Actuator selection and sizing

-Prof. Poonam Patil

Instrumentation Department
Bharati Vidyapeeth College of Engineering, Navi Mumbai

Types of valves are based on characteristics:

i. Linear
ii. Equal percentage
iii. Quick opening
CHARACTERISTICS GRAPH

1. Linear: Gives linear relationship between flow rate and stem travel
𝑄 = 𝑆
𝑄 𝑆
𝑚𝑎𝑥 𝑚𝑎𝑥

2. Quick Opening: with a small change in stem travel there is fast change in flow
rate.
3. Equal Percentage: Gives same % change in flow rate for a given % change in
stem position.
𝑆
(𝑆 )
𝑄 = 𝑄𝑚𝑖𝑛 𝑚𝑎𝑥𝑅

𝑅 = 𝑅𝑎𝑛𝑔𝑒𝑎𝑏𝑖𝑙𝑖𝑡𝑦

Numerical:
Q) A control valve operates from 3 to 15 psi control signal to have 40 gallons per
 minute flow rate. Express the signal i/p in terms of psi & % of range if
a) It is a linear valve from 0 to 90 gpm &
b) It is an equal % valve with rangeability 6 & 𝑄𝑚𝑖𝑛 = 15 𝑔𝑝𝑚

# For a linear valve equation of straight line 𝑦 = 𝑚𝑥 + 𝑐

 q=m(i/p)+c
y=flow rate in gpm (q)
x=i/p signal in psi
for 3 to 15 psi signal

x=3 psi q=0 gpm

x=15 psi q=90 gpm

𝑦 = 𝑚𝑥 + 𝑐
0 = (3) + 𝑐 1
90 = (15) + 𝑐 2

Solving equation 1 & 2 we get,

m=7.5 & c= -22.5

𝑦 = 𝑚𝑥 + 𝑐
𝑦 = 7.5𝑥 − 22.5

For y=40
40 = 7.5𝑥 − 22.5
7.5𝑥 = 40 + 22.5
62.5
𝑥=
7.5
𝑥 = 8.33 𝑝𝑠𝑖
for 40 gpm i/p signal is 8.33 psi

To get % of range i.e. 40 gpm out of 90 gpm

40
∗ 100 = 44.44%
90−0

Similarly, % of range for i/p signal 8.33 psi out of 3-15 psi,
8.33
∗ 100 = 69.41%
15−3

Therefore, % of i/p signal= 69.41%

b) for equal %=?
R=6 Q=40gpm
𝑄𝑚𝑖𝑛 = 15𝑔𝑝𝑚
𝑆
( )
𝑄 = 𝑄𝑚𝑖𝑛𝑅 𝑆𝑚𝑎𝑥
𝑆
( )
40 = 15 ∗ 6 𝑆𝑚𝑎𝑥

𝑆
( )
2.67 = 6 𝑆𝑚𝑎𝑥

𝑆
𝑆
log(2.67) = log (6( 𝑆𝑚𝑎𝑥 )) = 𝑙𝑜𝑔6
𝑆𝑚𝑎𝑥

𝑆
= 0.546
𝑆𝑚𝑎𝑥

= 54.6%
54.6% is the stem travel & the valve being equal % & the same value for % of a
range of flow rate.
I/P signal=54.7% of (15-3) of range
54.7 ∗ 12 = 6.564 𝑝𝑠𝑖
100

% flow rate of range= 54.6% (equal percentage)

 Control Valve Selection:

1. For liquid level control system with constant pressure drop a linear valve is
used.
2. For liquid pressure applications an equal % valve is used.
3. For compressible fluid pressure application use linear valve.
4. For ON-OFF control use quick opening valve.
5. For fast processes use equal % valve.
6. For slow processes use linear valve.
7. For high rangeability use equal % valve.
8. When process dynamics are not well known equal % valve is used.
9. For high temperature use butterfly valve
 10. For high pressure drop use globe, angle valve.
11.For corrosive services use ball valve.
12.For slurry liquid services, pinch or diaphragm valve is used.
13.For flashing application use globe, angle valve.
14.For abrasive liquid services, use globe & butterfly valve.
15.For gas applications use globe, pinch & angle valve.

ACTUATOR DESIGN

Below tables provide more specific recommendations depending on whether the system is for liquid
level, pressure control, flow control or any other type of system.
Actuator is defined as a device which receives the control signal from controller &
gives appropriate motion to the valve stem.
It also gives support to valve accessories such as valve positioner.
It is used to overcome the forces which are unbalanced due to friction, weight of
the moving part & control valve pressure drop.
A common misconception in our industry is that actuating a valve is as simple as
putting the most cost-efficient actuator on top of your valve of choice, but the
process is much more complicated than that. Selecting the correct actuator for the
size and purpose of the valve is key, but it’s only the first step. If the actuator isn’t
sized by a knowledgeable and technically trained expert, the results can be
disastrous and/or expensive.
When sizing an automated valve, the actuator must operate properly when on
demand, especially on Emergency Shutdown Valves (ESDVs). With constantly
increasing safety demands, more actuator buyers are taking the extra step of
requesting actuator sizing documentation.
For an actuator to be reliable, it must:

 Be capable of operating at the minimum supply pressure available

 Develop sufficient torque to overcome the valve torque throughout the
complete stroke
 Meet the service factor and safety factor established by the end user or what is
recommended by the valve manufacturer (whichever is higher).

An undersized actuator will be unable to operate the valve; on the other hand, an
oversized actuator has the potential to damage the stem of the valve as well as
being higher priced.
To size an actuator correctly, we need to understand:

 Minimum and maximum supply pressure

 Actuator type
 Fail mode
 Valve torque

Let’s look at what is required concerning the minimum and maximum supply
pressure. The normal pressure, which is often provided alongside the minimum and
maximum, should never be used to size the actuator.

MINIMUM SUPPLY PRESSURE

The actuator must be able to develop sufficient torque to operate the valve at the
minimum supply pressure. This will ensure the actuator will work even when the
supply pressure is at its lowest.
Can an actuator be sized for less than the minimum available supply pressure? Yes.
This practice is usually done when actuators are oversized and the maximum
torque of the actuator at the minimum supply pressure is exceeding the maximum
allowable stem torque. For this specific situation, a regulator and a relief valve
need to be added. The regulator will reduce the operating pressure even further,
below the minimum supply pressure, ensuring the actuator will not achieve a
torque output that could damage the valve. The relief valve will ensure that in the
event of a regulator failure, the output torque of the actuator at the minimum
supply pressure will not damage the valve stem. It’s recommended to set the relief
valve at 10% or 15% above the regulator setting.

MAXIMUM SUPPLY PRESSURE

The maximum supply pressure is important because the actuator must be able to
handle that pressure safely as well.
If it’s determined the actuator cannot handle the maximum supply pressure, there is
a way to adjust the package to perform safely. Installing a regulator and a relief
valve is a relatively straightforward and cost-effective solution. The more pressure,
the more torque the actuator has the potential to output; therefore, a regulator and a
relief valve also will reduce the probability the valve stem will be damaged due to
the excess torque from the actuator.
Properly sizing an actuator is an important step to realizing a valve’s full potential
safely and efficiently. Equally important is to choose the right type of actuator.

CHOOSING THE RIGHT ACTUATOR TYPE

There are subtle differences between the common actuator types, and
understanding the differences can help guide you when selecting the best one for
your application.
Rack and pinion actuators are more commonly used on small valves (<4 inches)
due to their small size and relatively low output torque. The torque output the
stroke is a straight line for rack and pinion actuators.
These actuators are most commonly used in process industries such as refining,
chemical and power generation.
Scotch yoke actuators are commonly used on bigger valves (/=4 inches) because
they have the capability to output higher torques.
The torque output throughout the stroke is a concave up parabola for a scotch yoke
actuator. This parabola is a result of a variable moment arm and is a unique
characteristic of a scotch yoke actuator. Since, in general terms, the torque is the
force generated by the pressure pushing the piston times the moment arm, the
torque at the mid position is lower than at the end positions because the moment
arm is minimum at the mid position and maximum at the end positions.

Spring return actuators use pressure to create a driving force in one direction and
a spring to return to the “home” position. Spring return actuators are usually
selected when the automated valve does not need to depend on an external motive
power to go to its home (open or close) position. For example, safety applications
like ESDVs most likely would need a spring return actuator.
Double-acting actuators use pressure to create a driving force to move in both
extend and retract directions. Double-acting actuators are usually selected when the
valve needs to stay in place (fail last) after the control signal or the supply pressure
has been lost. They also tend to be less expensive than spring return actuators.
As with any technical decision, many factors can impact which actuator is the
safest and most efficient option for your specific need. By working with engineers
and qualified supplier specialists, you will get the most out of the right valve
system for your unique application.

Parameters that affect actuator selection

The following parameters can affect the type of actuator that should be selected for
a valve :

1. Availability of power source: A hydraulic actuator cannot be used on

a plant if no source of high-pressure oil is available.

2. Torque and size of the valve: Large size and high pressure class
valves (such as a 30″ Class 1500 ball valve) require high torque for
operation. Selection of a very large pneumatic actuator for such a
large valve is not economical. A hydraulic actuator is recommended
in this case.

3. Failure mode: Pneumatic and hydraulic actuators stand in open or

closed positions during a power loss, unlike electrical actuators. These
types of valves are spring return, which means that upon power or
signal failure, the spring returns the valve to a predefined safe position
[1]. Therefore, for example, electrical actuators are not suitable for
emergency shut down valves that should be fully closed if power is
lost.

4. Speed of operation: Electrical actuators operate valves more slowly

than pneumatic and hydraulic actuators, so an electrical actuator may
not be an appropriate choice if an operations speed of 1 in./s or faster
is expected from the valve.
5. Frequency and ease of operation: It is common to use electrical
actuators for certain large size valves that are operated frequently
instead of manual operation, for ease of operation. For example, a 20″
class 300 manual ball valve with frequent operation is proposed to be
equipped with an electrical actuator just for ease of operation.
 6. Control accessories: Control accessories in electrical actuators are
integrated into the actuator, unlike pneumatic and hydraulic actuators.
In fact, electrical actuators do not require any space for control
accessories, which is an advantage. Hydraulic actuators have larger
control panels compared to pneumatic actuators.

7. Hazardous areas: The use of electrical actuators in a hazardous

environment may be limited in some cases. Different hazard zones
and classes are defined based on present of flammable gases or
vapours that may put restriction in usage of the electrical actuators.

8. Cost: Electrical actuators are the cheapest type of actuators, hydraulic

actuators are the most expensive and pneumatic lie between.

Actuator Basics-
The operating force is derived from compressed air pressure, which is applied to a
flexible diaphragm. The actuator is designed so that the force resulting from the air
pressure, multiplied by the area of the diaphragm, overcomes the force exerted (in
the opposite direction) by the spring(s).
With a larger valve and/or a higher differential pressure to work against, more
force is needed to obtain full valve movement.

To create more force, a larger diaphragm area or higher spring range is needed.
This is why controls manufacturers offer a range of pneumatic actuators to match a
range of valves – comprising increasing diaphragm areas, and a choice of spring
ranges to create different forces.

The diagrams in Figure 6.6.3 show the components of a basic pneumatic actuator
and the direction of spindle movement with increasing air pressure.
Shown in Figure 6.6.4. A direct acting pneumatic actuator is coupled to a control
valve with a reverse acting plug (sometimes called a ‘hanging plug’).
The choice between direct acting and reverse acting pneumatic controls depends on
what position the valve should revert to in the event of failure of the compressed
air supply. Should the valve close or be wide-open? This choice depends upon the
nature of the application and safety requirements. It makes sense for steam valves
to close on air failure, and cooling valves to open on air failure. The combination
of actuator and valve type must be considered.
Types of actuators- various combinations to give different types-

Diagram1 – Air to close/ Fail Open Direct action actuator(increase in signal stem
moves down)
Diagram2- Air to close/ Fail Open Reverse action actuator(increase in signal stem
moves up)
Diagram3- Air to Open/ Fail Close Reverse action actuator(increase in signal stem
moves up)
Diagram4- Air to Open/ Fail Close Direct action actuator(increase in signal stem
moves down)
Forces acting on Actuator to be considered while designing Actuator-
The forces to be considered while designing the actuator are static forces &
dynamic forces. Static forces are those that exist with the valve under pressure
but with no fluid flow in it whereas dynamic forces are created by the flow of fluid
flowing through valve.
1. Force due to friction
The source of friction is used mainly the stem packing used for actuator.

a. For Teflon V-ring packing

𝐹𝑓𝑟𝑖𝑐𝑡 = 𝐷𝑠𝑡𝑒𝑚 ∗ 100
b. For graphite packing
𝐹𝑓𝑟𝑖𝑐𝑡 = 𝐷𝑠𝑡𝑒𝑚 ∗ 340
c. For Teflon-Asbestos packing
𝐹𝑓𝑟𝑖𝑐𝑡 = 𝐷𝑠𝑡𝑒𝑚 ∗ 170
d. For extra packing
𝐹𝑓𝑟𝑖𝑐𝑡 = 𝐷 𝑠𝑡𝑒𝑚 ∗ 150

2. Diaphragm Force:
It is the force that acts on the diaphgram.

i. Air to Close
o Opening
D=min air supply x diaphragm area
o Closing
D=max air supply x diaphragm area

ii. Air to Open

o Opening
D=max air supply x diaphragm area
o Closing
D=min air supply x diaphragm area
3. Seat Force:
It is the force with which the valve is seated or closed. Hence this force
appears only while closing.
𝑆𝑡 = 50 ∗ 𝜋𝐷𝑠𝑒𝑎𝑡
(circumference)

4. Unbalanced Force:
This force is defined as the one which exists due to moving parts in the
valve. Note that always take absolute value (positive value) of unbalanced
force
a. For fail to close actuator
𝑢 = 𝑘ℎ∆𝑃𝑒𝐴𝑝 − 𝑃1𝐴𝑠
Where 𝑘ℎ= fluid force coefficient due to fractional valve stem
Travel
∆𝑃𝑒=Effective pressure drop
𝐴𝑝=Area of plug
𝐴𝑠=Area of stem
𝑃𝑉
𝐹𝐹 = 0.96 − 0.28 √
𝑃𝐶
𝑃1−𝑃2
𝐹𝐿 =
𝑃1−𝑃𝑉𝐶
𝑃𝑉𝐶 = 𝐹𝐹 𝑃𝑉
Therefore, ∆𝑃𝑒 = 𝐹𝐿 2(𝑃1 − 𝑃𝑉 )
Note: Flashing should be considered only while opening & many a
times unbalanced area is treated as plug area in this equation.

b. For fail to open actuator

𝑢 = 𝑘ℎ∆𝑃𝑒𝐴𝑝 − 𝑃2𝐴𝑠
Conventionally, the forces opposing a direct acting actuator are
negative. Hence 𝑘ℎ & 𝑢 are negative.
With flow tending to close the valve, 𝑘ℎ & 𝑢 are positive.
 In order to cope with the problem of instability caused by
negative fluid force gradients the valve manufacturer must adopt
design procedures to overcome lack of complete information.
One method is to list for each valve style & stem travel, a factor to
define the slope of negative gradient. This is denoted by 𝑘𝑛
𝑑 /𝑑
𝑘𝑛 = 𝑢 𝐻
𝑝𝑠𝑖
Where H= actual valve travel

Forces are related with the equations-

Air to Close Air to Open
Opening Opening
F+ D= S + u F+ S= D+ u

Closing Closing
D= F+ S+ u+ 𝑆𝑡 S= D+ u+ F+ 𝑆𝑡

Note to understand the above equations:

i. Spring force (S)& diaphragm force (D) always oppose each other.
ii. Seat force while closing will be upwards because during closing, force
is exerted on the seat in the downward direction.
iii. Unbalanced force (U) is always upward because it aims to get max
force space possible.
iv. Frictional force always opposes the direction of motion.
v. For satisfactory design determine the spring force while opening as
well as while closing & determine
minimum spring force
 Spring travel=
spring rate
 Spring travel should be greater than 1 for the actuator to work
satisfactorily
𝜋
A = A = (𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑠𝑡𝑒𝑚 𝑜𝑟 𝑝𝑙𝑢𝑔)2
s p
4
Numericals:

1. Check if given actuator works satisfactorily.

Type: FTO (ATC)
Packing: Teflon V-ring
𝑘ℎ= -0.16 for opening
= -1.0 for closing
1
Seat diameter= "
2
Fluid pressure=40-20 psig (for opening)
=50-10 psig (for closing)
Diaphragm-= 69” square
Spring rate available 275/370/460
Air Pressure 3-15 psig
Ans) Step 1: To calculate friction force,

𝐹𝑓𝑟𝑖𝑐𝑡 = 𝐷 𝑠𝑡𝑒𝑚 ∗ 100

1
𝐹
𝑓𝑟𝑖𝑐𝑡 = 2 ∗ 100 = 50𝑙𝑏

Step 2: To calculate diaphragm force,

For opening,
D= min air supply x diaphragm area
= 3 x 69 = 207 lb
For closing,
D= max air supply x diaphragm area
= 15 x 69 = 1035 lb

Step 3: To calculate unbalanced force

FTO 𝑢 = 𝑘ℎ∆𝑃𝑒𝐴𝑝 − 𝑃2𝐴𝑠
For opening,
𝜋 1 2 𝜋1
𝑢 = −0.16(40 − 20) ( ) − 20 ∗ ( )2
4 2 4 2
= −0.62 − 3.92
𝑢𝑜𝑝𝑒𝑛𝑖𝑛𝑔 = −4.5469 𝑙𝑏
For closing,
𝜋 1 2 𝜋 1 2
𝑢𝑐𝑙𝑜𝑠𝑖𝑛𝑔 = −1(50 − 10) ( ) − 10 ∗ ( )
4 2 4 2
= −7.85 − 1.963
𝑢𝑐𝑙𝑜𝑠𝑖𝑛𝑔 = −9.813

Note: Unbalanced force should always be taken as absolute value (i.e. positive
value)
Step 4: Seat Force
𝑆𝑡 = 50 ∗ 𝜋 ∗ 𝐷𝑠𝑒𝑎𝑡
1
= 50 ∗ 𝜋 ∗
2

= 78.53 𝑙𝑏

Step 5: To calculate the spring force

For opening
i. F+ D= S + u

S = F+ D - u
= 50+207-4.54 ..................................... (Take positive 4.54)
= 252.46
For closing
ii. 𝐷 = 𝐹 + 𝑆 + 𝑢 + 𝑆𝑡
𝑆 = 𝐷 − 𝐹 − 𝑢 − 𝑆𝑡
= 1035 − 50 − 9.81 − 78.53
= 896.6

Step 6- To calculate spring travel,

𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑠𝑝𝑟𝑖𝑛𝑔 𝑓𝑜𝑟𝑐𝑒
i. Spring travel=
𝑠𝑝𝑟𝑖𝑛𝑔 𝑟𝑎𝑡𝑒
252.46
=
275
=0.918 < 1
252.46
ii. Spring travel=
370
=0.682 < 1
252.46
iii. Spring travel=
460
=0.548 < 1
For any of the given spring rates. This actuator will not work satisfactorily since
spring travel is < 1.

Now we change the packing material. Teflon V-ring with asbestos packing.
Therefore, 𝐹𝑓𝑟𝑖𝑐𝑡 = 𝐷𝑠𝑡𝑒𝑚 ∗ 170
1
= ∗ 170 = 85 𝑙𝑏
2
𝑆𝑜𝑝𝑒𝑛𝑖𝑛𝑔 = 𝐹 + 𝐷 − 𝑢
= 85 + 207 − 4.54
= 287.46
𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑠𝑝𝑟𝑖𝑛𝑔 𝑓𝑜𝑟𝑐𝑒
Spring travel= 𝑠𝑝𝑟𝑖𝑛𝑔 𝑟𝑎𝑡𝑒
287.46
=
275
= 1.045 > 1
Conclusion- Therefore, with Asbestos packing the spring rate of 275 is sufficient
for the actuator to work satisfactorily.
Numerical 2- Check if the following actuator is satisfactory
FTC (Fail to close) service
Fluid=Benzene
Packing=Pure Graphite
Actuator area=69” square
Diaphragm pressure=3-36 psig
PV (vapor pressure) =18 psia
PC (critical pressure) =701 psia
Plug area=0.34” square
Cage seat friction=45 lb
Seat force=50 lb per inch of circumference
7
Seat diameter=2 inch
8
Spring rate=1100
𝐹𝐿=0.56
Fluid pressure=615-10 psig for closing
=600-15 psig for opening

Ans) Type of valve= FTC (Fail to Close) i.e. Air to Open

Step 1: To find frictional force

𝐹𝑓𝑟𝑖𝑐𝑡 = 𝐷𝑠𝑡𝑒𝑚 ∗ 340 + 𝑐𝑎𝑔𝑒 𝑠𝑒𝑎𝑡 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 (**Take this cage seat friction if value
is given else leave it)
1
= ∗ 340 + 45
2
= 215 𝑙𝑏

Step 2: To calculate diaphragm force

for opening
𝐷 = max 𝑎𝑖𝑟 𝑠𝑢𝑝𝑝𝑙𝑦 ∗ 𝑑𝑖𝑎𝑝ℎ𝑟𝑎𝑔𝑚 𝑎𝑟𝑒𝑎
= 36 ∗ 64
= 2484 𝑙𝑏
For closing
𝐷 = min 𝑎𝑖𝑟 𝑠𝑢𝑝𝑝𝑙𝑦 ∗ 𝑑𝑖𝑎𝑝ℎ𝑟𝑎𝑔𝑚 𝑎𝑟𝑒𝑎
= 3 ∗ 69
= 207 𝑙𝑏
Step 3: To calculate seat force
𝑆𝑒𝑎𝑡 𝑓𝑜𝑟𝑐𝑒 = 50 ∗ 𝜋 ∗ 𝐷𝑠𝑒𝑎𝑡
23
= 50 ∗ 𝜋 ∗
8
(𝑐𝑖𝑟𝑐𝑢𝑚𝑓𝑒𝑟𝑒𝑛𝑐𝑒 = 50 𝜋𝐷)
= 451.6 𝑙𝑏

Step 4: To calculate unbalanced force

Flashing service should only be considered for opening
𝑢 = 𝑘ℎ∆𝑃𝑒𝐴𝑝 − 𝑃1𝐴𝑠
Since it is flashing (P2 < PV ) , to calculate we have to replace P by 𝐹𝐿2(𝑃1 − 𝑃𝑉𝐶)
which is the effective P, i.e ∆𝑃𝑒
∆𝑃𝑒 =?
∆𝑃𝑒 = 𝐹𝐿2(𝑃1 − 𝑃𝑉 )

𝑃𝑉
𝐹𝐹 = 0.96 − 0.28 √
𝑃𝐶
18
= 0.96 − 0.28√ = 0.915
701

𝑃𝑉𝐶 = 𝐹𝐹 𝑃𝑉
= 0.915 ∗ 18 = 16.47 𝑝𝑠𝑖𝑎

∆𝑃𝑒 = 𝐹𝐿2(𝑃1 − 𝑃𝑉 )
= 0.562(600 − 16.47) = 187.995 𝑝𝑠𝑖𝑎

Since 𝑘ℎ is not given,

Assuming 𝑘ℎ = −1 for closing
𝑘ℎ = −2 for opening

𝑢 = 𝑘ℎ∆𝑃𝑒𝐴𝑝 − 𝑃1𝐴𝑠
For opening,
 𝜋 1
𝑢𝑜𝑝𝑒𝑛𝑖𝑛𝑔 = −2 ∗ 187.995 ∗ 0.34 − (600) ∗ ∗ ( ) 2
4 2

𝑢𝑜𝑝𝑒𝑛𝑖𝑛𝑔 = −245.29 𝑙𝑏

For closing,
𝑢𝑐𝑙𝑜𝑠𝑖𝑛𝑔 = 𝑘ℎ∆𝑃𝑒𝐴𝑝 − 𝑃1𝐴𝑠
= −1 ∗ 605 ∗ 0.34 − 615 ∗ 0.196
= −329.12

Step 5: To calculate spring force

𝑆𝑜𝑝𝑒𝑛𝑖𝑛𝑔 = 𝐷 + 𝑢 − 𝐹
= 2484 + 248.048 − 215
= 2517 𝑙𝑏

𝑆𝑐𝑙𝑜𝑠𝑖𝑛𝑔 = 𝐷 + 𝑢 + 𝐹 + 𝑆𝑡
= 207 + 320 + 215 + 451.60
= 1194.6 𝑙𝑏

Step 6: To calculate spring travel

min 𝑠𝑝𝑟𝑖𝑛𝑔 𝑓𝑜𝑟𝑐𝑒
𝑆𝑝𝑟𝑖𝑛𝑔 𝑡𝑟𝑎𝑣𝑒𝑙 =
𝑠𝑝𝑟𝑖𝑛𝑔 𝑟𝑎𝑡𝑒
1194
=
1100
= 1.08 > 1
Conclusion- Therefore, the spring rate 1100 of the given actuator will work
satisfactorily

Numerical 3-
Design an actuator for the following application
Control valve used is 6” cage guided angle valve, type – FTC
Packing – TFE asbestos
 1
Travel- 1 ”
2
1
Stem- ”
2
7
Seat- 2 ”
8
Cage seat friction= 40 lb
Stem friction= 160 lb
Seat force= 200 lb per inch
Unbalanced area= 0.34” sq
𝐹𝐿2 = 0.45
𝑘ℎ = −1 for closing
= −2 for opening

Fluid pressure=600-13 psig for opening

=615-0 psig for closing
Vapour pressure= 300psig
Critical pressure= 3206 psig
Actuator size= 69 sq.inch
Spring rate= 1100 lb per inch

Solution-
(Note- When stem friction and cage seat friction are given packing friction is
neglected)
Type of valve- FTC (ATO)
Step1- To calculate frictional force

𝐹𝑓𝑟𝑖𝑐𝑡 = 𝐷𝑠𝑡𝑒𝑚 ∗ 170 + 𝑆𝑡𝑒𝑚 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 + 𝑐𝑎𝑔𝑒 𝑠𝑒𝑎𝑡 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 (*𝐷𝑠𝑡𝑒𝑚 ∗

170𝑖𝑠 𝑡ℎ𝑒 𝑝𝑎𝑐𝑘𝑖𝑛𝑔 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑤ℎ𝑖𝑐ℎ 𝑖𝑠 𝑛𝑒𝑔𝑙𝑒𝑐𝑡𝑒𝑑*)
= 160 + 40
= 200 𝑙𝑏

Step 2: To calculate diaphragm force

for opening
𝐷 = max 𝑎𝑖𝑟 𝑠𝑢𝑝𝑝𝑙𝑦 ∗ 𝑑𝑖𝑎𝑝ℎ𝑟𝑎𝑔𝑚 𝑎𝑟𝑒𝑎
= 37.8 ∗ 69
= 2608 𝑙𝑏
For closing
𝐷 = min 𝑎𝑖𝑟 𝑠𝑢𝑝𝑝𝑙𝑦 ∗ 𝑑𝑖𝑎𝑝ℎ𝑟𝑎𝑔𝑚 𝑎𝑟𝑒𝑎
= 0 ∗ 69
= 0 𝑙𝑏

Step 3: To calculate seat force

Note- Here we do not use 200 lb per inch because it is not given per inch of what
(i.e circumference or area)
𝑆𝑒𝑎𝑡 𝑓𝑜𝑟𝑐𝑒 = 50 ∗ 𝜋 ∗ 𝐷𝑠𝑒𝑎𝑡
23
= 50 ∗ 𝜋 ∗
8
(𝑐𝑖𝑟𝑐𝑢𝑚𝑓𝑒𝑟𝑒𝑛𝑐𝑒 = 50 𝜋𝐷)
= 451.6 𝑙𝑏

Step 4: To calculate unbalanced force

Flashing service should only be considered for opening
𝑢 = 𝑘ℎ∆𝑃𝑒𝐴𝑝 − 𝑃1𝐴𝑠
Since it is flashing (P2 < PV ) , to calculate we have to replace P by 𝐹𝐿2(𝑃1 − 𝑃𝑉𝐶)
which is the effective P, i.e ∆𝑃𝑒
∆𝑃𝑒 =?
∆𝑃𝑒 = 𝐹𝐿2(𝑃1 − 𝑃𝑉 )

𝑃𝑉
𝐹𝐹 = 0.96 − 0.28 √
𝑃𝐶
300
= 0.96 − 0.28√ = 0.8743
3206

𝑃𝑉𝐶 = 𝐹𝐹 𝑃𝑉
= 0.8743 ∗ 300 = 262.3 𝑝𝑠𝑖𝑎

∆𝑃𝑒 = 𝐹𝐿2(𝑃1 − 𝑃𝑉 )
= 0.45(600 − 262.3) = 151.965𝑝𝑠𝑖𝑎
𝜋 2
***Note- or Unbalanced area
𝐴𝑝 = 4 ∗ 𝐷 𝑝𝑙𝑢𝑔
𝑢 = 𝑘ℎ∆𝑃𝑒𝐴𝑝 − 𝑃1𝐴𝑠
For opening,
𝜋 1
𝑢𝑜𝑝𝑒𝑛𝑖𝑛𝑔 = −2 ∗ 151.965 ∗ 0.34 − (600) ∗ ∗ ( ) 2
4 2

𝑢𝑜𝑝𝑒𝑛𝑖𝑛𝑔 = −220.9362 𝑙𝑏

For closing,
𝑢𝑐𝑙𝑜𝑠𝑖𝑛𝑔 = 𝑘ℎ∆𝑃𝑒𝐴𝑝 − 𝑃1𝐴𝑠
= −1 ∗ 615 ∗ 0.34 − 615 ∗ 0.196
= −329.025 𝑙𝑏

Step 5: To calculate spring force

𝑆𝑜𝑝𝑒𝑛𝑖𝑛𝑔 = 𝐷 + 𝑢 − 𝐹
= 2608.2 + 220.936 − 200
= 2629.13 𝑙𝑏

𝑆𝑐𝑙𝑜𝑠𝑖𝑛𝑔 = 𝐷 + 𝑢 + 𝐹 + 𝑆𝑡
= 0 + 329.025 + 200 + 451.60
= 980.625 𝑙𝑏

Step 6: To calculate spring travel

min 𝑠𝑝𝑟𝑖𝑛𝑔 𝑓𝑜𝑟𝑐𝑒
𝑆𝑝𝑟𝑖𝑛𝑔 𝑡𝑟𝑎𝑣𝑒𝑙 =
𝑠𝑝𝑟𝑖𝑛𝑔 𝑟𝑎𝑡𝑒
980.625
=
1100
= 0.89 < 1
Conclusion- Therefore, the spring travel of actuator is not satisfactory. We will
better change air pressure 0 – 37.8 psig, in such a way that the min limit of air
pressure is not 0psig, but made as 3psig.
OR
We can also increase the actuator area which is referred as diaphragm area and
no need to change the packing.