Kinetrol Actuators on Dilute and Dense Phase Conveying Diverters

Kinetrol actuator on dense phase diverter valves

Pneumatic conveying systems transfer powders, granules, and other dry bulk materials through an enclosed horizontal or vertical conveying line. Pressure differential and air flow is the motive force in pneumatic conveying. Through control of pressure or vacuum and the airflow inside the conveyor, the system can successfully move material.

Pneumatic conveying systems are classified into two types by their operating principle: dense phase and dilute phase.

The most common is dilute phase pressure conveying. Used for powders or granules, and most often with non-abrasive, non-fragile materials that have a light bulk density. Common examples are plastic granules, sugar,  flour, corn starch, activated carbon, zinc oxide, hydrated lime, and sodium bicarbonate. Dilute phase vacuum conveying is for materials that compress under pressure, for toxic materials, and are conveyed over short distances at low capacities.

Kinetrol on diverter valves

Dense phase pressure conveying is best for conveying fragile or abrasive materials over long distances. Commonly handled materials include feldspar, fly ash, silica sand, alumina, sorbitol, dextrose, carbon black, resins, cocoa beans, nuts, and certain cereals. Dense phase pressure conveying moves materials at a relatively low speed to reduce materials degradation, air consumption, and wear and tear on mechanical systems.

Diverters are used to direct the flow of conveyed material to branch lines. Because they are handling materials such as sand, gravel, whole grains, stone, cement, and coal, the diverter must be designed for handling very abrasive materials and for high cycles. Not only must the diverter be designed for this service, but the pneumatic actuator must also meet theses demanding requirements.

Kinetrol actuators have become the preferred quarter-turn pneumatic actuator for conveying diverters because of their dependability and ability to withstand tough operating environments. Kinetrol actuators are virtually immune to the high vibration, dusty atmospheres and provide years of maintenance free operation.

Kinetrol Actuators in Wood Power Pole Manufacturing

Wood treatment steam valve

Wooden utility power poles must be chemically treated to protect against pests, rot, and decay. The manufacturing process to apply the chemicals requires heat, vacuum, pressure, and harsh chemicals.

The pressure treatment process varies everything from full vacuum to prepare the poles to accept the treatment, to positive pressure and elevated temperatures (using steam) to force the chemical treatment into the pole.

Pole treatment vessel

There are three areas where automated valves are required: 

1) Steam control valve
2) Vacuum pump valve
3) Chemical flow control valve

The steam line at one plant was unreliable and very expensive. It was costing the plant about $4000. To help come up with a better, more economical solution, a  Kinetrol USA Distributor was invited in and specified a Kinetrol actuator, positioner and custom brackets for the existing steam line valve. 

Look carefully to see (2) Kinetrol
Actuators on chemical feed lines.

The retrofit was completed with the new Kinetrol actuator and positioner at a fraction of the previous actuator package cost. The customer was delighted the Kinetrol package gave them better control in a package that was much easier to service. 



KINETROL

FIELD TESTED | APPLICATION DRIVEN

Kinetrol Vane Actuator on FRAC Sand Hydraulic Classifier

Kinetrol actuator on
Hydraulic Classifier
underflow valve.

In very oversimplified terms, fracking is a process by which a fluid mixture consisting mostly of water and a proppant (typically sand) is pumped into a well under pressure to create fractures in the underlying rock. These fractures create more pathways for hydrocarbons (natural gas & oil) to flow to the well and results in higher production of oil or natural gas.

The term proppant is a mashup of the words "propping" and "agent" and is the material used to hold open cracks in the rock so that an available path to the well exists. The most common proppant used in the fracturing operation is sand.

A classification of very durable, high-purity quartz sand, with very round grains is referred to as "FRAC sand". The petroleum industry uses it widely due to its crush resistance. It is used in hydraulic fracking to allow the flow of oil, natural gas and natural gas liquids from rock.

A Hydraulic Classifier (also known as density separators) are machines that separate minerals of different specific gravities so a producer can classify them for use (in this case for FRAC sand production). They operate by allowing feed material to enter the top

FRAC sand underflow valve location
(courtesy of McLanahan)

of the unit, after which water is injected and creates an upward rising current. The result is a zone of suspended solids. Finer materials then flow over a weir at the top of the unit, while coarse solids collect in the lower area.  A PID controller maintains the water injection rate and the desired operating density by adjusting the underflow valve to maintain consistent output. The classifier automatically compensates for changes in feed rate.

A Kinetrol USA Midwest Distributor installed a Kinetrol actuator on a Hydraulic Classifier used at a FRAC-sand plant. Previously the customer used an electric actuator which cycled every 2-10 seconds. The electric actuator would burn up after 2 weeks. The Distributor sold them a Kinetrol pneumatic actuator which has worked now continuously for 2 years with no maintenance. The FRAC-sand plant has since purchased 10 more units.

Kinetrol Vane Actuators Replace High Maintenance Pneumatic Cylinders in Water Treatment Plant

Kinetrol Rotary Vane Actuator

A Kinetrol USA Western Distributor was told by a water treatment plant operator that two 10" Pratt butterfly valves with cylinder actuators were not working reliably. The valves were okay, but the pneumatic cylinders were a maintenance nightmare. Not only did they introduce far too much hysteresis (slop) in the actuator-to-valve movement, but they also leaked air, and in the winter time had to have a heater placed next to them to keep the cylinders from sticking. The cylinder seals were so poor moisture would penetrate the cylinder and freeze, rendering the actuator unresponsive.

An experienced, application savvy Distributor came to the water treatment plant's rescue. After looking at the application the Sales Engineer specified new butterfly valves and Kinetrol Model 14 double acting actuators, manual gear overrides, AP positioners with I/P, ULS limit switches, angle retransmit, and point-of-use filters.  He knew the Kinetrol actuators would not only eliminate the constant maintenance, but also provide much tighter control.

After 1 year of continuous service, the actuators have performed flawlessly without any downtime. The maintenance crew at the water treatment plant are so pleased they plan on standardizing.

Kinetrol Actuators. Field Tested. Application Driven.

Kinetrol actuators on butterfly valves for water treatment plant.

20" High Performance Butterfly Valve Closed in Under 1/2 Second!

Fast closing Kinetrol actuator

This video demonstrates how quickly a large butterfly valve can be closed with a Kinetrol vane actuator spring return unit. In this case, it's a 20" stainless steel high performance butterfly valve (HPBV) being tested in the shop.

You'll note the valve takes about 11 seconds to open, but only 0.4 seconds to close, using the Kinetrol spring return unit.

Quick closing valves are used in emergency situations to stop the flow of fluids that may contribute to uncontrolled combustion, cause backstream contamination, or allow spillage of hazardous materials.

Kinetrol Pneumatic Actuators at Work

Kinetrol rotary vane actuators are the true workhorse of the valve and damper actuation industry. Known for surviving applications with the highest cycle rates, the nastiest environments, and the most remote areas, Kinetrol actuators continue to provide years of maintenance-free service.





This video is a slide presentation of Kinetrol actuators at work.

1/4 Turn Electrohydraulic Valve Actuators

A hydraulic gear pump immersed in its own reservoir delivers pressurized oil to the vane-type 90° actuator via the control box, which contains non-return valves and solenoid valves to direct the flow into the actuator; with cam operated limit switches to control travel and (optionally) signal position to the user. The unpressurized side of the actuator is connected to the reservoir, so there is no net transfer of oil from reservoir to actuator. The pump and its motor run entirely on precision ball bearings, so that the friction and motor size can be minimized and life maximized; the efficiency resulting from this reduces the heating effect and allows 100% rating. A pressure release valve is built into the pump so that if the actuator load becomes jammed the torque is limited and dangerous over pressures or motor stalls are avoided.

Fail-safe spring return action uses a reliable low-stress-range sealed clock-type spring unit mounted coaxially with the actuator, together with a fail-open solenoid valve, to ensure reliable positioning when power is not supplied to the unit. A high flow external dump valve can be fitted to allow very rapid spring-driven action.

Double-acting models are supplied with solenoids arranged to give position locking when power is disconnected. An optional manual by- pass valve is available to allow manual override movement of a double acting when power is disconnected.

The interface between pump/reservoir unit and the control box allows mounting of the pump in different orientations at 90° to each other, so that the motor can be kept above the reservoir whether the actuator output axis is horizontal or vertical. External electrical connections are all made via a single accessible connector block in the control box, with the simplest possible switching needed to drive the unit. Two conduit entries are available, to allow easy separate connection of power and signal lines (if used). All internal wiring is connected via a central connector and fuse board, and the actuator is protected from supply surges by a metal oxide varistor suppressor.

For more information contact:

Kinetrol USA
www.kinetrolusa.com
972-447-9443