HYDRAULIC VALVE REMOTE CONTROL SYSTEM
OVERVIEW
Nordic Flow Control’s compact design for our Hydraulic Valve Remote Control Systems does not compromise on power. Our systems operate at a higher torque level even with our smaller actuators. Submerged applications are available, and maintenance is possible even during operation. By having a hand pump in a deck box with solenoid valves, manual operations are now possible.
Our Hydraulic Valve Remote Control Systems are tried and tested in the harshest conditions. The system consists of the hydraulic actuator, a power unit, solenoid valve cabinet, and the control station with operating system.
Our actuators and control systems are able to match and operate valves with no limitations.
BENEFITS
• Able to operate bigger size valves with smaller actuators • Able to use for submerged applications • Cost efficient • Reliable • Able to operate at hazardous areas • Simplicity of design and control
Nordic Flow Control Valve Remote Control Systems 1 COMPONENTS ACTUATORS Nordic Flow Control’s actuators are manufactured using sophisticated machinery in our own production plant. They convert hydraulic energy directly into a mechanical rotating movement by using the rack and pinion principle, elimi- nating cost from intensive servicing, maintenance and the sensitivity of transmission elements.
Our actuators are created for durability, performance and cost effectiveness. Our new NRA series actuators are now more compact and provide higher torque at even smaller sizes. They have a longer life span, with higher efficiency. Polymer bearings for smaller actuators and ball bearings for bigger actuators are used to reduce friction between the parts. Mounting is according to ISO5211 standards, but can be customised to meet other requirements.
With no need for valves to be dismounted, maintenance work during normal operations is possible, cutting down- time needed for repairs. A set of repair kit will be provided for every actuator supplied.
Features
• Compact and simple rack and pinion design • No external tubing • Replaceable brass rings • Submerged/Non-submerged • High reliability • Left chamber is equivalent to right chamber, and spares are interchangeable for the same model of actuators • Can be converted to spring return using the same actuator body • Bypass valve included for easy purging of line • Suitable for all Quarter-turn Valves • Adjustable OPEN/CLOSE positions • Meets the requirements from major classification authorities like American Bureau of Shipping, Det Norske Veri- tas, Lloyd’s Register of Shipping, Germanischer Lloyd, Bureau Veritas, China Classification Society and others • Suitable for Marine and Offshore applications Benefits
• Minimal parts/spares purchase required • Maintenance is possible during “live” operations, with no need to dismount valve during servicing and mainte- nance • Ease of repair and maintenance Optional Equipment
• Actuator-mounted Limit Switch (Continuous or ON/OFF) • Epoxy coating (Thickness and paint colour) • Submerged accessories • Emergency operation Hand Pump
2 Nordic Flow Control Valve Remote Control Systems A Closer Look At Nordic’s Actuators NRA SERIES DOUBLE ACTING ACTUATORS
TECHNICAL SPECIFICATIONS
Double Acting Hydraulic Actuator Single Acting Hydraulic Actuator Working Pressure 135 bar 135 bar Rotation 90o +/- 3o 90o +/- 3o Indication OPEN/CLOSE on shaft OPEN/CLOSE on shaft Protection IP65/IP68 IP65/IP68 Colour Black (Matte finish) Black (Matte finish) Hydraulic Media Recommended acid free hydraulic Recommended acid free hydraulic viscosity range 15 to 200 cSt viscosity range 15 to 200 cSt Working Temperature -15oC to 80oC (Standard) -15oC to 80oC (Standard)
Nordic Flow Control Valve Remote Control Systems 3 TECHNICAL SPECIFICATIONS – ACTUATOR DRAWINGS
4 Nordic Flow Control Valve Remote Control Systems Nordic Flow Control Valve Remote Control Systems 5 CABINETS AND DECK BOXES Solenoid Valve Cabinet
Nordic Flow Control’s Solenoid Valve Cabinet (SVC) centralised cabinet design houses all the non-IS solenoid valves that are used to control the direction of oil flow to the actuators. The solenoid valve cabinet is installed in safe, non- hazardous areas and the PLC I/O modules can be installed in the SVC per requirements.
The SVC receives signals from the switches in the control consoles or from the computer system which activates the solenoid valves.
Our SVC units come in standard 60, 72, and 96 control valve designs. The cable entry can be customised to be from the top, bottom or side to suit requirements.
The Cabinet Consists of:
• Solenoid Valves • Throttle Valves • Pressure Gauges • Feedback Indicator Switches • Quick coupling • CETOP 3 Manifolds • Flow switches and/or Volumetric Position Indicators (VPI) for ON/OFF or modulating feedback • PLC remote I/O Modules and necessary electrical components option in the processing compartment • High-Pressure Filter (Optional) TECHNICAL SPECIFICATIONS Working Pressure 135 bar Max Test Pressure 200 bar Fitting Connection 1/4” BSPP or 3/8” BSPP
Intrinsically Safe Deck Boxes
Nordic Flow Control’s watertight Deck Boxes with Centralised Intrinsically Safe (IS) solenoid valves are installed in hazardous areas.
The cabinet consists of: • IS Solenoid Valves • Throttle Valves • Pressure Gauges • Feedback Indicator Switches • Quick coupling • CETOP 3 Manifolds • Flow Switches and/or Volumetric Position Indicators (VPI) for On/Off or modulating feedback • All barriers are located at the Safe Area • High-Pressure Filter (Optional) TECHNICAL SPECIFICATIONS Working Pressure 135 bar Max Test Pressure 200 bar Fitting Connection 1/4” BSPP or 3/8” BSPP
6 Nordic Flow Control Valve Remote Control Systems NORDIC’S Model SVC 60 Solenoid Cabinet is able to hold 10 manifolds, Totaling 60 Solenoid Valves.
NORDIC’s Model SVC 72 Solenoid Cabinet is able to hold 12 Manifolds, Totaling 72 Solenoid Valves.
Nordic Flow Control Valve Remote Control Systems 7 NORDIC’s Model SVC 96 Solenoid Cabinet is able to hold 16 Manifolds, Totaling 96 Solenoid Valves.
Solenoid Valve Cabinet with Processing Cabinet
8 Nordic Flow Control Valve Remote Control Systems HYDRAULIC POWER UNIT
Nordic Flow Control’s Hydraulic Power Unit (HPU) is approved for use on several vessel classifications and facilities. Its proven reliable and compact design allows it to be placed and used in confined areas.
The HPU is designed for 100% standby. In the event of a power failure of the main input, the dual input feature enables the auxiliary input to cut-in automatically.
The control unit consists of a local starter cabinet or a remote operation panel in the control console with a manual switch for selecting the pump to be operated, giving the end user the flexibility to control the necessary functions both remotely and locally.
Nordic Flow Control Valve Remote Control Systems 9 Our HPU is delivered as a one skid-mounted unit, and it contains the following main components:
• Oil reservoir with a capacity to be calculated depending on the number of actuators • Electric motors to be controlled from separate starters • Hydraulic pump • Valves and Manifolds • Accumulator and charging kit • Starter Control Panel and Control Panel • Sight Glass • Level Switches • Pressure Switches for START/STOP of pumps at preset values • Safety Valves • Pressure Gauge • Oil temperature monitoring
The HPU has been reviewed as an extremely reliable power unit. From standard to customised units, they are very well designed. Our standard units come with two motors, for back up purposes and to extend the lifespan of our HPU.
All motors, the electrical cabinets and all other equipment come with IP55 protection to ensure greater performance.
Our HPU is designed to be user-friendly. The layout for the electrical and hydraulic components is placed systematically and the open design allows for easy access during maintenance.
Features • Excellent dependability • Local and remote control • Low level, high pressure, high temperature alarms • Automatic and manual control for motor START/STOP • Backup reservoir allowing for auto transfer between the two reservoirs if needed • IP56 protection on motors electrical cabinet and equipment • Comes in three standard sizes of 150, 250 and 350 litres reservoirs
TECHNICAL SPECIFICATIONS
Reservoir Volume 150l 250l 350l Pump Capacity / 2 Pumps 7l/min 14l/min 14l/min Max Working Pressure 170 bar Electric Motor (2 nos) Voltage 440 V/60 Hz/3 Ph/4 pole Power Consumption 2.2 kw/each 4 kw/each 5.5 kw/each Bladder Accumulator 20l 50l 2 x 32l
10 Nordic Flow Control Valve Remote Control Systems Nordic Flow Control Valve Remote Control Systems 11 12 Nordic Flow Control Valve Remote Control Systems Nordic Flow Control Valve Remote Control Systems 13 HYDRAULIC SYSTEM ACCESSORIES Double Pilot Block
The Double Pilot (DP) Block is designed to be used on both our NRA and NHR series of double acting actuators. It contains a throttling valve which is used for adjusting speed when regulating the valve’s opening and closing speeds.
DP Block THROTTLE VALVE
Features • A Double Pilot (DP) Check Valve with hydro-lock function to provide for loss of pressure in oil chamber caused by external factors • Throttling Valve for speed adjustment to minimise water hammering effect • A pressure relief valve set at 160 bars to prevent over-pressurising the actuators by releasing the hydraulic oil from the chamber if the pressure inside goes higher than 170 to 180 bar • A hand pump connection that allows emergency operation by means of a portable Hand Pump • Quick coupling to connect the hand pump for emergency operation of actuator during power failure
Operation For use with Nordic Double Acting Actuators: • DP Block consists of a Hydraulic DP Check Valve, quick connection for emergency hand pump operation, pressure relief valves attachment and speed adjustment • Able to be used on all Nordic actuator models
For use with Submerged Actuators: • DP is Mounted on the DPCO (Deck Plate) Block at the deck for easy manual override operations • A Submerged Cap will be added onto the actuator’s indicator • SPCO (Submerged Plate) Block will be placed on the actuator Submerged Applications Accessories
DPCO is the deck plate used to mount the DP/SAC Deck Plate block in the dry area for the actuator in submerged (DPCO) conditions.
By using the SPCO. We can cover Ports A and B with the Submerge actuator in submerged conditions. There will be a DP/ Plate (SPCO) SAC Block in the dry area.
The pinion gear is covered by the submerged cap when Submerged the actuator is in submerged conditions to prevent water Cap ingress.
14 Nordic Flow Control Valve Remote Control Systems SAC Block
Nordic Flow Control’s SAC Block is designed to be used on our NRA and NHR series single acting actuators. The SAC consists of a quick connection for emergency hand pump operation as well as a connection for throttle valves.
A throttling valve is also incorporated for adjusting speed, when regulating the valve’s opening/closing speed. This feature also greatly reduces the water-hammering effect.
SAC Block
DPCO Block
Features • Throttling valves to adjust the speed of the hydraulic oil flow • Quick coupling to connect the hand pump during emergency conditions or hydraulic power failure to open or close the valve
Operation For use with Nordic Single Acting Actuators: • The SAC Block consists of a quick connection for emergency hand pump operation and speed adjustment • Spring action by means of disc springs
For use with Submerged Actuators: • SAC Block is mounted on the DPCO (Deck Plate) Block at the deck for easy manual override operations • A Submerged Cap will be added onto the actuator’s indicator • SPCO (Submerged Plate) Block will be placed on the actuator
Nordic Flow Control Valve Remote Control Systems 15 Manifold
Our manifolds work with a stacked design that comes in 6-station blocks. The design allows placements behind each manifold in a solenoid valve cabinet and very compact hydraulic systems can be built upon each station.
Besides the A and B user ports, there are two throttle/stop valves on each station that regulates the flow and can be closed for repairs at the actuators.
The manifolds are provided with screws and recesses for cabinet mounting.
Features • Compact and unique design • Throttle valves on each station • Systems bleed valve on each manifold • Hand pumps connections for emergency operation
TECHNICAL SPECIFICATIONS
Working Pressure 135 bar Maximum Test Pressure 200 bar Fitting Connection 1/4” BSPP Weight of Nordic 6-Station 6 kg Weight of Bottom Section 2 kg Weight of Top Section 1 kg
Materials Manifold, Bottom and Top Block Aluminium 6061-T6 Throttle/Stop Valve Brass Hand Pump Connection Steel Seal Ring NBR
16 Nordic Flow Control Valve Remote Control Systems Components
In the top block, a system bleed valve and a pressure gauge (0 to 250 bar for P-line pressure) are incorporated. Top Block When purging the pressure line P to the tank line T, the bleed valve is to be opened.
In the bottom block, there are two hand pump connections on the P and T ports, which are incorporated for the emergency operation of the entire manifold. Bottom Block Before using the hand pump connection, the two stop valves that are incorporated in the P and T ports should be closed.
Blank Plate The blank plate is used for blanking off connections that are not used on the manifold.
A check valve is used in the manifold (T-line) in order to have flow moving in one direction, preventing back Check pressure. Valve The check valve is a standard feature in our manifold system.
Valve The throttle valve is used for speed adjustments and shut off.
Nordic Flow Control Valve Remote Control Systems 17 FEEDBACK UNITS MODULATING LIMIT SWITCH
Nordic Flow Control’s Modulating Limit Switch, for monitoring and modulating valves, is suitable for use in hazardous areas. Its robust and compact design conforms to EN50014 and EN50018, which makes it also suitable for Zone 1 and Zone 2 applications.
Features • Aluminium casting with powder coating body • Bolts on visual position indicator making it secure and weatherproof • Quick-set cam • Dual cable entry • Captive cover bolts • Easy mounting bracket
TECHNICAL SPECIFICATIONS
Enclosure Flameproof EExd IIB T6 and EExd IIC T6 Weatherproof Protection IP67/IP65 Coating External powder coated Anodized surface against corrosion (Optional) Area Zone 1, 2 Gas Classification Exd IIB(C) T6 Temperature Range -20°C to 85°C (Higher temperature available upon request) Cable Entry 2 x PT 3⁄4” 2 x PF 3⁄4” 2 x NPT 3⁄4” 2 x M20 X 1.5 upon request Maximum 4 Terminal 8 terminal strips (6 for switches, 2 for solenoid connection) Position Monitoring Indicator 0°C to 90°C Yellow - Open, Red - Close Switches 2 x mechanical switches Potentiometer Position transmitter 0 to 1 K Mounting Bracket VDI/VDE 3845 NAMUR
18 Nordic Flow Control Valve Remote Control Systems ON/OFF LIMIT SWITCH
/ iTheÊ "ON/OFF É"Ê ÌLimitÊ -ÜÌV SwitchÊ ÃisÊ >aÊ ÀÌ>ÀÞrotaryÊ «ÃÌpositionÊ `V>ÌÀindicatorÊ ÕÃi`usedÊ ÌtoÊ ÌÀmonitorÊ Ì itheÊ "* OPEN/CLOSE É "- Ê «ÃÌpositionÊ vofÊ Ì itheÊ Û>Ûi°valve.Ê The dome position indicator is constructed from high impact resistant polycarbonate material which offers instant recognition of valve position from up to 50 metres.
Features UÊ• 6ÃÕ>VisualÊ *ÃÌPositionÊ `V>ÌÀIndicator UÊ• +ÕVÃiÌQuick-setÊ V>cam UÊ• ÕÌ«ÌMulti-pointÊ ÌiÀ>terminalÊ ÃÌÀ«strip UÊ• Õ>DualÊ ÜÀiwireÊ «ÌÌ}potting UÊ• >«ÌÛiCaptiveÊ VÛiÀcoverÊ LÌÃbolts UÊ• >ÃÞEasyÊ ÕÌ}mountingÊ LÀ>ViÌbracketÊ
TECHNICAL SPECIFICATIONS
VÃÕÀiÊEnclosure 7i>Ì iÀ«Àv]Weatherproof,Ê *ÈÇIP67 /i«iÀ>ÌÕÀiTemperatureÊ ,>}iÊRange Óäc -20°CÊ ÌtoÊ nxc 85°CÊ /iÀ>TerminalÊ -ÌÀ«ÊStrip n8Ê «ÌÃpoints Position Indicator 0 to 90°C : Open – Yellow, Closed - Red ShaftShaft 304 stainless steel VÀMicroÊ -ÜÌV iÃÊSwitches 1Ãi`UsedÊ inÊ 1 ULÊ -CSAÊ >««ÀÛi`approved ÃiÀÌÃÊInserts ÀâiBronze ",}ÃÊO-Rings NitrileÌÀiÊ ,ÕLLiÀ®(Rubber) Cams Polycarbonate Spring & Cover ScrewsScrews 304 stainless steel 6Ì>}iÊVoltage >ÝÕMaximumÊ Óxä6]250V,Ê ACÊ ÀorÊ DC ÕÀÀiÌÊCurrent ä°È0.6AÊ £Óx6125VÊ ÀorÊ DCÊ £È16AÊ £|Ó*1⁄2HPÊ £Óx]125, Ê Óxä250Ê ACÊ £Èή16(3)AÊ Óxä6250VÊ -Ê /£xäT150 >LiCableÊ ÌÀÞÊEntry Ó2Ê ÝxÊ £|Ó»1⁄2”Ê *PFÊ */®(PT)Ê (NPT) */® -ÜÌV SwitchÊ /Þ«iÊType Ó-* /2SPDTÊ iV >V>MechanicalÊ ÃÜÌV iÃswitches Ê *ÀÝÌÞ(ProximityÊ ÃiÃÀîsensors) Painting Polyester powder coating with black colour À>ViÌÊBracket *>ÃÌVÉ*>ÌiPlastic/PlateÊ ÃÌiisteel
Nordic Flow Control Valve Remote Control Systems 19 VALVE POSITION INDICATOR
When the actuator is submerged, the measurement of the actuator position by means of direct indication is not feasible. Nordic Flow Control’s Valve *ÃÌPositionÊ `V>ÌÀIndicatorÊ 6*®(VPI)Ê V>canÊ LibeÊ ÕÃi`usedÊ vÀforÊ LÌ bothÊ ÃÕLiÀ}i`non-submergedÊ >`andÊ ÃÕLiÀ}i`submergedÊ applications, allowing accurate actuator measurement regardless of setup.
The basic intention of the VPI is to receive and measure position feedback from the actuator. The working principle behind is through the measurement of the oilÊ `ë>ViiÌdisplacementÊ yÜ°flow.Ê AÊ }i>ÀgearÊ Ü iiwheelÊ ViVÌi`connectedÊ ÌtoÊ Ì itheÊ oilÊ yÜflowÊ ÀÌ>ÌiÃrotatesÊ Ü iwhenÊ the actuator is rotated. The rotation of the gear wheel is also connected to a 3-wire potentiometer. The output signal from the potentiometer ranges from 0 to 1 K¾Ω.
VALVE POSITION SIDE VIEW TOP VIEW INDICATOR Features UÊ• ÝViiÌExcellentÊ `i«i`>LÌÞdependability UÊ• 7iWellÊ VÀ>vÌi`craftedÊ ÌtoÊ ÃÕÌsuitÊ ÃÌmostÊ µÕ>ÀÌiÀquarterÊ ÌÕÀturnÊ Û>ÛiÃvalves UÊ• }iiÀi`EngineeredÊ iëiV>ÞespeciallyÊ vÀforÊ >ÀiMarineÊ >`andÊ "vvà ÀiOffshoreÊ >««V>ÌÃapplications UÊ• ,iViÛiReceiveÊ «ÃÌpositionÊ vii`L>VfeedbackÊ vÀfromÊ >VÌÕ>ÌÀÃactuators UÊ• ,Ì>Ì>RotationalÊ }i>ÀgearÊ Ü iiwheelÊ ÃisÊ ViVÌi`connectedÊ ÌtoÊ >aÊ ÎÜÀi3-wireÊ «ÌiÌiÌiÀpotentiometer UÊ• "ÕÌ«ÕÌOutputÊ Ã}>signalÊ vÀfromÊ Ì itheÊ «ÌiÌiÌiÀpotentiometerÊ À>}iÃrangesÊ vÀfromÊ ä0Ê ÌtoÊ £1Ê K¾Ω
TECHNICAL SPECIFICATIONS
Maximum Working Pressure 135 bar Maximum Test Pressure 200 bar Rotation Indication Pointer /i«iÀ>ÌÕÀiTemperatureÊ ,>}iÊRange £nc -18°CÊ ÌtoÊ näc 80°C SOLENDIDSOLENOID VALUEVALVE Þ`À>ÕVHydraulicÊ i`>ÊMedia V`AcidÊ vÀiifreeÊ Þ`À>ÕVhydraulicÊ oil Viscosity 15 to 200 cSt >ÝÕMaximumÊ yÜflowÊ À>ÌirateÊ J@Ê £Îx135Ê L>ÀÊbar £x15Ê Él/min Weight 1.3kg ÌÀ>ÌFiltrationÊ ÀiµÕÀiiÌÃÊrequirements £ä10Ê μmÊ >LÃÕÌiabsoluteÊ ÀorÊ wiÀfiner iVÌConnectionÊ >ViÊFace /"*CETOPÊ ,RÊ Îx35HÊ ÃâisizeÊ Î3
Materials VPI ÕÃ}ÊHousing ÕÕAluminium Screws Stainless steel VPI WITH SOLENOIDSOLENDID
20 Nordic Flow Control Valve Remote Control Systems LOCAL INDICATOR
Nordic Flow Control Local Indicator is used to display the position of the valve (OPEN/CLOSE) locally if the valve is in a submerged location. Once the incoming pressure exceeds the pressure setting on the pressure relief valve inside the local indicator, the oil would flow to a small chamber, causing the piston to move towards one side; as a result the indicator would deflect and gives the OPEN/CLOSE status of the valve.
Local Indicator – Double Acting (Without Remote Signal)
TECHNICAL SPECIFICATIONS
Housing Aluminium c/w type 3 anodizing Screws Stainless steel Working Pressure 135 bar Weight 0.7 kg Hydraulic Media Acid free hydraulic oil Viscosity 15 to 200 cSt Filtration Requirements 25 μm absolute or finer Temperature Range -18ºC to 80ºC
Local Indicator – Single Acting (Without Remote Signal)
TECHNICAL SPECIFICATIONS
Housing Aluminium c/w type 3 anodizing Screws Stainless steel Working Pressure 135 bar Weight 0.7 kg Hydraulic Media Acid free hydraulic Oil Viscosity 15 to 200 cSt Filtration Requirements 25μm absolute or finer Temperature Range -18ºC to 80ºC
Nordic Flow Control Valve Remote Control Systems 21 HYDRAULIC HAND PUMPS
Fixed Portable The fixed hydraulic hand pumps are usually mounted The portable hydraulic hand pumps are used for manual in the series with the critical valves, e.g.: the shipside override at either the solenoid valve cabinet or the valve valve. location.
TECHNICAL SPECIFICATIONS
Maximum System Working Pressure 135 bar Maximum System Test Pressure 160 bar Maximum Hand Pump Pressure 170 bar Safety Valve Setting 180 bar Weight With 5L Oil 20 kg Oil Displacement Per Double Stoke 25 cm3 Oil Viscosity Range 15 to 300 cSt Temperature Range -15°C to 80°C Recommended Temperature Range NAS 1630/10 or ISO Solid Containment Code 18/15 Standard Hose 3 m (Other hoses on request)
22 Nordic Flow Control Valve Remote Control Systems NORDIC HYDRAULIC FIXED HANDPUMP
3 Way Ball Valve Port 1/4” BSP
Removable Handle
Nordic Flow Control Valve Remote Control Systems 23 NORDIC HYDRAULIC PORTABLE HANDPUMP
24 Nordic Flow Control Valve Remote Control Systems PNEUMATIC VALVE REMOTE CONTROL SYSTEM
OVERVIEW
Nordic Flow Control understands that space is a premium on a vessel; with that in mind, our Pneumatic Valve Remote Control System is perfect. We are able to do Centralised and Decentralised configurations for our system to suit your vessel, and we can provide for Submerged applications.
BENEFITS • Environmentally friendly • Cost efficient • Reliable • Explosion and fire safety • Simplicity of design and control
FEATURES • Maintenance is fuss free • DNV Type Approval • Normal working temperature of -32°C and 90°C • The actuators able to be actuated with pneumatic pressure for up to 8bar (optional up to 15bar) • Can be equipped with limit switches, solenoid valves, positioners, manual override wheels or unclutchable gearboxes • Broad range of couplings available to adapt the actuators to almost any valve
NORDIC PNEUMATIC ACTUATORS
FEATURES • DNV Type Approval • Normal working temperature of -32°C and 90°C • Constructed from silicone free materials that are resistant to oxidation • Actuator body conforms to ISO 5211, DIN 3337, VDE 3845 and NAMUR standards • Actuator construction conforms to PED Directive 97-23-EC and ATEX Directive 94-9-EC
Nordic Flow Control Valve Remote Control Systems 25 TECHNICAL SPECIFICATIONS
Scotch Yoke Design Actuator
No Description No Part No Description 1 Housing 14 Sleeve 27 Nut
2 Cover 15 Bushing 28 Stroke Bolt
3 Scotch Yoke 16 Washer 29 Nut
4 Trust Bearing 17 Plate 30 Pipe
5 Bushing 18 Gasket 31 Piston
6 Bolt 19 Sleeve 32 External Housing
7 Cylinder 20 O-Ring 33 Internal Housing
8 Bolt 21 O-Ring 34 External Spring
9 Stroke Bolt 22 Piston 35 Internal Spring
10 Gasket 23 O-Ring 36 Cap
11 Cover Nut 24 O-Ring
26 Nordic Flow Control Valve Remote Control Systems Pneumatic Actuators (Rack And Pinion Design) Double Acting Pneumatic Actuator
No Description No Part No Description 1 Actuator Body 6 Spring Clip 11 Stroke Bolt Washer 2 Pinion 7 Piston 12 Stroke Bolt Retaining Nut 3 O-Ring (Lower Pinion) 8 Piston Steel 13 End Cap 4 O-Ring (Top Pinion) 9 Stroke Bolt 14 End Cap Seals 5 Thrust Bearing (Pinion) 10 Stroke Bolt O-Ring 15 End Cap Bolts
Single Acting Pneumatic Actuator
No Description No Part No Description 1 Indicator 10 End Cap 19 Bearing (Top Pinion) 2 Spring Cap 11 Piston Bearing 20 Thrust Bearing (Pinion) 3 Thrust Washer (Pinion) 12 Piston Seal 21 Stroke Cam 4 Thrust Bearing (Pinion) 13 Piston Guide 22 Pinion 5 Actuator Body 14 Stroke Bolt 23 Bearing (Lower Pinion) 6 Piston 15 Stroke Bolt Retaining Nut 24 O-Ring (Lower Pinion) 7 Spring (Cartridge) 16 Stroke Bolt Washer 25 Plug 8 End Cap Seats 17 Stroke Bolt O-Ring 9 End Cap Bolts 18 O-Ring (Top Pinion)
Nordic Flow Control Valve Remote Control Systems 27 TECHNICAL SPECIFICATIONS
Pressure Ranges 2 to 8 bar Temperature Ranges -20°C to 80°C Operating Media Filtered dry or lubricated for non-corrosive gas Stroke Adjustment 0° and 90° with standard adjustments ±5° Lubrication All moving parts are factory lubricated for entire life cycle of actuator Connections Bottom drilling complies with ISO5211/DIN3337 to match valve. Interface with solenoid valve, shaft top end and top drilling for assembling accessories are in accordance with VDI/VDE-3845, NAMUR standard Indicator Position indicator with NAMUR mounting Pinion Hardened allow steel pinion is precision ground and nickel-plated (over 25μm) in order to reduce friction, provide maximum wear resistance. Full conformance with the newest standards of ISO5211 and DIN3337. The dimensions can be customised. Stainless steel and aluminium are also available. Actuator Body Aluminium extrusion is hard anodized (over 30μm) to protect against wear and corrosion while reducing piston friction to the absolute minimum. Other options such as nickel plating, PTFE and powder polyester painting are also available. Travel Adjustment Standard adjustment is ±5°in both the open and close positions through easily accessible external adjustment bolts High Performance Springs High tensile steel springs are coated with zinc phosphate for corrosion (for spring return only) resistance and longer service. The pre-loaded spring can be safely and rapidly disassembled. Bearings and Guides Highly durable compound material provides high trust stability with minimum friction and long life. O-Rings NBR o-rings provide trouble free operation at standard temperature ranges. Viton and silicone o-rings are available for high or low temperature applications.
28 Nordic Flow Control Valve Remote Control Systems Decentralised System
In a decentralised system, Namur mount solenoid valves are mounted on our pneumatic actuators. This configuration does away with the solenoid valve cabinet, saving space.
Nordic Flow Control Valve Remote Control Systems 29 NAMUR Mounted Solenoid Valves
TECHNICAL SPECIFICATIONS
Item 5, 3 Port 2 Position 5 Port 3 Position Fluids Compressed air and inert gase 2 Pressure 1.5 to 10 bar 2.0 to 10 bar Eff Sectional Area (mm2) – 5 bar 19 11.5 Ambient and Fluid Temperature 5°C to 6°C Response Time (5 bar) 25ms or less 35ms or less Maximum Working Frequency 5c/sec 3c/sec Manual Override Push button (Standard)/ Lever lock (Optional) Coil Insulation Class F-Class or equivalent Permissible Voltage Variation ±10% of rated voltage Off Minimum Residual Voltage AC: 20% or less/DC: 10% or less Power Consumption Holding – AC: 5.5VA (60 hz)/ DC: 2.5W
30 Nordic Flow Control Valve Remote Control Systems ELECTRIC VALVE REMOTE CONTROL SYSTEM
Electric Valve Remote Control System System Overview
OVERVIEW
Nordic Flow Control’s Electric Valve Remote Control Systems provide a compact, all-in-one solution for your electrical actuation needs.
BENEFITS • Combines high levels of functionality with precise positioning and multiple points • Electronic systems are easy to program for complex functions • Ease of maintenance
Nordic Flow Control Valve Remote Control Systems 31 COMPONENTS
Electrical Actuators
Features • Compact construction with a high output torque • Self-locking gear train maintains the position of the valve when the actuator is de-energised • Very good resistance to vibration • Adjustable mechanical travel limit stops prevent over travel • Emergency hand wheel and mechanical position indicator provided on all actuators as a standard • Fixing flange according to ISO standard • Removable drive socket for easy machining • Designed to fully open or close on an average of 20 to 30 times a day • Class III modulating actuators allows for selection between intermediate positions, for an average of 360 times per day, with a precision better than 2% • Waterproof enclosure • Corrosion resistant design • Explosion proof design • Motors are easily removable with front and rear totally enclosed lubricated ball bearings • Motors rated to S4 service (intermittent duty with starting under load) according to IEC 34-1
32 Nordic Flow Control Valve Remote Control Systems Components
• Transmission Gears The gear drive system is composed of 2 reduction stages: The first stage: A planetary system driven directly by a pinion on the motor drive shaft. The second stage: Driven by the satellite wheels of the planetary gear consisting of a worm and wheel gear type.
Since the planetary system permits a high speed reduction with an excellent efficiency, the subsequent gear is driven at a relatively low speed which ensures a better overall efficiency than normal standard gear designs. The gears are mechanically irreversible.
• Emergency Hand Wheel In case of loss of power supply or a faulty control system, the presence of a hand wheel enables the operator to easily drive the valve to any required position manually.
• Position Indicator A visual position indicator allows for a clear indication of the current valve position. In fact, this indicator is mechanically linked to the valve shaft.
• Travel Limit Switches Adjustment of travel limit switches is simply accomplished with a standard screwdriver, no disassembly is required. This reduces downtime due to maintenance.
• Asynchronous Motors The asynchronous motor technology offers the highest ratio of starting torque versus nominal torque. Thus, the actuator maximum torque capacity is available from the beginning of travel to unseat the valve.
• Motor Thermal Protection A built-in motor thermal switch protects the motor from excessive overheating conditions.
• Torque Sensors The output torque for valve operation is permanently measured by the lever deflection of the planetary gear external crown. This crown gear is maintained in position by two calibrated linear springs which can be set independently for each rotational direction to a desired torque value.
In the event the torque setting is reached, the crown lever compresses the spring to a point where a microswitch is tripped.
As this unique system is mechanically friction-free, exceptional precision and repeatability are obtained, which is highly appreciated when the device has to “close on torque”.
• Detachable Drive Bush The output drive socket can be easily removed from the actuator, without the use of any special tool, for adaptation to the valve shaft.
• Lifetime Lubrication The gear design permits lifelong lubrication by grease, thus reducing periodic maintenance requirements considerably.
Nordic Flow Control Valve Remote Control Systems 33 TECHNICAL SPECIFICATIONS General Specifications
Basic actuators include motor with thermal protection, gear case, emergency hand wheel, connection box, travel limit switches, torque switches and output drive with removable socket.
34 Nordic Flow Control Valve Remote Control Systems ELECTRO-HYDRAULIC UNIT (EHU)
The NORDIC Electro-Hydraulic Unit (EHU) is an integrated electro-hydraulic valve remote control system used for controlling valves and actuators remotely, developed to be mounted directly on Nordic’s actuators on board vessels and offshore platforms.
The EHU consists of a hydraulic pump driven by an electric motor. When in operation, the oil is siphoned from the tank through the suction filter to the pump, which then goes through the pilot operated check valve to the actuator port, causing the actuator to open the valves.
When the valve is fully opened, the motor will be stopped by a limit switch. The actuator in this instance will be hydraulically locked in position by the pilot check valve. Emergency operation can be conducted for both double and single acting EHU using the manual override using a portable hand pump connecting to the quick coupling port.
For single acting EHU, during loss of power, it causes hydraulic pressure drop and normally closed 2/2-way solenoid poppet valve open contact. Compressed spring will be released and quickly closes the valve for safety purpose.
Alternatively, NORDIC Electro-Hydraulic actuators can be operated locally through a Local Control Box. The Local Control Box contains two push buttons for “OPEN” and “CLOSE” functions, and a Local/Remote key to choose the mode of control, whether locally or remotely.
In addition, Electro-Hydraulic actuators can be interfaced through PROFIBUS.
ABOUT PROFIBUS
Applications PROFIBUS is able to seamlessly connect all types of devices without having to isolate process instruments from discrete devices with a second bus. In particular, PROFIBUS DP can be used to easily and reliably integrate Motor Control Centers (MCC), variable speed drives and switching gear with control systems.
PROFIBUS PA, which integrates seamlessly to DP, is used to network and provide power to field instruments. Both media types support the PROFIsafe profile for process safety, which allows the use of distributed fail-safe I/O.
The system is applied to network control of electro-hydraulic operated valves for ballast, bilge and fuel & cargo oil handling valve remote control systems. PROFIBUS DP serial communication is ideally suited to the control of NORDIC EHU. The PROFIBUS DP network can operate over a range of communication speeds and provides the mechanism for control of the actuator and feedback of EHU. The latest NORDIC EHU PROFIBUS DP cards support standard PROFIBUS DP.
Advantages • Suitable for marine applications • Adaptable for applications like easy plug and play • Capable of remote operation without any bus interface (bus optional) • Override possible on the Electro-Hydraulic itself through a Local Control Box or manually through a portable hand pump • The standard GSD files allow all PROFIBUS DP master devices to easily configure the system • Standardized I/O System reduces the number of spares needed • A network using PROFIBUS DP provides a cost effective method for connecting EHU in any location to the central control system simply and efficiently
Nordic Flow Control Valve Remote Control Systems 35 TECHNICAL SPECIFICATIONS Single Acting EHU
Nordic Double Acting Limit Switch Box Hydraulic Actuator Quick Coupling for Emergency Operation TerminalEnclosure Electro Hydraulic Unit Cable Entry 8 1a
2 3
4
5 Butterfly Valve 6
7
Circuit Diagram
Double Acting EHU
Limit Switch Box Needle Valve Quick Coupling for Emergency Operation Terminal Enclosure Electro Hydraulic Unit No. Item Cable Entry 1a /1b Single Acting Actuator/Double Acting 1b Actuator 2 2 Quick Coupling for Emergency Operation 3 4 Nordic Single Solenoid Valve (normally open) ActingHydraulic 2/2-way SolenoidPoppet Actuator Valve 4 5 Double Pilot Operated Check Valve 5 6 Electric Motor Butterfly Valve 6 Hydraulic Pump 7 7 Relief Valve 8 Throttle Valve for Single Acting Circuit Diagram Actuator Only (for emergency operation)
Single Acting EHU Double Acting EHU Working Pressure 135 Bar 135 Bar Ambient/Working Temperature -15oC to 40oC -15oC to 40oC Rotation 90o +/- 3o 90o +/- 3o Closing Clockwise Clockwise Indication On/Off on Drive Unit On/Off or Modulating on Drive Unit Enclosure Rating IP 65 IP 65 Viscosity Range 200 to 10 mm2/s 200 to 10 mm2/s Solenoid Valve 2/2-way, normally open poppet valve cartridge, - 230V AC coil Emergency Operation Emergency operations in the case of a loss of power Emergency operations in the case of a loss of power is carried out with a portable hand pump is carried out with a portable hand pump Motor Voltage Single phase AC, 230V AC 50/60Hz Single phase AC, 230V AC 50/60Hz Nominal Power 300W 300W Maximum Starting Current < 6A at 220V 50 Hz (varies with size of EHU) < 6A at 220V 50Hz (varies with size of EHU) Overload Protection Temperature switch opens at 140oC Temperature switch opens at 140oC Delivery Rate of Radial Piston Pump 0.2 ~ 0.5 l/min (varies with size of EHU) 0.2 ~ 0.5 l/min (varies with size of EHU) Maximum Operating Pressure 200 Bar 200 Bar Pump Relief Valve Preset to 145 Bar 145 Bar Duty Cycle S3 10% ED S3 10% ED
36 Nordic Flow Control Valve Remote Control Systems Nordic Flow Control Valve Remote Control System 99