Introduction to Valves - Actuators

Introduction to Valve Actuators

Valve actuators are selected based upon a number of factors including torque necessary to
operate the valve and the need for automatic actuation. Types of actuators include manual
handwheel, manual lever, electrical motor, pneumatic, solenoid, hydraulic piston, and
self-actuated. All actuators except manual handwheel and lever are adaptable to
automatic actuation.

Manual, Fixed, and Hammer Actuators

Manual actuators are capable of placing the valve in any position but do not permit
automatic operation. The most common type mechanical actuator is the handwheel. This
type includes handwheels fixed to the stem, hammer handwheels, and handwheels
connected to the stem through gears.

Handwheels Fixed to Stem

As illustrated in the image on the right handwheels fixed to the stem provide only the
mechanical advantage of the wheel. When these valves are exposed to high operating
temperatures, valve binding makes operation difficult.

Hammer Handwheel
As illustrated in the image, the hammer handwheel moves freely through a portion of its
turn and then hits against a lug on a secondary wheel. The secondary wheel is attached to
the valve stem. With this arrangement, the valve can be pounded shut for tight closure or
pounded open if it is stuck shut.

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Manually-Operated Gearbox

If additional mechanical advantage is necessary for a manually-operated valve, the valve

bonnet is fitted with manually-operated gear heads as illustrated in the image. A special
wrench or handwheel attached to the pinion shaft permits one individual to operate the
valve when two individuals might be needed without the gear advantage. Because several
turns of the pinion are necessary to produce one turn of the valve stem, the operating time
of large valves is exceptionally long. The use of portable air motors connected to the
pinion shaft decreases the valve operating time.

Manually-Operated Gearbox
If additional mechanical advantage is necessary for a manually-operated valve, the valve
bonnet is fitted with manually-operated gear heads as illustrated in the image. A special
wrench or handwheel attached to the pinion shaft permits one individual to operate the
valve when two individuals might be needed without the gear advantage. Because several
turns of the pinion are necessary to produce one turn of the valve stem, the operating time
of large valves is exceptionally long. The use of portable air motors connected to the
pinion shaft decreases the valve operating time.

Electric Motor Actuators

Electric motors permit manual, semi-automatic, and automatic operation of the valve.
Motors are used mostly for open-close functions, although they are adaptable to
positioning the valve to any point opening as illustrated in the image below. The motor is

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usually a, reversible, high speed type connected through a gear train to reduce the motor
speed and thereby increase the torque at the stem. Direction of motor rotation determines
direction of disk motion.
The electrical actuation can be semi-automatic, as when the motor is started by a control
system. A handwheel, which can be engaged to the gear train, provides for manual
operating of the valve. Limit switches are normally provided to stop the motor
automatically at full open and full closed valve positions. Limit switches are operated
either physically by position of the valve or torsionally by torque of the motor.

Pneumatic Actuators
Pneumatic actuators as illustrated in the image below provide for automatic or
semiautomatic valve operation. These actuators translate an air signal into valve stem
motion by air pressure acting on a diaphragm or piston connected to the stem. Pneumatic
actuators are used in throttle valves for open-close positioning where fast action is
required. When air pressure closes the valve and spring action opens the valve, the
actuator is termed directacting. When air pressure opens the valve and spring action
closes the valve, the actuator is termed reverseacting. Duplex actuators have air supplied
to both sides of the diaphragm. The differential pressure across the diaphragm positions
the valve stem. Automatic operation is provided when the air signals are automatically
controlled by circuitry. Semi-automatic operation is provided by manual switches in the
circuitry to the air control valves.

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Hydraulic Actuators
Hydraulic actuators provide for semi-automatic or automatic positioning of the valve,
similar to the pneumatic actuators. These actuators use a piston to convert a signal
pressure into valve stem motion. Hydraulic fluidis fed to either side of the piston while
the other side is drained or bled. Water or oil is used as the hydraulic fluid. Solenoid
valves are typically used for automatic control of the hydraulic fluid to direct either
opening or closing of the valve. Manual valves can also be used for controlling the
hydraulic fluid; thus providing semi-automatic operation.

Self-Actuated Valves
Self-actuated valves use the system fluid to position the valve. Relief valves, safety
valves, check valves, and steam traps are examples of self-actuated valves. All of these
valves use some characteristic of the system fluid to actuate the valve. No source of
power outside the system fluid energy is necessary for operation of these valves.

Solenoid Actuated Valves

Solenoid actuated valves provide for automatic open-close valve positioning as illustrated
in the image below. Most solenoid actuated valves also have a manual override that
permits manual positioning of the valve for as long as the override is manually
positioned. Solenoids position the valve by attracting a magnetic slug attached to the
valve stem. In single solenoid valves, spring pressure acts against the motion of the slug
when power is applied to the solenoid. These valves can be arranged such that power to
the solenoid either opens or closes the valve. When power to the solenoid is removed, the
spring returns the valve to the opposite position. Two solenoids can be used to provide for
both opening and closing by applying power to the appropriate solenoid.

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Single solenoid valves are termed fail open or fail closed depending on the position of
the valve with the solenoid de-energized. Fail open solenoid valves are opened by spring
pressure and closed by energizing the solenoid. Fail closed solenoid valves are closed by
spring pressure and opened by energizing the solenoid. Double solenoid valves typically
fail "as is." That is, the valve position does not change when both solenoids are de-
energized.
One application of solenoid valves is in air systems such as those used to supply air to
pneumatic valve actuators. The solenoid valves are used to control the air supply to the
pneumatic actuator and thus the position of the pneumatic actuated valve.

Speed of Power Actuators

Plant safety considerations dictate valve speeds for certain safety-related valves. Where a
system must be very quickly isolated or opened, very fast valve actuation is required.
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Where the opening of a valve results in injection of relatively cold water to a hot system,
slower opening is necessary to minimize thermal shock. Engineering design selects the
actuator for safetyrelated valves based upon speed and power requirements and
availability of energy to the actuator.

In general, fastest actuation is provided by hydraulic, pneumatic, and solenoid actuators.

However, solenoids are not practical for large valves because their size and power
requirements would be excessive. Also, hydraulic and pneumatic actuators require a
system for providing hydraulic or pneumatic energy. The speed of actuation in either case
can be set by installing appropriately sized orifices in the hydraulic or pneumatic lines. In
certain cases, the valve is closed by spring pressure, which is opposed by hydraulic or
pneumatic pressure to keep the valve open.

Electrical motors provide relatively fast actuation. Actual valve speed is set by the
combination of motor speed and gear ratio. This combination can be selected to provide
full valve travel within a range from about two seconds to several seconds.

Valve Position Indication

Operators require indication of the position of certain valves to permit knowledgeable
operation of the plant. For such valves, remote valve position indication is provided in the
form of position lights that indicate if valves are open or closed. Remote valve position
indication circuits use a position detector that senses stem and disk position or actuator
position. One type of position detector is the mechanical limit switch, which is physically
operated by valve movement.

Another type is magnetic switches or transformers that sense movement of their magnetic
cores, which are physically operated by valve movement.

Local valve position indication refers to some visually discernable characteristic of the
valve that indicates valve position. Rising stem valve position is indicated by the stem
position. Nonrising stem valves sometimes have small mechanical pointers that are
operated by the valve actuator simultaneously with valve operation. Power actuated
valves typically have a mechanical pointer that provides local valve position indication.
On the other hand, some valves do not have any feature for position indication.

Valve Actuators Summary

 Manual actuators are the most common type of valve actuators. Manual actuators
include handwheels attached to the valve stem directly and handwheels attached
through gears to provide a mechanical advantage.
 Electric motor actuators consist of reversible electric motors connected to the
valve stem through a gear train that reduces rotational speed and increases torque.

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  Pneumatic actuators use air pressure on either one or both sides of a diaphragm to
provide the force to position the valve.
 Hydraulic actuators use a pressurized liquid on one or both sides of a piston to
provide the force required to position the valve.
 Solenoid actuators have a magnetic slug attached to the valve stem. The force to
position the valve comes from the magnetic attraction between the slug on the
valve stem and the coil of the electromagnet in the valve actuator.

References: DOE-HDBK-1018/2

On the websites of AUMA and Rotork you will find the most diverse types of gearboxes
and actuators.

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