Petrobras prefers EH actuators - Rotork · and Foster Wheeler in the UK are managing the...

Rotalk - Issue 24 2

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

The Rotork EH self-containeddesign offers a tested and approvedalternative solution for linear andquarter-turn valve automation,for both double-acting and springreturn duties. In particular, theEH simplifies installation andcommissioning by eliminating therequirement for separate hydraulicpower units and associatedpipework, which are incorporated ina fully enclosed integral power unitcontaining an electric motor,

Petrobras prefers EH actuatorsfor the Osbra PipelineThirty-nine Rotork EH range electro-hydraulic modulatingactuators have been installed on the Osbra Pipeline inBrazil, replacing a competitor’s hydraulic actuatorsinstalled in the 1990’s when the pipeline was new.Petrobras, the pipeline operator, was dissatisfied with theperformance of the hydraulic actuators, which sufferedfrom frequent problems involving corrosion, hydraulicleaks and a lack of technical support from themanufacturer.

hydraulic pump and reservoir. Inaddition the EH actuator providessimplified remote control andindication together with localpushbutton control. Operatingcosts are further reduced byremoving the expense of regularmaintenance on hydraulic powerplants, especially in environmentallyexposed or remote areas.With a total length of 955km, theOsbra pipeline is an important partof the petrochemical distribution

network in Brazil, carrying multipleproducts (LNG, petrol, aviation fuel,kerosene and diesel) from refineriesto major consumer areas. Thethirty-nine linear and quarter-turnEH actuators have been retrofittedon the pipeline from the Replanrefinery in Campinas SP. The linearactuators control flow from thepipeline to tanks at the terminalswhilst the quarter-turn units areinstalled after the pumping stations.

The EH actuator is acompact, self-containedsolution for criticalapplications with theoption of stay-put orfailsafe ESD (emergencyshut down) operation.The actuator offers highoperating torqueperformance with thespeed and accuracy ofhydraulic operation,combined with low energyconsumption.

Sohar Refinery, OmanOver two hundred IQ actuators,mostly with Pakscan controlsystems, together with nearly onehundred GP and CP rangepneumatic actuators have beenordered for a new petrochemicalrefinery at Sohar in Oman. The $880million project, constructed by JGCCorporation, will produce petrol,propylene, LPG, naphtha, kerosene,gas oil and fuel oil when productionstarts in 2006.

Africa: OnshoreRotork IQ actuators are replacingmore than 100 electric actuators ofUSA origin on the Veba Oil Operationsoil terminal on the coast of Libya.

Africa: OffshoreQuarter-turn and linear pneumaticactuators have been ordered fromRotork Fluid System in the UK andItaly for the new Plutonio Prospectoffshore oil production platform thatwill operate in Angola’s Block 18field. Operated by BP and ShellExploration, the platform has beenengineered in the UK by MWKellogg Ltd. Two hundred and fiftypneumatic actuators will operate ballvalves from Valve EngineeringServices Ltd and a smaller quantity oflinear pneumatic actuators will operateBreda gate valves. All the actuatorsare being packaged with controlsystems and an additional quantity ofIQ electric actuators have also beenordered for the same project.

Nanhai ChemicalComplex, China"Even for China, the $4.3 billionpetrochemicals complex underconstruction in GuangdongProvince is enormous."Bechtel in the USA, Sinopec in Chinaand Foster Wheeler in the UK aremanaging the construction of thismajor petrochemical complex atNanhai in southern China, primarily toservice the domestic market. Rotork’sorders currently encompassapproximately two thousandpneumatic actuators and nearly twohundred IQ electric actuators, theelectric units equipped withFoundation Fieldbus connectivity.The Nanhai plant will be an integratedchemical complex including steamand electricity generation and otherutility provisions, storage, handlingand shipping facilities together witheffluent treatment and environmentalprotection plant. At the heart of thecomplex a "world-scale" condensateor naphtha cracker will produce800,000 tpa ethylene and 430,000tpa propylene for further onsiteproduction of petrochemicals.

ContractNews

Rotalk - Issue 24 3

The Clinton Water Treatment Plantin Illinois has been recentlymodernised and expanded,improving filtration quality andincreasing output.As part of the filter plant upgradeRotork Fluid System suppliedP and SP range pneumaticactuators, in various combinationsof double-acting and spring-returnfor isolating and modulating dutieswith stay-put or failsafe closedoperation on loss of power. Thetwenty-nine actuators, which areoperating butterfly valves on filterclarified and wash water circuitsand plug valves on filter sludgecircuits, are all controlled by aPakscan two-wire digital controlsystem.The on/off pneumatic actuatorswere fitted with Rotork’s standardremote control and indicationpackage, including the Pakscaninterface card, to energise openand close solenoid valves.However, the modulating actuatorsdemanded an innovative,customised package to facilitatePakscan connectivity. This wasachieved by equipping a Pakscangeneral purpose field control unit(GPFCU) with an electro-pneumatic transducer to send a 3-15 psi signal to the actuator’spneumatic positioner in responseto commands from the Pakscanloop.

Filter upgrade is firstfor Pakscan andmodulating pneumaticactuatorsMike Heuseveldt from Rotork Fluid System in RochesterUSA reports on the innovative use of the Pakscan two-wire control system to operate modulating pneumaticactuators.

Rotork Fluid System GP and P range pneumatic actuatorshave been installed during a safety shutdown improvementupgrade project at the Southern California Gas Company(SEMPRA) owned Playa del Ray gas storage facility near LosAngeles airport.The actuators were fitted on Rockwell plug valves in 12 and16 inch sizes, pressure rated at ANSI Class 900 and 300respectively. Due to the potential earthquake threat in thearea the actuators were equipped with cradles to provideadditional support and protection from seismic damage.

Safety shutdown withearthquake protection

Right: The Pakscan llS master stationneatly installed on the side of

the Clinton control cabinet.Below: Modulating actuator on

backwash supply valve and isolating actuators on filter-to-waste drain valves.

This is the first time thatPakscan has been usedfor modulating pneumaticactuation, providingfurther evidence of howthe benefits of Rotork’spredominance in electricactuation control systemscan be translated into theoperation of Fluid Systemequipment to meet theincreasingly sophisticatedexpectations of plantoperators.

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

Rotalk - Issue 24 4

IQ actuators installedat innovative newwater treatment plant

The new plant will run automaticallyunder PLC control - combined withan innovative intelligent MCC - usinga touch screen SCADA programme.Rotork electric actuators have beeninstalled for the operation of thevalves throughout the plant, themajority being butterfly valves fittedwith the latest Rotork IQT intelligentquarter-turn actuators. The new plant, which replaces anexisting single stage filtration workson the site, is being designed,constructed and commissioned byBiwater Treatment Ltd, who areresponsible for all civil works andM & E installations. The treatmentprocess consists of blending fromthe three sources, flash mixing andflocculation, pH control with lime,coagulation with aluminiumsulphate, dissolved air flotation, firststage rapid gravity filtration, secondstage pressure filtration formanganese removal and gaschlorination. Filter backwash wateris processed through a washwaterrecovery plant and the supernatantis returned to the head of works,whilst the sludge is stored forperiodic off-site tankering. Rotork actuators control the flow ofwater throughout the plant. Initially,two IQM modulating actuatorsregulate the inlet supply to thedissolved air flotation. Each of thefour first stage filters is equippedwith five lQT actuators to controlinlet, outlet and daily backwash andair scour operations. A similar lQTactuated valve configurationoperates the three secondarypressure filters. Keith Jones, Dee Valley Water'sproject manager, comments:"Rotork is the preferred supplier forvalve actuators at Dee Valley Watersites. At Pendinas they are beingcontrolled for the first time by a new,compact and intelligent MCC panelthat has been designed and built toour own specification. "The MCC starters communicatewith the PLC to give, as examples,early warning of failure and todownload operating parameters

Residents in picturesque north Wales will soonbenefit from an improved water supply from theDee Valley Water Plc. A new 4Mld (million litres aday) water treatment plant is being built atPendinas to simultaneously treat the water fromthree reservoir sources and meet the latest EUrequirements for manganese removal.

automatically should overloads bereplaced. Biwater's SCADAsoftware programme also storesdata on operating trends to furtherassist with plant utilisation andmaintenance planning." Alarms from the normally unmannedsite will be signalled by telemetry tothe Dee Valley Water operationscentre at Packsaddle. The plantitself is equipped with an emergencygenerator to keep it running during apower failure, supported by abattery back-up to ensure thefailsafe operation of key valveactuators. When completed, the £3.8millionproject will maximise the availablewater resources to provide areliable, quality water supply toconsumers.

It’s not often that Rotork actuatorsfeature in newspaper stories, but,as Rotork Area Manager for SouthCentral USA Skip Kuehn noted,an IQ25 achieved centre stage ina recent report from theMississippi News.The story announced the openingof a new $12.5 million pipelinesupplying a Nissan engineeringplant and associated businessesclose to Jackson with 5 milliongallons per day of treated waterfrom a new reservoir source.The pipeline provides a reliable,single source of water to an area

"With the flick of a switch…..millionsof gallons quietly began feedingNissan and its many suppliers."

A flick of the switch opens the valvesas the new water supply goes online.

that previously had to rely onmultiple smaller sources.

Biwater Project Manager RichardThomson and Rotork Sales EngineerJon Cox commissioning IQT actuatorson the Pendinas filters and confirming plant status on the MCC touch screen.



Rotalk - Issue 24 5

Capable of handling warships andcommercial vessels of virtually everysize and description, the 350 acrePortsmouth Naval Base has fourlocks and twelve dry docks, mainlydating from the early twentiethcentury. These are served by anetwork of several miles ofsubterranean two-metre diameterculverts, connecting three mainpumping stations to the locks anddocks.Cast iron penstocks and gate valveson the network were retrofitted withRotork electric actuators in fivephases between 1983 and 1996,replacing pneumatic equipment aspart of a major refurbishmentprogramme. Most of the actuatorsare sited in pits about two metresbelow road level and subject toharsh environmental conditions,including salt water spray, dust andrain. In spite of these challengingconditions, Mick Huitson confirmsthat the actuators have generallysurvived very well, due to theintegrity of the Rotork double-sealedwatertight enclosure design.Fleet Support Ltd, a commercialorganisation with a Ministry of

Landmark maintenancecontract securesuninterrupted operationof UK’s premiere navaldockyard

Defence pedigree, has beenoperating in Portsmouth Naval Basesince 1998 and, in partnership withthe Naval Base Commander,provides ship repair, facilitiesmanagement and logistics.Mick Huitson, who looks aftereverything from bikes to cranes andpumping stations, explains thesignificance of the actuatormaintenance contract: "Foroperational and safety reasons, themovement of millions of tonnes ofseawater in and out of locks anddocks must be strictly controlled bya safe system of work. Eachactuator has a unique key and canonly be operated by a competentperson when its key is drawn aspart of a secure, planned sequenceprepared by Salt Water Planner BobPowell, in accordance withoperational demands and the stateof the tide. Actuator failures wouldcause severe disruption whilst back-up measures were instigated."The contract gives us peace ofmind with this critically importantoperation. Rotork engineers havesurveyed and serviced all theactuators and maintenance hasbeen carried out in accordance withtheir recommendations, either in-situor at the Rotork factory. Repairedactuators are re-commissioned witha new 12 month warranty – byhanding over care to themanufacturer it’s a win-win situationfor both companies. We havedeveloped a good workingrelationship with Rotork, who arevery helpful and provide excellenttechnical support."Fleet Support’s work at Portsmouthencompasses contracts with theRoyal Navy, overseas navies andcommercial shipping, as well asfacilities management contractsbeyond the perimeters of the NavalBase. Recently completeddockyard orders include repairs tothe badly damaged destroyer HMSNottingham and the Americanguided missile destroyer USSWinston S. Churchill.

Rotork has won a landmark contract with FleetSupport Ltd for the maintenance of seventy-threeelectric valve actuators that control the safemovement of millions of tonnes of water during theflooding and emptying of giant dry docks and locksat the HM Naval Base in Portsmouth. The contract,described as a "win-win" solution for both involvedparties by Fleet Support Facilities Plant MaintenanceManager Mick Huitson, will rely on Rotork’s SiteServices department to keep the actuators in firstclass operating condition and minimise the risk ofunexpected interruptions to this vital dockyardfunction.

Mick Huitson pictured with a Rotork IQ70actuator operating a 36" gate valve in theNorth Pumping Station and (right) a 70ASyncropak actuator on the 9 Dock drainagepenstock.

"The contract gives us peace ofmind with this criticallyimportant operation."

Rotalk - Issue 24 6


Rotork’s Site Servicesdepartment has completed aneconomical upgrade contract togive a new lease of life totwenty-four actuators installedon the BP Kingsbury oil logisticsdistribution terminal inWarwickshire.The terminal serves petrol stations,commercial customers and airportsthroughout the Midlands. Theupgraded actuators are Rotork ‘A’range units, installed in the early1980’s on the tankside isolatingvalves to control storage tank fillingand emptying. At the time ofinstallation the actuators wereamongst the first to be linked by aRotork Pakscan two-wire digitalcontrol system to a centralisedcontrol room and mimic panel.With the passing of twenty years,advancements in technologyresulted in some of the controlsystem components becoming non-supportable, creating a risk ofinterruptions to the terminal’soperations should the systemdevelop a fault. Also, the actuators,which were still in good conditionand operating reliably, were too oldto be compatible with the newPakscan equipment that would berequired. However, BP wanted toavoid the expense of replacing themand asked Rotork’s Site Servicesengineers to find the most costeffective solution.Rotork’s successful proposal wasfacilitated by the modular design ofthe actuators. The original‘Syncropak Mark 2’ integral starterand control modules could besimply removed and replaced withnewer ‘Syncropak 1600 Series

Upgrade gives actuators a new lease of life

Mark 5’ units containing Pakscanfield units that provide connectivitywith the latest Pakscan systems. Inthis way all the actuators could bemodified without removing them fromthe valves and the existing site wiringcould be used to connect them tothe new panel in the central controlroom. These operations have beenperformed in the minimum of time,with virtually no disruption to the day-to-day operation of the terminal.At the mimic panel itself, furthersavings have been made byreplacing the original 240-channelPakscan master station with the 32-

channel Pakscan IIS derivative that isspecifically designed for installationswith relatively small numbers ofvalves. Therefore, as a result of thiscarefully planned contract, all theactuators have been given a newlease of life and equipped with thelatest two-wire digital controlsupervision.

From sea bed to test bed –Refurbishment contract confirms Rotork’s double-sealed enclosure

Rotork Site Services Engineers StuartAndrews and Peter Smith complete the work on the upgraded actuators andcommission the new Pakscan llS master station at BP Kingsbury.

With the cover removed, the internal electronics of this IQactuator can be seen to be entirely unaffected by eight weeks ofsubmersion in corrosive sea water.

Rotork Service Department at Bath is currently refurbishing over 350actuators that have endured nearly four weeks of submersion in up to 8metres of sea water.Initial inspection of the actuators confirmed that the IP68 watertightenclosure had done its job and double-sealing had restricted the bulk ofanticipated sea water damage to the actuators’ terminal compartments.Separate environmental sealing of the actuator terminalcompartment, known as double-sealing, is a benchmark designprincipal that Rotork first introduced in the 1960’s and hasincorporated in every new actuator design ever since.In this case, double-sealing gave Rotork the confidence to propose that theactuators could be successfully refurbished as a cost effective alternative toreplacing them with new units. Every refurbished actuator is fully bench-tested and provided with a new test certificate and warranty.Site Services Manager Mike Dale comments "This contract illustrates notonly the inherent robustness of the Rotork actuator design – enabling it tosurvive exceptionally harsh environments – but also the ability of our serviceand support teams to cope with unexpected challenges.

Saved by double-sealing

Rotalk - Issue 24 7


the virtues of

A new storm overflow tankinstallation at Highbridge is WessexWater’s first use of the Profibus DPprotocol for the monitoring andcontrol of valve actuators, which,says Wessex Water’scommissioning engineer Iain Harris:"should provide us with theprototype for similar installations inthe future. Wessex Water is alwayskeen to look into using the latestdevelopments in technology in orderto continue to be recognised byOfwat as being the most efficientwater and sewerage operator."At Highbridge two new storm tankshave been built to double thestorage capacity of the existinginstallation, which receives the flowfrom eight pumping stations in thesurrounding area. The plantexpansion is being designed,installed and commissioned by theprincipal contractor, M. J. Gleeson,in order to meet strict new consenttargets introduced by the UKEnvironment Agency to minimise therisk of untreated discharges to sea.At the same time new screens,filters, aeration tanks, settlementtanks and ultra-violet treatment plant

Rotork is a keyplayer at WessexWater’s first Profibusvalve actuation siteRotork IQ valve actuators with Profibus DP opencontrol system connectivity are helping WessexWater to improve the sewage treatment regimeand protect the popular tourist beaches on theSomerset coast at Highbridge.

have been installed at the WestHuntspill STW, which receives theoutflow from the Highbridge site, ata controlled rate of no more than300 litres/second.Rotork IQ actuators control the flowrate through the Highbridge plant aswell as the sequence of filling andemptying the storm tanks when thefull flow to site rate is exceeded. Atthis point the additional volume isautomatically diverted into thestorage tanks until the flow ratereturns to normal.All the processes at Highbridge arecontrolled on Profibus two-wirenetworks, linked to a new MitsubishiQ2AS-S1 PLC utilising a softwareprogramme written by WessexWater automation. Wessex Watersenior automation engineer DavidEvans explains: "A total of fourindependent Profibus networks areinstalled at Highbridge, eachnetwork linking flow meters, highand low level sensors and valveoperating equipment from differentmanufacturers. This type of flexibilityis a particularly useful benefit ofusing an open system such asProfibus when designing andoperating plant processes."The software programme fills tanks1 to 4 one after the other butempties them in an especiallyconfigured eight-part sequence toenable the process to reactimmediately to fluctuating ambientconditions. For the offsitemonitoring and reporting of alarmsfrom the fully automated site, thePLC is linked by a Seprol S500telemetry output to Wessex Water’sRegional Operations Centre at Bathand can be accessed from othercommunication centres. Commenting on the decision to useRotork IQ valve actuators on thissignificant Profibus application, IainHarris says: "Rotork has a goodtrack record of reliability at otherWessex Water sites. As well asintegrating successfully with theother Profibus controlled equipmenton site, the IQ actuator gives usgreater flexibility with control andinstrumentation, particularly with themaintenance and diagnostic abilitiesprovided by inbuilt data loggers."

Using the non-intrusive infra red link, Rotork Sales Engineer Mike Joslin downloadsoperating data from an IQ actuator at Highbridge and reviews the information withWessex Water Commissioning Engineer Iain Harris.

Refurbished actuators in as-newcondition awaiting despatch

NetworksexplainedAn Introduction to NetworksFieldbus control systems forvalve actuatorsSince the 1980’s Rotork has pioneered the use of field networks for thecontrol of actuators used in valve automation. There are over 100,000Rotork actuators installed with a fieldbus connection of one sort oranother, being used in over 2000 systems around the world. Many ofthese use popular industrystandard open protocolssuch as Profibus, Modbusor Foundation Fieldbus, butthe majority use Rotork’sown Pakscan system.Pakscan has beencontinually developed tomeet the growing demandsof valve automation over thelast 20 years and stillremains the system ofchoice with many users.

Why use a network?Traditional control systems use individual cables for each signal to begathered or supplied to the field equipment. These cables are taken tointerface panels and thence back to the control computer or PLC. Asthe actuators have become more important this has led to more andmore cables being required for the collection of the actuator data.Today this can result in more than 20 individual terminations beingrequired at each actuator. The proliferation of cables, cable trays andinterface racks etc, with the associated installation costs, increased inproportion to the size of the plant.

Imagine the impact of digital network technology! Suddenly, largenumbers of parallel wires can be replaced by single two, three or fourcore cables interconnecting scores of individually addressableactuators and carrying all – if not more – information between the plantand the control room.

Installation costs are dramatically reduced, plant efficiency is enhancedand reliability is improved. Furthermore, digital communications can fullyexploit the information gathering potential inherent in intelligentactuators to facilitate improved diagnostics and predictivemaintenance.

These new systems allow for rapid plant upgrades and simplify thework involved in altering plant functionality. This allows the owner tomore readily adapt their plant to changing market requirements.Engineering work is greatly simplified and commissioning timesreduced. Finally the cost of ownership will come down despite a higherinitial cost for some of the hardwareelements.

Proprietary and OpensystemsRotork was one of the first manufacturers to introduce a networkcapability to the world of actuators and valve control. ThePakscan product is unique to Rotork and uses a proprietary (orclosed) protocol for the network communication. The advantageof a Proprietary system is that the network can be optimised toexactly match the needs of the elements connected to it.

For example Pakscan can cope with extremely long datahighways (up to 20 km) without the need for any repeatingdevices, it is able to cope with the removal of power from anyactuators on the system at any time and also protects againstcable failures by providing dual communication paths at all times.There are no Open systems that can do this unless they areextensively modified from their original design. Almost all cablesystems, other than Pakscan, will be compromised by the needto cover such long distances. Pakscan has been continuallydeveloped over the last 20 years to meet the needs of itsintended market.

The same period of time has also witnessed the developmentand introduction of Open systems from Modicon (Modbus),Siemens (Profibus), Allen Bradley (DeviceNet), Emerson(Foundation Fieldbus) and many more. These various standardshave been passed into the public domain, documented andcontrolled by IEC and other authorities in the USA and Europe aswell as other parts of the world. Once released for public use thenew Open protocols have been adopted by many different typesof instrumentation and control systems, though their own originsare often easy to see.

The advantage promoted by Open systems is the ability to mixand match equipment from several different manufacturers on thesame bus highway. Thus a Profibus network can supportactuators, flow sensors and motor drives on the same datahighway. This can be a particular advantage where there are onlya few devices of each type: in these cases the use ofindependent, proprietary buses for each manufacturer isuneconomic

This is the first in a series of articles that will look atthe full range of networks supported by Rotork.

Part1

Rotalk - Issue 24 8


Choosing between aProprietary and Open systemMaking the choice between a Proprietary or an Open system is animportant decision when selecting the network system for valveactuators.

Unlike virtually every other piece of plant equipment, the valve actuatoris generally inactive for over 90% of the time. However, when it isrequired to operate it is usually for an important reason. Thereforeknowing that the valve and actuator are available for the task and thatit is successfully completed is an essential requirement.

Any of the Open systems is capable of reporting the actuator statusand carrying the command to move the valve. The choice betweenthem will depend on a number of factors such as distance from thecontrol room, number of devices required on the network, theavailability of compatible equipment for other tasks, the integrity ofthe control required and so on. So the advantage of an Opensystem to enable multiple devices from several manufacturers toshare a network may make choosing one of them the preferredselection. However, there is a penalty for this choice; all Opensystems have a relatively high data overhead to allow for messagetransactions, configuration and other network maintenancefunctions. This overhead has the effect of slowing the data refreshso that they must run at high communication data rates to restore asuitable refresh time.

So why should a Proprietary system be considered? Well it must offersome advantages and Pakscan does have many. It is often the casethat the valve actuator network only carries actuators from onesupplier. If that is to be the case then the Pakscan system can beused and many other advantages will immediately become apparent.

Because Pakscan has been specifically designed for actuatorcontrol it is geared to use on sites where they are found. Pakscancan achieve much longer highway lengths than any open system, itcan offer impressive data refresh times despite using apparentlyslow communication rates and, in addition, it offers increased safetyby including a high degree of fault protection. Pakscan also lendsitself ideally to the practice of isolating the valves by powering downthe actuators, this action does not affect the communicationshighway at all.

Pakscan will often prove to be better than an Open system once thefull operational parameters are examined. This coupled together withthe latest developments in Ethernet technology make Pakscan thenetwork of choice for Rotork actuators.

Rotalk - Issue 24 9


Existing system upgradesThe Pakscan Ethernet option can be retrospectively added to anexisting system to add Ethernet connectivity and the Web server. Thecombined hardware and software upgrades are available as upgradekits for most Pakscan IIE and IIS systems previously installed.

Ethernet

CommsUpdate

Proprietary System Open System

Pakscan Profibus

Distance (no repeaters) 20 km max, 6 km typical 1500 m max, 500 m typical

Number of devices 240 max, 60 typical 32 max without repeaters,typically 20

Highway redundancy Included automatically at Needs second data highway no extra cost and doubles the cost

Cable 2 core, twisted pair with 2 core twisted pair withoverall screen overall screen

Update time (typical) 1 second for 60 actuators 0.2 second for 20 actuators

Pakscan master stations now have the option of anEthernet connection.

The new addition to the range of Pakscan options allows connectionof the Pakscan master station to the DCS or PLC over an EthernetLocal Area Network using Modbus-TCP protocol. The simple to useconnection allows up to 10 coincident users to access data from themaster station and operates on 10BaseT and 100BaseT networks.The Modbus-TCP protocol encapsulates ordinary Modbus RTUmessages in a TCP data packet and is one of the easiest Ethernetprotocols to use. The data format used with this device is identical tothat already proven for use with all major DCS and PLC supplierssuch as Yokogawa, Honeywell, Emerson, Siemens and Allen Bradley.

One of the strongest features in the new option is the inclusion of anembedded web server. Operators and managers can simply browseto the master station using Internet Explorer or similar software. Oncecorrect password is entered the data available is impressive. Thereare screens showing the master station configuration, the order of thevalves on the Pakscan loop and the condition of the loopcommunications. For each actuator there are pages showing thecurrent status, any alarms present, torque profiles for IQ and IQTactuators and the tag data. In addition, with the right access thevalves can be controlled from these web pages.

Should an alarm be generated on the system for any reason, fromeither an actuator or the master station itself, the system can send anemail to a specified address indicating the nature of the fault and thetime it occurred.

The Pakscan Ethernet integrates seamlessly with PLC and DCSequipment and can be combined with Rotork’s In-Vision software formultiple user access with plant specific graphics. In-Vision also addsalarm and event logging to the system.

● Modbus TCP protocol● LAN connectivity● Embedded Web Server with

❍ Full control and monitoring of all actuators❍ Full control and monitoring of the loop❍ Full control and monitoring of the master station❍ Configuration of master station settings, tags, etc.❍ Torque profiles❍ ‘As wired’ loop map❍ Password protection

Proprietary/Open system comparisonPakscan and Profibus

Rotalk - Issue 24 10


Specifically, the automatedsedimentation tank system thatCCMUA installed has been able tosignificantly reduce operational andmaintenance costs, improve plantefficiency, help the facility exceedEPA environmental permitparameters and greatly reduceodour problems in the residentialareas near the plant.

The ProblemJohn Connelly, CCMUA’s assistantdirector of operations andmaintenance, said that automatingthe processes associated with thesludge and scum operation in theprimary settling tank area became avery high priority for CCMUA. In1999, the CCMUA focused onwhat, if any, improvements could bemade to its ten primarysedimentation tanks.Connelly said, "Every time we had

Camden County (NJ) Municipal UtilitiesAuthority realises significant cost savings withIQ actuators and Pakscan from Bob Elliott, our correspondent in the USAThe Camden County (New Jersey) Municipal Utilities Authority (CCMUA) has installed asophisticated system of Rotork valve actuators, two-wire communication loops and softwarein the primary sedimentation tank area of its main Delaware No. 1 Water Pollution ControlFacility. According to Herman B. Engelbert, Executive Director of the CCMUA, the installationhas resulted in major operational, maintenance, environmental, and cost-saving benefits.

heavy rain, an operator would haveto manually open as many as 30influent weir gates. In addition, wehad to do a lot of maintenance on30 existing scum gate actuatorsfrom another manufacturer. All in all,the system was outdated andlabour intensive."He said, "When we looked for anew method of control, we wanteda system that would provide a veryhigh level of automation, and onethat would require a minimum ofmaintenance. Also, it needed tointerface seamlessly with our BristolBabcock DCS."

The SolutionRobert Cornforth, director ofoperations and maintenance atCCMUA, said, "Because we are apublic agency, we have a specialcommitment to our constituents tomake sure that we have extremely

reliable systems and software inplace to meet our permits from theEPA and to exceed thoseparameters.""Also," Cornforth said, "we havebeen diligent in keeping our ratesdown. We have a goal of lookingfor the most reliable and cost-effective operational solutions."After a thorough search of availabletechnology, CCMUA decided toinstall 30 Rotork IQ actuators on aPakscan two-wire communicationloop to operate the influent gates atthe ten primary sedimentationtanks. In addition, they retrofitted30 influent weir gates with IQactuators.The Edwin Elliot & Co., a Rotorksales representative located inLafayette Hill, PA, worked withCCMUA to help make the projecta success.

There are ten primarysedimentation tanks at theDelaware No. 1 plant.Wastewater takes about 12to 15 hours to flow throughthe tanks. During primarytreatment, solids settle to thebottom of the tanks and forminto sludge. The sludge isscraped off the bottom andheld for further processing.Also, oil and grease scum isskimmed off the top anddelivered to scum wells. Atotal of 60 Rotork IQactuators on two Pakscantwo-wire communicationloops automatically operatethe influent sluice gates aswell as scum slide gates.

Rotorkin Control



Exeeco Sales Director Ian Elliottreports on another successful Jordanactuator introduction, this time atDrax Power Ltd in Yorkshire.Drax is the UK’s largest, cleanest andmost efficient coal-fired power station.Already equipped with a flue gasdesulphurisation (FGD) plant thatremoves 90% of sulphur dioxide(SO2)emissions from boiler gases tomeet forthcoming legislation, thestation is now actively seeking toreduce its oxides of nitrogen (NOx)

Jordan provides all-electric damperactuation solutions at UK power stations

Simon Finley with the newJordan SM6000 electricactuator installation atLittlebrook Power Station and(left) the now redundanthydraulic power pack that theactuator has superseded.

The Jordan unit replaces traditionalhydraulic equipment and powerpacks that demand regularmaintenance and require continuouselectrical power to maintainhydraulic pressure. By comparison,Jordan actuators only use electricitywhen operating and have a lowrequirement for routinemaintenance. Introduced in 2002,the SM6000 is widely used forcontinuously modulating duties inambient temperatures up to 108ºC(225ºF) in the internationalsteelmaking, papermaking, powergeneration and oil refining industries.Littlebrook is an oil fired powerstation that was first commissionedin 1981. Now owned by RWEnpower the station is currently calledupon to ‘top up’ the National Gridwith up to 1370 megawatts ofpower at times of peak demand.For this reason it is essential that thestation’s generating plant is able torespond to National Grid demandswith speed and flexibility.Dave Baylis, Littlebrook’s Control &Instrumentation Engineer, wasseeking a reliable and cost-effectivereplacement for the original hydraulicvane control equipment on theboiler gas recirculating plant whenhe was made aware of the JordanSM6000 actuator by ExeecoTechnical Sales Engineer SimonFinley. Exeeco is the EuropeanService Centre for all Jordanproducts, within the Rotork valveactuation group. The SM6000 is arugged self-contained lever armactuator delivering positionalaccuracy within one-tenth of 1%throughout a standard stroke of upto 313 degrees, thereby offering allthe essential characteristics for thisimportant application at Littlebrook.Exeeco’s comprehensive experienceof power station maintenance andmodernisation projects enabled thecompany to propose an upgradepackage encompassing the removalof existing plant, actuator installationincluding a new fabricated pedestal,electrical contracting andcommissioning. For addedconvenience it was possible to usethe existing site cabling to power thenew actuator and connect toremote control continuous feedbackcircuits. Commissioning wasachieved by means of the actuatorísinnovative keypad and fluorescentdisplay, enabling the installation tobe brought on line with speed andaccuracy.

Below: Exeeco Sales DirectorIan Elliott demonstrates remotecommissioning of the Jordandigital amplifier, a major featureof the Jordan LA2000 range.

Environmentalupgrade at Drax

Littlebrook Power Station in the South East of London is the first power station in the UK to installa Jordan SM6000 electric actuator for fully modulating vane control on the boiler plant.

emissions ahead of the EU Large Combustion PlantDirective (LCPD) that comes into force in 2008.This is achieved by installing Boosted Over-Fire Air (BOFA)systems, involving specially designed fans, ducting and

dampers, on the generating plant. Drax is currentlyinstalling the technology on the first of its six 660 MWunits. The system is designed and installed by MitsuiBabcock, utilising specialised dampers manufacturedby Damper Technology for fan isolation and modulationof the over-fire air draught. Damper Technologyappointed Exeeco as the specialist supplier foractuators and associated services for the project.Exeeco selected Jordan LA2000 range electric linearactuators for the automation of the dampers on thisparticularly harsh duty. The actuators are controlledby a 4-20mA signal, fed to the actuatorís digitalamplifier, which can be remotely mounted to enablethe actuator to operate in ambient temperatures up to225ºF (108ºC). This, combined with a modulatingduty rating of 2000 starts/hour and precisepositioning, makes the LA2000 an ideal lowmaintenance solution for many power stationapplications.



The Exxon Mobil TYWS, located onTsing Yi Island on the west side ofHong Kong, was designed and builtby Chiyoda Engineering and hasbeen operating since 1993. Thepurpose of the automation contract,which was awarded to Rotork Hong

Automated fire-fighting systemintroduced at oil storage farmRotork IQ electric actuators with a Pakscan two-wire control system and In-Visionoperating software have been used to automate valves, pumps and associated equipmenton one of Hong Kong’s largest oil storage tank farms.

Hong, was to actuate the existingmanually operated fire fightingsystem and introduce computerisedcontrol. The automated system isdesigned to react to diverseoperating scenarios and account forwind direction, the location of the

fire and its severity.A total of ninety-six IQ actuatorshave been installed on existing gatevalves and foam pumps, whilstthirty-nine Rotork general purposefield control units (GPFCU) havebeen used to connect the non-

Left: View towards the jetty area of theExxon Mobil TYWS site.

Below: The In-Vision operating softwareplant overview screen.

The ability to meet critical deliverieswith top quality product has enabledRotork Gears to fend off fiercecompletion from Europeanmanufacturers and win sub-seagearbox orders for a large andprestigious hydrocarbondevelopment project in Asia.Rotork Gears has been selected byGerman valvemaker WernerBohmer to supply gearboxoperators for subsea ball valves.The first order for twelve SSW5/B4units has been supplied, with furthercontracts anticipated throughoutnext year.The SSW5/B4 gearboxes weresupplied with pressurecompensation, high visibilityindication, direct vertical mountedROV inputs and stainless steelhandwheels for emergencyoperation in the event of ROV failure.They are mounted on WernerBohmer forged Duplex (ASTM A182F51) fully welded ball valves(pictured right).

Rotork Gears wins sub-sea gearbox orders for Asian development projectThe ability to meet critical deliveries with top quality product has enabledRotork Gears to fend off fierce completion from European manufacturersand win sub-sea gearbox orders for a large and prestigious hydrocarbondevelopment project in Asia.

Rotork Gears manufactures a full rangeof gearboxes designed to withstand theharsh challenges of sub-sea operatingenvironments, that can be customisedwith a wide range of optional features tomeet the specific requirements of everyapplication. For further information contact RotorkGears on 0113 205 7276 or email [email protected]

actuator components of the systemto the Pakcan control loop. Theloop is operated by a Pakscan IIEmaster station, running In-Visionsoftware.

Left: SSW5/B4 sub-seagearboxes ready fordespatch from theRotork Gears factory

Rotorkin Control



Operation of the radial gates wasliterally beyond the limits for theactuators that have been replaced.Fitted with mechanical limitswitches, they could not cope withthe exceptionally long strokerequired to fully operate the gates.External limit switches weretherefore installed to operate directlyon the gate stems, but these hadproved to be less than 100%reliable and on occasions hadcaused damage to the installationby failing to stop the gates in time.IQ intelligent electric actuators havereplaced mechanical limit switcheswith a Hall Effect magnetic pulsesystem that accurately measuresand controls the stroke without therestrictions inherent in gears andswitches. The system converts theactuator’s output centre columnrotation into an electronic signalwhich is compared to position limitsprogrammed and stored within asecure, non-volatile memory,removing any chance of amechanical failure.Working for the UK EnvironmentAgency, Rotork has carried out allaspects of the actuatormodernisation project. Rotork’sspecialist Site Services Departmentdesigned and fabricated newadaptation and installed IQ40

New Rotork actuators go beyond the limitsof old to achieve reliable river gate operationRotork IQ intelligent electric valve actuators have beenretrofitted at an important UK river gate and weir toimprove river level control and secure more reliableautomatic operation.

intelligent actuators. Rotork projectsand services company Exeecocarried out the electrical installationincluding connection to a telemetrylink and associated panelmodifications. In this way, work onall four gates was completed in aperiod of only four weeks. As partof the customised installation, theactuators’ handwheels have beenremoved and replaced with specialadaptors for a hand-held hydraulicpower pack. In the event ofemergency operation during powerfailure this will enable the gates tobe moved as quickly as possible.The new actuators are controlledfrom a level sensor positioned ashort distance upstream of theinstallation. Signals from the levelsensor trigger sequential operationof the individual gates in order toachieve accurate river level controlunder all ambient conditions. Thecomputerised programme is linkedby telemetry into the EnvironmentAgency ARTS supervisory system,based at the main monitoring andcontrol room at Peterborough.Under normal circumstances,operation of Bedford Sluice is fullyautomatic, but the actuators areprogrammed to transmit an alarm inthe event of any malfunction, tofacilitate immediate remedial action.

Bedford Sluice on the River Nene at Northampton is the main controlstructure before the Northampton Washlands, an environmentally sensitiveamenity area supporting a wide range of outdoor sport and leisureactivities. The four radial gates on Bedford Sluice regulate the river flowthrough the City of Northampton to prevent flooding and maintain waterlevels for nearby facilities including the River Nene Navigation, the NeneWhitewater canoe course and a rowing club.

The patented IQ non-contacting position measuringsystem is the most simple yet devised for actuatorcontrol.With only one moving part, the resolver convertsoutput centre column rotation into an electronic signalwhich is then compared to position limits stored withina safe, non-volatile memory.

IQ position measurement

Russell Gillet, Operations Officer for the Environment Agency, inspects one of the newRotork IQ40 actuator installations on Bedford Sluice.


A total of 68 Skilmatic quarter-turnactuators have been supplied,providing two-position operationwith failsafe closed emergencybackup. The actuators operatefrom a 220V single phase electricalsupply with a separate 24Vd.c.emergency shutdown switch circuitand remote position indication. Onloss of power or signal the actuatorsmust shut the dampers within 30seconds. Using Skilmatic’s selfcontained electro-hydraulic designfor this purpose removes therequirement for additional failsafebattery packs for operation duringpower failure.

Skilmatic actuators survive fire test for roadtunnel contractSkilmatic failsafe electric actuators have been ordered for ventilation dampers in the famous SaintBernard road tunnel. Built in the 1950’s, the 5854 metre long tunnel, which connects Italy andSwitzerland, is being equipped with new Trox dampers during a ventilation and fire protectionupgrade programme.

Known as the SI range, the newSkilmatic actuators utilise the Rotorkintrinsically safe hand held settingtool to facilitate non-intrusivecommissioning and the setting ofcontrol and indication functions inany environment, day or night.The actuator’s easy to readilluminated LCD display providesvalve position, control and alarmicons as well as giving access tocomprehensive diagnosticinformation and help screens. Thedouble-sealed electrical controlmodule also enables connectivity tothe Rotork Pakscan two-wirecontrol system or Open fieldbusprotocols such as Profibus,Modbus, DeviceNet and FoundationFieldbus.These sophisticated control,indication and diagnostic benefitscompliment Skilmatic’s traditionaldesign strengths. The actuatorsoffer the simplicity and flexibility ofelectrical operation, combined withthe precision of hydraulic control.Built to IP68/NEMA6 watertightspecifications with the option ofATEX and FM explosionproofcertification, SI actuators are suitablefor single phase, three phase or24Vdc power supplies.For more information, visitrotork.com, view or downloadpublication E711E.

Skilmatic passes theRotork intelligence testSkilmatic electric modulating and failsafe actuators for quarter-turn and linear valves arenow available with innovative non-intrusive infra red technology and intelligence that hasbeen the cornerstone of the success of Rotork’s market leading IQ range.

Installed actuators are fitted withtemperature protection jackets toprovide additional security ofoperation in the event of a fire. Thecritical importance of this dutydictated that the actuator had tosuccessfully complete a stringent firetest before it could be specified for theapplication. The independent test,which was carried out by WarringtonFire Research, involved cycling anactuated damper every fifteen minutesfor over two hours in an ambienttemperature of 200°C (400°F). Afterthe test the fire jacket was removedand the actuator inspected to ensurethat it was still able to operate.

Installed actuators are fitted withtemperature protection jackets toprovide additional security ofoperation in the event of a fire. Thecritical importance of this dutydictated that the actuator had tosuccessfully complete a stringent firetest before it could be specified for theapplication. The independent test,which was carried out by WarringtonFire Research, involved cycling anactuated damper every fifteen minutesfor over two hours in an ambienttemperature of 200°C (400°F). Afterthe test the fire jacket was removedand the actuator inspected to ensurethat it was still able to operate.

ActuationNews




Syncrude operates the largest oilsands crude oil production facility inthe world at Alberta, producing 13%of Canada’s annual oil requirement.Rotork is closely involved in capitalinvestment projects which willincrease production by a further100,000 barrels a day.Illustrated here, a 72" Tricentric highperformance butterfly valve (HPBV)equipped with Rotork EH Rangeelectro-hydraulic actuator has beensupplied for modulating duty on anacid gas service line. Thevalve/actuator adaptation

ContractNews

Syncrude update

accommodates a steam line couplingthrough the valve stem and body tokeep the internals warm and inhibitthe precipitation of sulphur from theacid gas. Similar packages are alsobeing provided for 72" and 84"HPBVs, including the IQ electricallyactuated version shown below.

On another area of the contract, gearbox manufacturerMaxTorque pulled out all the stops to design andmanufacture these large, heavy duty gearboxes for four keyvalves in record time. The quarter-turn gearboxes neededto handle 120,000 ft/lbs of torque and operate in less than60 seconds at ambient temperatures of minus 50°C. In theevent, all four gearboxes were ready for delivery after onlysixteen weeks, including testing on MaxTorque’s brand new290,000 ft/lb test rig that confirmed the operating time at 44seconds.

"Bomb proof" Switchboxes andmounting kits for the Royal NavyATEX certified switchboxes and high integrity valve mounting kitsdesigned to withstand a direct missile strike are being supplied for theRoyal Navy in a £50,000 contract with Actuation Valve Control Ltd.The switchboxes will be used on the vital fire fighting systems on thenavy’s new Type 45 destroyers, being built at the BAE shipyard in

Scotstown. As pictured, the switchboxes are mounted onCamtorq actuators that will operate Starlinevalves on pipelines carrying specialised Inergin firefighting fluid at a pressure of 200 barg. Toachieve the contract criteria, switchboxes had tosurvive MOD "bomb proof" testing with forces of70G vertical and 30G horizontal, and still operate.

Previously Rotork Valvekits has supplied similarequipment to Actuation Valve Control for navalships including HMS Albion, HMS Wave Knightand HMS Wave Rider, but this is the first time thatthe equipment is to be used on front line theatreattack and intercept warships.

Short lead timeswin Middle EastordersA complete product solutionencompassing mounting kits,pedestals and gearboxes hasearned Rotork Valvekits a secondorder with Shipham Valves for amajor oil production project in theMiddle East.The ability to supply all theequipment for 137 valves on a shortlead time won the business forValvekits, together with the qualityand contract performance achievedduring the previous order.Design work began in August andthe first deliveries made inSeptember this year. "Success withthe first two stages of the projectshould enable Valvekits andShiphams to achieve more ordersfor the same site next year," saysValvekits MD Martin Hunt.

New Valvekitssales engineerfor Europe

Jos Bode has joined the ValvekitsEuropean sales team to coverGermany, Belgium and theNetherlands. Jos has twentyyears successful sales experiencewith European valvemakers,including HP Valves and WouterWitzel.

Valv

ekits


A valve that was installed in 1895has been retrofitted with Rotork IQactuators during an upgradeprogramme on a dam at Adelaide inSouth Australia. The 975mmdiameter double door stop valvewas installed on the pipeline fromthe Happy Valley dam, built in1890’s to provide the increasingpopulation of Adelaide with a reliablewater source.In 2003, the South Australian WaterCorporation – a long-standingcustomer of Rotork Australia –began a 20million dollarmodernisation project on the dam toaddress safety issues related toflooding and earthquakes, since alarge population now residesdownstream of the dam. SA Waterwished to use the old valve as ascour valve to draw down thereservoir level should floodingbecome imminent.Before the work could start, thevalve’s internal condition wasassessed by SA Water’s divingteam, who had to swim for over 30metres down the 915mm diameterpipeline in order to carry out theinspection. Once the valve’s

Spencer Jenner from RotorkMelbourne reports:

New actuators secure third century ofoperation for Australian water valve

Rotork IQ actuator installation in progresson the in-situ valve.

The fish ladder at Hagestein on theRiver Lek, a tributary of the Rhine, isone of an increasing number thathave been built to encourage thereturn of migrating fish to the mainrivers of the Netherlands. Thedramatic improvement in watercleanliness brought about by thecountry’s successful environmentalpolicies has enabled salmon toreturn to old spawning grounds,although their progress can behampered by man-made barragesand sluices.

A helping hand for migratingsalmon

Rijkswaterstaat, the responsibleauthority, is therefore buildingspecially designed fish passages, orladders, around the obstructions,controlled by adjacent sluice gatesthat regulate the river flow underchanging ambient conditions. Theuse of Rotork IQ electric actuatorsfacilitates automatic operation of thesluice gates in response to signalsfrom level sensors.

condition was confirmed as good,SA Water’s valve expert MichaelStasiuk designed new adaptation toenable two Rotork IQ actuators andgearboxes to be fitted to the valve,in-situ in the reservoir outlet tower,20 metres below water level.The completion of the retrofit worknow enables the valve to becontrolled remotely – securing itsusefulness into the third century ofoperation.

The Happy Valley doubledoor valve during itsoriginal installation

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.com

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