toenvironmental sealing.The gas pipeline, constructed forGujarat State Petronet Ltd byLarsen & Toubro Ltd, is scheduledfor completion this year and will befollowed by another section, runningapproximately 130kms betweenBaroda, Kalol and Ahmedabad.
…and the Middle East
Rotork’s new Houston contact details are:Rotork Controls Inc.
9777 West Gulf Bank, Suite 15AHouston, Texas 77040.
Tel: 713-856-5640
For further information on Rotalk articles and features contact Katrina Swinson at Rotork Bath . . . . ➔
Rotalk - Issue 22 11
The Jordan SM-6000 actuatorpictured here has provided thesuccessful solution to anarduous, high temperature gasrecirculation damper applicationat a Wisconsin power plant.The upgrade was necessary toreplace an old Jordan unit that hadbeen operating in the dust ladenenvironment at temperatures up to85°C (185°F) for over fifteen years.The challenging environmentnecessitated the swiftest possiblechange-out, minimising the risk ofexposure to contamination duringinstallation and commissioning. Thiswas economically facilitated by thenew actuator’s compatibility with theexisting mounting pad and theconvenience of push-button
High temperature, lowmaintenance solution forpower plant upgrade
activated commissioning.The SM-6000 offers a number offeatures that deliver improvedperformance for this type ofapplication. Firstly, it has anunrestricted modulating duty rating,so can be continuously positionedto aid boiler combustion and reduceemissions. It also features an easilyprogrammed digital amplifier withinits watertight enclosure, providingswift access to status anddiagnostic information on afluorescent display. The actuator’soil filled gearbox provides reliable,maintenance free operation attemperatures up to 225°F, assuringthe longest possible working life withthe minimum risk of costly repairs orunscheduled maintenance.
The popular Jordan 1000 Seriesactuator, designed to meet theexacting requirements ofclosed-loop modulatingpositioning control, has nowreceived full ATEX approval forhazardous area applications.Available in either rotory or linearversions, 1000 Series actuatorsutilise DC brushless stepper motorand digital amplifier technologies toachieve highly accurate positioningand unrestricted modulating duty.Applications include control valves,
ATEX approvalfor 1000 Series
metering pumps, regulators, pilotvalves, small quarter turn valves,dampers and other low-to-mediumtorque/thrust applications.The recently introduced, internallymounted digital amplifier makes the1000 Series even easier to set upand adjust. Technically advancedelectronics are simply programmedby pressing one of the five on-boardbuttons and turning the adjustmentknob until the desired position oreffect is reached.
To find out about thecomplete Jordan productrange, contact your nearestRotork/Jordan office for acopy of the new Jordanbrochure (publicationnumber GOO5E) ordownload it from theupdated and revitalisedRotork website:www.rotork.com
NewJordanbrochure
ActuationNews
The order follows closely on there-enforcement of Rotork’sFoundation Fieldbus registeredapproval through successfultesting to the latest ITK4 standard,which ensures that hardware fromdifferent manufacturers will co-exist on the same FF networkwithout causing any operationalproblems.
Rotork chosen for ARAMCO’sfirst Foundation Fieldbuselectric valve actuator projectRotork IQ intelligent electric valve actuators withFoundation Fieldbus (FF) connectivity are being installedat the first ARAMCO site in Saudi Arabia to utilise the FFprotocol for electric actuators. Approximately 40 IQactuators are being installed on new valves at Abqaiq,an important part of the ARAMCO Master Gas System,during the enlargement of gas compression and watertreatment plant.
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The order also follows Rotork’sapproved listing for connection tothe Delta V automation system, akey part of the PlantWebarchitecture that is predominantwith Foundation Fieldbusapplications, which has beenspecified for the ARAMCO Abqaiqproject.
UK head officeRotork Controls Limitedtel Bath 01225 733200fax 01225 [email protected]
USA head officeRotork Controls Inctel Rochester (585) 328 1550fax (585) 328 [email protected]
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www.rotork.com
Rotork’s single source actuationabilities have been recognisedwith the award of a majorcontract for Fluid System and IQelectric actuators for a new on-shore gas plant at Assaluyeh onthe Arabian Gulf.More than 1000 Rotork pneumaticactuators and 250 electric actuatorsare being ordered by valvemakersfor butane and propane productionand storage facilities, sulphur
Single-source valve actuatorcontracts for Arabian Gulfgas plant
recovery plant and other utilities beingbuilt by Hyundai Engineering &Construction and Snamprogetti.The huge 2000MMscfd (millionstandard cubicfeet per day)plant isscheduled tobe completedby thebeginning of2005.
For an associated project, Rotork FluidSystem has won the order forHPG (High Performance Gas)actuators to operate giant pipelineball valves.
Ten double-acting actuators will operate 56”pipeline ball valves, pressure rated at ANSI Class600 and 900. The actuators are being built andpackaged at Fluid System’s new Italian factory.
Pipeline order forHPG actuators
Both approvals contributed toRotork’s selection duringdiscussions with ARAMCO’sengineering designer ABBLummus and contractor Technip,who wrote the specification. Tomeet the specific requirements ofthis contract, Rotork engineereda special wiring diagram for theactuators, enabling control fromlocal panels to override theFieldbus loop when requested.A Rotork IQ actuator with thespecially modified FoundationFieldbus card was supplied toDelta V manufacturer Emersonfor evaluation and approval of thisfeature.
Strengthened Saudi serviceLocal after sales support forthese actuators will benefit fromthe appointment of Dan Bensonto strengthen our agent’s team ofRotork specialists. Dan, whooriginally joined Rotork as anapprentice, spent two years inthe international sales departmentat Bath head office before joiningAl-Hugayet Trading Establishmentin Damman earlier this year.
ARAMCOcontinued from page 11
Rotork electric actuators are amongst the most compact available, even sothere are still times when restricted space around valves can create potentialproblems. So how can you be certain that the actuators in your plant will fit inthe space available? Also, how can you ensure the best configurations for easeof wiring, commissioning, interrogation, handwheel operation and maintenance?
The easiest way is to use Rotork’s new 3D Solid Models software, which givesyou a completely accurate three-dimensional representation of every IQ, IQT andQ range actuators’ external shape, that can be quickly scaled, manipulated andadded to your existing CAD drawings. Each actuator variation has beenindividually modelled to avoid having to cut and paste components together.Using 3D Solid Models you will swiftly identify any unexpected obstructions orpotential interferences, whilst you can also alter actuator configurations toachieve maximum user friendliness during installation and operation.
3D Solid Models is available in all the popular CAD formats – Parasolid, ACIS,IGES, STEP, and Stereolithography. You can download your preferred formatsfrom the ‘3D Solid Models’ page on the Rotork website, or obtain a CD ROMwith all formats from your Rotork office or representative.
Plant designers – will it fit?Now you can easily find out
Fluid System salesappointmentsTo service the increased world-
wide demand for FluidSystem actuators,Nigel Willis has beenappointed InternationalSales Manager.Nigel has more thantwelve yearsexperience of theinternational fluid poweractuation market, muchof it gained in theMiddle East.
At the Lucca salesoffice VittorioSteffani has beenappointed Italian
