23

Valve Actuation News from Rotork

Application, contract and

product reports from the
worldwide Rotork valve
actuator family
Rotork in Control
Contract News
Fluid System News
Focus on Jordan
Actuation Update

Rotalk - Issue 23

Key-milestone pipeline Contract

News
performance displays
Rotorks international strengths
Rotork offices in the UK, USA, Italy, Holland, Singapore
and Japan have worked together to successfully satisfy
the entire major valve actuation and control requirement
for the prestigious PGN Sumatra Singapore natural gas
pipeline, described at its opening ceremony as a keymilestone in bilateral co-operation between Indonesia
and Singapore.
The pipeline runs from Grissik in
South Sumatra to Singapores Sakra
Island, supplying Singapore with its
third source of natural gas for
generating electricity over the next
twenty years. Rotorks contracts
involve actuation equipment and
services from virtually every part of
the companys product portfolio.
Fluid System at Singapore won the
order from PGN for eighty
pneumatic pipeline actuators,
together with gas-over-oil actuators
for skid mounted plant at two
metering and supply stations. Built
at Rotorks Italian factory, most of
the actuators were shipped to
Singapore for fitting to ball valves
made by Audco, Cooper Cameron
and PBVS.
Meanwhile, Rotork Japan was
working with the contractor and
engineering vendor responsible to
the metering stations operator
Power Gas regarding other diverse
actuation requirements at the two
sites, one at Jurong Island and the
other at Senoko, north of
Singapore. Rotork Japan
successfully proposed an actuation
package comprising IQ and
Skilmatic electric actuators from the
UK, an EH electro-hydraulic unit
from the USA and a large number
of Exeeco and Alecto manual
gearboxes from the UK and
Holland. The Skilmatic and EH

actuators were supplied specifically

for emergency shutdown and
modulating duties in areas where air
supplies for conventional pneumatic
actuators were not available.
The final element of the project
involved the remote control and
supervision of the valves at Jurong

Island and Senoko from a single

control room at Senoko. Working
with system integrator Willogen,
Rotork Singapore proposed the use
of Pakscan IIS network systems at
both sites, with a telemetry link
between them to facilitate control
from a single point. To achieve this,
Rotork engineered Pakscan
connectivity for the EH and
Skilmatic actuators and integrated
them into the Pakscan loops.
Acceptance by Power Gas of this
final part of the proposal completed
the success of one of the most
comprehensive and diverse
actuation packages ever undertaken
by Rotorks international family of
companies.

Above: IQ intelligent electric actuators

fitted to Hatanaka ball valves.

Right: Fluid system gas-over-oil actuators

operating PBVS trunnion mounted ball
valves (900mm) on skid mounted gas
station metering duties.
Below: Fluid System pneumatic actuator
fitted to fully welded Cameron ball valve
(900mm), providing gas station shut-off
duty.

For further information on Rotalk articles and features contact Nicky Harrington at Rotork Bath . . . .

Rotalk - Issue 23

Failsafe electric actuators

for wellhead choke valves

Rotork Skilmatic electric failsafe actuators have been ordered for

wellhead choke valve duties on an oil field development project in
North Africa. Twenty-five Skilmatic Model SHL417 flameproof
linear actuators will operate Severn Glocon Series 5000 high
pressure (Class 1500) severe service globe valves supplied to the
Lasmo Elephant Field Development Project, via engineering group
MAN in Germany.
Skilmatic actuators provide an
economical alternative to the
conventional centralised hydraulic
installations traditionally used for
these applications. Benefits include
simplified installation and
instrumentation costs as well as
reduced operating and maintenance

expenditure. The Model SHL417

is specifically designed for the
4-20mA modulating control of linear
control valves, accepting an
analogue or digital input signal to
provide accurate positional control
with minimal power consumption.
An electrically operated, self-

contained hydraulic system

operates valve movement in one
direction, at the same time
compressing an internal spring to
operate the valve in the opposite
direction. On loss of power the
actuator can be set to either failsafe
or stay put, whilst the positioner
discrepancy alarm provides remote
indication of a system error.
The Skilmatic SHL417 actuators
ordered for this project are ATEX
certified for operation in Zone 1,
Division 1 hazardous areas and
environmentally sealed to IP65
(NEM4)

Maizuru Terminal, pictured

here, is the latest Maritime
Defence Force installation in
Japan to be automated with
Rotork IQ intelligent electric
valve actuators and Pakscan
digital control systems.
Rotork Japan has been
involved in the modernisation
of several of these fuel supply
depots since the Rotork
IQ/Pakscan package was
adopted as the standard
system for the automation
project. To-date, over 300

Telephone (+44)(0)1225 733200 or email nichola.harrington@rotork.co.uk

Rotork
in Control

Above:
Skilmatic electric failsafe actuators at the
Severn Glocon factory in Gloucester,
where they have been mounted on
200mm (8) severe service globe control
valves for wellhead choke valve duty.

Electro-hydraulic
actuators offer an
economical alternative
to traditional hydraulic
installations

actuators have been installed

at six locations.
Some of the IQ actuators
installed at Maizuru are
subjected to especially harsh
weather conditions, including
heavy winter snow, due to its
location on the coast of the
Sea of Japan. In addition,
Maizuru is the first installation
in the programme to
incorporate a hot standby
Pakscan master station
within the DCS operating
network.

Rotalk - Issue 23

Rotork wins major

valve actuator
orders for Singapore
water reclamation
scheme
Rotork intelligent electric valve actuators have been
ordered for installation throughout the liquids processing
plant at a giant new waste water treatment plant under
construction in Singapore.
The Changi Water Reclamation
Plant (CWRP) is the cornerstone of
the first phase of the Singapore
Deep Tunnel Sewerage System,
featuring state-of-the-art, compact
and covered treatment facilities,
ultimately designed to handle up to
2.4 million m3/day when completed
in 2006. The plant design and
engineering is provided by
CH2MHILL, Corvallis, USA and their
Singapore office.
Over fifteen hundred of the
actuators ordered are Rotork IQ and
IQT intelligent units for installation on
CWRP Liquids Module 1,
encompassing head-works, primary
and secondary sedimentation tanks,

bioreactors and effluent pump

stations. IQ and IQT actuators
share the same advanced features,
including infra-red non intrusive
commissioning and communication,
on-board data-logger and systemon-a-chip intelligent technology
providing comprehensive control
and indication flexibility.
Many of the actuators will be factory
fitted with Rotork Profibus
connectivity cards for integration
with the centralised automation and
control system planned for CWRP.
The largest portion has been
ordered by Fouress Engineering
(India) Ltd for the operation of
butterfly valves. These, and others
ordered by manufacturers of ball
and pinch valves, will be supplied to
engineering contractors United
Engineers, Singapore, and Voltas
India.
Left:
Orders for Changi include many IQT
actuators for the direct operation of
butterfly valves.
Below:
An artists impression of the Changi
Water Reclamation Plant.

Contract
News

Valve
control
package for
major refit at
Saudi refinery

Rotork is supplying a valve control package

comprising 352 IQ intelligent electric actuators
with Pakscan 2-wire digital control and
In-Vision SCADA software for an important
upgrade project at an oil refinery on the Red
Sea coast in Saudi Arabia.
Rotorks contract is a central part
of the modernisation programme
at the Saudi Aramco Rabigh
Refinery awarded to Canadian
engineering consultant SNC
Lavalin, which will ultimately see
the installation of a Yokogawa
DCS to control the plant.
The project involves the removal
of Rotork A range actuators that
have been operating for
approximately twenty years and
retrofitting the latest IQ intelligent
actuators on the existing valves.
Rotorks specialist Site Services
Department will perform much of
the retrofit design work, as Mike
Dale, Site Services Manager,
explains: Rotork has over 40
years experience of retrofitting
valve actuators. This valuable
resource will be extensively used
during the completion of the
Rabigh project.

Equipped as standard with

data loggers, the new IQ
actuators will enable refinery
maintenance staff to
download comprehensive
diagnostic operating
information, using dedicated
IQ-Insight software.
Pakscan will initially provide
stand-alone digital control of
the actuators on fibre optic
loop networks supervised by
five fully redundant 120
channel hot standby master
stations, utilising In-Vision
software. Following installation
of the Yokogawa DCS the
Pakscan loops will be
integrated into the plant-wide
system whilst the In-Vision will
be retained for maintenance
purposes. Each IQ actuator
will be connected to the twowire network via Rotorks
Pakbox, enabling individual
actuators to be electrically
isolated and removed from the
network for maintenance
without disrupting network
communications.
Rotorks Saudi based
engineers will supervise the
installation of the new
actuators and Pakscan
network, led by Dan Benson,
Rotorks Area Manager for the
Kingdom. Dan comments:
We are proud to be
associated with such a
prestigious Saudi Aramco
contract and look forward to a
close working relationship with
the In Kingdom SNC office
and Aramco project team.
Rotorks ability to handle large
projects in the Kingdom is
enhanced by local workshop
facilities, supported by our
local agent Al Hugayet.

For further information on Rotalk articles and features contact Nicky Harrington at Rotork Bath . . . .

Rotalk - Issue 23

At a stroke Jordan wins

metering pump orders
Jordan Series 1000 and 1500 modulating actuators
have been adopted by two world-leading metering
pump manufacturers for applications demanding
automatic electrical stroke adjustment.

Metering pumps are designed for

fluid metering and controlled volume
duties often at high flow rates and
pressures up to 1200 bar in
process industries ranging from oil
and gas to food and drinks.

Focus on
Jordan
A diverse range of applications
includes flow metering, acid dilution,
gas odourisation, polyethylene
cross-linking and chemical injection.
Leading international manufacturers
Lewa in Germany and OMG in Italy
now use Jordan actuators when
electrical stroke length adjustment
is specified.
Pump stroke adjustment is a
demanding duty that regulates the
pump performance, requiring a swift
modulating action that can be
continuously rated, in response to a
4-20mA control signal. Jordan
actuators combine compact
dimensions, accurate performance
and repeatability within 0.25% to
suit all these requirements. For
hazardous area duties, they are
available with ATEX, FM or CSA
explosionproof certification.
Currently, in excess of 150 actuators
have been sold to the two
manufacturers, including an order
from Lewa for fifteen units at a
BASF chemical plant in Germany,
and thirty-two units ordered by
OMG for installation on the Jebel Ali
L project in UAE.
Left:
Metering pumps equipped with Jordan
1500 Series actuators at the Lewa
factory.

High temperature
actuators

Data acquisition
by Ethernet
Jordan has developed a special
Ethernet data acquisition link, initially for
use by one of the largest energy
producers in the USA.

A new leaflet from Jordan draws

attention to the actuators high
temperature performance,
explaining that most of the
companys product range is
designed for ambient operating
temperatures of up to 120C
(250F).

Designed to fit 1000 Series actuators, the Ethernet

option is expected to be extended to the entire
Jordan product range. The option runs an HTTP
web server using TCP/IP protocol and enables the
customer to obtain diagnostic data from the
actuator by simply logging on to the internet
and clicking a few buttons. In this way the
customer can set parameters, view diagnostics
and logged data, perform self-tests and control
the actuator remotely via a standard web
browser.
The original Jordan Ethernet application involves
twenty-eight separate hydro-electric turbine
plants, where the actuators are used to reoxygenate water that has passed through the
turbines to protect the downstream environmental
ecology.

Telephone (+44)(0)1225 733200 or email nichola.harrington@rotork.co.uk

Rotalk - Issue 23

IQT technology
Rotork
in Control
secures reliable
valve actuation for
Colorado Springs Utilities
Dom DeBaggis, Rotork Rockies Area Sales Manager, reports on an impressive
retrofit success utilising IQT actuators at a community-owned water treatment plant.

Rotork IQT intelligent electric valve actuators have been

installed at the Colorado Springs Utilities Ute Pass water
treatment plant located in Green Mountain Falls, Colorado,
to secure improved reliability on the filtration equipment.
Colorado Springs Utilities is a fourservice community-owned
organisation providing natural gas,
electricity, water and wastewater
services to the Pikes Peak region in
Colorado. The Ute Pass WTP, one
of the six water treatment plants
operated by the Utilities, is a 2 MGD
(million gallons a day) packaged
plant, now consisting of four filters.
The plant was originally
commissioned in 1987 and a
capacity increase from 1 to 2 MGD
was completed in the summer of
2003.
From the initial operation of the
enlarged plant Utilities personnel
were dissatisfied with the reliability of
the incumbent valve actuators when
compared with the performance of
Rotorks IQ/IQT non-intrusive
intelligent technology at several
installations in other plants. Through
their outside engineering consultant
they requested a quotation from
Municipal Treatment Equipment
(MTE), Rotorks municipal sales
agent in Denver, for replacement
IQT actuators. MTE handled sizing

and Rotork arranged a special

delivery, resulting in orders for four
IQT250 and twenty IQT125 units to
fit butterfly valves in sizes ranging
from 3 to 8.
IQT technology and software tools
enabled Utilities personnel to install
and commission all the actuators
with impressive speed and efficiency,
with only minimal assistance and
training from Rotork and MTE.
Extensive use of IQ-Insight software
enabled actuator configuration
information to be saved and then
downloaded to other IQTs installed
on identical valves, resulting in
valuable time savings as it was
necessary to shut down two filters at
a time during the changeover.

Extensive use of
IQ-Insight software
enabled actuator
configuration
information to be
saved and then
downloaded to
other IQTs installed
on identical valves

Record delivery
time secures
power station
start-up
Please pass on to all the
people at Rotork Bath our
thanks for a job well done.
This important achievement
would not have been possible
without their hard work and
dedication. We all appreciate
the great effort Rotork Bath
and Mississauga contributed
to make this happen. Wayne
Boyd, President and CEO,
Canatom NPM Inc.
This impressive endorsement was
received upon the announcement
that Qinshan Unit 2 power station
near Shanghai began commercial
operation on 24th July 2003, four
months ahead of the originally
scheduled date.
Rotork has been the major
supplier of nuclear qualified valve
actuators on the Qinshan 1400
megawatt Unit 2 project, but a last
minute on-site problem with one
unit threatened to jeopardise the
reactor start-up date. Eradication
of the problem demanded the
building of a replacement 90NA1
unit at Rotork Bath, shipping and
installation within a record tenweek lead time.
Close co-operation between
Canadian and UK Rotork offices,
the customer Canatom NPM Inc
and main contractor AECL
secured the successful
completion of the task, enabling
the planned start-up of the new
reactor to proceed on time and
Qinshan Unit 2 to join Unit 1 in
commercial operation.

Footnote Colorado Springs

Utilities have also retrofitted four
additional IQT actuators at one of
their remote flow control facilities,
whilst Rotork will also provide
more than twenty IQTs for
installation at their Northern Water
Reclamation facility, currently
under construction.

For further information on Rotalk articles and features contact Nicky Harrington at Rotork Bath . . . .

Rotalk - Issue 23

Rotork helps to
preserve and
enhance historic
rivers at Heathrow

1.5 metre wide penstocks are

operated automatically by Rotork
IQ25 actuators in response to
analogue signals from adjacent
ultrasonic level sensors installed in
the river beds. The actuators are
fitted with Rotork Folomatic
proportional controllers and CPT
current position transmitters to
enable progressive penstock
movement and position signalling
to commence when the bank full
trigger level is approached
downstream of the off-take
structures. The actuators continue
to shut the penstocks until the water
level is stabilised, ensuring that the
rivers are kept full but the banks are
not breached. A telemetry link from

each installation transmits

information on penstock status,
positions and upstream/downstream
water levels to a central control room
at Heathrow Airport.
The Fontaine penstocks feature fully
enclosed operating mechanisms
with bevel gearboxes, enabling the
Rotork actuators to be installed in
ergonomically convenient positions.
This facilitates access to the
actuators during installation,
inspection and maintenance and
removes any requirement for high
level walkways or temporary
scaffolding.
The Twin Rivers Diversion project
was started in November 2002 and
completed in May 2004.

Left and below:

The Longford River off-take penstocks.
Note that the IQ25 electric actuators
have had their handwheels removed and
replaced with square key drives,
facilitating manual operation with a
portable power tool.

Rotork Folomatic
facilitates partial valve
movements for
accurate river level
control.

Rotork IQ intelligent electric valve actuators are being used in

an ecologically important Twin Rivers Diversion project
associated with the construction of the new Terminal 5 (T5) at
London Heathrow Airport. Twenty-three actuators operate
stainless steel penstocks manufactured by H. Fontaine Ltd to
control the flows within new open channels, built to divert the
courses of two of Londons historical rivers around the
western perimeter of the 260ha Heathrow T5 site.

David Palmer of Black & Veatch

Consulting and Rivers Team Leader
at T5 owners BAA plc explains:
BAA opted to divert the Longford
and Duke of Northumberlands
Rivers around the western
perimeters of the airport rather than
bury the existing courses in culverts

beneath the proposed development.

The new diverted channels have
been designed with significant
ecological enhancements in order to
maximise the environmental values
of the rivers.
At the head of each channel, offtake structures incorporating seven

Actuators in major Hong Kong utility projects

Hundreds of Rotork electric valve actuators are being
installed throughout two new major utility projects,
built to serve the burgeoning population and economy
of Hong Kong.

Eric Li at Rotork Hong Kong has

been closely involved with both
projects since construction first
started in the 1990s. Black Point
Power Station (above), situated in
northwest New Territories, will be
one of the worlds largest natural
gas-fired combined-cycle power
stations when completed in 2006,
with a planned generating capacity
of 2,500MW. Nearly 400 Rotork
actuators are installed on the

CAPCO owned project, which is

being built by a consortium
comprising Alstom Combined
Cycles International and the General
Electric Company at a total cost of
around HK$ 24 billion.
In addition to Hong Kongs largest
power station, Rotork actuators also
feature throughout the territorys
newest water treatment works at Tai
Po (right). Here, nearly 500 Rotork
IQ actuators are being installed on
plant that will eventually have a
designed treatment capacity of
1.2 million m3/day. The advanced
treatment process encompasses
coagulation, flocculation and
clarification by dissolved air flotation,
aerated biological filtration for

ammonia removal, rapid gravity

filtration and final disinfection.
Provision is also made for the
inclusion of ozone and GAC filters if
found to be necessary. Designed
by Black & Veatch, the plant is
being constructed by Gammon

Telephone (+44)(0)1225 733200 or email nichola.harrington@rotork.co.uk

Skanska. With a total cost

approaching HK$ 2 billion, Tai Po
water treatment and water transfer
facilities will ensure that Hong
Kongs water supplies meet the high
standards laid down by the World
Health Organisation.

Rotalk - Issue 23 8

Electro-hydraulic solution
to power stations control
valve headache

Rotork
in Control

A heavy duty Rotork EH electro-hydraulic linear actuator has solved an expensive and
repetitive valve operating problem at the Entergy Willowglen power station in Mississippi.
The valve an Edward Class 2500
14 x 12 x 14 high pressure nonreturn globe control valve on boiler
feed water pump discharge service
was motorised with an obsolete
electric actuator that was no longer
supported by its manufacturer. The
actuator was regularly causing selfinflicted damage to its drive bush
and gearbox when the valve was
operated, forcing the station to
repair it on an annual basis.
Because all the required
replacement parts were not
available from the manufacturer,
they had to be specially made,
dramatically increasing the
repair cost.
Seeking a solution to the problem,
Entergy contacted Rotork.

Rotorks suggestion was to replace

the electric actuator with an EH
range electro-hydraulic linear unit
customised for the plants
requirements which would utilise
the same electrical power supply
but operate the valve hydraulically,
providing the swift and responsive
actuation required without the risk of
damage to either valve or actuator.
Modifications were also made to
increase the actuators manual
override operating speed before the
unit was fitted in the middle of 2001,
since when it has been providing
reliable and problem-free service.
In September 2003, Rotork sales
engineer Skip Kuehn was allowed to
invite engineers from another power
company, who had similar problems

with a number of Class 2500

pressure seal bypass valves, to visit
the Willowglen site and find out
about the EH actuators
performance. Entergy were able
to supply a very positive
recommendation, reflecting their
satisfaction with the EH installation.

Before

After

EH actuator delivers
swift, responsive
valve positioning
from an electrical
power source.

Award winning performance from

Spare Parts Cell
The important contribution made by Rotorks Spare Parts Cell
to the successful on-time completion of a challenging
Canadian power station upgrade project has been recognised
by the award of a special commemorative plaque.
Bruce Power Station in Ontario was undergoing a major
environmental upgrade programme which included
refurbishment of Rotork nuclear qualified valve actuators that
had been installed when the station was built in the 1970s.

(continued on page 14)

Clockwise from left: Paul Kennedy with

Spare Parts Cell members Gary Barnett,
Simon Mellowes and Richard Knight.

Rotork helps South West

Water to make the most
of renewable energy

Rotork IQM actuator operating the linear water inlet valve on one of the turbines at
Mary Tavy. Far right: Rotork d.c. actuators on the main turbine inlet valves.

Rotork electric valve actuators are

contributing to a noteworthy
renewable energy refurbishment
programme at a power station
owned by South West Water.
Opened in 1932, the plant at Mary
Tavy is still Englands largest hydroelectric power station, working with
smaller stations at nearby
Morwellham and Chagford to
produce a total of 3,340 kW of
electricity from the water resources
of Dartmoor.
When the plants were acquired by
South West Water in the 1990s,
they were still largely operating with

their original 70 year old turbines,

switchgear and gauges. As such
they represent an important piece of
industrial archaeology, attracting
regular visits from educational,
institutional and engineering groups.
South West Water has therefore
embarked on a refurbishment
programme that will improve
efficiency without altering the
authentic overall appearance of the
plant and machinery, panels and
gauges. The 850,000 project
entails the installation of new turbine
wheels, modern switchgear and
valve actuation, and the introduction

For further information on Rotalk articles and features contact Nicky Harrington at Rotork Bath . . . .

Rotalk - Issue 23 9

21st Century upgrade at

National Grid Transco
Bacton includes new
Rotork valve actuators
Rotork has been awarded phased contracts to install new electric actuators
on an approximate total of three hundred major valves during a strategic
modernisation and upgrade programme at the National Grid Transco (NGT)
gas terminal at Bacton in Norfolk. Rotork is replacing earlier versions of its
own actuators which, in many cases, have been in operation since the
Bacton plant first began processing North Sea natural gas in the early 1970s.
Actuator replacement is being
carried out by Rotorks specialist
Site Services Department, working
closely within the daily operational
constraints of the site to minimise
the risk of any interruption to normal
plant operation. The latest ATEX
certified Rotork IQ2 intelligent
electric actuators are being installed,
the majority being IQ70 models
operating buried service 900mm
(36) Cameron pipeline ball valves.
Most of the valves control the
movement of gas received from
three North Sea gas producers

of automated site control under PLC

supervision.
Nine Rotork electric actuators are
being retrofitted at Mary Tavy,
replacing manually operated
equipment to control and govern
the flow rate of water into the three
Pelton wheel and three Francis
wheel turbines on the site, an
operation that used to require
constant manual attention. Six
Rotork IQM modulating actuators will
continuously alter the position of the
original linear water inlet valves in
response to signals received from
the PLC. Three Rotork actuators
with d.c. motors and Rotorkdesigned battery control panels are
also installed to automatically shut
the main inlet gate valves to the
turbines in the event of a power
failure or similarly important alarm.
Actuator installation is an integral

situated on an adjacent site. The

gas undergoes filtering, blending
and quality assurance processes,
including checks on calorific value,
volume, pressure and temperature,
before it is pumped into the NGT
National Transmission System.
For the last two phases Rotork took
on the total installation responsibility
including the electrical work and
appointed Dabbrooks Ltd from
Great Yarmouth to connect the
actuators to Bactons upgraded
centralised monitoring and control
system. Each actuator provides

continuous valve position and

availability data, supported by alarm
signals covering, for example, loss
of power or incomplete valve
movement. As a part of the NGTwide Ulysses Project, data from the
Bacton control system is also being
communicated by telemetry to NGT
operational headquarters at Hinckley
in Leicestershire.
Rotorks contracts are being
performed in several stages. Work
began in 2002 and is expected to
continue for another two years.

Careful retrofit
planning minimises
the risk of disruption
to normal plant
operation.
Pictured new Rotork IQ70 actuators
installed at NGT Bacton.

part of the turbine refurbishment

contract that has been awarded to
the turbines original manufacturers,
Gilbert Gilkes & Gordon Ltd.
Steve Cryer, South West Waters
Hydro Manager, is enthusiastic
about the future of hydro-power in
the area. He explains: The
programme at Mary Tavy is the first
part of a scheme to increase our
production of renewable energy at a
total of nine existing hydro-electricity
sites. In addition a new station is

Rotork actuators
control turbine
operation with
permanent failsafe
security.

being built and there are plans for a

further four. Most of the work is
being carried out by our experienced
in-house staff and a centralised
workshop is being established at

Telephone (+44)(0)1225 733200 or email nichola.harrington@rotork.co.uk

Mary Tavy to service all the plants.

Automation will not only improve
efficiency but also enable our staff
to work with more flexibility at the
power stations.

Rotalk - Issue 23

10

Rotork impresses with filter ATEX approved

plant upgrade performance explosionproof
Rotorks performance throughout a major water treatment
switchboxes in
works upgrade project has made a good impression.
demand
Rick Velderman, Maintenance
Supervisor at the Wyoming Water
Treatment facility in Holland,
Michigan, enthuses: We are very
happy with the performance of the
Rotork actuators on this project.
From the time that they have been
installed, we have had virtually
trouble-free operation and an overall
much smoother plant process. The
Rotork units are a major reason for
this improvement.
The Wyoming Water Treatment
facility has upgraded twelve filters for
improved reliability and operational
efficiency, opting for the electrical
actuation of existing filter and pump
control valves. Equipment replaced
consisted of water hydraulic
cylinders with external torque arms
that had been in operation for over
twenty-five years. The plant
required new electric actuators for
sixty-three butterfly valves ranging in
size from 18 to 48, as well as two
large 24 and 30 ball valves for high
service pump check service.
All isolating duty valves were
equipped with IQ intelligent
actuators and IW gearboxes, whilst
modulating and failsafe filter valves
were fitted with Skilmatic electrohydraulic actuators. In addition, the
large butterfly and ball valves on the
high and low service pump circuits
were equipped with EH range
electro-hydraulic units, completing
an all-electric isolating, modulating
and failsafe valve actuation solution,
from a single source.
The impact of the new actuator
installations has been immediately
noticed, as Rick Velderman
explains: We see a big benefit
over our old actuators from a
maintenance standpoint, one being
the functionality of remote SCADA
control and local control at the
actuators. This is a big plus from a

maintenance standpoint, since we

need to be down at the valves
working on equipment. Being able
to simply stroke valves and have
consistent response is very
important. The Rotork units give us
this ability. It is also very nice to
have two different actuator
technologies supplied and
supported by the same company.
We were all extremely impressed
with Rotorks on-site training, that
was provided as part of the project.
The local rep and the Rotork area
salesman came in with actual units,
dismantled them and taught us real
maintenance. Several of my guys
have since commented that Rotork
was right at the top of the list of all
suppliers on this large project, in
terms of quality of training.

Last years introduction of ATEX

certified explosionproof
switchboxes has created a much
higher level of demand than
could have been predicted, says
Rotork Valvekits MD Martin
Hunt. The SIRA certified, ATEX
approved Circa 7000 switchbox
range encompasses switch,
sensor, ASI 2-wire connectivity
and remote position feedback
options. A unique feature of the
Circa range is the high visibility
beacon position indicator,
which has also received ATEX
explosionproof approval, due to
its rugged, compact design.
ATEX certification is establishing
the Circa 7000 as a high quality
and economical switchbox

choice throughout its UK and

European markets. Recent
applications include twenty units
for valve position indication at a
petroleum tank farm in Holland.
Valvekits contract encompassed
the supply of new manual valve
gear operators, switchboxes and
mounting brackets.

Lock, stock and barrel

Valvekits has recently supplied
a customised, key operated
interlocking adaptation for
installation on a hazardous
chemical delivery valve for
Severn Trent Water.
Designed by Integrated Safety
Solutions Ltd the installation
uses a sequenced key routine
to permit the safe delivery of
sulphuric acid through a 3-way
ball valve, ensuring that it is
routed to a storage tank and
preventing any possibility of it
being discharged to the drain
via the third valve outlet.

We are very happy with the performance of the Rotork

actuators on this project. From the time that they have
been installed, we have had virtually trouble-free operation
and an overall much smoother plant process. The Rotork
units are a major reason for this improvement.

Exclusive framework for Rotork Exeeco at

Scottish and Southern Energy
Rotork Exeeco has achieved an
exclusive framework agreement for
the supply, installation and servicing
of Rotork products at power
stations owned by Scottish and
Southern Energy plc. The new
agreement follows several years of
close co-operation between the
two organisations during actuation
upgrade projects at several power
stations.
The framework covers the repair,
renewal and replacement of all

actuator types, whether electric,

pneumatic or hydraulic, together
with on-site specialist services
during tightly programmed outages
as well as servicing and running
repairs.
Exeeco Sales Director Ian Elliott
explains: Offering Scottish and
Southern Energy an exclusive
framework for our products and
services was seen as a welcome
move forward for both companies.
Working closely with our clients

helps to give them confidence and

promotes a working partnership in
sourcing the best technical and
product solutions in this specialised
field.
Rotork Exeeco can claim over 30
years experience of actuation and
automation in power plants. As the
largest service provider in its field in
the UK, Exeeco currently holds term
maintenance contracts with over
75% of the power generation plants
in the UK.

Ian Elliott meets Andy Cunnah,

Maintenance Manager at Scottish and
Southern Energys Keadby Power
Station during an on-site training
programme performed within the
framework agreement.

For further information on Rotalk articles and features contact Nicky Harrington at Rotork Bath . . . .

Rotalk - Issue 23

Fina Antwerp Olefins chooses

fireproofed Rotork valve
actuators for increased safety

11

Contract
News

The Fina Antwerp Olefins refinery has been the subject of a

thorough revamp and expansion project known as NC2X, which is
now in its final stages. The project has the objective to increase
annual ethylene production capacity to 1.4 million tonnes whilst also
introducing improved safety systems.
Rotork valve actuators are already
used on the site, which was originally
built fifty years ago. Therefore, IQ
and AQ electric actuators, together
with Fluid System actuators, mostly
fitted with K-Mass fireproof coatings,
were specified for the automation
and expansion of the NC2 plant,
which has been in operation since
1969. For the compressors, located
at the beginning of the process, a
special design was conceived to
automate the large, previously
manually operated emergency block
(shut down) valves. These gate
valves, in sizes up to 42, isolate and
protect the main plant from the
supply of product in the event of a
gas leak or fire.
Due to the critical importance of the
application to plant safety, the IQ
actuator installations required
customisation to comply with
detailed specifications. This was
successfully achieved with the
involvement of Dirk Stroeckx (Fina),
Chris DePaepe (Kellog, main
contractor), Mike Gover (Rotork UK)
and Frederik Van Acker (Prodim
Rotorks agent in Belgium).
The design ensures accurate
remote valve position indication to

enable the compressors to be safely

shut down. Each valve spindle is
fitted with an indication rod the
same length as the valve size (42
inch valve = 42 inch indication rod).
The rods are made of two materials
in equal proportion top half
stainless steel, bottom half
aluminium.
Each IQ actuator is equipped with a
K-Mass coated covertube, twice the
length of the indication rod, in the
middle of which are attached three
proximity switches in a 120 array,
fitted in springed cover tubes so
that they push against the indication
rod to ensure positive contact
throughout valve movement.
These switches indicate
aluminium but cannot see stainless
steel, therefore providing three
additional valve 50% closed
signals independently from the
actuator.
Dirk Stroeckx explains: This
system was required for additional
safety and independent availability.
We chose 50% closed indication as
we dont want to wait until the
valves are completely closed before
tripping the compressors.
Our experience with Rotork

Frederik Van Acker from Rotork agent

Prodim inspects one of the IQ actuator
and proximity switch installations at the
Fina Antwerp Olefins refinery.

products has been good.

Personally I think they are very
reliable and of good quality. We are
also very satisfied with the level of
service provided by Prodim.

Team effort
achieves specific
safety demands

Rotork valve actuators help

with Thames Water sewage
treatment improvement
programme
Rotork electric valve actuators have been specified for the
mechanical and electrical upgrade programme at one of
Londons largest sewage treatment works.
Rotork IQ range intelligent actuators
are replacing obsolete equipment at
Thames Water Deephams STW,
which serves a population of over
800,000 in the London boroughs of
Barnet, Brentfield, Enfield and
Tottenham.
The majority of new actuators are
being installed on valves and
penstocks on primary sedimentation
tanks in a project designed to
introduce automatic desludging at
the site. Together with the
introduction of new inlet screens,
refurbishment of aeration lanes and
final sedimentation tanks, the
Deephams upgrade will enable

Telephone (+44)(0)1225 733200 or email nichola.harrington@rotork.co.uk

100% of the plant to meet strict

new Environment Agency consent
targets.
Rotorks specialist retrofit team
carried out a survey of the valves
requiring new actuators, which were
ordered by contractor Laing
ORouke under the terms of
Rotorks framework agreement with
Thames Water. Laing ORouke are
carrying out all the installation work
at Deephams, including linking the
actuators to a new centralised PLC
control system that will supervise
the daily treatment of up to 460,000
cubic metres (tonnes) of effluent at
the site.

Rotalk - Issue 23

Applications,
worldwide locations...
Peru: Automated gas measurement

Pictured at the Flow-Quip

valvemaking plant in Tulsa,
Oklahoma, this shipment of P range
and R range pneumatic actuators
are to be installed on gas
measurement skids for the Camisea
Project in southern Peru. Each

Rotork actuated valve package is

equipped with a manual override
and stainless steel control cabinet
with remote and local valve controls.
The consignment is en-route to
specialist skid manufacturer Daniel
Measurement in Houston, Texas.

12

Fluid System News

Russia: Offshore production platform

One of a consignment of large

pneumatic actuators ordered from
Fluid System at Leeds by
valvemaker Tomoe Tritec for the
Sakhalin Island offshore platform in

Russia. The actuators will operate

600mm (24) Class 1500 butterfly
valves as part of a control valve
package ordered by Dresser. The
project main contractor is Amec.

Russia: Anti-surge pipeline skid

Kuwait: Online catalyst regeneration

Rotork area manager Keith Phillips

is pictured at the factory of Mogas
Industries in Houston, manufacturer
of severe service metal seated ball
valves. This consignment of
pneumatically actuated valves is on
the way to a Chevron/Kuwait
National Petroleum Company

project in Kuwait for online catalyst

regeneration duty. Front-end
engineering and design was
performed by ABB Lummus in
Houston and detailed engineering
was carried out in South Korea by
LG Engineering.

SPX Daniel Valve in the USA

required an actuator for a 100mm
(4) V-port ball control valve that
would operate normally with an 80
psi supply pressure but could also
cope with up to 1000 psi. This
unusual requirement has been met

by utilising a Fluid System spring

return hydraulic actuator package
recommended by Rotork Houston.
The actuator operates a bypass
valve in order to activate the antisurge skid on a pipeline project in
Russia.

Texas: Cogeneration pipeline

Rotork Houston worked with Barber
Industries to fulfil this demanding
application, where no external
source of actuation energy is
available. The solution was a
specially designed, self-contained
hydraulic control system, operating
a Rotork H range spring return
hydraulic actuator. The only
intervention required is the manual
re-pumping of the actuator control

system in the event of a signalled

hydraulic fluid release to the
reservoir.
Three of these actuated valve
packages are being supplied for the
Exxon Mobil Beaumont
Cogeneration Pipeline project in
Texas, through Mustang Engineering
in Houston. The valves are 400 mm
(16) Class 300 and Class 600
Dresser ball valves.

For further information on Rotalk articles and features contact Nicky Harrington at Rotork Bath . . . .

Rotalk - Issue 23

Distribution Update:
Houston, Texas
Established and experienced valve
automation specialist Baro Controls
is the new distributor for Rotork electric
and fluid power actuators in Texas.
With premises in Houston, Corpus
Christie, Beaumont, Dallas, San
Antonio and Midland Odessa, Baro
stocks a comprehensive range of
Rotork pneumatic and electric
actuators, positioners, limit switches
and gear operators, as well as valves
from world leading manufacturers.
Baros experienced actuation
specialists are on hand to design
automation solutions to individual
specifications, supported by in-house
fabrication and packaging facilities.
Baro Controls President Shelly White
comments Rotorks comprehensive
product line and commitment to
quality and growth first attracted us,
heralding the signing of this landmark
agreement. For more information:

leo.laborde@rotork.com
tom.matthews@rotork.com

Durban,
South Africa
Valve & Automation has been
appointed exclusive distributor for
Rotork Fluid System products in
South Africa. With a new factory in
Durban, supported by offices in
Johannesburg, Richards Bay and
Secunda, Valve & Automation has
years of experience of fluid power
actuation markets in the oil, gas
petrochemical and paper industries.
Rotork Africa General Manager
Howard Mutters enthuses This is a
major step forward in our ability to
provide a complete product offering.
For many years Rotork in South Africa
has been associated with electric
actuators and control systems. We
can now look forward to greater
market awareness for our complete
range of actuation products.
For more information:

13

Deanquip strengthens
Fluid System in Australia
Rotorks acquisition of Deanquip Valve Automation Pty
at Melbourne brings comprehensive local support and
service to Fluid System sales in Australia.
Deanquip, established for over
twenty years, specialises in the
control and monitoring of pipeline
and process valves and wellhead
controls in the oil and gas
production, transmission, mining
and process industries.
As Fluid Systems latest Centre of
Excellence, Deanquip now offers
exceptional experience in the

design, fabrication and packaging of

valve automation solutions,
supported by installation,
commissioning and field
maintenance services.
More information can be obtained
from Lydon Dean, General Manager,

lyndon@deanquip.com.au

howard.mutters@rotork.co.za

Another GO success

IP66 & 67M Certification

for CP, GP and LP actuators
India: Natural gas distribution
Photographed at the premises of
valvemaker Audco India Ltd, these
GO range gas-over-oil actuated
valves are some of the total of thirty
similar packages supplied for the
GSPL Paguthan to Baroda pipeline
in Gujarat State, India. Customer
satisfaction with Rotorks

performance during the initial stage

of this pipeline project has resulted
in Rotork actuators being specified
throughout the next phase of the
scheme, involving approximately
130 km of pipeline connecting
Baroda to Kaloi and Ahmedabad.

Rotorks CP, GP and LP pneumatic scotch-yoke and linear actuators have

been successfully tested for IP66, IP67M (tested whilst operating) and
Deluge watertight and dustproof certification.
Tests were performed in Italy by independent testing authority Nemko S.p.A.
using standard-build Rotork products. Following stringent test procedures,
including total immersion, the actuators were dismantled and neither water
nor dust were found to be present inside any of the enclosures.
The photographs show the recently launched CP range compact quarterturn actuator during dust, water jet and submersion testing.

Telephone (+44)(0)1225 733200 or email nichola.harrington@rotork.co.uk

Rotalk - Issue 23

Enhanced

(continued from page 8)

Award winning performance

The stations operators supplied
their local Rotork sales office at
Mississuaga with a list of
replacement seals, bearings and
mechanical components for the
eighteen Rotork 30NA and 40NA
actuators involved, all of which were
required on a fast turnaround to
meet the shutdown schedule. To
assist with identification, the station
also supplied examples of many of
the items required, taken from the
actual actuators.
Rotork Ontario passed the parts list
and samples to the Spare Parts Cell
at UK Bath head office for
immediate action, where it quickly
became apparent that not all the
required parts were still on the
shelf. This would dictate extended
delivery times whilst the out of stock
items were identified and procured,
which might jeopardise the stations
planned re-commissioning date. On
receipt of this news Bruce Power
despatched engineer Perry Karsten
to Bath to assist Rotork senior
contracts engineer Paul Kennedy in
checking and tabulating all the
missing parts that now needed to
be urgently ordered.
Paul takes up the story: In view of
the age of these actuators it is not
surprising that some of the required
items were not immediately
available. However, access to the

actual actuators detailed

engineering drawings, build
schedules and test certificates at
Bath helped us to quickly and
accurately pinpoint all the relevant
parts, in most cases check them
against the samples supplied and
then begin the task of sourcing
replacements.
We had to search as far as Japan
to successfully find some parts, but
in the event this was a worthwhile
effort as the manufacturer proved
able to supply us in only seven
days. In fact, the entire Bruce Power
spares order was eventually fulfilled
in less than three weeks, including
the creation of a complete list of
non-metallic actuator components
and materials required as an
essential part of their environmental
qualification approval procedures.
Without the support of the
dedicated Spare Parts Cell team it is
very unlikely that this could all have
been achieved within such a short
timescale.
As a result of these efforts, the
refurbishment of the actuators did
not delay the re-commissioning of
the power station which was
completed on time. To
commemorate this achievement,
Bruce Power awarded a specially
commissioned plaque to Rotork as
a permanent record of the event.

Rotork Gears-up in the USA

Clay Hightower, Rotork Gears' Americas General Manager, reports:

Modbus
connectivity

14

Actuation
Update

for Rotork electric actuators

Rotork electric valve actuators are now available with improved

connectivity to the popular Modbus automation protocol,
facilitating an increased range of control and communication
information including historical operating data.
Fitted within the environmentally
sealed actuator enclosure for
maximum reliability, the Rotork
Modbus card uses the familiar
Modbus RTU protocol on a low
cost RS485 communication
network. With the card fitted, all the
normal commands associated with
moving the actuator become
available on the Modbus multi-drop
highway for PLC supervision. When
fitted to IQ and IQT intelligent
actuators the Modbus card also
makes available a subset of the
standard data logger feedback
information. A torque profile is
provided for every valve operation
together with the total number of
times that the motor starter has
been energised in each direction.
This information can be accessed
periodically to update the control
system with the latest data.
Generally, up to thirty-two actuators
can be connected to a single
RS485 network with a typical cable
length of one and a half kilometres
and a data transfer speed of 9600
baud, making Rotork Modbus
installations ideally suitable for the
centralised control of small to
medium sized processes such as
water treatment plants.
Three versions of the card are
available single channel, with and
without repeater, and dual channel.
The single channel is the simplest

implementation, connecting the

actuator to one RS485 highway and
including an additional input for a
standard analogue instrument
signal. The single channel with
repeater module includes an internal
repeater to allow the Modbus
highway to be extended over
greater distances or for applications
where a ring is to be constructed.
The dual channel module caters for
applications where redundant
highways are used for high integrity
field connection. The two channels
are isolated from each other and
provide independent
communications.

Modbus connectivity is
available for all Rotork current
range electric actuators, either
as a factory fitted option for
new units or retrofitted on
existing installations.

Left: Rotork Gears' machinist Ray Torres

gets busy completing another order for
AB series gearboxes at Rochester.

Rotork Gears now has the

capability to assemble AB series
and ILGS series quarter-turn
gearboxes from component
stocks held at Rochester.
In addition, to serve short lead
time orders for manual

gearboxes, we now bore and key

IW worm gearbox drive sleeves,
thread IB bevel and IS spur
gearbox drive sleeves and
machine quarter-turn quadrants
to customers' specifications.
This investment in new

machinery and Increased stock

should greatly increase the level
of service to existing customers
and increase penetration of the
small valve manufacturing and
distribution markets.

The new Modbus brochure can be

downloaded from www.rotork.com

For further information on Rotalk articles and features contact Nicky Harrington at Rotork Bath . . . .

Rotalk - Issue 23

15

Approvals first for

Rotork in Australia

Seminars spread
the IQT word
Rotork International Sales has recently completed a
series of seminars to update agents and customers at
strategic locations on the benefits of the latest IQT
actuator technology.
As these photos illustrate, Rotork
agents were given full product
training and maintenance seminars
venues in Riga, Vienna and Dubai.
Meanwhile, at five locations in India
and Pakistan, countries of
increasing importance to Rotork,
customers were given presentations
on IQT actuators and the latest
version of IQ-Insight set-up,
configuration and diagnostics
software. Rotorks success in this
part of the world is illustrated by a
recent order for over 100 IQ valve
actuators for the White Oil Pipeline
project.

Roy Pentland (left) of ISC hands Rotorks AS/NZS3800 accreditation certificate

(no. PRD/R61/0143) to Peter Gingell, QA Manager at Rotork Ballarat.

Rotorks subsidiary in Australia is the first valve actuation company in

that country to achieve essential third-party accreditation to the latest
AS/NZS3800 standard for the overhaul and repair of explosionproof
electrical equipment in hazardous atmospheres.
Accreditation is a mandatory
requirement in Australia for
companies that install or work on
electrical equipment in hazardous
areas, or have workshops for the
repair and overhaul of such
equipment.
Companies must prove that they
have the approved systems and
procedures in place, as well as
competent people to carry out
the work.
Rotork Australia employed the
services of ISC (International
Standards Certifications Pty Ltd.)
to obtain AS/NZS3800

Telephone (+44)(0)1225 733200 or email nichola.harrington@rotork.co.uk

compliance at its head office

workshops at Ballarat to cover
the overhaul and repair of all
Rotork Exd certified electric
valve actuators.
Rotork Australia General
Manager Lee Howard
comments: I believe that we
are the only actuation company
in Australia to receive this
accreditation. Access to
original Rotork hazardous area
certification drawings gives us
the exclusive ability to overhaul
Rotork equipment to the
AS/NZS3800 standard.

Rotalk - Issue 23 16

The pressure is on for IQ actuators in China

http://www.rotork.com
UK head office
Rotork Controls Limited
tel Bath 01225 733200
fax 01225 333467
mail@rotork.co.uk
USA head office
Rotork Controls Inc
tel Rochester (585) 328 1550
fax (585) 328 5848
info@rotork.com
Rotalk is published and printed
in the UK.
Produced by FTPublicity
tel 01225 865399

Rotork is supplying a projected total

of over 700 IQ actuators on the
4000 kilometre pipeline, described
as the largest and most significant
gas industry project ever planned in
China.
Rotork actuators on the take-off
installations are IQM modulating
versions, seen here operating

Mokveld Class 600 axial flow control

valves. These are the critical first in
line control valves that reduce gas
pressure from the main transmission
line operating pressure of up to 99
bar to the downstream distribution
network pressure of 25 to 45 bar.
Rotork b.v. in the Netherlands has
supplied IQM10 and IQM12 model

actuators to Mokveld Valves for the

operation of axial flow control valves
in sizes from 100mm (4) to 250mm
(10) for off-take applications on the
West to East pipeline, which, when
completed in 2005, will have the
capacity to carry 12 billion cubic
metres of gas a year from the Tarim
Basin oilfields to the Yangtze Delta.

Skilmatic in Kazakhstan Lean times

oilfield development
is good
Rotork Skilmatic has received the first orders for wellhead
manifold actuators for the Alibekmola Onshore Infield
Gathering project in the Republic of Kazakhstan.
Orders for 130 actuators have
been received from Kurvers
Piping in Italy for the operation of
100mm Class 900 ball valves on
production wellheads in ambient
temperatures as low as -35C.
The ATEX approved Skilmatic
electro-hydraulic design was
selected for the application
following eight months of
discussions and design work
with design contractor Kellog
Brown & Root.
During discussions, space
considerations were a major
concern. The Skilmatic selfcontained design was chosen as
the most technically suitable

solution due to the overall space

available, speed of operation, low
temperature, maintenance and cost.
The actuators will be installed in
vertical and horizontal orientations
on wellhead production and test
loops handling crude oil and sour
gas at pressures up to 135 bar. The
actuators, which operate from a
single-phase 230Volt electrical
supply, are configured to failsafe
closed and equipped with manual
hand pump overrides.
It is expected that this project will
run for a number of years as this
important oilfield is developed and
linked to the Caspian Sea and
beyond.

news from
Holland
Rotork Gears has
announced that manual
gearboxes from the
Losser factory in
Holland will be available
on short delivery lead
times as new, Lean
production systems
come into effect.
Full details will be
published in the next
Rotalk issue.

rotork.com

The IQ intelligent electric valve actuators pictured here are on one of

the current total of thirty-eight take-off stations installed on the West
to East natural gas pipeline in China.