Kinetrol Vane Actuators: The Optimal Solution for High Heat and Dust-Intensive Industrial Applications

In the demanding world of industrial processing, environments characterized by high heat and extreme dust present significant challenges for machinery and equipment. The frequent cycling of valves in these conditions demands robust and reliable solutions. Kinetrol vane actuators emerge as the premier choice for such harsh applications thanks to their unique design and performance features.

Industries like metal processing, cement manufacturing, and power generation often experience extremely high temperatures. Similarly, environments like mining and construction are inundated with particulate matter. This combination of high heat and dust can lead to rapid degradation of machinery and increased maintenance demands, causing downtime and escalating costs. In such settings, valves play a critical role in regulating flow and pressure, and their efficient operation is crucial for maintaining process continuity and safety.

Kinetrol vane actuators stand out in these challenging environments due to their robust construction and high torque output. They are specifically designed to withstand the rigors of extreme temperatures and dust. This durability reduces the need for frequent replacements and ensures reliable performance, a critical factor in maintaining process efficiency and safety.

The simplicity of maintenance with Kinetrol actuators is another significant advantage. Easy maintenance is a boon when every minute of downtime can be costly. These actuators are also versatile, capable of adapting to various environmental conditions, and suitable for multiple industrial applications.

Real-world applications in mining and cement manufacturing industries demonstrate how Kinetrol actuators improve efficiency and safety. In mining operations, for instance, the actuators have shown remarkable resilience in managing frequent valve cycling amidst dust-laden air. At the same time, in cement manufacturing, they have proven their mettle in withstanding high-heat conditions without faltering in performance.

In conclusion, Kinetrol vane actuators are the optimal solution for industrial applications facing the dual challenges of high heat and extreme dust. Their robust design, reliable performance, and easy maintenance make them ideal for industries requiring frequent valve cycling under harsh conditions. Investing in these actuators not only enhances operational efficiency but also significantly contributes to the overall safety and longevity of the equipment.

The article is informative for professionals in industries where equipment durability and reliability are paramount under challenging conditions. It positions Kinetrol vane actuators as a reliable and efficient solution backed by real-world applications and expert insights. It makes a strong case for industries to consider Kinetrol vane actuators for their durability, reliability, and overall operational efficiency in extreme conditions.

For more information, contact:
Kinetrol USA
https://kinetrolusa.com
972-447-9443

New Model 60 Extends Kinetrol Reliability and Precision to Larger Class of Valves

With a torque output of 356,977 lbf in (pound force inch) at 100 psi., the new Kinetrol Model 60 pneumatic rotary actuators doubles the output capability for Kinetrol actuators. Now, loyal Kinetrol users can get the same precise, long-lasting and trouble free operation for larger valve installations. Prior to the Model 60's introduction, the Kinetrol Model 30, capable of producing 168,000 lbf in, was the largest Kinetrol size available. With the doubling of output torque capability, Kinetrol can now provide better control and longer life to larger ball, butterfly and plug valves. In the past,  shorter life, less reliable scotch yoke actuators were the only option available.



The Kinetrol Model 60 Standard Features Include:

• Double-Acting and Spring-Return options
• 2” Air ports as standard
• Standard working temperature range from -40°F to +176°F
• Angle of travel adjustable from 80 to 100 degrees
• Displaced volume is 6284 in³
• Kinetrol VLS / ULS / XLS Limit Switch Box options
• AP Positioner options
• ATEX Category 2 approval
• Housing: Sand cast aluminum alloy
• Vane & Output shaft: SG Iron, zinc plated
• Shaft bushings: PTFE coated bronze
• Seals: Molded polyurethane
• Seal expenders: Stainless spring steel

For more information, visit this link.
Kinetrol USA
972-447-9443
https://kinetrolusa.com

New Rotary Actuator Catalog from Kinetrol

Kinetrol, the manufacturer of the most reliable 1/4 turn pneumatic actuator on the market today, has published a new rotary vane actuator catalog. The new catalog can be downloaded here. 

The catalog includes up-to-date information on:

• Kinetrol Valve and Damper Actuators
• Spring Return Units
• Electro-pneumatic Positioners
• Pneumatic Positioners
• Limit Switches
• Indicators
• Solenoid Valves
• Geared Manual Overrides
• Failsafe Spring Return Handles

Since 1958, Kinetrol has manufactured the most comprehensive range of high performance pneumatic double-acting and spring-return rotary vane actuators. Today, Kinetrol proudly carries the well-earned and distinguished reputation for manufacturing the most reliable pneumatic actuator used in severe service and high cycle applications.

Kinetrol USA
972-447-9443
https://kinetrolusa.com

New Product: Kinetrol Model 60 Rotary Vane Actuator

Kinetrol is pleased to announce the introduction of the new Model 60 Actuator which will now increase the torque capability of the Kinetrol range to 356,977 inch pounds.

Kinetrol Model 60 Feature and Options

• Double-Acting and Spring-Return options
• 2” Air ports as standard
• Standard working temperature range: -40°F
• to +176°F
• Angle of travel adjustable 80 to 100 degrees
• Displaced volume: 6284 in³
• Weight (less coupling): 998.7 pounds
• Coupling weight: 48.5 pounds
• VLS / ULS / XLS Limit Switch Box options
• AP Positioner options
• ATEX Category 2 approved

Kinetrol Model 60 Materials of Construction

• Casing: Sand cast aluminum alloy
• Vane & Output shaft: SG Iron, zinc plated
• Shaft bushes: PTFE coated bronze
• Seals: Molded polyurethane
• Seal expenders: Stainless spring steel
• Coupling: Weldable mild steel, zinc plated

For more information, contact Kinetrol USA by calling 972-447-9443 or visit their web site at https://kinetrolusa.com.

Kinetrol Vane Actuators in Sugar Production: Suger Cane Processing

First in a 2-part series on the use of Kinetrol pneumatic vane actuators in the production of sugar.  The first part focusses on sugar cane processing. The second focusses on sugar beet processing.

Sugar is produced in over 130 countries worldwide. Around 80 percent of sugar is produced from cane, which is grown in tropical and sub-tropical regions. The remaining 20 percent is manufactured from beet grown in more temperate climates. Refined sugar is both chemically and functionally identical whether it is produced from cane or beet.

Transportation – Cane is loaded into lorries or rail trucks and taken to the mills for processing. On arrival the cane is washed to remove rocks and leaves.

Shredder – The shredder shreds the cane and reduces it into fibrous material to expose the sucrose bearing cells. This allows for the extraction (milling) process to maximize the removal of the sugar juice from the cane.

Milling – This is the extraction process whereby the sugar is removed from the cane. The shredded cane is crushed between heavy, grooved metal rollers to separate the juice from the fibre. The milling process involves a number of mills which are made up of three rollers arranged in a triangular formation. As the cane is crushed in the mills hot water (or recovered impure juice) is sprayed onto the crushed cane. The resultant dark green juice (sometimes called vesou) is then sent to a mixed juice tank for storage before clarification.

The cane fiber (called bagasse) is recycled as a fuel for the mill’s boiler furnaces. Importantly, milling must take place within 36 hours of the cane being cut.

Kinetrol units are used to control the flow of water to the spray system. It is necessary to ensure that sufficient water is used to remove the sugar content without flooding the cane.

Clarification and Filtering – Clarification is where soluble and insoluble impurities (sand, soil, etc.) are removed. The vesou is heated and then lime is added to the juice. Clear sugar juice is run off from the top of the clarifier. The muddy juice, extracted from the bottom of the clarifier, is mixed with fine bagasse and filtered to recover more sugar. This process can be repeated to ensure maximum recovery of sugar. The final recovered mud & bagasse mix is used as a soil treatment on the cane farms.

Kinetrol units are used to control the flow of the vesou to the clarifier. Controlled flow reduces turbulence which allows for quicker settling times. Kinetrol's are also be used to control the recirculation flow of the sugar juice to the clarifier.

Evaporation – The clear juice from the clarifier is concentrated into a syrup by boiling it under vacuum in evaporators. Around two-thirds of water in the juice is removed in the evaporation process leaving an end syrup with approximately 65-70 percent sugar content.

Kinetrol actuators are used to control the flow of steam to the evaporation tanks. In addition they control the flow of the juice through the evaporators. This is because of their reliability in the higher ambient temperatures in the process area.

Vacuum Pans – The syrup is concentrated further by boiling it in vacuum pans. Here it is ‘seeded’ with small sugar crystals to allow crystallization to take place. When the the sucrose concentration reaches the desired level the mixture of crystals and syrup, called massecuite, is sent to the centrifuges.

Kinetrol actuators control the input of heating steam into the pans as well as the flow of the massecuite through the process.

Centrifuges – High speed centrifuges separate the massecuite into sugar crystals and by-products (molasses).

Kinetrol actuators control the massecuite feeding system into the centrifuges. Accurate control of the valves feeding the centrifuges is necessary to prevent overloading and leakage of the centrifuges.

Kinetrol actuators also control the water inlets of the automated wash system for the centrifuges.


Dryers – Damp sugar crystals are dried in heated dryers before being sorted in sizes and either packed or stored.

Kinetrol's reliability, especially under hot, humid conditions, are crucial factors for our units being used within the sugar industry. Depending on the plant and location the actual ‘processing’ season varies from around four months for sugar beet to six months for sugar cane. During this short time it is essential that plants have no production issues as this will have a dramatic effect on the productivity and therefore competitiveness of the plant. The reliability and robustness of the Kinetrol units means they continue to function through each production season year after year.

Kinetrol’s ability to maintain an unchanged torque rating even with wear of the lip seals, means critical valves continue to function correctly over time. This is especially true with a product that is highly viscous in the later stage of production (e.g. thick juice, molasses).

With some plants being non-operational for many months of the year there does exist time for service & maintenance or replacement of rack & pinion actuators. However as margins within the sugar industry are low, the total cost of ownership for Kinetrol units over a number of production seasons makes them a more cost effective solution.

For more information, contact Kinetrol USA by calling 972-447-9443 or by visiting https://kinetrolusa.com.

Changes to the Kinetrol VLS Limit Switch Box: KUSA-TSB123

After a decade since the launch of the Kinetrol Universal Limit Switch Box it has become necessary to replace the tooling. As a result, we have taken the opportunity to make some improvements to the design.

With the continued pressure for modularization and commonality the new precision die cast switch box will offer some positive improvements over the current model, more internal space for future developments and will be known as the VLS Limit Switch Box.

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DOWNLOAD THE FULL TECHNICAL 

BULLETIN HERE

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For more information, contact Kinetrol USA by calling 972-447-9443 or visit https://kinetrolusa.com.

Even In the Hot Seat, Kinetrol Actuators Perform

This picture is of what used to be a Kinetrol
097-120 and the valve it secured.

Liquid-phase oxidation of hydrocarbons is used in the production of  terephthalic acid (TPA).  Air is the source of oxygen gas in the oxidation processes. The air for the reaction is supplied by large compressors.

A chemical manufacturer in the southeastern USA experienced a catastrophic fire in their compressor house 2014. The fire caused extensive damage to the facility and equipment, and shut down production for months. The compressor alone cost $30 million.

As part of the compressor safety shutdown system, two 6" Class 150 high performance butterfly valves with Kinetrol 097-120 actuators were installed on the process air lines. In the the event of an emergency, these valves needed to quickly close, and then stay closed, under any - and all - conditions.

Close-up view of the Kinetrol
Actuator. A melted ball of metal.

Immediately upon activation of the emergency alarm, the two Kinetrol actuated assemblies received their signal and closed the valves quickly and tightly. As the fire raged, the actuators kept the valves secure, even after the extreme heat from the fire completely melted the actuator housings and internals.

As you can see from the pictures, the actuators were completely destroyed, but the valves stayed closed and and escalation of the emergency was prevented.

For more information, contact Kinetrol USA by calling 972-447-9443 or visit https://kinetrolusa.com.

Why Do Kinetrol Actuators Last So Long?

Kinetrol actuators are known world-wide for their extremely long service life, even in harsh environments. Here are a few reasons why.

KintrolUSA.com
972-447-9443

Kinetrol Actuators Protect People and Property with Reliable Performance in Chemical Plant Fire

The Kinetrol actuator is completely
unrecognizable,  having been melted in a fire.

A chemical plant in the Southeast USA that manufactures PTA (purified terephthalic acid) experienced a compressor house fire, causing extensive equipment damage and shutting down production for months.

The building houses a $30 million dollar compressor that supplies process air to reactors to begin the PTA manufacturing process.

As part of the safety system, (2) two 6" class 150 high performance butterfly valves with Kinetrol 097-120 and open/closed limit switches were installed on process air lines of one production unit.

During the fire, the two Kinetrol actuated valve assemblies performed exactly as required, shutting the valves tightly and keeping them shut even after the heat of the fire completely melted the actuator housings.

Closer view.

The actuators had been in service one year at the time of the fire.  Unlike many other Kinetrol actuator applications, these were not chosen for their high cycle capability,  nor for their long service life. In this application Kinetrol was chosen for their absolute reliability in critical situations.

For more information, contact Kinetrol USA by calling 972-447-9443 or by visiting https://kinetrolusa.com.

New EL Positioner Installation Video from Kinetrol USA

The video below is new from Kinetrol USA and provides detailed instructions on how to install a Kinetrol model EL electro-pneumatic positioner.

The EL positioner controls airflow to an actuator and moves it to a position determined by a 4-20mA signal and using a unique low power proportional servo valve. The combination of EL positioner and Kinetrol vane actuator provide fast, smooth and precise control for industrial valves and dampers.

https://kinetrolusa.com
972-447-9443

Updated Kinetrol Rotary Actuator Catalog - March 2018

Here is the March 2018 edition of the Kinetrol Rotary Actuator Catalog. You may view it in the embedded viewer below, or download it from this link.

Kinetrol Rotary Actuator Catalog March 2018 from Kinetrol USA

Epoxy Stove Enamel Finish: A Kinetrol Advantage

Kinetrol actuators are well-known for their bright yellow, epoxy stove enamel finish. This coating is engineered to protect the exterior of their pneumatic actuators and accessories. But what is "epoxy stove enamel"?

Epoxy stove enamel is a high quality stoving finish that provides excellent adhesion to a substrate. Epoxy stove enamel forms a very hard, abrasion resistant, chemical and solvent resistant coating that stands up to many extreme environmental conditions. Epoxy stove enamel finish provides high level chemical/corrosion resistant qualities, and is used often in applications such as machinery, industrial equipment, and heavy duty transport machinery.

Kinetrol actuators are engineered specifically for high-cycle, dirty, and corrosive applications. The combination of epoxy stove enamel finish and stainless steel external hardware provide Kinetrol actuators outstanding protection from dirt and harmful chemicals.

Kinetrol USA
https://kinetrolusa.com
972-447-9443

Who makes the most reliable industrial valve actuator?

With millions of actuators performing reliably around the world, the Kinetrol vane actuator's outstanding cycle life, smooth and precise movement, and environmentally rugged design makes it the best choice for all of your valve actuation needs.

https://kinetrolusa.com

Pneumatic Valve Actuator Assembly Designed to Prevent Water Hammer

Kinetrol vane actuator and
dashpot assembly

Water hammer occurs when the flow of fluid in a pipe rapidly changes. The result can be very high pipe pressures, mechanical stress on pipe supports, and possible reversal of flow. If not controlled it can cause pipe bursting, broken pipe supports and joint leakage.

The "hammering" is due to a pressure wave created by the instantaneous change in fluid velocity when a valve is suddenly closed or opened. Controlling valve closure time is one of the most economical ways to minimize water hammer. To do this efficiently, while still meeting the process requirements, the use of a variable speed mechanism to control valve stroke is used. One unique, economical and space savings approach is to use a pneumatic vane actuator coupled with a rotary damper (or dashpot).

Rotary dashpots are precision fluid damping devices which give a smooth resistance to shaft rotation which increases with angular velocity.

In this case, a pump station in the USA was having repeated problems with a large, open reservoir hydraulic actuator used to dampen valve opening and closing.  It was overly cumbersome and costly to maintain.

In its place, the pumping station installed Kinetrol Size 14 double acting actuators with digital speed controllers and Kinetrol LJ rotary dampers (with through-shafts to facilitate position feedback) installed on 12” Pratt butterfly valves.

The addition of the bi-directional, sealed dashpots smooth the normal travel, damp any valve flow induced disc oscillations, and provide at least 40 seconds travel time on air and/or electrical power failure.

Using pulsed outputs with programmable delay between steps, the actuators provide a 10 minute opening & closing time for the full 90 degree travel. The system is adjustable between 3-15 minutes with less than one degree increments., and other opening and closing ranges are available.  The actuators use fail-free logic, but fail-hold & fail-safe are available.

These assemblies were commissioned in early Fall of 2017 and are working very well. Their use will be replicated at other pump stations operated by the same customer.

This open reservoir hydraulic actuator was huge and a maintenance headache. 

Kinetrol Actuator Feature Video

Here's a new Kinetrol vane actuator feature video. Please take a minute to watch. Hope you enjoy.

Vane, Shaft and Seal Design: The Critical Difference in Pneumatic Rotary Valve Actuators

Click images for larger view.

The vane actuator produces rotary motion through the application of air pressure to a "vane' attached directly to an output shaft.

There are several manufacturers of pneumatic, rotary vane valve actuators on the market. Outwardly they appear similar. Internally, there's a world of difference in their design and their performance.

In higher quality vane actuators, the vane and shaft are machined from a single piece of steel. Casting and machining adds cost, but also adds performance. Lower quality actuators save cost by using a 2-piece vane/shaft combination. These are more likely to be affected by backlash or lost motion.  In other words, a one-piece shaft and vane assembly transfers 100 percent of the vane movement directly to the shaft. Two-piece designs may lose movement over time, reducing control and accuracy.

Higher quality pneumatic vane actuators incorporate a pair of “lip seals” around the vane. The durable and resilient polyurethane seals provide two key benefits; eliminating the need for o-rings; and eliminating shaft seals. Dual, opposing lip seals are located each side of the vane. They isolate the vane and shaft from the air supply and create an area from the shaft through the center of the vane that remains unpressurized, eliminating the need for pressure seals around the top and bottom of the shaft.

Some lower quality vane actuator designs use an o-ring around the entire vane, exposing the o-rings to mechanical stress and rolling. Higher quality actuators back their polyurethane lip seals with stainless steel expanders that maintain the integrity of the seal to the actuator housing.

The heart of the pneumatic vane actuator is simple design. Manufacturers often promote the concept of "a single moving part", referring to the vane/shaft/seal assembly. But despite this claim, all pneumatic vane actuators are not the same. You owe it to yourself and your organization to "look under the hood".  See what level of engineering and quality you're really getting.

How Kinetrol Pneumatic Rotary Vane Actuators Work

Kinetrol pneumatic rotary vane actuators use a one piece vane and shaft produce rotary torque on the shaft output drive. The vane is assembled inside a 2-piece clam-shell enclosure. The presence of the vane creates two air chambers. By pressurizing and venting opposing chambers, the resulting pressure differential across the vane provides torque to the shaft. Torque output of the rotary vane actuator remains constant throughout the full rotation of the shaft.

http://www.kinetrolusa.com | 972-447-9443

14 Reasons to Choose the Kinetrol AP Pneumatic Valve Positioner

AP postioner on Kinetrol actuator.

The AP pneumatic positioner combines smoothness and accuracy with convenience and simplicity of use. It provides unparalleled performance and real industrial robustness, easy calibration, and is well adapted to a whole range of valve and damper applications. AP options include high flow valves, direct mount or industry standard discrete mount housings, 4-20mA angle retransmit, limit switches, Clear Cone position indicator as well as I/P convertors. Below are 14 features that make the AP positioner a standout among all other valve positioners.

1. Enclosure and Lid – robust die-cast metal with tough corrosion-resistant epoxy coating and O-ring sealing. Layout gives easy access to all adjustments on removal of lid.
2. Spool Valve – highly reliable, all metal, 5 port proportional valve controls the air flow. Three versions, with different flowrates, are easily interchangeable.
3. Carrier Plate Assembly – integrated assemblies carrying the feedback shaft and cam plus angle retransmit drive and pot (when specified). Easily removed for conversion or maintenance.
4. Interchangable Port Plate – easily convertible for different flowrate options.
5. Feedback Pot Drive – zero backlash, proven trouble free for life.
6. Retransmit Pot – high quality conductive plastic servo–type with ball bearings. Proven long life and high precision.
7. Actuator Interface – options include NAMUR standard, Kinetrol male square or Kinetrol direct mount female square. Quick external conversion allows bracket mounting to any rotary or linear actuator.
8. Internal Angle Scale – with adjustable indicator for easy field calibration.
9. Exhaust Snubber Screws – allow travel speed reduction down to 1/ 3 x full speed, independently in each direction, by screwing in to restrict exhaust air flow.
10. Gauge Port – as standard.
11. Span and Zero Adjustment – quick and easy thumbwheel setting with slotted locking screw.
12. Feedback Cam – quick and easy reversal ( for rotational sense handing) or replacement (to change the response characteristic) of the cam is facilitated by a spring loaded retention device.
13. Feedback Shaft – innovative collet connection permits quick – fit/release of the actuator interface and eliminates backlash.
14. Airflow Changeover Block – allows selection of direction in which positioner moves (for direct mount models).

9 Kinetrol Features Providing Unmatched Actuator Performance

1. Long life epoxy or PTFE internal finish
2. Easy stop adjustment at each end of stroke for accurate seating
3. Corrosion resistant zinc (non-incendive) or aluminium alloy case
4. Integral vane/shaft casting - only one moving part
5. Manual override square and position indicator
6. Stainless steel expanders ensure long term lipseal / case contact
7. Double opposed, Polyurethane, lip seals for effective sealing and long maintenance free life
8. Space filling/energy absorbent sideplates (polymer or metal)
9. Durable epoxy stove external enamel finish

Kinetrol USA - http://www.kinetrolusa.com | 972-447-9443

Pneumatic Actuator Application Guide for The Asphalt Industry

There are two main types of asphalt plants, batch and continuous. Batch plants are the most widespread and offer the greatest flexibility. Single batch mixes can be produced per each customer’s requirements. Individual components are weighed and metered separately every 50-60 seconds to produce a complete batch. Continuous plants produce single mix asphalt in large quantities without interruption. The production system is simplified, which reduces maintenance, but offers less flexibility.

The following Application Guide concentrates on batch plants, although similarities exist between both.

You can read the guide below, or download it from Kintrol USA'a site here.

Pneumatic Actuator Application Guide for The Asphalt Industry from Kinetrol USA