Shafer™ ECAT Emissions Controlled Actuator TechnologyA unique, eco-friendly, valve operating system for natural gas pipelines

Zero Emissions Valve Actuation for Natural Gas Pipelines

The oil & gas industry has come under intense pressure to reduce methane emissions

Gas transmission companies now have a proven valve operating system featuring the Shafer rotary vane gas-over-oil actuator to help tackle the challenge of reducing methane emissions. This gas-over-oil actuator was specifically designed for pipeline applications where rugged, dependable equipment is vital.

For 70 years, Shafer actuators with their control components have been used in over 100,000 field proven pipeline applications. The new Shafer Emissions Controlled Actuation Technology (ECAT) encompasses the functional characteristics of the rotary vane in a novel design eliminating emissions typically associated with gas-over-oil systems.

What if your actuation system had the capability to use high pressure pipeline gas to power the actuator and then re-inject the power gas back into the pipeline to eliminate emissions?

Shafer ECAT is a field proven and highly reliable ‘Gas-Under-Oil’ valve operating system with no associated gas emissions

Emerson’s Actuation Technologies developed an alternative to gas-over-oil powered actuators for environmentally sensitive applications.

Like conventional gas-over-oil technology, gas from the pipeline is used as the power source for the actuator, the new Shafer ECAT will not exhaust gas into the atmosphere at the end of the actuator’s stroke.

The ECAT encompasses the time tested performance of the Shafer gas-over-oil actuator in a closed loop system with the benefit of no associated emissions.

Emerson provides our customers the most innovative actuation technologies with unprecedented performance needed for needed to today’s industrial demanding environments. The Shafer ECAT valve operating system is unlike any other gas-over-oil or direct gas actuator on the market.

Actuation • Control Valves • Isolation Valves Regulators & Relief Valves • Valve Instrumentation & Accessories

Actuator and Control

Components

Pump and Motor with Reservoir

Rotary Vane Actuator

ECAT Gas Re-injection System

Unique ‘Gas-Under-Oil’ Re-injection AccumulatorThe innovative accumulator design enables pipeline gas to pressurize hydraulic fluid which powers the actuator. The orientation of the accumulator, known as gas-under-oil, facilitates the gas re-injection process and allowing liquids to naturally gravitate back into the pipeline.

Versatile Re-Injection Power PackThe power pack supports utility electrical power or solar power for remote applications.

Fail-Safe Reserve PowerIn the event of an electrical power failure, the accumulator will maintain reserve hydraulic power for a specified number of valve strokes.

Manual Hydraulic Hand PumpFor commissioning or emergency operation, a hydraulic hand pump may be used to directly stroke the actuator or to re-charge the accumulator.

“Shafer ECAT is a valve operating system for critical pipeline applications where dependability of the equipment is essential. The system applies progressive technology to prevent emissions but also uses our proven technology and controls that we have relied on for years, to stroke valves under the most demanding conditions. It is an excellent solution for environmentally sensitive applications.”– Mike McQuade, Senior Product Manager Emerson Automation Solutions, Actuation Technologies

Easy System Readiness MonitoringGas control room can easily verify that the actuator is in the “ready to stroke” state with simple limit switch feedback.

Sequence 1: The actuator is fully charged in the ready-to-close position

In the first sequence, the actuator is in the open position awaiting a demand to close signal. The valve may be operated locally, remotely or automatically by a variety of sensory and control devices. Until a demand signal is received, the piston accumulator remains in the fully charged state at the same pressure as the pipeline.

In the second sequence, the actuator has received a demand to close signal and the actuator control system opens the flow paths to the rotary vane. The pressurized gas in the accumulator forces hydraulic fluid into the actuators closing port and powers the actuator in the clockwise direction. At the same time, non-pressurized fluid from the actuator’s opening port returns to the reservoir. Finally, the actuator has reached the fully closed position.

Principle of OperationThe Shafer rotary vane actuator and field proven control components are used to provide torque output and the required valve control function. Refer to the Shafer RV-Series brochure (DOC.6P.SRV.UK REV C 04-12) for additional information.

Sequence 2: The actuator is midway through the closing stroke and then fully closed

Actuator Fully Open

Reservoir

Gas-Under-Oil Accumulator

Pipeline Gas

Pipeline Gas Pipeline Gas

Piston

Electric Motor

Pump

Control

Control Control

Actuator Mid Stroke

Actuator Fully Closed

Reservoir Reservoir

Gas-Under-Oil Accumulator

Gas-Under-Oil Accumulator

Piston

Piston

Electric Motor Electric Motor

Pump Pump

3

The Shafer ECAT system utilizes a compact electro-hydraulic motor and pump as the energy source to re-inject power gas back into the pipeline. Following valve operation, the motor/pump will automatically start, forcing hydraulic fluid back into the accumulator. As the accumulator fills with fluid, the power gas is re-injected back into the pipeline. The motor only runs for a short time during the gas re-injection process. Once the gas re-injection process is complete, the motor automatically stops and the system remains in a fully charged “ready to stroke” state awaiting a command to open the valve. When an open command is received, the control directs the flow paths to rotate the actuator in the counter-clockwise direction and the gas re-injection process repeats.

Sequence 3: With closing stroke completed, the actuator begins the gas re-injection process

27

42 43

41

40

31

GAS PIPELINE

39

23

38

22

21

3029

34

M

18

24

25

26

32

28

20

33

35

19

36

44

45

POWER OIL

RETURN OIL

2

CLOSE

1 11

4

1514

12

10

9 87

65

16

P

PC

C

CLOSE

OPEN 13

3

17

37

PNEUMATICMANIFOLD

46

47

Actuator and Control Components

Gas Pipeline

ECAT Gas Re-injection System

Pipeline Gas Pipeline Gas

ControlControl

Actuator Fully Closed

Actuator Fully Closed

Reservoir Reservoir

Gas-Under-Oil Accumulator Gas-Under-Oil

Accumulator

Piston

Piston

Electric Motor Electric Motor

Pump Pump

The shaded area of the schematic illustrates the standard Shafer rotary vane actuator and control system. The ECAT portion of the overall system has been adjoined on the right. The ECAT function is to provide gas re-injection with zero emissions.

Features and Applications

When you specify Shafer, you receive a complete system, factory tested, field proven with the longest warranty in the industry. The Shafer ECAT is backed by a ten year warranty.

The Shafer ECAT can be operated locally, remotely or automatically by a variety of sensory and control devices. We have developed over 4,000 individual control systems to meet the many requirements of our customers.

Typical applications for the ECAT include:

• Emergency shut down• Mainline isolation• Linebreak protection• Remote valve control• Station fire-gate and blowdown• High/low pressure shutoff• Prevention of mercaptan odor

The Shafer ECAT produces constant torque output over the full 90° valve rotation. Constant torque output is an exceptional performance advantage if abnormal, high flow conditions are present such as linebreak.

The Shafer ECAT system can be configured as a versatile solution for both new actuators and retrofitting on existing equipment. The gas re-injection system can be powered by electrical power, UPS systems or solar power allowing for installation in remote areas where utility power may be unavailable or unreliable.

The Shafer ECAT valve operating system is weather proof and explosion proof (Class I, Div I) with a standard temperature rating down to -20°F or an optional rating down to -50°F.

The Shafer ECAT provides a sound solution for densely populated areas where the odor of natural gas is problematic for local residents. It is compatible with existing Shafer hardware and can be purchased as an upgrade for most existing installations.

The Emerson logo is a trademark and service mark of Emerson Electric Co. © 2018 Emerson Electric Co. Shafer™ is a registered trademark of one of the Emerson family of companies. All other marks are the property of their respective owners. © 2018 Emerson. All rights reserved. DOC.8P.ECAT.EN REV A 06-18

www.emerson.com/shafer

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A Safe, Intelligent Control Technology For Natural Gas Pipeline Applications

The new Emissions Controlled Actuation Technology encompasses all the functional characteristics of the rotary vane in a novel design that eliminates the emissions that have been associated with gas-over-oil systems.

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