1、Cylinder and Vane Actuators and Controls Design and Installation M66 Printed on recycled paper Printed in the United States of America American Water Works Association 6666 West Quincy Avenue Denver, CO 80235-3098 awwa.org Manual of Water Supply PracticesM66 Cylinder and Vane Actuators and Controls
2、Design and Installation Copyright 2015 American Water Works Association All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording, or any information or retrieval system, except in the form
3、of brief excerpts or quotations for review purposes, without the written permission of the publisher. Disclaimer The authors, contributors, editors, and publisher do not assume responsibility for the validity of the document or any consequences of its use. In no event will AWWA be liable for direct,
4、 indirect, special, incidental, or consequential damages arising out of the use of information presented in this book. In particular, AWWA will not be responsible for any costs, including, but not limited to, those incurred as a result of lost revenue. In no event shall AWWAs liability exceed the am
5、ount paid for the purchase of this book. Sr. Manager, Editorial Development and Production: Gay Porter DeNileon Sr. Production Editor: Sandra Lankenau If you find errors in this manual, please email booksawwa.org. Possible errata will be posted at www.awwa.org/resources-tools/resource.development.gr
6、oups/manuals-program.aspx. Library of Congress Cataloging-in-Publication Data Cylinder and vane actuators and controls: design and installation. First edition.pages cm (AWWA manual; M66)Includes bibliographical references and index.ISBN 978-1-62576-116-3 (alk. paper)1. Slide-valves. 2. Hydraulic ser
7、vomechanisms. 3. Pneumatic control valves. 4. Blades. 5. Waterworks. I. DeNileon, Gay Porter, editor. II. American Water Works Association. TD491.C95 2015628.10284-dc232015035968 ISBN-13 978-1-62576-116-3 eISBN-13 978-1-61300-347-3 iii AWWA Manual M66 Contents Figures, v Tables, vii Preface, ix Ackn
8、owledgments, xi Chapter 1 Introduction 1 History, 1 Purpose, 2 General Application, 3 Supply Medium, 3 References, 5 Chapter 2 Principles of Operation .7 General Descriptions, 7 Thrust Calculations, 9 Torque Characteristics, 11 Position Characteristics, 13 Sizing Considerations, 13 Actuator Torque C
9、haracteristics, 14 References, 16 Chapter 3 Types of Construction .17 Linear Cylinder, 17 Quarter-Turn Scotch-Yoke, 19 Quarter-Turn Rack-And-Pinion, 20 Quarter-Turn Pivoting Cylinder, 21 Quarter-Turn Link-Lever, 21 Quarter-Turn Vane, 22 References, 23 Chapter 4 Controls 25 Valve Control Concepts, 25
10、 Control System Components, 26 Solenoid Valves, 26 Flow-Control Valves, 28 Control Circuits, 29 Positioners, 31 Position Feedback Devices, 33 Fluid Power Supply Systems, 33 Air Compressor Systems, 33 Hydraulic Oil Supply Systems, 34 Electro-Hydraulic Actuators, 35 Water Supply Systems, 36 References
11、, 37 iv AWWA Manual M66 Chapter 5 Special Equipment .39 Handwheel Override, 39 Lockout Mechanism, 39 Spring Return, 40 Accumulators, 42 Chapter 6 Installation and Adjustment 45 Storage, Handling, and Mounting, 45 Setting of the Travel Stops, 47 References, 48 Chapter 7 Maintenance and Safety 49 Regu
12、lar Maintenance, 49 Troubleshooting, 50 Safety Concerns, 51 Glossary, 53 Index, 57 AWWA Manuals, 61 v AWWA Manual M66 Figures 1-1 Quarter-turn vane-type actuator provides remote control of a ball valve, 2 2-1 Cylinder actuator provides linear thrust, 8 2-2 Various quarter-turn mechanisms, left to ri
13、ght: lever; link-and-lever; rack-and-pinion; scotch-yoke, 9 2-3 Rack-and-pinion mechanism, 10 2-4 Vane mechanism, 10 2-5 Typical slide gate for waterworks applications, 10 2-6 Typical globe valve geometry, 11 2-7 Both forces A and B produce a torque of 20 ft-lb, 11 2-8 Torques for a butterfly valve,
14、 12 2-9 Torque characteristics of various cylinder and vane actuators, 14 3-1 Hydraulic cylinder, 18 3-2 Slide gate with cylinder actuator, 18 3-3 Scotch-yoke lever actuator, 19 3-4 Slotted lever mechanisms, 20 3-5 Rack-and-pinion actuator, 20 3-6 Rack-and-pinion actuator with double-acting external
15、 cylinder, 21 3-7 Pivoting cylinder actuator, 22 3-8 Link-lever actuator, 22 3-9 Vane actuator, 23 4-1 Basic hydraulic symbols, 27 4-2 Four-way solenoid valve and schematic, 28 4-3 Flow-control valve, 29 4-4 Basic control circuit for double-acting cylinder, 30 4-5 Basic control circuit for double-ac
16、ting cylinder with timed stroke, 30 4-6 Control circuit for a pneumatic spring return actuator, 31 4-7 Valve positioner, vane actuator, and handwheel override worm gear unit mounted on a butterfly valve, 32 4-8 Pneumatic valve positioner, 32 4-9 Electro-pneumatic valve positioner, 33 4-10 Smart valv
17、e positioner, 33 4-11 Valve feedback unit with position beacon, 34 4-12 Air compressor system, 34 4-13 Air distribution system, 35 4-14 Low- and high-pressure oil hydraulic system, 35 vi AWWA Manual M66 4-15 Electro-hydraulic quarter-turn actuator, 36 4-16 Water supply system, 37 5-1 Worm-gear manua
18、l override with declutch mechanism, 40 5-2 Jackscrew manual override for cylinder, 40 5-3 Hand pump manual override for cylinder, 41 5-5 Cylinder actuator with spring return, 41 5-4 Example of lockout mechanism on cylinder actuator, 41 5-6 Vane actuator with spring return, 42 5-7 Water accumulator t
19、ank, 43 5-8 Hydraulic oil accumulators, 43 6-1 Actuator data form in part from AWWA C541, Appendix A, 46 6-2 Open and closed adjusting screws on a ball valve hydraulic actuator, 47 7-1 Cylinder head with tie rod nuts, 50 7-2 Cylinder actuator limit screws, 51 vii AWWA Manual M66 Tables 1-1 Summary o
20、f media properties, 4 2-1 Actuator application factors, 13 2-2 Typical sizing chart for spring return cylinder actuators, 15 This page intentionally blank. ix AWWA Manual M66 This new AWWA Manual of Water Supply Practices presents the general principles of hydraulic and pneumatic power actuators for
21、 use with waterworks valves. The principles used for selecting, sizing, and installing actuators are detailed. This is a discussion of rec- ommended practice, providing guidance on generally available actuators and their appli- cation, not an American Water Works Association (AWWA) standard. Questio
22、ns about specific situations or applicability of the guidance provided here to specific valves and actuators should be directed to the manufacturer or supplier. Operators, technicians, and engineers will find the information contained in this manual useful for understanding the use and application o
23、f hydraulic and pneumatic power actuators. There are many special actuators that are beyond the scope of this man- ual and require special consultations with those suppliers. The valve thrust and torque information is generic, and actual data from the valve manufacturer should be obtained before mak
24、ing the final selection of actuator size and options. This manual provides infor- mation on the hydraulic and pneumatic actuators listed in AWWA Standard C541 Hydrau- lic and Pneumatic Cylinder and Vane-Type Actuators for Valves and Slide Gates, latest edition, including the following: Linear cylind
25、er actuator Quarter-turn cylinder actuator Quarter-turn vane actuator This manual refers to AWWA standards, which are available for purchase from AWWA by calling (800) 926-7337 or online at www.awwa.org. Manufacturers graciously provided valve illustrations and other documentation. AWWA does not end
26、orse any manufacturers products, and the names of the manufactur- ers have been removed from the material provided. Metrification note: Cylinder sizes are listed in their current US designation: inches. To obtain an approximate metric equivalent, use a conversion factor of 25.4 mm per inch. Preface
27、This page intentionally blank. xi AWWA Manual M66 The AWWA Subcommittee on AWWA Manual M66, which developed this manual, had the following personnel at the time of approval. John V. Ballun, Chair J.V. Ballun, Val-Matic Valve & Manufacturing Corporation, Elmhurst, Ill. (AWWA) B.E. Bosserman, Engineer
28、ing Consultant, Mission Viejo, Calif. (AWWA) G. Eaton, Festo Corporation, Dallas, Texas (AWWA) M. English, Pentair Valves & Controls, Pelham, Ala. (AWWA) F.L. Hinker, Consulting Engineer, Santa Rosa, N.M. (AWWA) J.R. Holstrom, Val-Matic Valve & Manufacturing Corporation, Addison, Ill. (AWWA) M. Ford
29、, Kinetrol USA Inc., Wakefield, R.I. (AWWA) B. James, TTR Group Inc., Oakville, Ont. (AWWA) A.W. Libke, DeZURIK, Sartell, Minn. (AWWA) M. MacConnell, Metro Vancouver, Burnaby, B.C. (AWWA) W.H. Peffley, Crawford Murphy & Tilly, Springfield, Ill. (AWWA) F.R. Underwood, K-Tork Actuators & Controls, Dal
30、las, Texas (AWWA) J. Wilber, American AVK, Littleton, Colo. (AWWA) The AWWA Standards Committee on Power Actuating Devices for Valves and Slide Gates, which reviewed and approved this manual, had the following personnel at the time of approval: Fred L. Hinker, ChairAmzad Ali, Vice-Chair General Inte
31、rest Members A. Ali, ADA Consulting, Surrey, B.C. (AWWA) B.E. Bosserman, Engineering Consultant, Mission Viejo, Calif. (AWWA) F.L. Hinker, Consulting Engineer, Santa Rosa, N.M. (AWWA) K.H. Hipps, CDM Smith Inc., Chicago, Ill. (AWWA) T.J. McCandless 1 , Standards Engineer Liaison, AWWA, Denver, Colo.
32、 (AWWA) J.P. Musich, Wright-Pierce, Topsham, Maine (NEWWA) W.H. Peffley, Crawford Murphy & Tilly, Springfield, Ill. (AWWA) Acknowledgments 1Liaison, nonvoting xii AWWA Manual M66 Producer Members R. Arnold, Rotork Controls Inc., Rochester, N.Y. (MSS) J.V. Ballun, Val-Matic Valve & Manufacturing Corp
33、oration, Elmhurst, Ill. (AWWA) P.E. Brunelle, Rodney Hunt Company, Orange, Mass. (AWWA) L.H. Elliott, EIM Company Inc. Valve Controls, Missouri City, Texas (VMA) J.R. Holstrom, Val-Matic Valve & Manufacturing Corporation, Addison, Ill. (AWWA) M.D. Rooney 2 , Emerson, Lynchburg, Va. (AWWA) F.R. Under
34、wood, Rotork, Dallas, Texas (AWWA)User S. Carpenter, San Diego County Water Authority, Escondido, Calif. (AWWA) T.W. Knowlton, Salem & Beverly Water Supply Board, Beverly, Mass. (NEWWA) M. MacConnell, Metro Vancouver, Burnaby, B.C. (AWWA) P. Ries, Denver Water Department, Denver, Colo. (AWWA) 2Alter
35、nate 1 AWWA MANUAL M66 Chapter 1 Introduction Hydraulic and pneumatic actuators are externally mounted on ball, plug, and butter- fly valves, and on slide gates to provide automatic control of these devices in water and wastewater applications. When combined with control devices such as solenoid val
36、ves or positioners, the valves and gates can be used to remotely control water and waste- water treatment processes or process variables including flow and pressure. Many of these actuators also have the feature of providing field-adjustable operating times and, when equipped with pneumatic or hydra
37、ulic power systems, can continue to operate after loss of electrical power. HISTORY Simple gate valves date back to ancient times in Greek and Roman water and irrigation systems. These gates were mostly operated by manual levers or screws. It was not until the industrial revolution and the use of st
38、eam power that valves became automated with power actuators. Since then, hydraulic and pneumatic actuators have been a staple in water and wastewater systems, particularly as valves grew in size and became extremely difficult to operate manually. The advent of automation made it desirable to operate
39、 valves remotely with computerized process control systems. Figure 1-1 illustrates a ball valve equipped with a pneumatic vane-type actuator that controls the flow from a high-service water pump. Given the increased use of automatic process systems, the use of power actuators continues to grow. The
40、power actuator positions the valve in response to system-control signals to complete a system-control loop. When flow or pressure must be controlled as part of a process, a sensing device such as a pressure transmitter or flowmeter sends a sig- nal to a process controller, which in turn compares the
41、 signal to the desired system param- eter and sends a position signal to the power actuator. The power actuator is directly coupled to the closure member of the control valve and is therefore an essential element of the control loop (Skousen 1997). 2 CYLINDER AND VANE ACTUATORS AND CONTROLSDESIGN AN
42、D INSTALLATION AWWA Manual M66 Since a number of valve types are used to control processes, a similar number of various actuator types are used to control these valves. In response, the valve industry has developed actuators for both linear and rotary valves. When automated valves are needed, either
43、 hydraulic actuators or electric motor actuators are specified. Electrical actu- ators provide great versatility in valve automation, but hydraulic actuators provide the ability to store energy and operate the valve without electrical power. Hydraulic systems also provide safe operation of valves, w
44、hich may be located in hazardous environments. Furthermore, in the event of an electrical power outage, hydraulic and pneumatic systems can still function to provide safe shutdown or isolation of the system. Electric and hydraulic actuators are used regularly in many industries, including oil, gas,
45、and power, but their use for the waterworks industry was standardized by AWWA Standard C540 in 1987. In 2008, AWWA C540 was withdrawn and replaced by standards AWW A C541, Hydraulic and Pneumatic Cylinder- and Vane-Type Actuators for Valves and Slide Gates, and AWWA C542, Electric Motor Actuators fo
46、r Valves and Slide Gates. Note, like all AWWA standards, C541 and C542 are updated regularly, as necessary depending on new technology and requirements. PURPOSE The purpose of this manual is to explain the fundamental concepts of hydraulic and pneu- matic power actuators so users with a technical ba
47、ckground can understand, specify, and install these actuators on valves and slide gates. The information in this manual must be used in conjunction with data from actuator and valve manufacturers to select and size the correct actuator models for specific applications. Sizing parameters such as thru
48、st and torque are explained so the sizing method- ologies recommended by actuator manufacturers can be applied to specific applications. Also, the effects of certain valve application parameters, such as flow rate or differential pressure, on actuator operation are discussed. Figure 1-1 Quarter-turn
49、 vane-type actuator provides remote control of a ball valve Source: Courtesy of Val-Matic Valve & Mfg., Corp. INTRODUCTION 3 AWWA Manual M66 Finally, installation and operation guidelines are presented for startup procedures and troubleshooting power actuators in the field. GENERAL APPLICATION Cylinder-type actuators produce a linear motion to operate a slide gate. Hydraulic or pneumatic pressure is applied to either side of the cylinder piston to generate linear force or thrust. The cylinder rod is attached to the gate and causes it to rise and fall i
