actuator guideline en r00 - ИНЖАВТОМАТИКАСЕРВИС · 2014-09-02 · 5 guidelines...

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1 GUIDELINES SAMSON ACTUATOR SIZING Created from V42 / Bam Nr. 006 Revision Nr. 00 Last update 2014-05-15 Table of Contents 1 Forces involved ..................................................................................................................................................... 2 2 Actuator Data ........................................................................................................................................................ 3 3 Valves for Flow-to-Open (FTO) Service .............................................................................................................. 4 3.1 Assumptions ................................................................................................................................................ 4 3.2 Actuator results ............................................................................................................................................ 4 3.3 Acceptance Criteria ..................................................................................................................................... 6 3.4 Troubleshooting ........................................................................................................................................... 6 4 Actuator Characteristic.......................................................................................................................................... 8 4.1 Spring and Ideal Actuator Characteristics ................................................................................................... 8 4.2 Real Actuator Characteristic ........................................................................................................................ 8 4.3 Effects on Actuator Sizing ........................................................................................................................... 9 5 Valves in Flow-to-Close (FTC) Service.............................................................................................................. 10 5.1 Assumptions .............................................................................................................................................. 10 5.2 Actuator Results ........................................................................................................................................ 11 5.3 Acceptance Criteria ................................................................................................................................... 12 5.4 Trouble Shooting ....................................................................................................................................... 12 5.5 Custom Spring Ranges .............................................................................................................................. 14 Figures Figure 1 - Pressure Balanced Plug w/o Bellows ................................................................................................ 2 Figure 2 - Standard Plug w/o Bellows ............................................................................................................... 2 Figure 3 - Actuator Fail-Safe Position ............................................................................................................... 3 Figure 4 - Free Body Diagramm FTO (F A,req-close ) ............................................................................................ 4 Figure 5 - Free Body Diagram FTO (F A,req-open ) ................................................................................................. 4 Figure 6 - Spring Characteristic (ATO) ............................................................................................................. 5 Figure 7 - Spring Characteristic (ATC) ............................................................................................................. 5 Figure 8 - Natural and Ideal Actuator Characteristics (ATC) ............................................................................ 8 Figure 9 - Real Force Measurements ................................................................................................................. 8 Figure 10 - Computational Fluid Dynamics Simulation (FTC) ......................................................................... 8 Figure 11 - Spring and Real Characteristics ...................................................................................................... 9 Figure 12 - Slope of Real Characteristics .......................................................................................................... 9 Figure 13 - Free Body Diagram FTC (F A,req-close ) ............................................................................................. 10 Figure 14 - Free Body Diagram FTC (F A,req-open ) ............................................................................................. 10 Tables Table 1 - Highest Span [bar] for Standard Spring Ranges ............................................................................... 13 Table 2 - 15mm Custom Spring Ranges with Increased Stiffness ................................................................... 14 Table 3 - 30mm Custom Spring Ranges with Increased Stiffness ................................................................... 15 Table 4 - 60mm Custom Spring Ranges with Increased Stiffness ................................................................... 16 Scope The goal of this guideline is to describe and guide engineers through the SAMSON’s pneumatic linear actuators sizing. After reading this guideline the engineers should understand which forces are included in the actuator sizing, the fundamentals of the values shown on the calculation sheet, how to interpret the calculated values, and how to select the proper actuator when using SAMSON Valve Sizing Program (SVS) Version 7.06e or later and SAMSON Valve Sizing Specialist (SVSS) Version 2.04 or later. The exact equations for each calculation, rotary actuator calculations, and linear actuator sizing for 3-way valves (see guideline 003) will not be found in this document.

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Page 1: Actuator Guideline EN R00 - ИНЖАВТОМАТИКАСЕРВИС · 2014-09-02 · 5 GUIDELINES SAMSON ACTUATOR SIZING Created from V42 / Bam Nr. 006 Revision Nr. 00 Last update

1

GUIDELINES SAMSON ACTUATOR SIZING

Created from V42 / Bam

Nr. 006 Revision Nr. 00 Last update 2014-05-15

Table of Contents 1 Forces involved ..................................................................................................................................................... 2

2 Actuator Data ........................................................................................................................................................ 3

3 Valves for Flow-to-Open (FTO) Service .............................................................................................................. 4

3.1 Assumptions ................................................................................................................................................ 4

3.2 Actuator results ............................................................................................................................................ 4 3.3 Acceptance Criteria ..................................................................................................................................... 6

3.4 Troubleshooting ........................................................................................................................................... 6

4 Actuator Characteristic.......................................................................................................................................... 8

4.1 Spring and Ideal Actuator Characteristics ................................................................................................... 8

4.2 Real Actuator Characteristic ........................................................................................................................ 8

4.3 Effects on Actuator Sizing ........................................................................................................................... 9

5 Valves in Flow-to-Close (FTC) Service .............................................................................................................. 10

5.1 Assumptions .............................................................................................................................................. 10 5.2 Actuator Results ........................................................................................................................................ 11

5.3 Acceptance Criteria ................................................................................................................................... 12

5.4 Trouble Shooting ....................................................................................................................................... 12

5.5 Custom Spring Ranges .............................................................................................................................. 14

Figures Figure 1 - Pressure Balanced Plug w/o Bellows ................................................................................................ 2

Figure 2 - Standard Plug w/o Bellows ............................................................................................................... 2

Figure 3 - Actuator Fail-Safe Position ............................................................................................................... 3

Figure 4 - Free Body Diagramm FTO (FA,req-close ) ............................................................................................ 4

Figure 5 - Free Body Diagram FTO (FA,req-open) ................................................................................................. 4

Figure 6 - Spring Characteristic (ATO) ............................................................................................................. 5

Figure 7 - Spring Characteristic (ATC) ............................................................................................................. 5

Figure 8 - Natural and Ideal Actuator Characteristics (ATC) ............................................................................ 8

Figure 9 - Real Force Measurements ................................................................................................................. 8

Figure 10 - Computational Fluid Dynamics Simulation (FTC) ......................................................................... 8 Figure 11 - Spring and Real Characteristics ...................................................................................................... 9

Figure 12 - Slope of Real Characteristics .......................................................................................................... 9

Figure 13 - Free Body Diagram FTC (FA,req-close) ............................................................................................. 10

Figure 14 - Free Body Diagram FTC (FA,req-open) ............................................................................................. 10

Tables Table 1 - Highest Span [bar] for Standard Spring Ranges ............................................................................... 13

Table 2 - 15mm Custom Spring Ranges with Increased Stiffness ................................................................... 14 Table 3 - 30mm Custom Spring Ranges with Increased Stiffness ................................................................... 15 Table 4 - 60mm Custom Spring Ranges with Increased Stiffness ................................................................... 16

Scope The goal of this guideline is to describe and guide engineers through the SAMSON’s pneumatic linear actuators sizing. After reading this guideline the engineers should understand which forces are included in the actuator sizing, the fundamentals of the values shown on the calculation sheet, how to interpret the calculated values, and how to select the proper actuator when using SAMSON Valve Sizing Program (SVS) Version 7.06e or later and SAMSON Valve Sizing Specialist (SVSS) Version 2.04 or later. The exact equations for each calculation, rotary actuator calculations, and linear actuator sizing for 3-way valves (see guideline 003) will not be found in this document.

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GUIDELINES SAMSON ACTUATOR SIZING

Created from V42 / Bam

Nr. 006 Revision Nr. 00 Last update 2014-05-15

1 Forces involved The Friction Force (FR1, FR2) is caused by the packing or the pressure balancing (when applicable) as the plug is moving or starts moving. This force always works in the opposite direction of motion and is calculated on the entire circumference of the stem for the packing. The pressure balancing calculation uses either the seat diameter (standard design) or the plug diameter (cage type designs). The Weight Force (FG), caused by the mass of all the moving parts, is calculated in both key directions parallel to the plug stem. The following parts are included in this calculation: plug head, plug stem, actuator stem, spring plate and all parts used to connect these parts to each other. The Closing Force (FS) is the amount force needed to ensure the leakage rate for the required leakage class. Each leakage class corresponds to a required N/mm factor. This factor and the circumference of the sealing surface are used to calculate the resulting closing force. The Flow Force (FF) is the static force produced from the pressure differential (∆p) seen by the plug head surface. For each spot along the travel range, the critical values are calculated and compared for each of the defined “worst case” scenarios. The Bellow Force (FB) is a combination of the bellows spring rate force and the bellows pressure force. The bellows spring rate force is calculated from the bellows zero point and acts with a direction and force that is dependent on the position of travel in relation to it’s zero point. The spring rate used is dependent on the size and pressure class of the bellows. The bellows pressure force is calculated from the area of the bellows perpendicular to the plug stem and the pressure difference between the design pressure of the valve (internal) and atmosphere (external). Both forces together make up the bellows force. Because the bellows pressure force is almost always greater than the bellows spring rate force, the bellows force direction of action is defined in the same direction as the bellows pressure force.

Figure 1 - Pressure Balanced Plug w/o Bellows

Figure 2 - Standard Plug w/o Bellows

FR

FS

FM

FF

FF

FG

FS

FR2

FR1

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GUIDELINES SAMSON ACTUATOR SIZING

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2 Actuator Data For each given actuator the amount of opening and closing force available is set with each bench range. It can only be changed by changing the spring range or actuator size. The Samson Valve Sizing Software allows you to choose these values yourself or they will be automatically entered by the program. After understanding these values this type of actuator will help the understanding on how it can be changed to fit the application. The pneumatic linear actuator is used to create the force needed by the valve, to ensure solid control throughout the entire range of operation. The factors that have influence on its operation and are to be determined through calculation, are described below.

- The diaphragm area (AM), often referred to as actuator size, is the area upon which the signal pressure coming from the positioner acts within the actuator to create the force needed to move the stem up and down. The force (F) created is calculated by multiplying the pressure (p) and the area (A) in which the pressure acts. (F=p*A) By increasing the diaphragm area the same amount of pressure can be used for greater forces.

- The bench range (pst,0…pst,100) shows the beginning and ending pressure for a rated travel. These are variable and are dependent on the type and number of springs used within the actuator in combination with the diaphragm size. The span between the values, as well as the values themselves, can be specifically chosen to meet the needs of the application.

- The supply pressure (psu) is the amount of pressure needed for the actuator to fulfill it’s duties. It is of great importance to the calculation and can be a limiting factor given by the customer. Unless otherwise required from the customer or calculation, the standard supply pressure is 0.2 bar (3psi) above the upper spring range value.

- The fail-safe action for each actuator is needed in the case of a loss of supply pressure. The two types of action discussed in this document are stem extends and stem retracts. o The function stem extends is referred to as Air To Open (ATO) , where the springs are in the upper

chamber and cause the stem to extend when air is not supplied. (Figure 3, right) o The function stem retracts is referred to as Air To Close (ATC), where the springs are located in the

lower chamber and force the stem to retract when air is not supplied. (Figure 3, left)

Figure 3 - Actuator Fail-Safe Position

ATC ATO

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GUIDELINES SAMSON ACTUATOR SIZING

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3 Valves for Flow-to-Open (FTO) Service In good actuator sizing four main points need to be handled properly to size a suitable actuator. The fundamental assumptions for calculation lay the scientific foundation for calculation, the mathematical calculations that provide the relationships between the parameters given, and the interpretation of the values and troubleshooting that follow will result in a proper sizing. These four points are described in this section for FTO applications when sized with the SAMSON Valve Sizing Program.

3.1 Assumptions

All assumptions pertain to opening or closing the valve throughout the entire travel range.

3.1.1 Closing the valve - Friction force acts against the direction of motion - Weight acts in both directions - Sealing force acts against the actuator force - Bellows force acts against the actuator force - When the diameter of the seat bore is greater than the diameter of the plug stem, p2 is used to calculate the

max. bellows force - When the diameter of the seat bore is less than the diameter of the plug

stem, p1 is used to calculate the max. bellows force. The maximum occurs when the valve is fully open.

- Flow force acts against the actuator force - When the diameter of the seat bore is less than the diameter of the plug

stem, the max. flow force is calculated with p1 and the stem diameter. - No flow forces in the direction of closing are considered - FA,req-close =FR+FG+FS+FB+FF

3.1.2 Opening the valve - Friction force acts against the direction of motion - Weight acts in both directions - Sealing force is not considered - Bellows force is not considered because it aids in opening the valve - Only flow forces in the direction of closing are considered - FA,req-open=FR+FG+|FF|

3.2 Actuator results

The req. act. force (Fa req.) is the summation of all forces needed to close the valve. No actuator values are used in this calculation. Changing the valve selection will change this value. No safety factor is calculated into this value. See figures 4 and 5. The actuator force (Fa) for the actuator entered in the actuator data section, displays the force exerted on the valve stem. Only changing the actuator selection will change this value. ATO: Diaphragm area and the lower value of

Figure 4 - Free Body Diagramm FTO (FA,req-close )

Figure 5 - Free Body Diagram FTO (FA,req-open)

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the bench range directly affect this calculation. ATC: Diaphragm area and the difference between the upper bench range value and the supply pressure affect this calculation. The close safety factor (Fa/Fa req.) is the safety factor between the specified actuator force (Fa) and the required closing actuator force (Fa req.) The open safety factor (Ff/Fw) is the safety factor between the specified actuator opening force and the required actuator opening force. The max. act. force (Fmax) represents the lower of two possible forces according to the valve selected in each calculation. The first is the stem force allowable (bending moment) for the stem length, thickness, and material. Customized stem

lengths require special consideration and should be checked separately. Increased length stems often have a much smaller allowable force. The standard lengths (std or extended) are included in the program. The second force checked is for soft sealing plugs and is calculated on the entire soft-sealing circumference. If soft sealing is specified, the lower (limiting) force is posted for Fmax. The max. dp on plug (d. pmax) is the combination of the closing safety factor (Fa/Fa req.) and the max. actuator force (Fmax). Max. dp on plug represents the highest ∆p allowable on the plug while still staying within the limits given for Fa/Fa req. and Fmax.

The req. start bench range (ps0 req) defines the minimum starting value for the actuator bench range based on the valve selected. Only changing the valve will have influence on this value. This value can be seen on Figure 6 and 7 above. ATO: The FA,req-close value is used to calculate this pressure. ATC: The FA,req-open is used to calculate this pressure The req. diff. psu-ps100 (dps) is the minimum difference between the upper bench range and the supply pressure. This value can be seen on Figure 6 and 7 above. ATO: The FA,req-open is used to calculate this pressure. ATC: The FA,req-close value is used to calculate this pressure. The hysteresis (Hyst.) is included in the actuator results tab in the valve sizing program, but is not printed on the calculation sheet. Because it is only a calculation of the valve/actuator combination, it should not be considered as the hysteresis for the entire control valve. This hysteresis value is dependent on the total friction force, the actuator stiffness, and the diaphragm size.

Figure 6 - Spring Characteristic (ATO)

Figure 7 - Spring Characteristic (ATC)

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3.3 Acceptance Criteria

No matter which actuator fail safe setting (ATO, ATC) is selected, the acceptance criteria are the same. If the following statements are true, the actuator is suited for the application

Close safety factor Fa/Fa req. ≥ 1.10 (1.30 recommended)

Open safety factor Ff/Fw ≥ 1.10 (1.50 recommended)

Max. actuator force Fmax > Actuator force - Fa

Hysteresis < 30%

3.4 Troubleshooting

3.4.1 ATO Actuators Fa/Fa req. < 1.1 – In this case the actuator force (Fa) is not high enough. To increase this force, first choose a spring range with a higher beginning range. Using the required start bench range (ps0req.) as a guide, will make the selection much easier. If no beginning range value is higher than ps0req., increase the diaphragm area or include a pressure balancing in the valve when possible. Ff/Fw < 1.1 – This occurs when the supply pressure entered is too low. Use the required differential psu-ps100 (dps) as a guide. Adding dps to the upper spring range value equates to the minimum supply pressure needed. If the minimum supply pressure is over 6 bar, a different spring range or a larger diaphragm is needed. In this service Ff/Fw is normally much greater than 1.1.

3.4.2 ATC Actuators Fa/Fa req. < 1.1 – In this case the actuator force (Fa) is not high enough. Increase the supply pressure using d ps as a guide. By adding at least dps onto the top of the upper bench range value you will come to the minimum supply pressure needed. If d ps is greater than 3 or the min. supply pressure needed is over 6 bar, increase the diaphragm area. Ff/Fw < 1.1 – This occurs when the lower spring range value entered is too low. Use the required start bench range (ps0req.) as a guide. If no spring ranges start higher than ps0req., increase the diaphragm area.

3.4.3 Independent of fail-safe action Fmax < Fa – This occurs for one of two different reasons. Either the stem material or the soft sealing is too weak to handle the actuator force.

- If soft sealing is not configured then Fmax represents the max force for the selected stem material and size. By changing/increasing either of the two, the Fmax value can be increased, otherwise decrease the actuator force (Fa). (ATO see section 3.4.1; ATC see section 3.4.2)

- If soft sealing exists it will be the limiting factor. In this case you can only decrease the force needed either by limiting the customers design pressure (shut-off pressure) or decreasing the actuator force. Use the value max dp on plug (d. pmax) as a guide to how far the customers design pressure needs to be reduced. If a decrease in actuator force results in one of the other two criteria to drop below acceptable levels, decreasing the customer’s design pressure is the only option. High closing pressures are often difficult, if not impossible, with soft sealing.

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Hysteresis > 30% – A hysteresis value this high, normally only occurs with pressure balancing plugs or some graphite packings. If the friction factors in the packing and pressure balancing cannot be decreased by changing its material, the diaphragm size or actuator stiffness must be increased. Decreases in diaphragm size or actuator stiffness will not help the hysteresis. To aid in sizing maximize the absolute value for the product of the diaphragm area and the spring range difference. Maximize → | Am*(pst,100 – pst,0) |

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4 Actuator Characteristic

4.1 Spring and Ideal Actuator Characteristics

All four combinations of fail-safe action and flow direction (FTC/FTO, ATO/ATC) result in a specific performance. The actuator pressure (signal pressure) vs travel graph of this performance is known as the actuator characteristic. When a valve has no ∆p across it, the pressure vs. travel graph is known as the spring characteristic. When a ∆p is seen by the valve, the actuator characteristic is shifted up or down depending on the direction of flow and the fail-safe direction of the actuator itself. Under the assumption that the ∆p seen by the plug remains the same throughout it’s travel, the plug would see a constant flow force, which would translate to a constant pressure shift. With this assumption an ideal actuator characteristic is formed (Figure 8).

4.2 Real Actuator Characteristic In an ideal actuator characteristic the force needed to control the valve remains constant throughout the entire travel range; however, this is not the case in a practical application. In reality as the plug retracts out of the seat, the ∆p seen by the plug will decrease. When the change in force throughout the entire travel of the valve is considered a real actuator characteristic is formed.

To effectively size an actuator, especially with FTC applications, the real actuator characteristic should be considered. In a real actuator characteristic all the changes in force that occur throughout the entire travel range are taken into consideration. The computational fluid dynamics (CFD) simulation in figure 10 shows that as the valve opens the back pressure on the lower side of the valve is increased. The reduction in ∆p shown in the CFD, would in theory, equate to a reduction of force needed to withstand the pressure drop. The practical testing proved these theories as seen in figure 9.

Figure 8 - Natural and Ideal Actuator Characteristics (ATC)

Figure 9 - Real Force Measurements

Figure 10 - Computational Fluid Dynamics Simulation (FTC)

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4.3 Effects on Actuator Sizing When these effects of the force changes are factored into a spring characteristic, a real actuator characteristic is created. In Figure 11 one spring characteristic and two differing real characteristics are shown for an FTC application. In both real actuator characteristics, a change in slope is apparent. The inflection point is very close to 70%. When a signal of approximately 0.6 bar is given to this actuator with the highest ∆p, it will have two possible corresponding stem positions; 65% and 75%. If this signal was given to the actuator, it would possibly begin to oscillate around the inflection point, and become very unstable. Through research and testing on this subject it was found that the slope of the real actuator characteristic can be used to ensure stable control. The slope may be positive or negative, depending on fail safe position, as long as it does not cross the slope limit. In other words, to ensure stable control, it is important that for each signal given to the actuator only one stem position is possible. This is done by increasing the actuator stiffness. The actuator stiffness is the absolute value of change in pressure over 100% of the rated travel. The actuator stiffness can be taken directly from the actuator spring range. For example in figure 11, a spring range of 3.5…2.2 bar has an actuator stiffness of 1.3 bar. The real actuator characteristic for two different ∆p are shown in the same figure. The higher ∆p has shifted even further from it’s spring characteristic. Figure 12 shows the slopes of the actuator characteristics shown in figure 11. Earlier the slope was identified as the limiting factor. Now figure 12 shows that the slope limit for the higher ∆p was broken and the lower ∆p is still acceptable.

Figure 11 - Spring and Real Characteristics

Figure 12 - Slope of Real Characteristics

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5 Valves in Flow-to-Close (FTC) Service In any good actuator sizing four main points need to be handled properly to size a suitable actuator. The fundamental assumptions for calculation lay the scientific foundation for calculation, the mathematical calculations that provide the relationships between the parameters given, and the interpretation of the values and troubleshooting that follow will result in a sound sizing. These four points are described in this section for FTO applications when sized with the SAMSON Valve Sizing Program.

5.1 Assumptions

All assumptions pertain to opening or closing the valve throughout the entire travel range.

5.1.1 Closing the valve - Friction force acts against the direction of motion. - Weight acts in both directions. - Sealing force acts against the actuator force. - Bellows area force (due to the lower bellows area) acts against the

actuator force. - The flow forces acting to open the valve are at their greatest when p1

equals p2. This can occur when the valve is in operation and completely open, or when the valve is completely closed. Both cases are considered.

- Flow forces acting in the closing direction are not considered for this calculation.

- FA,req-close =FR+FG+FS+FB+(p1-p0)APlug Stem

5.1.2 Opening the valve - Friction force acts against the direction of motion. - Weight acts in both directions. - Sealing force is not considered. - Bellows force is not considered because it aids in opening. - Flow forces act against the actuator. - Flow forces acting in the opening direction are not considered. - FA,req-open=FR+FG+|FF|

Figure 13 - Free Body Diagram FTC (FA,req-close)

Figure 14 - Free Body Diagram FTC (FA,req-open)

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5.2 Actuator Results

The req. act. force (Fa req.) is the summation of all forces needed to close the valve and sets a requirement for the actuator. Changing the valve selection will change this value. No safety factor is calculated into this value. The actuator force (Fa) for the actuator entered in the actuator data section, displays the force exerted on the valve stem. Only changing the actuator selection will change this value. ATO: Diaphragm area and the lower value of the bench range directly affect this calculation. ATC: Diaphragm area and the difference between the upper bench range value and the supply pressure, affect this calculation. The close safety factor (Fa/Fa req.) is the safety factor between the specified actuator force (Fa) and the required actuator force (Fa req.). The open safety factor (Ff/Fw) is the safety factor between the specified actuator opening force and the required actuator force. The max. act. force (Fmax) represents the lower of two possible forces according to the valve selected in each calculation. The first is the stem force allowable due to bending moment for the stem length, thickness, and material. Customized stem lengths require special consideration and should be checked separately. Increased length stems often have a much smaller allowable force. The standard lengths (std or extended) are included in the program. The second force checked is for soft sealing plugs and is calculated on the entire soft-sealing circumference. If soft sealing is specified, the lower (limiting) force is posted for Fmax. The max. dp on plug (d. pmax) is the combination of the closing safety factor (Fa/Fo req.), opening safety factor (Ff/Fw), the max. actuator force (Fmax), and the dynamic FTC flow force. Of the limits set for the actuator and valve selected, the corresponding ∆p on the plug is calculated. The minimum of these reverse calculated values is set as the limiting factor of max. dp on plug. For a further explanation of the dynamic FTC flow force, refer to the actuator characteristics section. The req. start bench range (ps0req) defines the minimum starting value for the actuator bench range based on the valve selected. Only changing the valve will have influence on this value. ATO: The FA,req-close value is used to calculate this pressure. ATC: The FA,req-open is used to calculate this pressure. The req. diff. psu-ps100 (dps) is the minimum difference between the upper bench range and the supply pressure. This value makes up for the actuator characteristic shift that occurs when a ∆p is applied to the valve. (see Sections 4.1 and 4.2) If this value is not kept the actuator will not open fully due to the lack of supply pressure. ATO: The FA,req-open is used to calculate this pressure. ATC: The FA,req-close value is used to calculate this pressure. The req. bench range (dpst100-0) is included only in FTC calculations. The minimum slope of the real actuator characteristic that still allows for stable control of the valve entered is used to calculate the minimum actuator stiffness for the given actuator size and valve travel. These requirements are explained in section 4 over actuator characteristics. The hysteresis (Hyst.) is included in the actuator results tab in the valve sizing program, but is not printed on the calculation sheet. This hysteresis value is dependent on the total friction force, the actuator stiffness, and the diaphragm size. Because it is only a calculation of the valve/actuator combination, it should not be considered as the hysteresis for the entire control valve.

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5.3 Acceptance Criteria

Close safety factor Fa/Fa req. ≥ 1.10 (1.30 recommended)

Open safety factor Ff/Fw ≥ 1.10 (1.50 recommended)

Max. actuator force Fmax > Actuator force - Fa

Max. ∆p on plug dp max ≥ Design Pressure P1 max

Hysteresis % < 30%

5.4 Trouble Shooting

5.4.1 Tips - Keep the seat bore of the valve to a minimum. - Larger diaphragm areas are not always better. - Use standard spring ranges when possible. The custom spring ranges should only be used when the

standard ranges are not enough. Refer to Table 1-4 - Use the guidance of dpst100-0, ps0req., and d ps simultaneously when searching for an actuator.

5.4.2 Independent of fail-safe action

5.4.2.1 If Fa/Fa req. < 1.1, Ff/Fw < 1.1, or dp max < P1 max; all three values need to be fit to a different actuator. - Read out the following three values for the calculated membrane area: dpst100-0, ps0req., and dps - For the same membrane size, find an actuator that has the following parameters.

o Actuator stiffness > dpst 100-0 o Beginning spring range value > ps0req. o Upper spring range value + dps < 6

- If the highest span is available in the standard spring ranges (Table 1) look through the standard spring ranges first. If not, look within the custom spring ranges in Tables 2-4.

- If the calculated size cannot meet these parameters, changing the diaphragm size is required. - If no spring ranges are found for the FTC application, an FTO application should be used.

5.4.2.2 If Fmax < Fa, either the stem material or the soft sealing is too weak to handle the actuator force. - If soft sealing is not configured then Fmax represents the max force for the selected stem material and

size. By changing/increasing either of the two, the Fmax value can be increased, otherwise decrease the actuator force (Fa). (ATO see see section 3.4.1; ATC see section 3.4.2)

- If soft sealing exists it will be the limiting factor. In this case decreasing the actuator force (Fa) needed either by putting a limit on the customers design pressure (shut-off pressure) or decreasing the actuator force. Use the value max dp on plug (d. pmax) as a guide to how far the customers design pressure needs to be reduced. If a decrease in actuator force results in one of the other two criteria to drop below acceptable levels, decreasing the customer’s design pressure is the only option. High closing pressures are often difficult or impossible with soft sealing.

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Because the actuator stiffness on many of the standard actuators is not large enough for FTC service, many special ranges have been developed in order to meet the demands of FTC service. Table 1 shows the maximum span(dpst100-0) for all standard spring ranges.

Table 1 - Highest Span [bar] for Standard Spring Ranges

Diaphragm Area

Travel

15 mm 30 mm 60 mm

120 cm² 2.4 - -

240 cm² 2.4 - -

350 cm² 2.4 - -

700 cm² 1.2 2.4 -

750 cm² 1.2 2.4 -

1000cm² 0.6 1.2 2.4

1400-60 cm² - 1 2

1400-120 cm² - 0.6 1.2

2800 cm² - 0.6 1.2

5600 cm² - 0.6 1.2

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5.5 Custom Spring Ranges The following tables are the possible spring ranges to use when increased stiffness is required. Because these spring ranges are all new many have yet to be assigned variant ID numbers (VID). VIDs are not needed for offers. When orders come in VIDs will be assigned.

Table 2 - 15mm Custom Spring Ranges with Increased Stiffness

Bench Range Force Example

VID Diaphragm Area Span Start Finish Start [N] Finish [N]

750 cm² 2,4 bar 1,2... 3,6 bar 9000... 27000 N 4208444 1000 cm² 1,5 bar 0,2... 1,7 bar 2000... 17000 N 3717861 1000 cm² 1,5 bar 0,6... 2,1 bar 6000... 21000 N 1000 cm² 1,5 bar 1,0... 2,5 bar 10000... 25000 N 1000 cm² 1,5 bar 1,3... 2,8 bar 13000... 28000 N 4228338 1000 cm² 1,5 bar 1,7... 3,2 bar 17000... 32000 N 4116371 1000 cm² 1,5 bar 2,5... 4,0 bar 25000... 40000 N 1000 cm² 1,0 bar 0,2... 1,2 bar 1500... 11500 N 1000 cm² 1,0 bar 0,7... 1,7 bar 7000... 17000 N 1000 cm² 1,0 bar 1,2... 2,2 bar 11500... 21500 N 1000 cm² 1,0 bar 1,7... 2,7 bar 17000... 27000 N

1400 -120 cm² 1,6 bar 0,8... 2,4 bar 11200... 33600 N 4049780 1400 -120 cm² 1,6 bar 1,3... 2,9 bar 18200... 40600 N 1400 -120 cm² 1,6 bar 1,7... 3,3 bar 23800... 46200 N 4193782 1400 -120 cm² 1,6 bar 2,4... 4,0 bar 33600... 56000 N 4158267 1400 -120 cm² 1,2 bar 0,8... 2,0 bar 11200... 28000 N 1400 -120 cm² 1,2 bar 1,2... 2,4 bar 16800... 33600 N 1400 -120 cm² 1,2 bar 1,6... 2,8 bar 22400... 39200 N 4210827 1400 -120 cm² 1,2 bar 2,0... 3,2 bar 28000... 44800 N 4193871 1400 -120 cm² 0,8 bar 0,4... 1,2 bar 5600... 16800 N 1400 -120 cm² 0,8 bar 0,8... 1,6 bar 11200... 22400 N 1400 -120 cm² 0,8 bar 1,2... 2,0 bar 16800... 28000 N

2800 cm² 0,8 bar 1,6... 2,4 bar 44800... 67200 N 2800 cm² 0,8 bar 2,0... 2,8 bar 56000... 78400 N 2800 cm² 0,8 bar 2,4... 3,2 bar 67200... 89600 N 5600 cm² 0,8 bar 1,6... 2,4 bar 89600... 134400 N 5600 cm² 0,8 bar 2,0... 2,8 bar 112000... 156800 N 5600 cm² 0,8 bar 2,4... 3,2 bar 134400... 179200 N

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Table 3 - 30mm Custom Spring Ranges with Increased Stiffness

Bench Range Force Example VID Diaphragm Area Span Start Finish Start [N] Finish [N]

1000 cm² 3,0 bar 0,2... 3,2 bar 2000... 32000 N 3673932 1000 cm² 3,0 bar 0,5... 3,5 bar 5000... 35000 N 4210854 1000 cm² 3,0 bar 1,0... 4,0 bar 10000... 40000 N 4225390 1000 cm² 2,0 bar 0,2... 2,2 bar 2000... 22000 N 1000 cm² 2,0 bar 0,7... 2,7 bar 7000... 27000 N

1400 -120 cm² 3,2 bar 0,8... 4,0 bar 11200... 56000 N 4210808 1400 -120 cm² 3,0 bar 2,0... 5,0 bar 28000... 70000 N 1400 -120 cm² 2,4 bar 0,8... 3,2 bar 11200... 44800 N 1400 -120 cm² 2,4 bar 1,2... 3,6 bar 16800... 50400 N 1400 -120 cm² 2,4 bar 1,6... 4,0 bar 22400... 56000 N 1400 -120 cm² 2,4 bar 3,2... 5,6 bar 44800... 78400 N 1400 -120 cm² 2,2 bar 0,5... 2,7 bar 7000... 37800 N 4087845 1400 -120 cm² 1,6 bar 0,4... 2,0 bar 5600... 28000 N 1400 -120 cm² 1,2 bar 0,4... 1,6 bar 5600... 22400 N 1400 -120 cm² 1,2 bar 1,6... 2,8 bar 22400... 39200 N

2800 cm² 1,6 bar 1,6... 3,2 bar 44800... 89600 N 2800 cm² 1,6 bar 2,0... 3,6 bar 56000... 100800 N 2800 cm² 1,6 bar 2,4... 4,0 bar 67200... 112000 N 2800 cm² 1,6 bar 2,8... 4,4 bar 78400... 123200 N 2800 cm² 1,6 bar 3,2... 4,8 bar 89600... 134400 N 2800 cm² 0,8 bar 0,8... 1,6 bar 22400... 44800 N 2800 cm² 0,8 bar 1,2... 2,0 bar 33600... 56000 N 2800 cm² 0,8 bar 1,6... 2,4 bar 44800... 67200 N 5600 cm² 1,6 bar 1,6... 3,2 bar 89600... 179200 N 5600 cm² 1,6 bar 2,0... 3,6 bar 112000... 201600 N 5600 cm² 1,6 bar 2,4... 4,0 bar 134400... 224000 N 5600 cm² 1,6 bar 2,8... 4,4 bar 156800... 246400 N 5600 cm² 1,6 bar 3,2... 4,8 bar 179200... 268800 N 5600 cm² 0,8 bar 0,8... 1,6 bar 44800... 89600 N 5600 cm² 0,8 bar 1,2... 2,0 bar 67200... 112000 N 5600 cm² 0,8 bar 1,6... 2,4 bar 89600... 134400 N

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Table 4 - 60mm Custom Spring Ranges with Increased Stiffness

Bench Range Force Example

VID Diaphragm Area Span Start Finish Start [N] Finish [N]

2800 cm² 3,2 bar 1,6... 4,8 bar 44800... 134400 N 2800 cm² 1,6 bar 0,8... 2,4 bar 22400... 67200 N 4339037 5600 cm² 3,2 bar 1,6... 4,8 bar 89600... 268800 N 5600 cm² 1,6 bar 0,8... 2,4 bar 44800... 134400 N 4318729