SPECIAL TOPIC : Actuation & Automation
Reinventing Failsafe Electric Actuator Technology Utilizing Pneumatic Actuators
The valve automation industry continues to expand throughout all manufacturing and processing sectors . There is a growing demand for innovative technologies to increase safety , production efficiencies , and reduce loss of material ; be it a gas , liquid , pellet , or slurry . Successful companies , regardless of size , that focus on safely driven or failsafe technologies , continue to benefit in many ways . This includes increased employee safety , reduced loss of expensive or hazardous materials , better relationships with surrounding communities , and healthier dialogue with environmental activist groups .
By Bob Connal , Founder and IP Developer - Hybrid Automation Inc . & Tim Chicoine , Director of Sales - WedgeRock Engineered Solutions
The growing demand for true , spring return failsafe electric actuation will become a high-growth business sector . Figure 1 provides an overview of the entire valve automation sector , worldwide . It is difficult to estimate the percent growth of failsafe actuation , but it will happen . As one can see from recent research and market reports , the actuation industry is forecasted to grow by a compounded annual growth of 13.9 % through 2027 . 1
Since the advent of electric and pneumatic valve automation , there has been a ‘ firewall ’ between the two operating systems . This holds true for fail-in-place and failsafe applications .
Actuator Types
Contingent upon the availability of compressed air , pneumatic actuators have been the default product of choice for valve automation , especially in fail-safe applications . In remote areas with no access to compressed air , various forms of electric actuation , including fail-safe electric actuators are viable options due to either access to grid power or the increasing availability and applicability of solar power . Both operating systems , pneumatic and electric , have positive and negative attributes , depending upon the application .
New technology has been developed which combines the functionality of pneumatic and electric actuators into a single operating platform . The new technology capitalizes on reliable spring return pneumatic control with the flexibility of electrically operated actuation . The result is a true mechanical spring , a failsafe electric operating platform . This patented technology provides a standalone system that can plug into a wall outlet ( or other operating voltage ) without a connection to remote energy and maintenance-intensive compressors , which often require long runs of tubing .
Figure 1 : Compound Annual Growth Forecast of the Actuator Industry . 1
By competing directly with all failsafe electric actuators , operators can promote faster cycle speeds , reliability of pneumatic actuators , and a zero-ventto-atmosphere operating system . Pneumatic actuation provides a low cost of initial ownership as it combines proven reliability , capable of hundreds of thousands of cycles . Pneumatics are well suited for harsh environments including high vibration and temperature , as depending upon the operating system design , electric actuators may have issues .
Over the life of a pneumatic actuator , the cost of running large , energy-intensive compressors combined with ongoing maintenance to mitigate air leaks and provide clean , dry air are frequently overlooked in lifetime actuator costs .
Methane Mitigation in the Oil & Gas Industry
With the recent focus on achieving ESG goals , along with pressure from the EPA for methane mitigation at new , reconstructed , or modified facilities , oil & gas producers are actively looking for alternate solutions to natural gas-driven pneumatic controllers .
Figure 2 : Hybrid Automation System installed on a Pneumatic operated valve . 2
16 Valve World Americas | September 2023 • www . valve-world-americas . net