Linear Piston Actuators: by Sekhar Samy, CCI, and Dave Stemler, CCI
Linear Piston Actuators: by Sekhar Samy, CCI, and Dave Stemler, CCI
Linear Piston Actuators: by Sekhar Samy, CCI, and Dave Stemler, CCI
Actuators
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n Stroke Speeds
∆X =
Fstatic - Fdynamic
Ksystem
(1)
∆Cv =
( ooCv )
x
∆X (3)
Fdynamic = Summation of dynamic friction forces, such as, packing, In Appendix B, we have presented a calculation showing how to
seals and piston rings perform resolution calculations in a typical feedwater regulator
application. Poor control, high vibration and pressure swings are
Ksystem = Summation of pneumatic and mechanical stiffness at the
endemic of this application. In this application, high rangeability and
valve travel of interest
fine resolution are required to maximize control. Long stroke lengths
For a valve stroke with total stroke “H”, in terms of percentage and a stiff actuator is the key to performance enhancements. The
resolution equation may be rewritten as follows: authors use such calculations to diagnose control problems in actual
plant applications.
Fstatic - Fdynamic 1
∆X = 100%
H The pneumatic stiffness of a typical double-acting piston actuator
Ksystem
(2)
easily allows positioning accuracy’s of 0.5% where required; in
comparison, positioning accuracy’s of a diaphragm actuator ranges
from 2% to 5%.
It is clear from equation that larger the “stiffness” of the actuator,
smaller its resolution. With smaller resolution better process control is Controllability under Transient Conditions
possible. Similarly, longer the stroke smaller the resolution.
Operability under transient conditions, whether they are fluid
Appendix A, derives the expression for the stiffness of a pneumatic flow related buffeting forces or a system related pressure transient
spring diaphragm actuator and a piston actuator. phenomenon - a piston actuator would be better able to resist such
forces due to its inherent high stiffness. If one could estimate the
For a spring diaphragm actuator it is magnitude and waveform of the transient pressures, it is possible to
study its effect on the controllability of the valve.
Kd = γ A PL
+Kspring
LL Environmental Qualification
(14)
Environmentally qualified actuators must withstand high ambient
temperatures, radiation, high mechanical stresses due to vibration or
And the lowest stiffness at a given supply pressure occurs when LL = fast actuation, seismic loads and finally any Design Basis Events.
H. For a double acting piston actuator the stiffness is
Piston actuators feature a high thrust to weight ratio because they
can operate at higher supply pressures. This also helps to keep the
PU PL + Kspring
Kp = γ A design compact without much overhanging mass, which will reduce
LU + LL
(15) the natural frequency of the actuator-yoke system. Higher natural
frequency system is desired when the valve is designed to withstand
seismic loads.
The lowest stiffness generally occurs when LU = LL. Refer, to the
The only elastomers in a piston actuator are o-rings, which are robust
Appendix A for the nomenclature and figures. The piston actuator is
because the stresses on the o-rings are quite low. Diaphragm actuators
definitely stiffer when compared to a equivalent spring diaphragm
with fabric reinforced diaphragms are under higher stresses and
actuator.
typically fail at the bolt holes due to high stress concentrations.
These gate valves retrofitted with the system media operated actuators
now offer the most reliable solution. They use piston actuators except
the power source is the system media itself. They provide such a large
Figure 1: Ramp Velocity Profile thrust margin that all concerns for accurately estimating wedging and
un-wedging forces under a variety of scenarios become unnecessary.
The velocity profile of a actuator is shown in figure 1. The system
ramps up to a final velocity then travel at the constant final velocity
REFERENCES
and ramps down as the actuator reaches its final position. A first order
system reaches 99.8% of its final value in six Time Periods. So the 1) Borden G., Friedmann P. Editors, 1998, “Control Valves
ideal time required to reach the final velocity desired should about 6 – Practical Guide of Measurement and Control”, Instrument Society
times the Time Period of system, i.e., Tr > 6Ts of America, Research Triangle Park, North Carolina, USA
Actuators with lower stiffness and equipped with volume boosters 2) Ludema K., 1996, “Friction, Wear, Lubrication – A Textbook in
for fast stroke speeds are prone to oscillatory problems. Any attempts Tribology” CRC Press, Boca Raton, FL, USA
to speed up a system makes the system Time Period impede the
ATTRIBUTE PNEUMATIC PISTON SPRING DIAPHRAGM ELECTRIC MOV ELECTRO- SYSTEM MEDIA
HYDRAULIC OPERATED
Economy for built in Thrust Medium Low High High Very High
Output Margin
Overall Dimensional Medium Large Compact Large Compact
Envelope
Stiffness Medium to High Low to Medium Very High High to Very High Very High
Fail Safe Spring or Volume Spring supplemented by Standby Power Accumulator As available system
Tank Volume Tank if necessary Source required media
Stroking Speed Fast with Fast with accessories Slow Very Fast Very Fast
accessories
Purchase Cost Low to Moderate Low High Very High Very High
In a double acting actuator both sides of the piston are filled with
air. In a diaphragm actuator one side is filled with air and the spring
V2 = V1 - Ax
(7) side is connected to the atmosphere. Notice the large volume of air
that would be trapped in the bottom of the spring diaphragm actuator
even when the valve is closed. In a piston actuator this volume is
minimized to a small value. When this fact is applied to equation it
Substituting (6) and (7) into (8) and re-arranging: is clear that smaller the volume, higher the stiffness. This makes the
spring diaphragm operator to have a lower stiffness when compared
to a piston actuator. Further, this has one other important consequence
when throttling at low plug lifts. Commonly, known as the “Bath
P1V1 γ = ( P1+
kx
A
)
(V1 - Ax)γ
(8)
Stopper Effect”, spring diaphragm operators with flow over the plug
and throttling at low lifts can slam into the seat causing severe water
( ) ( )
γ
kx Ax hammer. So most of the time they are specified as flow under the
P1V1 γ = P1+ V1γ 1−
A V1 plug. This problem does not occur with well designed piston actuators
which can have stiffness approaching very large values and can be
used in flow over the plug applications.
VU
LU = Comparing equations and it can be seen a piston actuator that
A (12)
operates at a higher supply pressure would be much stiffer when
compared to a diaphragm actuator.
VL
LL =
A (13)
PL
Kd= γA + Kspring (14)
LL
1003