Actuators.

There are three types.

Pneumatic – Electrical – Hydraulic.

At many places we keep hearing complaints about hydraulic actuators from maintenance, operations and reliability
people. Although it is critical application which only hydraulic can handle, the maintenance etc issues are tying their
hands to go for pneumatics, even if that reduces performance drastically.

Pneumatic and Hydraulic actuators are same in principle. Both use a fluid to move piston, that is connected to valve
stem of another shaft. Pneumatic uses compressed air. Hydraulic uses pressurized fluid. Both need a system to create
and maintain fluid pressure. And to keep that air or oil clean/dry etc.

The difference in used fluid makes big difference in the applications.

In the pneumatic, when a signal is received, the air starts building pressure on one side of diaphragm to move the
piston. But air is compressible. Hence there is a delay until piston actually moves. And then it overshoots the targeted
position. The constantly changing force dynamics in pipe / process parameters, make this air compressed or expand.
Hence the pneumatic actuator CAN NOT maintain stiffness. These problems are handled easily by hydraulic actuator.
Hydraulic actuator also transfers pressurized oil to actuator cylinder to move piston. But because oil is non-
compressible. Hence piston movement is instant when receives signal. And process side fluctuations do not affect
hydraulic oil.

Hydraulics are to be used where fast response and precision control are very essential. Hence in fast loops – flow control
and pressure control – only hydraulic actuators to be used. If Pneumatics are used then they CAN NOT give that
precision control or fast response, and that DOES result into high operational expenses.
But Hydraulic actuators are complex in structure. Mainly because of filtration system required to keep oil clean. Any dust
or moisture in oil is not acceptable. And pumping arrangement is required to keep pressure maintained. The continuous
pumping also builds up heat and make oil break thus building up wax in system. Which creates operation of actuator a
big problems. Especially at crucial locations or applications. at one SEC plant, they had been encountering problems
mostly during startup or shutdown of unit, where bypass failed to open or close when required. Investigation shows that
solidified oil getting accumulated inside solenoid valve’s piston, causing it to stuck. Which needs cleaning etc and that
delaying startup. High temperatures also damage o-rings of system, causing oil spillages. Continuous pumping results
into increase in oil viscosity and high pressure in system.

And hence at some places they have used pneumatic for high thrust/torque values. Maybe to avoid using potentially
dangerous hydraulic oil in high temperature environment. Using pneumatic for it, results into huge equipment size and
engineering expenses. And still loses heavily on crucial performance. At LP/HP valves or Governor control, pneumatic
cannot be used.

Advantages of Pneumatic: Disadvantages of Hydraulic.

1. Cost Effective. 1. High Capital Cost

2. Continuous Duty 2. High Maintenance

3. Fast Operating Speeds 3. Large Qty’s of Fluid

4. Fail-safe Capable 4. Motor Runs Constantly

5. Ease of Maintenance 5. Not Usually Accepted By

Mainstream Eng’s
6. Intrinsically Safe

7. Operating simplicity
Disadvantages of Pneumatic Advantages of Hydraulic actuators.
1. Slow Response 1. Excellent Response

2. Low Stiffness 2. Continuous Duty

3. Poor Repeatability 3. Excellent Repeatability

4. Cost of Ownership 4. Good Stability

5. Need Clean Dry Air 5. Fast Speeds

6. Fail-in-place not standard 6. Compact for Size/Force Output

7. Footprint dimensions 7. Fail-Safe Capable

Only Hydraulic Actuators can meet the performance requirements

Pneumatic actuator limitations:
• Repeatability (0.5%)
• Deadtime (2 seconds)
• Low frequency response

All this creases a big dilemma for decision making. This is where REXA brand of actuators is helpful. It gives performance
– speed, accuracy, stiffness – of hydraulic actuator. And without hydraulic actuator’s maintenance headaches.

We had been able to address these issues with our hydraulic actuator, to the fullest satisfaction. Just to intrigue, while
other hydraulic actuator might have 30 gallons of oil and high maintenance filtration system, for the same our hydraulic
actuator will have half a liter oil and DOES NOT have filtrations system. At many Aramco installations, they had not even
attended to maintenance for quite few years. There was no need to. They have started recommending it to other
groups. SEC Hail tested one actuator and after seeing its performance, is ordering more.

Design criteria of REXA Next generation hydraulic actuators.

. Electrically driven
• Microprocessor based
• Mechanically simple (few moving parts)
• Capable of continuous operation (100% duty)
• Capable of precise positioning regardless of valve friction or process dynamics
• Low Power consumption
• Fail-safe option
• Compact
• Eliminate oil tank

The fast speeds are required to catch furnace pressure excursions and keep the pressure within certain safety trip
points. If the ID fan drive can react fast enough and "catch" the excursion then it saves the boiler from tripping off-line
(which could cost this plant close to $500,000 a day - depending on the price of coal and electricity).