SIPOS AKTORIK

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Features and benefits of modernactuators

and effects on plant operations

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SIPOS Aktorik is a manufacturer of electric actuators

The main focus of the corporate activities is:

Design and development, manufacturing and sales of electric actuators;

Conceptual design and realisation of solutions for water and power applications;

Development of tailor-made customer solutions;

Worldwide sales and service.

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Company history

Arising from Siemens, SIPOS Aktorik can look back at more than 100 yearsexperience in design, production and sales of electric actuators.

October 1999 the Siemens actuator division was outsourced to a newly founded

company SIPOSAktorik GmbH.

SIPOS Aktorik took over all obligations and rights arising from the Siemens

actuator business, also the spare part supply for former Siemens actuator

series.

SIEMENS

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SIPOS Aktorik - Products

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Markets

Water & waste water plants Conventional power plants

Desalination District cooling Pump stationsPipelines

Nuclear power plants

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SIPOS AktorikGermany

Tel. +49 (0)9187-9227-0Fax +49 (0)9187-9227-5111

E-mail [email protected]@sipos.de

Sales & Service worldwide

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Actuators in a power and water treatment plants

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Valve maker Control system


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Actuators automate safety relevant valves

Actuators automate control valves (turbine control, damper control)

Actuators influence process reliability

Actuators need cabling and system requirements

Actuators influence the wear of valves

Actuators influence plant performance

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Mechanically robust, long lifetime (lubrification, wear, corrosion, operation time)

Robustness against mechanical influences (temperature, shock)

Easy to install and commission (faults may result from wrong installation)

High accuracy (precise control of processes)

Robustness against electrical influences (overvoltage, undervoltage, EMC)

High availability (7/24) (spares availability, repair time, replacement time)

What is expected from an actuator

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SIPOS 3 MCSIPOS 3 SIPOS 5 Flash

Modern actuators: evolution from mechanics to electronics


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SIPOS 5integrated frequency converter

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Conventional actuator SIPOS 5

800 parts 100 parts


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SIPOS 5 Flashdifferences to conventional

actuators No mechanical end switches

No mechanical torque switches

No reversing contactors

No tripping delay, no overtorque in any condition

Variable speed drive, full motorprotection (overvoltage,

temperature)

Modular design (3 gearbox sizes, 8 motor sizes, 5 electronics

sizes cover the full range)

Softwarefunctions can be activated when needed (e.g.

positioner, process controller, external speed control,)


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Last stop -

LobbyFree fall

fun on the

way down

Elevators operated by a conventional actuator

Fast stop

on the 15th floor

On the way up


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SIPOS 5 Flashcharacteristics

Speed reduction in the end positionsgo easy on the valve

Driving a valve at full speed into or outof its end position can cause

seat damage,

additional maintenance costs,

plant downtime.

The SIPOS 5 Flash with its integratedfrequency controller automatically

reduces the motor speed

controls the torque

gentle operation reduces wear


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Asynchronous motor

Signaling gear or encoder

Hand crank /-wheel

Power PCBControl PCB

Plug connection

Gearbox

Modular design

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Speed changingstandard functions

Standard speed controlThe output speed can be adjusted at any time

in 7 steps in the chosen speed range.

Customize whats needed - when its needed !

Adjust the valve operating time to process necessities


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SIPOS 5 Flashthe main thing to remember

Change speed at any time!


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Robustness in mechanical design


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Power train features

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Fixed connection between

motor and wormshaftlow tolerance hard-hard

toothing,

Worm wheel &

output shaft,

are one piece

Worm wheelWorm shaft

Control head with integrated

frequency converter definingspeed and torque of motor

3 phase motor


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Mechanical design of SIPOS 5

One stage, low tolerance

worm gear box, self locking

Motor direct connected to

worm shaft

Longlife bearings and seals

Minimum of parts

Casing of Aluminium Alloy

3 ph Universal motor

Simple manual operation O ring seals

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SIPOS 5 Flashthings to remember

Loads according EN60068-2-6 up to 5g acceleration tolerated

High tech aluminium alloy casing

Hardhard toothing

Minimum of mechanical parts

Temperature range -20

C to 60

C (+80

C optional)

Recommended spares (500 installed actuators):

2 electronics heads

3 signalling gearboxes

2 handwheels


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High accuracy


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High accuracy by software features

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Positioner with adaptive dead band

Rise Time: parameter for fine-tuning of acceleration and deceleration

Variable Speed: reduction of kinetic energy before reaching new setpoints


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PositionerAdaption of deadband in case of bad signals

EMC toughness

Upward adaption

Minimizing switching cyclescaused by disturbances

control loop remains stable

Downward adaption

Minimizing deadzoneminimizing control deviation


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Influence of actuator parameter Rise time

Rise time 0.1s

Travel time approx. 3 s

No speed reduction when

approaching to setpoint

Rise time 2s

A higher rise time helps to adjust the actual value to

the setpoint.

However overshooting may occur.

Setpoint/ac

tualvalue[%]

Setpoint/ac

tualvalue[%]

time time


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Influence of Speed Reduction

With speed reduction

Travel time ca. 3s

Rise time 0.1s

No overshooting due to speed reduction,

even with very low rise times.

Speed reduction is SIPOS 5 Flash standard.

A DC-break can additionally be activated

Without

Speed reduction

time time

Setpoint/actualvalue[%]




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Topic:

Voltage fluctuations

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Source of Voltage fluctuations

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Cable length

Electrical grounding inappropriate

Disturbances from generators and pumps

Switching of loads

Transformators

Plant start and rundown procedures

The electric grid in a powerplant is worse than outside


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Voltage Fluctuations and challenges for electric actuation

Plant Operators want the valve to be operable in case of over- and undervoltage

do not want to have overtorque on the valve

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Voltage Fluctuations and challenges for electric actuation

Why is this a challenge? Voltage fluctuations affect motor operation / performance

In case of undervoltage a conventional actuator could not be able to operate the

valve

To compensate this actuators are sized to certain undervoltage conditions

This means in times of nominal voltage the actuator motor can producean overtorque that can damage the valve.

Then again the valve has to be oversized to compensate

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The sizing issueovertorque

When sizing conventionalactuators to work with nominal torque at -20%undervoltage

it causes an overtorquewith a factor of 1.56 at nominal voltage

it causes an overtorquewith a factor of 2.25 at 20% overvoltage

in case of switch-off failure.

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Voltage fluctuations handling with SIPOS 5

SIPOS 5 actuators feature integrated frequency converter

intelligent electronics

Advantages concerning power supply:

Voltage fluctuations of

up to -30% and + 20% are tolerated

and do not lead to system failure.

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Reliability

The maximum output torque for SIPOS 5 actuators isalways the defined preset torque

at -30% undervoltage

at Nominal voltage

at +20% overvoltage

from 40 Hz to 70 Hz

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N/A

The motor sees no

under- or overvoltage due tofrequency converter

N/A; speed reduction in

end positions

N/ATripping torque is the

stall torque of the motor at

selected speed and torque

Overtorque in a modern SIPOS 5 actuator:

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Conventional actuator SIPOS 5 actuator


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What is expected from an actuator

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Mechanically robust, long lifetime

Robustness against mechanical influences

Easy to install and commission

High accuracy

Robustness against electrical influences

High availability

Reduction of mechanical parts,

Use of premium materials

User Interface clear and understandable

Easy mechanical mounting

Premium materials, small tolerances,

smart software solutions

Integrated frequency converter, motor

protection

Modular structure, spares concept,

SIPOS 5 solution


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Sales and Service Partner for GCC

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P.O. Box 32950,

Abu DhabiUAE

Tel. + 971 2 4470902

Managing Director: Mr. Ahmed Sobhi
http://adoset.com.yellow.mysitehosted.com/


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SIPOS 5HiMod


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Applications with very high requirements

Control valves Boiler start-up valves

Dampers

Turbine regulation

Injector valves

Feedwater pump control

and other applications with high accuracy and dynamic requirements!

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SIPOS new TOP Product:

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HiModPrecision in continuous dutyThe new electric actuator SIPOS 5 HiMod was

developed to operate in conditions where the

highest quality of control is an absolute prerequisite.

Key features: Precision: max. 0.1% to 0.2% tolerance

Continuous duty: Meets Class D requirements of EN 15714-2

Reliable and robust: 5 year guarantee on motor and gear components

Double-sealed: Protection in tough environments

Easy non intrusive commissioning without tools

Comprehensive software functions: Essential actuation for 'smart' solutions


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Continuous duty

Standard SIPOS 5 Flash HiMod feature:

Class D continuous modulation according

to EN 15714-2 (Ed. Oct. 2009)

For continuous modulating duty, one start consists of

at least revolution,

with a load of at least 30% of the rated torque

SIPOS 5 HiMod has been tested concerning this modulation class,

considering the most critical ambient conditions

60C / 140F ambient temperature; (80C / 176F with separate mounting ).

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SIPOS HiMod:3600

1800

1200

starts per hour

Continuous dutyEN 15714-2

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SIPOSSelected references in MENA

SIPOS has supplied many standard and modulating actuators topower and desalination plants.

Here a few:

Power and Desalination Plant JebelAli L, UAE

Tripolis West power plant, Libya

Ataka power plant, Egypt

Shoubra El Kheima power plant, Egypt

Ras Djinet power plant, Algeria

Skikda power plant, Algeria

Khoms power plant, Libya Rabigh power plant, KSA

Al Hunnay Water Distribution, KSA


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SIPOSReferences in MENA

SIPOS has supplied standard and modulating actuators for various districtcooling plants, e.g.:

Yas Island

Zayed Military City

Al Raha Beach 2

Al Raha Beach 4 Ajman 2

Sheikh Zayed Road

Al Rigga

Dubai Metro

Mohammed Bin Zayed City

Spinneys

ARAMCO

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