VValve Actuation News from Rotorkalve Actuation News from … · 2018-11-12 · Saudi refinery...

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Application, contract andproduct reports from theworldwide Rotork valveactuator family

❒ Rotork in Control❒ Contract News❒ Fluid System News❒ Focus on Jordan❒ Actuation Update

Valve Actuation News from RotorkValve Actuation News from Rotork

Rotalk - Issue 23 2

For further information on Rotalk articles and features contact Nicky Harrington at Rotork Bath . . . . ➔

ContractNews

The pipeline runs from Grissik inSouth Sumatra to Singapore’s SakraIsland, supplying Singapore with itsthird source of natural gas forgenerating electricity over the nexttwenty years. Rotork’s contractsinvolve actuation equipment andservices from virtually every part ofthe company’s product portfolio.Fluid System at Singapore won theorder from PGN for eightypneumatic pipeline actuators,together with gas-over-oil actuatorsfor skid mounted plant at twometering and supply stations. Builtat Rotork’s Italian factory, most ofthe actuators were shipped toSingapore for fitting to ball valvesmade by Audco, Cooper Cameronand PBVS.Meanwhile, Rotork Japan wasworking with the contractor andengineering vendor responsible tothe metering stations’ operatorPower Gas regarding other diverseactuation requirements at the twosites, one at Jurong Island and theother at Senoko, north ofSingapore. Rotork Japansuccessfully proposed an actuationpackage comprising IQ andSkilmatic electric actuators from theUK, an EH electro-hydraulic unitfrom the USA and a large numberof Exeeco and Alecto manualgearboxes from the UK andHolland. The Skilmatic and EH

“Key-milestone” pipelineperformance displays Rotork’s international strengthsRotork offices in the UK, USA, Italy, Holland, Singaporeand Japan have worked together to successfully satisfythe entire major valve actuation and control requirementfor the prestigious PGN Sumatra – Singapore natural gaspipeline, described at its opening ceremony as a “key-milestone” in bilateral co-operation between Indonesiaand Singapore.

Below: Fluid System pneumatic actuatorfitted to fully welded Cameron ball valve(900mm), providing gas station shut-offduty.

actuators were supplied specificallyfor emergency shutdown andmodulating duties in areas where airsupplies for conventional pneumaticactuators were not available.The final element of the projectinvolved the remote control andsupervision of the valves at Jurong

Island and Senoko from a singlecontrol room at Senoko. Workingwith system integrator Willogen,Rotork Singapore proposed the useof Pakscan IIS network systems atboth sites, with a telemetry linkbetween them to facilitate controlfrom a single point. To achieve this,Rotork engineered Pakscanconnectivity for the EH andSkilmatic actuators and integratedthem into the Pakscan loops.Acceptance by Power Gas of thisfinal part of the proposal completedthe success of one of the mostcomprehensive and diverseactuation packages ever undertakenby Rotork’s international family ofcompanies.

Above: IQ intelligent electric actuatorsfitted to Hatanaka ball valves.

Right: Fluid system gas-over-oil actuatorsoperating PBVS trunnion mounted ballvalves (900mm) on skid mounted gasstation metering duties.

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Telephone (+44)(0)1225 733200 or email [email protected]

Skilmatic actuators provide aneconomical alternative to theconventional centralised hydraulicinstallations traditionally used forthese applications. Benefits includesimplified installation andinstrumentation costs as well asreduced operating and maintenance

Failsafe electric actuatorsfor wellhead choke valves

Rotork Skilmatic electric failsafe actuators have been ordered forwellhead choke valve duties on an oil field development project inNorth Africa. Twenty-five Skilmatic Model SHL417 flameprooflinear actuators will operate Severn Glocon Series 5000 highpressure (Class 1500) severe service globe valves supplied to theLasmo Elephant Field Development Project, via engineering groupMAN in Germany.

expenditure. The Model SHL417is specifically designed for the4-20mA modulating control of linearcontrol valves, accepting ananalogue or digital input signal toprovide accurate positional controlwith minimal power consumption.An electrically operated, self-

contained hydraulic systemoperates valve movement in onedirection, at the same timecompressing an internal spring tooperate the valve in the oppositedirection. On loss of power theactuator can be set to either failsafeor stay put, whilst the positionerdiscrepancy alarm provides remoteindication of a system error.The Skilmatic SHL417 actuatorsordered for this project are ATEXcertified for operation in Zone 1,Division 1 hazardous areas andenvironmentally sealed to IP65(NEM4)

Electro-hydraulicactuators offer aneconomical alternativeto traditional hydraulicinstallations

Rotorkin Control

Maizuru Terminal, picturedhere, is the latest MaritimeDefence Force installation inJapan to be automated withRotork IQ intelligent electricvalve actuators and Pakscandigital control systems.Rotork Japan has beeninvolved in the modernisationof several of these fuel supplydepots since the RotorkIQ/Pakscan package wasadopted as the standardsystem for the automationproject. To-date, over 300

actuators have been installedat six locations.Some of the IQ actuatorsinstalled at Maizuru aresubjected to especially harshweather conditions, includingheavy winter snow, due to itslocation on the coast of theSea of Japan. In addition,Maizuru is the first installationin the programme toincorporate a ‘hot standby’Pakscan master stationwithin the DCS operatingnetwork.

Above:Skilmatic electric failsafe actuators at theSevern Glocon factory in Gloucester,where they have been mounted on200mm (8”) severe service globe controlvalves for wellhead choke valve duty.

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ContractNewsValve

control package formajor refit atSaudi refineryRotork is supplying a valve control packagecomprising 352 IQ intelligent electric actuatorswith Pakscan 2-wire digital control andIn-Vision SCADA software for an importantupgrade project at an oil refinery on the RedSea coast in Saudi Arabia.

Rotork’s contract is a central partof the modernisation programmeat the Saudi Aramco RabighRefinery awarded to Canadianengineering consultant SNCLavalin, which will ultimately seethe installation of a YokogawaDCS to control the plant.The project involves the removalof Rotork ‘A’ range actuators thathave been operating forapproximately twenty years andretrofitting the latest IQ intelligentactuators on the existing valves.Rotork’s specialist Site ServicesDepartment will perform much ofthe retrofit design work, as MikeDale, Site Services Manager,explains: “Rotork has over 40years experience of retrofittingvalve actuators. This valuableresource will be extensively usedduring the completion of theRabigh project.”

Equipped as standard withdata loggers, the new IQactuators will enable refinerymaintenance staff todownload comprehensivediagnostic operatinginformation, using dedicatedIQ-Insight software.Pakscan will initially providestand-alone digital control ofthe actuators on fibre opticloop networks supervised byfive fully redundant 120channel hot standby masterstations, utilising In-Visionsoftware. Following installationof the Yokogawa DCS thePakscan loops will beintegrated into the plant-widesystem whilst the In-Vision willbe retained for maintenancepurposes. Each IQ actuatorwill be connected to the two-wire network via Rotork’sPakbox, enabling individualactuators to be electricallyisolated and removed from thenetwork for maintenancewithout disrupting networkcommunications.Rotork’s Saudi basedengineers will supervise theinstallation of the newactuators and Pakscannetwork, led by Dan Benson,Rotork’s Area Manager for theKingdom. Dan comments:“We are proud to beassociated with such aprestigious Saudi Aramcocontract and look forward to aclose working relationship withthe In Kingdom SNC officeand Aramco project team.Rotork’s ability to handle largeprojects in the Kingdom isenhanced by local workshopfacilities, supported by ourlocal agent Al Hugayet.”


The Changi Water ReclamationPlant (CWRP) is the cornerstone ofthe first phase of the SingaporeDeep Tunnel Sewerage System,featuring state-of-the-art, compactand covered treatment facilities,ultimately designed to handle up to2.4 million m3/day when completedin 2006. The plant design andengineering is provided byCH2MHILL, Corvallis, USA and theirSingapore office.Over fifteen hundred of theactuators ordered are Rotork IQ andIQT intelligent units for installation onCWRP Liquids Module 1,encompassing head-works, primaryand secondary sedimentation tanks,

Rotork wins majorvalve actuatororders for Singaporewater reclamationscheme

bioreactors and effluent pumpstations. IQ and IQT actuatorsshare the same advanced features,including infra-red ‘non intrusive’commissioning and communication,on-board data-logger and ‘system-on-a-chip’ intelligent technologyproviding comprehensive controland indication flexibility.Many of the actuators will be factoryfitted with Rotork Profibusconnectivity cards for integrationwith the centralised automation andcontrol system planned for CWRP.The largest portion has beenordered by Fouress Engineering(India) Ltd for the operation ofbutterfly valves. These, and othersordered by manufacturers of balland pinch valves, will be supplied toengineering contractors UnitedEngineers, Singapore, and VoltasIndia.

Rotork intelligent electric valve actuators have beenordered for installation throughout the liquids processingplant at a giant new waste water treatment plant underconstruction in Singapore.

Left:Orders for Changi include many IQTactuators for the direct operation ofbutterfly valves.Below:An artist’s impression of the ChangiWater Reclamation Plant.


Focus onJordan

Metering pumps are designed forfluid metering and controlled volumeduties – often at high flow rates andpressures up to 1200 bar – inprocess industries ranging from oiland gas to food and drinks.

Jordan has developed a specialEthernet data acquisition link, initially foruse by one of the largest energyproducers in the USA.Designed to fit 1000 Series actuators, the Ethernetoption is expected to be extended to the entireJordan product range. The option runs an HTTPweb server using TCP/IP protocol and enables thecustomer to obtain diagnostic data from theactuator by simply logging on to the internetand clicking a few buttons. In this way thecustomer can set parameters, view diagnosticsand logged data, perform self-tests and controlthe actuator remotely via a standard webbrowser.The original Jordan Ethernet application involvestwenty-eight separate hydro-electric turbineplants, where the actuators are used to re-oxygenate water that has passed through theturbines to protect the downstream environmentalecology.

At a stroke – Jordan winsmetering pump orders

A diverse range of applicationsincludes flow metering, acid dilution,gas odourisation, polyethylenecross-linking and chemical injection.Leading international manufacturersLewa in Germany and OMG in Italynow use Jordan actuators whenelectrical stroke length adjustmentis specified.Pump stroke adjustment is ademanding duty that regulates thepump performance, requiring a swiftmodulating action that can becontinuously rated, in response to a4-20mA control signal. Jordanactuators combine compactdimensions, accurate performanceand repeatability within 0.25% tosuit all these requirements. Forhazardous area duties, they areavailable with ATEX, FM or CSAexplosionproof certification.Currently, in excess of 150 actuatorshave been sold to the twomanufacturers, including an orderfrom Lewa for fifteen units at aBASF chemical plant in Germany,and thirty-two units ordered byOMG for installation on the Jebel Ali‘L’ project in UAE.

A new leaflet from Jordan drawsattention to the actuators’ hightemperature performance,explaining that most of thecompany’s product range isdesigned for ambient operatingtemperatures of up to 120°C(250°F).

High temperatureactuators Data acquisition

byEthernet

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Jordan Series 1000 and 1500 modulating actuatorshave been adopted by two world-leading meteringpump manufacturers for applications demandingautomatic electrical stroke adjustment.

Left:Metering pumps equipped with Jordan1500 Series actuators at the Lewafactory.

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Colorado Springs Utilities is a four-service community-ownedorganisation providing natural gas,electricity, water and wastewaterservices to the Pikes Peak region inColorado. The Ute Pass WTP, oneof the six water treatment plantsoperated by the Utilities, is a 2 MGD(million gallons a day) packagedplant, now consisting of four filters.The plant was originallycommissioned in 1987 and acapacity increase from 1 to 2 MGDwas completed in the summer of2003.From the initial operation of theenlarged plant Utilities personnelwere dissatisfied with the reliability ofthe incumbent valve actuators whencompared with the performance ofRotork’s IQ/IQT non-intrusiveintelligent technology at severalinstallations in other plants. Throughtheir outside engineering consultantthey requested a quotation fromMunicipal Treatment Equipment(MTE), Rotork’s municipal salesagent in Denver, for replacementIQT actuators. MTE handled sizing

IQT technologysecures reliablevalve actuation forColorado Springs Utilities

Dom DeBaggis, Rotork Rockies Area Sales Manager, reports on an impressiveretrofit success utilising IQT actuators at a community-owned water treatment plant.

Rotork IQT intelligent electric valve actuators have beeninstalled at the Colorado Springs Utilities’ Ute Pass watertreatment plant located in Green Mountain Falls, Colorado,to secure improved reliability on the filtration equipment.

and Rotork arranged a specialdelivery, resulting in orders for fourIQT250 and twenty IQT125 units tofit butterfly valves in sizes rangingfrom 3” to 8”.IQT technology and software toolsenabled Utilities’ personnel to installand commission all the actuatorswith impressive speed and efficiency,with only minimal assistance andtraining from Rotork and MTE.Extensive use of IQ-Insight softwareenabled actuator configurationinformation to be saved and thendownloaded to other IQTs installedon identical valves, resulting invaluable time savings as it wasnecessary to shut down two filters ata time during the changeover.

“Please pass on to all thepeople at Rotork Bath ourthanks for a job well done.This important achievementwould not have been possiblewithout their hard work anddedication. We all appreciatethe great effort Rotork Bathand Mississauga contributedto make this happen.” WayneBoyd, President and CEO,Canatom NPM Inc.This impressive endorsement wasreceived upon the announcementthat Qinshan Unit 2 power stationnear Shanghai began commercialoperation on 24th July 2003, fourmonths ahead of the originallyscheduled date.Rotork has been the majorsupplier of nuclear qualified valveactuators on the Qinshan 1400megawatt Unit 2 project, but a lastminute on-site problem with oneunit threatened to jeopardise thereactor start-up date. Eradicationof the problem demanded thebuilding of a replacement 90NA1unit at Rotork Bath, shipping andinstallation within a record ten-week lead time.Close co-operation betweenCanadian and UK Rotork offices,the customer Canatom NPM Incand main contractor AECLsecured the successfulcompletion of the task, enablingthe planned start-up of the newreactor to proceed on time andQinshan Unit 2 to join Unit 1 incommercial operation.

Record deliverytime securespower stationstart-up

Rotorkin Control

Footnote – Colorado SpringsUtilities have also retrofitted fouradditional IQT actuators at one oftheir remote flow control facilities,whilst Rotork will also providemore than twenty IQTs forinstallation at their Northern WaterReclamation facility, currentlyunder construction.

Extensive use ofIQ-Insight softwareenabled actuatorconfigurationinformation to besaved and thendownloaded toother IQTs installedon identical valves

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David Palmer of Black & VeatchConsulting and Rivers Team Leaderat T5 owners BAA plc explains:“BAA opted to divert the Longfordand Duke of Northumberland’sRivers around the westernperimeters of the airport rather thanbury the existing courses in culverts

Rotork helps topreserve andenhance historicrivers at Heathrow

beneath the proposed development.The new diverted channels havebeen designed with significantecological enhancements in order tomaximise the environmental valuesof the rivers.” At the head of each channel, off-take structures incorporating seven

Rotork Folomaticfacilitates partial valvemovements foraccurate river levelcontrol.

Eric Li at Rotork Hong Kong hasbeen closely involved with bothprojects since construction firststarted in the 1990’s. Black PointPower Station (above), situated innorthwest New Territories, will beone of the world’s largest naturalgas-fired combined-cycle powerstations when completed in 2006,with a planned generating capacityof 2,500MW. Nearly 400 Rotorkactuators are installed on the

Actuators in major Hong Kong utility projects

CAPCO owned project, which isbeing built by a consortiumcomprising Alstom CombinedCycles International and the GeneralElectric Company at a total cost ofaround HK$ 24 billion.In addition to Hong Kong’s largestpower station, Rotork actuators alsofeature throughout the territory’snewest water treatment works at TaiPo (right). Here, nearly 500 RotorkIQ actuators are being installed onplant that will eventually have adesigned treatment capacity of1.2 million m3/day. The advancedtreatment process encompassescoagulation, flocculation andclarification by dissolved air flotation,aerated biological filtration for

ammonia removal, rapid gravityfiltration and final disinfection.Provision is also made for theinclusion of ozone and GAC filters iffound to be necessary. Designedby Black & Veatch, the plant isbeing constructed by Gammon

Hundreds of Rotork electric valve actuators are beinginstalled throughout two new major utility projects,built to serve the burgeoning population and economyof Hong Kong.

Rotork IQ intelligent electric valve actuators are being used inan ecologically important “Twin Rivers Diversion” projectassociated with the construction of the new Terminal 5 (T5) atLondon Heathrow Airport. Twenty-three actuators operatestainless steel penstocks manufactured by H. Fontaine Ltd tocontrol the flows within new open channels, built to divert thecourses of two of London’s historical rivers around thewestern perimeter of the 260ha Heathrow T5 site.

1.5 metre wide penstocks areoperated automatically by RotorkIQ25 actuators in response toanalogue signals from adjacentultrasonic level sensors installed inthe river beds. The actuators arefitted with Rotork Folomaticproportional controllers and CPTcurrent position transmitters toenable progressive penstockmovement and position signallingto commence when the “bank full”trigger level is approacheddownstream of the off-takestructures. The actuators continueto shut the penstocks until the waterlevel is stabilised, ensuring that therivers are kept full but the banks arenot breached. A telemetry link from

each installation transmitsinformation on penstock status,positions and upstream/downstreamwater levels to a central control roomat Heathrow Airport.The Fontaine penstocks feature fullyenclosed operating mechanismswith bevel gearboxes, enabling theRotork actuators to be installed inergonomically convenient positions.This facilitates access to theactuators during installation,inspection and maintenance andremoves any requirement for highlevel walkways or temporaryscaffolding.The “Twin Rivers Diversion” projectwas started in November 2002 andcompleted in May 2004.

Skanska. With a total costapproaching HK$ 2 billion, Tai Powater treatment and water transferfacilities will ensure that HongKong’s water supplies meet the highstandards laid down by the WorldHealth Organisation.

Left and below:The Longford River off-take penstocks.Note that the IQ25 electric actuatorshave had their handwheels removed andreplaced with square key drives,facilitating manual operation with aportable power tool.


The valve – an Edward Class 250014” x 12” x 14” high pressure non-return globe control valve on boilerfeed water pump discharge service– was motorised with an obsoleteelectric actuator that was no longersupported by its manufacturer. Theactuator was regularly causing self-inflicted damage to its drive bushand gearbox when the valve wasoperated, forcing the station torepair it on an annual basis.Because all the requiredreplacement parts were notavailable from the manufacturer,they had to be specially made,dramatically increasing therepair cost.Seeking a solution to the problem,Entergy contacted Rotork.

Electro-hydraulic solutionto power station’s controlvalve headacheA heavy duty Rotork EH electro-hydraulic linear actuator has solved an expensive andrepetitive valve operating problem at the Entergy Willowglen power station in Mississippi.

Rotork’s suggestion was to replacethe electric actuator with an EHrange electro-hydraulic linear unit –customised for the plant’srequirements – which would utilisethe same electrical power supplybut operate the valve hydraulically,providing the swift and responsiveactuation required without the risk ofdamage to either valve or actuator.Modifications were also made toincrease the actuator’s manualoverride operating speed before theunit was fitted in the middle of 2001,since when it has been providingreliable and problem-free service.In September 2003, Rotork salesengineer Skip Kuehn was allowed toinvite engineers from another powercompany, who had similar problems

EH actuator deliversswift, responsivevalve positioningfrom an electricalpower source.

Rotork electric valve actuators arecontributing to a noteworthyrenewable energy refurbishmentprogramme at a power stationowned by South West Water.Opened in 1932, the plant at MaryTavy is still England’s largest hydro-electric power station, working withsmaller stations at nearbyMorwellham and Chagford toproduce a total of 3,340 kW ofelectricity from the water resourcesof Dartmoor.When the plants were acquired bySouth West Water in the 1990’s,they were still largely operating with

Rotork helps South WestWater to make the mostof renewable energy

their original 70 year old turbines,switchgear and gauges. As suchthey represent an important piece ofindustrial archaeology, attractingregular visits from educational,institutional and engineering groups.South West Water has thereforeembarked on a refurbishmentprogramme that will improveefficiency without altering theauthentic overall appearance of theplant and machinery, panels andgauges. The £850,000 projectentails the installation of new turbinewheels, modern switchgear andvalve actuation, and the introduction

with a number of Class 2500pressure seal bypass valves, to visitthe Willowglen site and find outabout the EH actuator’sperformance. Entergy were ableto supply a very positiverecommendation, reflecting theirsatisfaction with the EH installation.

Rotork IQM actuator operating the linear water inlet valve on one of the turbines atMary Tavy. Far right: Rotork d.c. actuators on the main turbine inlet valves.

Before After

The important contribution made by Rotork’s Spare Parts Cellto the successful on-time completion of a challengingCanadian power station upgrade project has been recognisedby the award of a special commemorative plaque.Bruce Power Station in Ontario was undergoing a majorenvironmental upgrade programme which includedrefurbishment of Rotork nuclear qualified valve actuators thathad been installed when the station was built in the 1970’s.

Award winning performance fromSpare Parts Cell

Clockwise from left: Paul Kennedy withSpare Parts Cell members Gary Barnett,Simon Mellowes and Richard Knight.(continued on page 14)

Rotorkin Control

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being built and there are plans for afurther four. Most of the work isbeing carried out by our experiencedin-house staff and a centralisedworkshop is being established at

Mary Tavy to service all the plants.Automation will not only improveefficiency but also enable our staffto work with more flexibility at thepower stations.”


Rotork actuatorscontrol turbineoperation withpermanent failsafesecurity.

of automated site control under PLCsupervision.Nine Rotork electric actuators arebeing retrofitted at Mary Tavy,replacing manually operatedequipment to control and governthe flow rate of water into the threePelton wheel and three Franciswheel turbines on the site, anoperation that used to requireconstant manual attention. SixRotork IQM modulating actuators willcontinuously alter the position of theoriginal linear water inlet valves inresponse to signals received fromthe PLC. Three Rotork actuatorswith d.c. motors and Rotork-designed battery control panels arealso installed to automatically shutthe main inlet gate valves to theturbines in the event of a powerfailure or similarly important alarm.Actuator installation is an integral

part of the turbine refurbishmentcontract that has been awarded tothe turbines’ original manufacturers,Gilbert Gilkes & Gordon Ltd.Steve Cryer, South West Water’sHydro Manager, is enthusiasticabout the future of hydro-power inthe area. He explains: “Theprogramme at Mary Tavy is the firstpart of a scheme to increase ourproduction of renewable energy at atotal of nine existing hydro-electricitysites. In addition a new station is

Actuator replacement is beingcarried out by Rotork’s specialistSite Services Department, workingclosely within the daily operationalconstraints of the site to minimisethe risk of any interruption to normalplant operation. The latest ATEXcertified Rotork IQ2 intelligentelectric actuators are being installed,the majority being IQ70 modelsoperating buried service 900mm(36”) Cameron pipeline ball valves.Most of the valves control themovement of gas received fromthree North Sea gas producers

21st Century upgrade atNational Grid TranscoBacton includes newRotork valve actuatorsRotork has been awarded phased contracts to install new electric actuatorson an approximate total of three hundred major valves during a strategicmodernisation and upgrade programme at the National Grid Transco (NGT)gas terminal at Bacton in Norfolk. Rotork is replacing earlier versions of itsown actuators which, in many cases, have been in operation since theBacton plant first began processing North Sea natural gas in the early 1970’s.

Careful retrofitplanning minimisesthe risk of disruptionto normal plantoperation.

situated on an adjacent site. Thegas undergoes filtering, blendingand quality assurance processes,including checks on calorific value,volume, pressure and temperature,before it is pumped into the NGTNational Transmission System.For the last two phases Rotork tookon the total installation responsibilityincluding the electrical work andappointed Dabbrooks Ltd fromGreat Yarmouth to connect theactuators to Bacton’s upgradedcentralised monitoring and controlsystem. Each actuator provides

continuous valve position andavailability data, supported by alarmsignals covering, for example, lossof power or incomplete valvemovement. As a part of the NGT-wide Ulysses Project, data from theBacton control system is also beingcommunicated by telemetry to NGToperational headquarters at Hinckleyin Leicestershire.Rotork’s contracts are beingperformed in several stages. Workbegan in 2002 and is expected tocontinue for another two years.

Pictured – new Rotork IQ70 actuatorsinstalled at NGT Bacton.

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Last year’s introduction of ATEXcertified explosionproofswitchboxes has created a muchhigher level of demand thancould have been predicted, saysRotork Valvekits’ MD MartinHunt. The SIRA certified, ATEXapproved Circa 7000 switchboxrange encompasses switch,sensor, ASI 2-wire connectivityand remote position feedbackoptions. A unique feature of theCirca range is the high visibility‘beacon’ position indicator,which has also received ATEXexplosionproof approval, due toits rugged, compact design.ATEX certification is establishingthe Circa 7000 as a high qualityand economical switchbox

ATEX approvedexplosionproofswitchboxes indemand

choice throughout its UK andEuropean markets. Recentapplications include twenty unitsfor valve position indication at apetroleum tank farm in Holland.Valvekits’ contract encompassedthe supply of new manual valvegear operators, switchboxes andmounting brackets.

Rotork Exeeco has achieved anexclusive framework agreement forthe supply, installation and servicingof Rotork products at powerstations owned by Scottish andSouthern Energy plc. The newagreement follows several years ofclose co-operation between thetwo organisations during actuationupgrade projects at several powerstations.The framework covers the repair,renewal and replacement of all

Exclusive framework for Rotork Exeeco atScottish and Southern Energy

actuator types, whether electric,pneumatic or hydraulic, togetherwith on-site specialist servicesduring tightly programmed outagesas well as servicing and runningrepairs.Exeeco Sales Director Ian Elliottexplains: “Offering Scottish andSouthern Energy an exclusiveframework for our products andservices was seen as a welcomemove forward for both companies.Working closely with our clients

helps to give them confidence andpromotes a working partnership insourcing the best technical andproduct solutions in this specialisedfield.”Rotork Exeeco can claim over 30years experience of actuation andautomation in power plants. As thelargest service provider in its field inthe UK, Exeeco currently holds termmaintenance contracts with over75% of the power generation plantsin the UK.

Rick Velderman, MaintenanceSupervisor at the Wyoming WaterTreatment facility in Holland,Michigan, enthuses: “We are veryhappy with the performance of theRotork actuators on this project.From the time that they have beeninstalled, we have had virtuallytrouble-free operation and an overallmuch smoother plant process. TheRotork units are a major reason forthis improvement.”The Wyoming Water Treatmentfacility has upgraded twelve filters forimproved reliability and operationalefficiency, opting for the electricalactuation of existing filter and pumpcontrol valves. Equipment replacedconsisted of water hydrauliccylinders with external torque armsthat had been in operation for overtwenty-five years. The plantrequired new electric actuators forsixty-three butterfly valves ranging insize from 18” to 48”, as well as twolarge 24” and 30” ball valves for highservice pump check service.All isolating duty valves wereequipped with IQ intelligentactuators and IW gearboxes, whilstmodulating and failsafe filter valveswere fitted with Skilmatic electro-hydraulic actuators. In addition, thelarge butterfly and ball valves on thehigh and low service pump circuitswere equipped with EH rangeelectro-hydraulic units, completingan all-electric isolating, modulatingand failsafe valve actuation solution,from a single source.The impact of the new actuatorinstallations has been immediatelynoticed, as Rick Veldermanexplains: “We see a big benefitover our old actuators from amaintenance standpoint, one beingthe functionality of remote SCADAcontrol and local control at theactuators. This is a big plus from a

Rotork impresses with filterplant upgrade performance

maintenance standpoint, since weneed to be down at the valvesworking on equipment. Being ableto simply stroke valves and haveconsistent response is veryimportant. The Rotork units give usthis ability. It is also very nice tohave two different actuatortechnologies supplied andsupported by the same company.“We were all extremely impressedwith Rotork’s on-site training, thatwas provided as part of the project.The local rep and the Rotork areasalesman came in with actual units,dismantled them and taught us realmaintenance. Several of my guyshave since commented that Rotorkwas right at the top of the list of allsuppliers on this large project, interms of quality of training.”

Valvekits has recently supplieda customised, key operatedinterlocking adaptation forinstallation on a hazardouschemical delivery valve forSevern Trent Water.Designed by Integrated SafetySolutions Ltd the installationuses a sequenced key routineto permit the safe delivery ofsulphuric acid through a 3-wayball valve, ensuring that it isrouted to a storage tank andpreventing any possibility of itbeing discharged to the drainvia the third valve outlet.

Lock, stock and barrel

“We are very happy with the performance of the Rotorkactuators on this project. From the time that they havebeen installed, we have had virtually trouble-free operationand an overall much smoother plant process. The Rotorkunits are a major reason for this improvement.”

Rotork’s performance throughout a major water treatmentworks upgrade project has made a good impression.

Ian Elliott meets Andy Cunnah,Maintenance Manager at Scottish andSouthern Energy’s Keadby PowerStation during an on-site trainingprogramme performed within theframework agreement.



Rotork valve actuators are alreadyused on the site, which was originallybuilt fifty years ago. Therefore, IQand AQ electric actuators, togetherwith Fluid System actuators, mostlyfitted with K-Mass fireproof coatings,were specified for the automationand expansion of the NC2 plant,which has been in operation since1969. For the compressors, locatedat the beginning of the process, aspecial design was conceived toautomate the large, previouslymanually operated emergency block(shut down) valves. These gatevalves, in sizes up to 42”, isolate andprotect the main plant from thesupply of product in the event of agas leak or fire.Due to the critical importance of theapplication to plant safety, the IQactuator installations requiredcustomisation to comply withdetailed specifications. This wassuccessfully achieved with theinvolvement of Dirk Stroeckx (Fina),Chris DePaepe (Kellog, maincontractor), Mike Gover (Rotork UK)and Frederik Van Acker (Prodim –Rotork’s agent in Belgium).The design ensures accurateremote valve position indication to

Fina Antwerp Olefins choosesfireproofed Rotork valveactuators for increased safetyThe Fina Antwerp Olefins refinery has been the subject of athorough revamp and expansion project known as NC2X, which isnow in its final stages. The project has the objective to increaseannual ethylene production capacity to 1.4 million tonnes whilst alsointroducing improved safety systems.

enable the compressors to be safelyshut down. Each valve spindle isfitted with an indication rod thesame length as the valve size (42inch valve = 42 inch indication rod).The rods are made of two materialsin equal proportion – top halfstainless steel, bottom halfaluminium.Each IQ actuator is equipped with aK-Mass coated covertube, twice thelength of the indication rod, in themiddle of which are attached threeproximity switches in a 120° array,fitted in springed cover tubes sothat they push against the indicationrod to ensure positive contactthroughout valve movement.These switches indicate aluminium but cannot ‘see’ stainlesssteel, therefore providing threeadditional “valve 50% closed”signals independently from theactuator.Dirk Stroeckx explains: “Thissystem was required for additionalsafety and independent availability.We chose 50% closed indication aswe don’t want to wait until thevalves are completely closed beforetripping the compressors.“Our experience with Rotork

Team effortachieves specificsafety demands

products has been good.Personally I think they are veryreliable and of good quality. We arealso very satisfied with the level ofservice provided by Prodim.”

Frederik Van Acker from Rotork agentProdim inspects one of the IQ actuatorand proximity switch installations at theFina Antwerp Olefins refinery.

Rotork IQ range intelligent actuatorsare replacing obsolete equipment atThames Water Deephams STW,which serves a population of over800,000 in the London boroughs ofBarnet, Brentfield, Enfield andTottenham.The majority of new actuators arebeing installed on valves andpenstocks on primary sedimentationtanks in a project designed tointroduce automatic desludging atthe site. Together with theintroduction of new inlet screens,refurbishment of aeration lanes andfinal sedimentation tanks, theDeephams upgrade will enable

Rotork valve actuators helpwith Thames Water sewagetreatment improvementprogramme

100% of the plant to meet strictnew Environment Agency consenttargets.Rotork’s specialist retrofit teamcarried out a survey of the valvesrequiring new actuators, which wereordered by contractor LaingO’Rouke under the terms ofRotork’s framework agreement withThames Water. Laing O’Rouke arecarrying out all the installation workat Deephams, including linking theactuators to a new centralised PLCcontrol system that will supervisethe daily treatment of up to 460,000cubic metres (tonnes) of effluent atthe site.

ContractNews

Rotork electric valve actuators have been specified for themechanical and electrical upgrade programme at one ofLondon’s largest sewage treatment works.



Applications,worldwide locations...

Kuwait: Online catalyst regeneration

Rotork area manager Keith Phillipsis pictured at the factory of MogasIndustries in Houston, manufacturerof severe service metal seated ballvalves. This consignment ofpneumatically actuated valves is onthe way to a Chevron/KuwaitNational Petroleum Company

project in Kuwait for online catalystregeneration duty. Front-endengineering and design wasperformed by ABB Lummus inHouston and detailed engineeringwas carried out in South Korea byLG Engineering.

Peru: Automated gas measurement

Pictured at the Flow-Quipvalvemaking plant in Tulsa,Oklahoma, this shipment of P rangeand R range pneumatic actuatorsare to be installed on gasmeasurement skids for the CamiseaProject in southern Peru. Each

Rotork actuated valve package isequipped with a manual overrideand stainless steel control cabinetwith remote and local valve controls.The consignment is en-route tospecialist skid manufacturer DanielMeasurement in Houston, Texas.

One of a consignment of largepneumatic actuators ordered fromFluid System at Leeds byvalvemaker Tomoe Tritec for theSakhalin Island offshore platform in

Russia: Offshore production platform

Russia. The actuators will operate600mm (24”) Class 1500 butterflyvalves as part of a control valvepackage ordered by Dresser. Theproject main contractor is Amec.

Russia: Anti-surge pipeline skid

SPX Daniel Valve in the USArequired an actuator for a 100mm(4”) V-port ball control valve thatwould operate normally with an 80psi supply pressure but could alsocope with up to 1000 psi. Thisunusual requirement has been met

by utilising a Fluid System springreturn hydraulic actuator packagerecommended by Rotork Houston.The actuator operates a bypassvalve in order to activate the anti-surge skid on a pipeline project inRussia.

Texas: Cogeneration pipelinesystem in the event of a signalledhydraulic fluid release to thereservoir.Three of these actuated valvepackages are being supplied for theExxon Mobil BeaumontCogeneration Pipeline project inTexas, through Mustang Engineeringin Houston. The valves are 400 mm(16”) Class 300 and Class 600Dresser ball valves.

Fluid System News

Rotork Houston worked with BarberIndustries to fulfil this demandingapplication, where no externalsource of actuation energy isavailable. The solution was aspecially designed, self-containedhydraulic control system, operatinga Rotork H range spring returnhydraulic actuator. The onlyintervention required is the manualre-pumping of the actuator control



performance during the initial stageof this pipeline project has resultedin Rotork actuators being specifiedthroughout the next phase of thescheme, involving approximately130 km of pipeline connectingBaroda to Kaloi and Ahmedabad.

Rotork’s CP, GP and LP pneumatic scotch-yoke and linear actuators havebeen successfully tested for IP66, IP67M (tested whilst operating) andDeluge watertight and dustproof certification.Tests were performed in Italy by independent testing authority Nemko S.p.A.using standard-build Rotork products. Following stringent test procedures,including total immersion, the actuators were dismantled and neither waternor dust were found to be present inside any of the enclosures.The photographs show the recently launched CP range compact quarter-turn actuator during dust, water jet and submersion testing.

Photographed at the premises ofvalvemaker Audco India Ltd, theseGO range gas-over-oil actuatedvalves are some of the total of thirtysimilar packages supplied for theGSPL Paguthan to Baroda pipelinein Gujarat State, India. Customersatisfaction with Rotork’s

India: Natural gas distribution

IP66 & 67M Certification for CP, GP and LP actuators

Another GO success

Deanquip, established for overtwenty years, specialises in thecontrol and monitoring of pipelineand process valves and wellheadcontrols in the oil and gasproduction, transmission, miningand process industries.As Fluid System’s latest Centre ofExcellence, Deanquip now offersexceptional experience in the

Deanquip strengthensFluid System in AustraliaRotork’s acquisition of Deanquip Valve Automation Ptyat Melbourne brings comprehensive local support andservice to Fluid System sales in Australia.

design, fabrication and packaging ofvalve automation solutions,supported by installation,commissioning and fieldmaintenance services.More information can be obtainedfrom Lydon Dean, General Manager,[email protected]

Houston, TexasEstablished and experienced valveautomation specialist Baro Controlsis the new distributor for Rotork electricand fluid power actuators in Texas.With premises in Houston, CorpusChristie, Beaumont, Dallas, SanAntonio and Midland Odessa, Barostocks a comprehensive range ofRotork pneumatic and electricactuators, positioners, limit switchesand gear operators, as well as valvesfrom world leading manufacturers.Baro’s experienced actuationspecialists are on hand to designautomation solutions to individualspecifications, supported by in-housefabrication and packaging facilities.Baro Controls’ President Shelly Whitecomments “Rotork’s comprehensiveproduct line and commitment toquality and growth first attracted us,heralding the signing of this landmarkagreement.” For more information: [email protected]@rotork.com

Distribution Update:Durban, South AfricaValve & Automation has beenappointed exclusive distributor forRotork Fluid System products inSouth Africa. With a new factory inDurban, supported by offices inJohannesburg, Richards Bay andSecunda, Valve & Automation hasyears of experience of fluid poweractuation markets in the oil, gaspetrochemical and paper industries.Rotork Africa General ManagerHoward Mutters enthuses “This is amajor step forward in our ability toprovide a complete product offering.For many years Rotork in South Africahas been associated with electricactuators and control systems. Wecan now look forward to greatermarket awareness for our completerange of actuation products.”For more information:[email protected]

EnhancedModbusconnectivityfor Rotork electric actuators

The station’s operators suppliedtheir local Rotork sales office atMississuaga with a list ofreplacement seals, bearings andmechanical components for theeighteen Rotork 30NA and 40NAactuators involved, all of which wererequired on a fast turnaround tomeet the shutdown schedule. Toassist with identification, the stationalso supplied examples of many ofthe items required, taken from theactual actuators.Rotork Ontario passed the parts listand samples to the Spare Parts Cellat UK Bath head office forimmediate action, where it quicklybecame apparent that not all therequired parts were still “on theshelf”. This would dictate extendeddelivery times whilst the out of stockitems were identified and procured,which might jeopardise the station’splanned re-commissioning date. Onreceipt of this news Bruce Powerdespatched engineer Perry Karstento Bath to assist Rotork seniorcontracts engineer Paul Kennedy inchecking and tabulating all themissing parts that now needed tobe urgently ordered.Paul takes up the story: “In view ofthe age of these actuators it is notsurprising that some of the requireditems were not immediatelyavailable. However, access to the


(continued from page 8)

actual actuators’ detailedengineering drawings, buildschedules and test certificates atBath helped us to quickly andaccurately pinpoint all the relevantparts, in most cases check themagainst the samples supplied andthen begin the task of sourcingreplacements.“We had to search as far as Japanto successfully find some parts, butin the event this was a worthwhileeffort as the manufacturer provedable to supply us in only sevendays. In fact, the entire Bruce Powerspares order was eventually fulfilledin less than three weeks, includingthe creation of a complete list ofnon-metallic actuator componentsand materials required as anessential part of their environmentalqualification approval procedures.“Without the support of thededicated Spare Parts Cell team it isvery unlikely that this could all havebeen achieved within such a shorttimescale.”As a result of these efforts, therefurbishment of the actuators didnot delay the re-commissioning ofthe power station which wascompleted on time. Tocommemorate this achievement,Bruce Power awarded a speciallycommissioned plaque to Rotork asa permanent record of the event.

Award winning performance ActuationUpdate

Fitted within the environmentallysealed actuator enclosure formaximum reliability, the RotorkModbus card uses the familiarModbus RTU protocol on a lowcost RS485 communicationnetwork. With the card fitted, all thenormal commands associated withmoving the actuator becomeavailable on the Modbus multi-drophighway for PLC supervision. Whenfitted to IQ and IQT intelligentactuators the Modbus card alsomakes available a subset of thestandard data logger feedbackinformation. A torque profile isprovided for every valve operationtogether with the total number oftimes that the motor starter hasbeen energised in each direction.This information can be accessedperiodically to update the controlsystem with the latest data.Generally, up to thirty-two actuatorscan be connected to a singleRS485 network with a typical cablelength of one and a half kilometresand a data transfer speed of 9600baud, making Rotork Modbusinstallations ideally suitable for thecentralised control of small tomedium sized processes such aswater treatment plants.Three versions of the card areavailable – single channel, with andwithout repeater, and dual channel.The single channel is the simplest

implementation, connecting theactuator to one RS485 highway andincluding an additional input for astandard analogue instrumentsignal. The single channel withrepeater module includes an internalrepeater to allow the Modbushighway to be extended overgreater distances or for applicationswhere a ring is to be constructed.The dual channel module caters forapplications where redundanthighways are used for high integrityfield connection. The two channelsare isolated from each other andprovide independentcommunications.

Rotork electric valve actuators are now available with improvedconnectivity to the popular Modbus automation protocol,facilitating an increased range of control and communicationinformation including historical operating data.


The new Modbus brochure can bedownloaded from www.rotork.com

Rotork Gears now has thecapability to assemble AB seriesand ILGS series quarter-turngearboxes from componentstocks held at Rochester.In addition, to serve short leadtime orders for manual

Rotork Gears-up in the USAClay Hightower, Rotork Gears' Americas General Manager, reports:

gearboxes, we now bore and keyIW worm gearbox drive sleeves,thread IB bevel and IS spurgearbox drive sleeves andmachine quarter-turn quadrantsto customers' specifications.This investment in new

Left: Rotork Gears' machinist Ray Torresgets busy completing another order forAB series gearboxes at Rochester.

machinery and Increased stockshould greatly increase the levelof service to existing customersand increase penetration of thesmall valve manufacturing anddistribution markets.

Modbus connectivity is

available for all Rotork current

range electric actuators, either

as a factory fitted option for

new units or retrofitted on

existing installations.



Roy Pentland (left) of ISC hands Rotork’s AS/NZS3800 accreditation certificate(no. PRD/R61/0143) to Peter Gingell, QA Manager at Rotork Ballarat.

Approvals first forRotork in Australia

Rotork’s subsidiary in Australia is the first valve actuation company inthat country to achieve essential third-party accreditation to the latestAS/NZS3800 standard for the overhaul and repair of explosionproofelectrical equipment in hazardous atmospheres.

Accreditation is a mandatoryrequirement in Australia forcompanies that install or work onelectrical equipment in hazardousareas, or have workshops for therepair and overhaul of suchequipment.Companies must prove that theyhave the approved systems andprocedures in place, as well ascompetent people to carry outthe work.Rotork Australia employed theservices of ISC (InternationalStandards Certifications Pty Ltd.)to obtain AS/NZS3800

compliance at its head officeworkshops at Ballarat to coverthe overhaul and repair of allRotork Exd certified electricvalve actuators.Rotork Australia GeneralManager Lee Howardcomments: “I believe that weare the only actuation companyin Australia to receive thisaccreditation. Access tooriginal Rotork hazardous areacertification drawings gives usthe exclusive ability to overhaulRotork equipment to theAS/NZS3800 standard.”

As these photos illustrate, Rotorkagents were given full producttraining and maintenance seminarsvenues in Riga, Vienna and Dubai.Meanwhile, at five locations in Indiaand Pakistan, countries ofincreasing importance to Rotork,customers were given presentationson IQT actuators and the latestversion of IQ-Insight set-up,configuration and diagnosticssoftware. Rotork’s success in thispart of the world is illustrated by arecent order for over 100 IQ valveactuators for the White Oil Pipelineproject.

Seminars spreadthe IQT wordRotork International Sales has recently completed aseries of seminars to update agents and customers atstrategic locations on the benefits of the latest IQTactuator technology.


http://www.rotork.com

UK head officeRotork Controls Limitedtel Bath 01225 733200fax 01225 [email protected]

USA head officeRotork Controls Inctel Rochester (585) 328 1550fax (585) 328 [email protected]

Rotalk is published and printedin the UK.Produced by FTPublicitytel 01225 865399rotork.comOrders for 130 actuators have

been received from KurversPiping in Italy for the operation of100mm Class 900 ball valves onproduction wellheads in ambienttemperatures as low as -35ºC.The ATEX approved Skilmaticelectro-hydraulic design wasselected for the applicationfollowing eight months ofdiscussions and design workwith design contractor KellogBrown & Root.During discussions, spaceconsiderations were a majorconcern. The Skilmatic self-contained design was chosen asthe most technically suitable

Skilmatic in Kazakhstanoilfield development

Rotork is supplying a projected totalof over 700 IQ actuators on the4000 kilometre pipeline, describedas the largest and most significantgas industry project ever planned inChina.Rotork actuators on the take-offinstallations are IQM modulatingversions, seen here operating

The pressure is on for IQ actuators in China

The IQ intelligent electric valve actuators pictured here are on one ofthe current total of thirty-eight take-off stations installed on the Westto East natural gas pipeline in China.

Mokveld Class 600 axial flow controlvalves. These are the critical “first inline” control valves that reduce gaspressure from the main transmissionline operating pressure of up to 99bar to the downstream distributionnetwork pressure of 25 to 45 bar.Rotork b.v. in the Netherlands hassupplied IQM10 and IQM12 model

actuators to Mokveld Valves for theoperation of axial flow control valvesin sizes from 100mm (4”) to 250mm(10”) for off-take applications on theWest to East pipeline, which, whencompleted in 2005, will have thecapacity to carry 12 billion cubicmetres of gas a year from the TarimBasin oilfields to the Yangtze Delta.

Rotork Skilmatic has received the first orders for wellheadmanifold actuators for the Alibekmola Onshore InfieldGathering project in the Republic of Kazakhstan.

solution due to the overall spaceavailable, speed of operation, lowtemperature, maintenance and cost.The actuators will be installed invertical and horizontal orientationson wellhead production and testloops handling crude oil and sourgas at pressures up to 135 bar. Theactuators, which operate from asingle-phase 230Volt electricalsupply, are configured to failsafeclosed and equipped with manualhand pump overrides.It is expected that this project willrun for a number of years as thisimportant oilfield is developed andlinked to the Caspian Sea andbeyond.

Rotork Gears hasannounced that manualgearboxes from theLosser factory inHolland will be availableon short delivery leadtimes as new, ‘Lean’production systemscome into effect. Full details will bepublished in the next‘Rotalk’ issue.

‘Lean’ timesis goodnews fromHolland

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