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

Valve Automation Package for Tough Hog Fuel Boiler Applications

Hog fuel boiler actuator.

Hog fuel boilers are wood-fired boilers used predominantly in paper mills, sawmills, and wood processing plants. The term “hog fuel” refers to the wide variety of wood and wood wastes used to feed the boilers (called hogged fuel). Hog fuel contains wood residue, wood waste products, bark, sawdust, planer shavings, and wood chunks that are processed into coarse chips and clumps.

The ash from burning wood and wood wastes has a very high pH, high enough to make the wood ash exhibit a corrosive characteristic, which must be considered when selecting valves and actuators. All equipment in contact, or in close proximity, to this ash must stand up to the wet, corrosive, and dirty environment.

To facilitate the removal and transport of the ash, water is introduced for handling and management, thus creating corrosive slurries. Control valves with pneumatic actuators are used to control water flow and slurry flow. The environment is extremely dirty, and as mentioned above, corrosive. Any equipment connected to this process must be designed with performance and maintenance in mind.

Kinetrol rotary vane actuators, spring return units, and EL positioners are ideal for this type of service. Standard design features such as epoxy enamel finishes, stainless steel screws, sealed housings, and direct mount configurations provide an automation package that is proven to outlast other types of actuators and assemblies in very challenging environments.

Does Your Valve or Damper Need More Than 90 Degrees Rotation?

180 degree actuator

Kinetrol’s 180° actuator is produced by adding a 2:1 step-up linkage onto the output shaft of well proven 90° vane actuators.

Factory fitted, direct mount linkage units are available to suit model 02, 03, 05, 07, 09, 12, 14 and 16 actuators, giving a neat single unit with no mount kits or brackets. The linkage’s unique geometry gives constant 2:1 step-up so that the output torque remains constant throughout the actuator's travel.

The all-steel mechanism of the linkage employs rolling contacts to minimise frictional losses and wear, and to maximise life. The linkage is lubricated for life, and encased in a robust, fully sealed die cast alloy casing. Exterior surfaces are protected by a corrosion resistant epoxy stove enamel finish. Standard adjustable endstops on the 90 degree actuator can be used to set the angle of travel. The other end of the 90 degree actuator allows the full range of Kinetrol modular accessories to be fitted directly.

• Simple compact unit - No external moving parts
• Unique linkage design - converts to 180° travel 120° option available 
• Constant gear-up ratio through travel range - Hence constant output torque 
• Rolling contact linkage mechanism - Ensures low wear, long life, low friction 
• Linkage sealed for life - Protected from the environment, long maintenance free life 
• Compatible with all Kinetrol modules - Direct mounted spring returns, limit switch boxes, positioners etc.
• Adjustable endstops

180 Degree Rotary Vane Actuator from Kinetrol USA