Innovative Flow Control Technologies Assist: Australia's Programme For Clean LNG

INDUSTRY LEADING FLOW CONTROL NEWS FROM THE WORLD OF ROTORK
Innovative flow control

technologies assist
Australias programme
for clean LNG
Full Story p2
NEW Pressure Regulators from Rotork Fairchild: Page 19
Rotork Contract News
Pakscan wireless valve control is perfect fit
for tank farm automation. p8
Rotork Product News
Rotork Gears introduces new valve gearbox
with GOST Standard dimensions. p18
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Innovative flow control technologies assist
Australias programme for clean LNG
Rotork ow control products have
been selected for applications
throughout the giant Queensland
coal seam gas-to-LNG (Liqueed
Natural Gas) projects in Australia.
To date, Rotorks international
sales network has received orders
for more than 5000 valve actuators,
embracing electric, electro-
hydraulic, pneumatic and gas-over-
oil technologies.
The three projects Queensland Curtis LNG,
Santos GLNG and Australia Pacific LNG - are
developing coal seam gas in Queenslands Surat
and Bowen Basins. Hundreds of kilometres of
pipelines will link the natural gas production
wells on the Queensland mainland with a world-
class LNG production plant under construction
on Curtis Island, which will initially produce more
than twenty seven million tonnes of LNG for
export each year. These coal seam gas projects
are centred on a clean and efficient energy
source with half the carbon dioxide emissions
of coal.
For the upstream mainland wellheads, HART

(Highway Addressable Remote Transducer)
enabled Rotork CVA modulating electric
actuators have been ordered for process valve
control at an eventual total of 2000 widely
distributed sites. In addition to the natural
COVER STORY
.
If you would like to receive future editions of
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For every person who opts to receive the magazine
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their copy of the magazine
to its chosen charity, WaterAid.
COVER STORY
Innovative flow control technologies assist
Australias programme for clean LNG.......................... 2-3
CONTRACT NEWS
Rotork Group contract news from around
the world................................................................... 4, 6-15
COMPANY NEWS
Rotork Group company news from around
the world.......................................................... 16-17, 22-23
PRODUCT NEWS
Rotork Group product news from around
the world................................................................. 5, 18-21
INDUSTRY LEADING FLOW CONTROL
NEWS FROM THE WORLD OF ROTORK
CVA actuators at the valvemakers factory awaiting shipment to site.
gas, CVA actuators will also control the
flow on the extraction process for coal seam
water. This resource will be treated for use by
agricultural and industrial customers as well as
supplementing domestic water supplies.
CVA actuators deliver continuous, repeatable
modulating control with a programmable fail
to position option. Resolution, repeatability
and hysteresis performance is less than 0.1%
of full scale, offering suitability for the most
demanding control valve applications. Among
other advantages, innovative CVA electric
actuation removes the expense of installing and
maintaining instrument air supplies at these
remote sites, where the pressure of the gas
itself is too low to provide a viable source for
actuator operation.
3 Receive future editions of electronically by emailing information@rotork.com
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CVAs are also preferred because electric
actuation eliminates the release of any
environmentally harmful gas into the
atmosphere during valve operations as well
as facilitating solar powered operations in the
remote locations.
Nearly 1000 Rotork Skilmatic SI and EH
range electro-hydraulic actuators have been
ordered for control valves, shutdown valves,
wellhead skids and metering skids. These self-
contained actuators combine the simplicity and
convenience of electrical operation with the
modulating precision of hydraulic actuation and
the reliability of mechanical failsafe motion.
Designed to SIL3 standards for use in safety
critical applications, Skilmatic actuators are
also programmable for partial stroke testing,
enabling valves to be tested without interrupting
routine processes.
The orders for Rotork electric actuators are
completed with IQ actuators for various
isolating valve automation duties. All the Rotork
electric actuator ranges feature advanced and
user-friendly non-intrusive programming and
commissioning technologies, combined with
integral data logging, diagnostics and asset
management capabilities.
The balance of Rotork orders on this giant
project involves fluid power actuators for the
pipeline and the LNG plants on Curtis Island.
The majority of these are CP and GP range
pneumatic actuators operating butterfly valves
on LNG production lines.
Rotork CVA and Skilmatic actuators installed on a typical Queensland Gas wellhead skid. On the left, a CVA
actuator, model CVQ1200, operates a 3 inch (DN80) ball valve to control the gas flow and pressure. Behind
the CVA, a Skilmatic Model SI-Q51 electro-hydraulic actuator operates a 2 inch (DN50) safety shutdown ball
valve on the water extraction line. The Skilmatic Model SI-Q60 on the right is controlling a 4 inch (DN100)
safety shutdown ball valve on the gas line.
Rotork IQ3 intelligent electric valve actuator
(below) with non-intrusive bi-directional hand
held setting tool for setting up, commissioning,
monitoring, adjustment and downloading of
data logger records for diagnostics and asset
management. Rotork IQ, CVA and Skilmatic
electric actuator designs share versions of
this technology.
The actuators are customised with control
packages to meet specific operating duties,
including SIL2 and SIL3 applications.
The remainder are GO range gas-over-oil
actuators, most of which are for the large
mainline pipeline shutdown valves.
GO actuators are designed to use the pressure
of the pipeline gas as the motive power source.
Integral control functions facilitate a wide range
of duties, usually safety related and including
line break, low pressure close, high differential
inhibit and ESD.
Rotork GO actuators (above) are built on a modular
basis and incorporate integral control functions for
a wide range of duties which are usually safety related.
Rotorks international sales network has made an
important contribution to this success, with orders
received at Rotork offices in Australia, China, Singapore,
Italy and the USA. As well as providing a simplified
contractual route for the different products, the Rotork
global organisation has the ability to co-ordinate
manufacture at various production centres and secure
on-time deliveries to customers across the world. In
Australia, Rotork has moved to larger premises in order
to fully support the Queensland projects.
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Rotork ow control equipment has been installed
throughout a major water industry AMP5
environmental improvement project at a sewage
treatment works serving Somersets largest
tourist resort on the south west coast of England.
Rotork assists Wessex Waters environmental
improvement scheme for leisure beaches
This IQ3 unit, the latest version of Rotorks intelligent actuation product range,
drives through Rotork IB gearboxes and extension drive shafts to control the
position of the two outlet modulating penstocks on the sites new Ultra-Violet
disinfection plant.
Wessex Water has invested 26
million at the site to achieve
improved bathing water quality for
the resort of Weston-super-Mare.
The improvements will ensure that
the site can cope with increased
population and continues to
comply with standards set by the
Environment Agency. The work
has been completed ahead of the
revised Bathing Water Directive,
which comes into force in 2015
and introduces more stringent
water quality standards.
New process plant and equipment
has been constructed to improve
secondary treatment by the
replacement of submerged
biological contactors with an
efficient and reliable four-channel
activated sludge plant (ASP),
combined with increased final
settlement capacity. This enables
newly installed Ultra-Violet
disinfection plant to achieve better
microbial reduction and meet strict
consent levels in the final effluent.
The upgraded site is designed to
deliver a flow to full treatment
(FFT) rate of 1050 litres/second.
Additional work on the site has
involved the introduction of
storm settlement tanks with a
capacity of 21,000 m
3
(tonnes) to
assist the reduction of over-spills
in combination with a separate
programme to remove surface
water flows into the areas foul
sewer network.
Rotorks scope of supply for flow
control in the project encompasses
IQ multi-turn and IQT quarter-turn
intelligent electric actuators and IB
manual gearboxes for motorised
and hand operated valves and
penstocks throughout the new
works. All electric actuators are
Profibus-DP V1 network enabled
and centrally controlled by a
bespoke SCADA system designed
by the Wessex Water Automation
Team. The use of Profibus
technology, a standard feature
of Wessex Waters automation
programmes, delivers significant
savings in cabling, terminations,
PLC hardware and labour.
The SCADA system runs the
automated processes and collects
control, status and diagnostic
data from each actuator. This
information is available on the
site and at Wessex Waters
regional operation centre at
Bath, where remote diagnostics
has proved to be a cost effective
method of maintenance and
service by identifying the right
operational staff to be sent to site
if required.The upgrade project
at Weston-super-Mare STW has
been performed by a partnership
made up of the Halcrow Group,
Dean & Dyball Civil Engineering,
Nomenca and Wessex Engineering
& Construction Services. The
Rotork equipment was supplied in
accordance with the Framework
Agreement which the company
holds with Wessex Water.
Profibus-DP V1 enabled Rotork IQT intelligent electric valve actuators control the
air supply to the new activated sludge plant (ASP) at Weston-super-Mare STW.
Rotork IB gearboxes are installed for the manual operation of isolating valves at
site locations including the pumping stations.
For over 30 years Schischek
has been supplying electric
explosionproof products for
building services and HVAC
applications in many industries,
including onshore and offshore oil
and gas, reneries, chemical plants,
laboratories, pharmaceuticals,
water treatment and ship building.
Schischek actuators enable Rotork
to increase activity in hazardous
and non-hazardous area HVAC
markets and also ll a gap in the
product range which is applicable
to small valves, especially in the
processing industries.
Schischek manufactures electric actuators
for quarter-turn and linear valve and damper
operation, each available with a spring-return
failsafe capability and with Ex or Red
explosionproof or In non-explosionproof
enclosure specifications.
The Max range is manufactured in two body
sizes for quarter-turn operation at output
torques between 5 and 150 Nm with an
on-site selectable stroke time of 3, 15, 30,
60 or 120 seconds. The selectable stroke
time is one of a number of options that are
built into the standard product, including the
adaptable power supply and choice of on/
off, three-position or modulating control. For
position signalling and feedback a 4-20 mA or
0-10V supply can be utilised, whilst two end of
travel auxiliary position switches are optionally
available. The ExMax and ExRun actuators have
a T6/T5 Temperature and IIC Explosion Group
classification enabling them to be used safely in
ATEX rated Zones 1 and 21 in the presence of
dangerous gases, mists and vapours. The T6/T5
Focus on Schischek actuators
temperature classification enables the actuator
to operate at ambient temperatures up to
40C/50C and an integral heater automatically
maintains reliable actuator operation at
temperatures down to -40 C, facilitating the
installation of standard products in extreme
environments.
For failsafe operation in either direction an
integral spring return version is available for
output torques up to 60 Nm, which can be
programmed to operate with a 1, 3, 10 or
20 second stroke time. In its failsafe version
the actuator is available with SIL2 safety
integrity level approval. Max actuator duties in
explosionproof environments include dampers
for smoke, temperature or fire protection
and the operation of ball and butterfly valves,
typically in sizes up to 50 mm (2 inches).
For linear on/off, three-way or regulating
control, Run actuators offer an output torque
range of 500 to 10,000 N and stroke lengths
between 5 and 60 mm. Up to five running
times between 2 and 15 seconds per millimetre
are selectable on-site, together with the self-
adaptable power supply and choice of position
signal and feedback supply. The Run actuator
is not available in a linear failsafe configuration,
but this function is achieved by the combination
of a Max actuator and Lin gearbox. The Lin
converts the actuators quarter-turn output into
a linear stroke, selectable at lengths between 10
and 42 mm.
Both Schischek and Rotork are known for
manufacturing products of the highest quality
and reliability. These products complement
each other and enable Schischek to significantly
extend its offering in the HVAC market,
supported by Rotorks worldwide presence in
almost 100 countries.
Rotorks rack and pinion pneumatic actuators
are one example of a product that gives
Schischek the ability to increase its offering to
encompass electrical sensors and monitoring
equipment with electric and pneumatic
actuation. In another scenario, Rotorks range
of larger explosionproof electric actuators can
be used with Schischek actuators to increase
versatility and scope of supply. Motorway
tunnels in Melbourne, Heathrow Airports T5
terminal and the London Olympic Village are
just three of many locations where Rotork IQ
intelligent electric actuators are used for fire
control and HVAC applications. Power stations
are another area of activity, where large linear
and rotary Rotork electric and pneumatic
actuators are used for applications including the
modulating control of inlet and draft dampers
for boiler combustion control.
At the other end of the size range, Rotorks
abilities in the process industries benefit from
the option of using Schischek electric actuators
to control small linear valves requiring up to
10 kN operating force and quarter-turn valves
with torque requirements up to 150 Nm. By
providing isolating and modulating control with
a failsafe function, these products sit neatly
below Rotorks ranges of electric control valve
actuation products, including CVA and CMA
process control actuators, broadening the scope
of supply in plants containing large and small
bore pipework and introducing the option of an
all-electric solution in every area of the process.
Left: Schischek ExRun actuator for linear on/off, three-way or regulating valve control
Right: Schischek ExMax explosionproof actuator operating a quarter-turn air control damper
Robust stainless steel enclosures are available as an
alternative to the standard aluminium in harsh and
aggressive environments
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Retrofit upgrade replaces actuators after sixty
years unbroken aerospace industry service
Dating from 1953, the Rotork
Model 100A actuators were part of
a contract to operate the valves on
one of the worlds first large scale
supersonic wind tunnels. Designed
and built by the then newly formed
Aircraft Research Association
at Bedford, the Transonic Wind
Tunnel was an ambitious project
created to keep the British aviation
industry at the cutting edge of
technology by testing the effects of
supersonic speeds on new aircraft
designs. The facility is operated
by a 25,000 hp AC motor and a
13,000 hp DC motor. In addition
a 10,000 hp compressor is used
to provide extra power to enable
testing at high transonic and
supersonic speeds up to mach 1.4
(1065 mph approx).
In the early 1950s Rotork was still
in its infancy and the award of this
significant and prestigious contract
was a milestone on the route to
the establishment of what is now
the worlds leading manufacturer
of valve actuators and flow control
products. Since the wind tunnel
was first commissioned in 1956
it has been in virtually continuous
daily operation, testing military
and civil aircraft from around the
world. It has played a vital role
in the development of legendry
projects including the TSR2, Harrier
jump-jet and Concorde. Today the
work continues with programmes
including Airbus, the Eurofighter
Typhoon and the Lockheed Martin
F-35 JSF.
Remarkably, although designed for
isolating valves, the Rotork 100A
actuators have been performing
modulating duties throughout their
sixty years of service, constantly
altering the position of large gate
valves by small degrees to control
the level of wind speeds and
provide the data that is needed for
the highly accurate measurement
of test results. It is the automation
of this process with a bespoke
control system incorporating a
Modbus control network which
has necessitated the replacement
of these units with new IQ3M
actuators that are specifically
designed for modulating duties.
Because there is a constant
demand to use the wind tunnel,
careful and detailed planning
has taken place to ensure that
the retrofit operations can be
successfully completed in the brief
periods of time that are available
between test programmes. The
restricted access around the valves
also demands particular attention.
Detailed planning paid off when
the first two actuators were
removed and the replacement
IQ3M actuators installed and
commissioned in two days, half
the allocated time allowed before
the wind tunnel was due to
re-start operations.
Richard Harvey, Senior Process
Engineer at the Aircraft Research
Association, is pleased with
Rotorks contribution to the
success of the project. He explains:
We are currently undergoing a
1.5million upgrade programme
for equipment that controls our
Transonic Wind Tunnel. One
of the packages of work that is
being undertaken is to replace
our auxiliary compressor valve
drive units. These were selected
because they are amongst the
oldest pieces of equipment on site
and they are being used on a daily
basis. The existing Rotork 100A
actuators have functioned very
well considering they are being
used well outside of their rated
specification, but at 60 years old
they were due for retirement.
The replacement valve drives
needed to be very reliable and have
an accurate positional indication as
they are vital for the operation of
the tunnel and the data we collect.
We approached Rotork with our
specification who pointed us in
the direction of the new IQ3M35
actuator. I was delighted with the
vast amount of information and
precise control that I could achieve
using the Modbus interface card.
The installation was a success and
the tunnel drivers have reported
that the new actuators provide
them with much better control.
We are now looking towards our
next maintenance period where
the remaining actuators are due to
be replaced.
Some of the very rst valve actuators to carry the
Rotork name are being replaced with the companys
latest intelligent IQ3 actuators after sixty years of
unbroken service on a demanding and critical duty in
the aerospace industry.
Richard Harvey, Senior Process Engineer at the Aircraft Research Association,
inspects the same valve, now retrofitted with a new Rotork IQ3M actuator.
One of the original Rotork 100A valve actuator installations.
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Compressor stations along the
route are designed to preserve
the pressure level in the networks
and transfer the gas for local
area consumption. These are
among the pipeline locations
where Rotork valve actuation
technologies are widely utilised.
The compressor station on the
natural gas pipeline at Erzincan
in eastern Turkey, serving the
countrys Anatolian area, is a
typical example. Here, Rotorks
well established agent Omas
Teknik Pazarlama Temsilcilik
has supplied, installed and
commissioned actuators for
operational and safety-related
duties.
The Erzincan station consists of
four turbine/compressor units
maintaining a pipeline flow rate
of between 1.6 and 2 million
standard cubic metres per hour,
which helps to increase the
networks overall transportation
capacity. Rotork valve actuators
are integrated into an ABB
automation system that controls
the compressor station and other
processes including a high integrity
safety system for emergency
shutdown, instrumentation and
other electrical equipment.
The safety-related valve duties are
performed by Rotork GO Range
gas-over-oil actuators operating
ISO Class 600 ball and plug valves
in 16 inch and 48 inch sizes. The
GO Range uses the pipeline gas
as the motive power source. The
gas is delivered to oil tanks that
convert the gas into hydraulic
pressure and this pressurised
hydraulic oil is used to drive Rotork
scotch-yoke quarter-turn or linear
valve actuators.
Using pressurised oil as the
driving force provides powerful
and smooth actuator control
and isolates the cylinder from
the pipeline gas. This prevents
contaminants from entering the
hydraulic cylinder, eliminating
corrosion and seal deterioration
and extending actuator life.
At the centre of the gas-over-
oil system, the multi-function
manifold block integrates gas
control functions to facilitate
a wide range of valve control
options. Standard gas control
systems are complemented with
optional equipment for functions
including Line Break, Low Pressure
Close, High Differential Inhibit
and Emergency Shutdown (ESD).
The manifold has the facility for
a high-flow hand pump, pressure
relief and a locking handle for safe
commissioning. High pressure and
low pressure control logic designs
are also available, together with
torque limiting devices for valve
and drive train protection.
Rotork GO actuators are
IP66M/67M third party certified
and approved for environmental
protection, together with CE and
ATEX hazardous area certification.
The standard working operating
pressure range is 10 to 105 barg,
enabling a quarter-turn operating
torque of up to 600,000 Nm and
linear thrust of 5,000,000 N to suit
pipeline valves of virtually all sizes
and description.
Operational isolating duties at
Erzincan are performed by Rotork
IQ intelligent valve actuators with
secondary gearboxes, operating
ISO Class 600 ball valves in 24, 28
and 48 inch sizes. The benefits of
IP68 watertight and ATEX certified
Rotork IQ actuator technologies
are widely recognised for isolating
and regulating valve duties in the
oil, gas and pipeline industries. The
use of solid-state electronics as an
alternative to switch mechanisms
and counter limiting devices,
combined with programmable
micro-processor based control
and instrumentation functionality,
offers many proven benefits.
Rotork selected for routine and safety-related valve
control duties on Turkeys pipeline network
These include non-intrusive
configuration and data transfer by
means of a hand held instrument
via a secure, bi-directional link.
This system is used to perform all
switch setting and commissioning
functions that were traditionally
only achieved by removing
electrical covers. Using the multi-
lingual menu on the actuator
display screen, it is quick and easy
to commission the valve, with or
without mains power connected.
The same instrument is used to
download operating information
from the actuators data logger.
The inclusion of a data logger
enables an event-by-event history
of valve activity to be generated,
including torque profiles
produced during each opening
and closing. Using Rotorks IQ-
Insight2 software, these can be
compared with the valve torque
signature profile logged during the
commissioning process to identify
the trend of valve operating wear
or isolate tight spots and other
problems. Analysis of this data
improves asset management
through fault diagnostics and
preventative maintenance.
The compressor station at
Erzincan is one of several in Turkey
that have incorporated Rotork
actuators into the automation
system. Others include Kirsehir,
Eskisehir, Hanak and Sivas, with
more planned for the future.
Rotorks abilities as a single
source for electric and fluid
power actuators, combined with
the expertise, experience and
comprehensive facilities available
at a local level from Omas, provide
vital contributions to the award of
these contracts and subsequent
product support.
Pipelines carrying products including natural gas
from Asian countries traverse Turkey en-route
for export to other final destinations or as a
source of energy for domestic consumption.
Rotork GO Range gas-over-oil valve actuator installations at the Erzincan
compressor station.
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In 2011, an operating division of
Martin Midstream Partners (MMLP)
began building a single product tank
farm at the Port of Corpus Christi,
Texas, consisting of six 100,000
barrel tanks and four booster pumps
to serve nearby truck and ship
loading terminals. Originally, the
facility was designed for a single
hydrocarbon product. The terminals
original specifications did not require
any automated valves to isolate the
individual storage tanks.
During construction, MMLP
decided to upgrade and introduce
the capability to handle a second
product, which necessitated the
requirement of isolating the tanks
to avoid cross-contamination.
To achieve this, MMLP specified
Rotork electric valve actuation
under centralised control. The
explosion proof Rotork IQ non-
intrusive intelligent actuators are
monitored and controlled by a Rotork
Pakscan P3 digital system, designed
specifically for valve actuation duties
and the environments associated
with hazardous area petrochemical
plants and storage areas. The Rotork
system incorporates all appropriate
interlocks which safeguard the
integrity of the terminal operations.
For this project, MMLP has been
able to take advantage of additional
functionality and further economies
through the introduction of Pakscan
P3 with a wireless field network.
Wireless Pakscan eliminates virtually
all the costs associated with the
installation of wiring, cable ducts,
safety barriers and associated
equipment required for network
cabling, whilst enabling an increased
level of information from the
actuators to be communicated over
the wireless network.
Chris Duke, Rotorks lead service
technician on the project, explains:
The customer didnt want to add
a lot of new conduit and wiring to
control the actuators, so the wireless
Pakscan system was a perfect fit.
The installation consists of 16
Rotork IQ40 non-intrusive intelligent
actuators, one Pakscan P3 wireless
master station and three network
repeaters, which are used to
overcome radio black spots and
ensure the redundancy of the
network. As far as start-ups go, this
was by far the easiest of any type of
control system that I have seen.
Some pre-commissioning of the
wireless system was performed at
the Rotork factory in Rochester prior
to delivery and, once in the field, I
installed the wireless antennas on
each actuator and gave each unit its
unique address. When this was done
I powered up the master station and,
as if by magic, all sixteen actuators
populated the network within a
few minutes. The customer was
very impressed with the job done
and how quickly everything came
together.
Following the success of this project,
the same actuation and control
system will be extended to three
additional tanks to be built during
the second phase of construction at
this facility.
Pakscan wireless valve control is the
perfect fit for tank farm automation
The Rotork Pakscan wireless valve control system
is described as a perfect fit for a petroleum tank
farm automation project in the USA.
Rotork IQ valve actuator installations on one of the storage tanks at the
MMLP Corpus Christi tank farm, illustrating the simplified site wiring
(power cabling only) facilitated by the wireless Pakscan P3 control system.
Rotork Pakscan P3 Master Station.
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Another golden opportunity
At the same time as the network at the MMLP
plant was being commissioned, the installation
of another wireless Pakscan network was being
completed for an application in an entirely
different industry gold mining.
The Newmont underground gold mine
in Nevada utilises Geotube
dewatering
technology to separate sediment from both
ground and extraction process water. The filter
systems, which are installed above ground,
Rotork IQ40 actuators installed on the four booster pumps, again illustrating the simplified site wiring.
Note the wireless Pakscan antennas on each actuators terminal housing.
are fabricated from a woven material which
is permeable to water while retaining solids
and sludge. Excess water drains through small
pores, resulting in effective dewatering of the
contained material, which is then processed to
extract the gold.
The large scale filtering operation has been
automated by the motorisation of the filter
inlet and isolating valves with Rotork IQ electric
actuators. A total of 15 actuators have been
installed on valves over a widely distributed area
A section of the Geotube
dewatering plant, with the Rotork IQ actuators installed on the inlet pipework on
the right hand side. In total there are 12 filter bags, of which 3 can be seen in this view below.
and a Modicon PLC has been introduced to
supervise the operation of the plant.
Here again, the utilisation of the wireless
Pakscan P3 network for the monitoring and
control of the valve actuators has delivered a
reliable and economical solution, eliminating
the cost of installing any additional site wiring
apart from the actuator power cables. All the
actuators are in line-of-sight of the Pakscan
coordinator module, with the distance to each
actuator ranging between 68 metres to 132
metres. The externally mounted coordinator
is connected to the Pakscan P3 master station
in the control room by a 15 metre cable. The
master station communicates with the Modicon
PLC using Modbus TCP Ethernet protocol.
James Hall and Mark Dennis from Rotorks service
team complete the non-intrusive commissioning of
one of the 12 Rotork IQT actuators that control the
flow of water into the filter bags.
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This schematic illustrates how different actuator designs as well as instrumentation such as
flow sensors can be monitored and controlled on the same wireless Pakscan P3 network.
Flow Sensor
Wireless
Repeater
Wireless Coordinator
Flow Sensor
Wireless
Repeater
Wireless Coordinator
Rotork Pakscan P3 wireless
First introduced in 2009, the
Rotork Pakscan P3 wireless
network control system is a further
development of the Pakscan
system used in thousands of plants
throughout the world today.
Simply stated, the system
establishes a secure wireless mesh
network that is used to control
actuators and other field devices
throughout the plant and to gather
important operating data for asset
management and preventative
maintenance from the connected
valve actuators.
The wireless system operates on the license-free, globally
recognised 2.4 GHz ISM (Industrial Scientific and Medical)
frequency band and has a line-of-site operating range
between each device of approximately 30 metres indoors
and 100 metres outdoors. Up to 60 actuators can mesh
with a wireless coordinator.
In a Pakscan wireless mesh network, each actuator on the
network can act as an independent router to help signals
get to their intended destination. A correctly designed
network will be configured to provide two or more paths
between each actuator and the wireless coordinator.
Therefore, if the normal traffic route is blocked or if a
hardware or communication failure should occur, it can
be overcome as the network dynamically determines an
alternate route for the data to travel. This self-healing
network mimics the loop-back capabilities of the
established Pakscan two-wire loop.
In such a network, privacy and security are high priorities.
To prevent unauthorised commands being sent to devices
over the wireless network, all control data is encrypted
using the Advanced Encryption Standard (AES). Additional
encryption is incorporated into the system to prevent
unauthorised devices joining the network and to prevent
a message replay attack.
The Pakscan P3 wireless network card gives the user
access to all the standard control and monitoring features
and data available from the wired Pakscan system,
together with the diagnostic and asset management
information stored as standard by Rotork IQ actuator
data logger and configuration files, which is otherwise
only downloadable locally, using the IQ hand held
commissioning and communication tools. Using built-in
web pages it allows easy extraction of these files from the
control room over the wireless network.
The wireless system consists of three
main hardware components:
A Pakscan P3 master station fitted with
a wireless interface module, which is
typically connected to the plants control
system using industry-standard Modbus
protocol over either a serial or Ethernet
connection.
A Pakscan P3 wireless coordinator
module, which can be mounted, either
indoors or outdoors, up to 200 metres
away from the P3 master station
(further if standard fibre optic converters
are employed) and which functions
as the base station for the systems
robust mesh network.
A wireless actuator module installed on
each actuator on the wireless network.
IQ Pro actuator
showing Pakscan P3
wireless network card
installed.
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Retrofit upgrade at Turkeys largest refinery
chooses Rotork valve automation
Retrofit work in progress. Engineers from Omas work on one of the tank farm
manifolds at the Tupras Izmit refinery.
Rotork valve actuation
and two-wire digital
control technology has
been chosen for a major
upgrade and automation
programme at the Tupras
Izmit renery in Turkey.
Tupras is Turkeys largest industrial
company and leading refiner,
operating four refineries of which
Izmit is the largest. First opened
in 1961, production at Izmit
of commodities including LPG,
naphtha, petrol, jet fuel, kerosene
and diesel is now running at over
11 million tons a year.
More than 900 explosionproof
Rotork IQ intelligent electric valve
actuators will be installed in a four
stage project to motorise manually
operated valves on the refinerys
tank farms. Nearly 800 of the
actuators will be retrofitted on
existing valves whilst the balance
will consist of new actuated valve
packages.
Many of the actuators will be
factory fitted with intumescent
fireproof coatings, as shown
picture bottom right.
The non-intrusive, explosionproof
and permanently watertight design
of the Rotork IQ has a proven
record of long term reliability
and low cost of ownership in
the petrochemical industry.
Secure non-intrusive and wireless
technology is utilised for setting
control parameters, commissioning
and downloading integral
dataloggers to provide vital
diagnostic information for asset
management programmes.
The retrofit project at Izmit is
being performed by Rotorks well
established agent in Turkey, Omas
Teknik Pazarlama Temsilcilik.
Omass responsibilities include the
design and fabrication of valve
adaptation, installing the new
actuators, commissioning and on-
site support.
The new actuated valve packages
are being assembled and tested
in the Omas workshops prior to
delivery to site.
The expertise, experience and
comprehensive facilities available
from Omas at a local level are key
components in the success of this
major retrofit project.
Due to the size of the refinery
site, groups of IQ actuators in
different areas will be monitored
and controlled by a total of twenty
Rotork Pakscan P3 digital bus
networks. Designed specifically
for valve actuation applications
and the spacious environments
associated with tank farm
installations, Pakscan incorporates
secure field communications with
inbuilt network redundancy. Each
network is controlled by a Pakscan
P3 master station which provides
a local centre for monitoring and
control and links the network to
the sites SCADA system.
The tank farm upgrade at Izmit is
part of a massive modernisation
and expansion programme at the
Tupras refinery. This also includes
the construction of new refinery
facilities on an adjacent site by
the Spanish company Tcnicas
Reunidas, for which more than
400 IQ electric actuators are being
supplied through Rotorks Spanish
subsidiary company.
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The Fairchild Model 10 Regulator is also used
on the test instrument for Fluid loss of clay
component of geo-synthetic clay liners.
Rotork Fairchild pressure regulators
selected for high accuracy
research applications
More than 100 IQ actuators and two Pakscan P3 hot-standby
master stations have been supplied, fully installed, cabled and
commissioning by Rotork Iberia.
The Olivenza Thermosolar power plant is the second plant to be
operated by the Spanish company Ibereolica. Rotork supplied IQ
range electric actuators with Pakscan digital control at the companys
first plant, Moron Thermosolar, and the satisfactory experience on
this project, where installation and commissioning was performed on
time and without incident, has enabled Ibereolica to select the same
Rotork equipment again. As with the Moron project, Seridom has
been the main contractor for Olivensa Thermosolar.
Rotork selected for valve
automation at the Olivenza
Thermosolar power plant
Right: One of the many Rotork IQ actuator installations
at the Olivenza Thermosolar power plant.
Rotork intelligent electric valve actuation with digital
two-wire monitoring and control has been specified
for valve automation at the Olivenza Thermosolar
power plant in Spain, a CSP (Concentrated Solar Power)
technology facility generating eco-friendly electricity
for up to 50,000 households.
Panel mounted Fairchild Model 10 Regulators are
used on the Measurement of index flux through
saturated geo-synthetic clay liner specimens
using a flexible wall permeameter test rig at
TRI Australasia.
Rotork Australia has supplied
Fairchild Model 10 pressure
regulators for research
applications demanding highly
accurate pressure control at the
TRI Australasia facility near to
Queenslands Gold Coast.
TRI Australasia offers highly specialised
services including a range of geo-synthetic
testing and quality assurance programmes
for a multitude of industries. The Fairchild
Model 10 regulators have been installed on
two processes where compressed air is used
to check for the content of water retention
within clay. Both processes demand highly
accurate set point pressure supplies in order
for the tests to maintain reliable results.
Fairchild Model 10 regulators are designed
for applications where high performance
and reliable set point accuracy are essential.
Suitable for system pressures up to 34 bar
(500 psi) and flow capacities up to 63 cubic
metres/hour (40 SCFM), the Model 10 offers
nine set point pressure ranges and is easily
able to achieve the +/- 0.5% accuracy required
for the TRI application.
Commenting on the Fairchild product, TRI
Australasias Divisional Director Warren
Hornsey said We chose the Fairchild
product due to the accuracy required and the
strong name within the industry. It was also
important for us to have the support that
Rotork Australia can offer from their local
Brisbane office.
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Manufactured at the Rotork Fluid
Systems factory in Lucca, Italy, the
actuators have been supplied to
valvemakers in India for installation
on Phase 2 of the Kochi-Koottanad
Bangalore-Mangalore Pipeline
project.
The actuators will operate above
ground and buried service ESD
(Emergency Shutdown) ball valves
along the length of the 30 inch
diameter, 879 kilometre pipeline,
which runs from a new 5 million
tonne annual capacity LNG import
terminal constructed by Petronet
at Kochi, on Indias south-west
coast. Rotorks contract included
packaging the actuators with
cabinet mounted limit switches and
controls, together with gas storage
tanks for the ESD duty.
GP actuators are manufactured in
double-acting and spring return
configurations with torque outputs
up to 600,000 Nm (5,000,000 lbf.in).
Certifications include IP66M/67M,
ATEX94/9/EC and PED 93/27/EC
and the actuators are also suitable
for use in SIL2 and SIL3 rated
safety systems.
The swift delivery of a total of 82 large GP Range
pneumatic valve actuators has assisted the
completion of a natural gas pipeline owned by the
Gas Authority of India Ltd many months ahead of
the originally planned schedule. The order represents
the largest supply of actuators from a single
manufacturer on the entire pipeline.
Rotork GP actuators mounted on 30 inch pipeline ball valves await shipment
from the valvemakers factory for buried service installations on the Kochi-
Kootanad Bangalore-Mangalore Pipeline.
Swift delivery of Rotork actuators assists
early completion of new gas pipeline
Rotork Gears completes landmark contract
for Chinese subsea valve industry
Rotork Gears has successfully completed a
landmark contract in the history of the Chinese
subsea valve industry.
The Chinese manufactured subsea double block and bleed valve equipped
with WGS gearboxes in a landmark contract for Rotork Gears.
In 2012 the government in China
initiated an incentive policy to
encourage the countrys valve
making industry to develop its own
subsea valves to serve a market that
has been traditionally dominated
by foreign manufacturers. Through
its factory in China, Rotork Gears
has been working closely with the
Chinese valve makers involved
with subsea valve production to
provide technical and engineering
support, drawing on over 30 years
experience of subsea gearbox
design and manufacture.
Early in 2013 these efforts were
rewarded with an order from the
Shanghai Pudong Hanwei Valve
Company. The contract involves
two WGS Series subsea gearboxes
fitted to a double block and bleed
valve for a natural gas pipeline in
the Bohai Sea. The 8 inch Class
600 valve is being installed a depth
of 30 metres on a pipeline serving
the Suizhong SZ36-1 oilfield and
operated by the China National
Offshore Oil Corporation (CNOOC).
Designed for heavy duty subsea
applications, the Rotork WGS
quarter-turn gearbox features a
worm shaft supported on taper
roller bearings, a high strength
alloy steel worm screw and a
membrane or piston type pressure
compensator to enable operation
at any depth. Gearboxes can be
equipped with a high visibility
position indicator, vertical or
horizontal ROV inputs and a
handwheel for diver operation.
Self locking and available with
many gearing ratios, WGS
gearboxes are permanently
lubricated and designed for output
torques up to 500,000 Nm.
14
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River weir upgrade illustrates Rotorks
extended scope capabilities
Another part of Rotorks activity involves
actuators that are retrofitted on site as part of
improvement projects which often also include
additional work such as mechanical, electrical
and civil engineering. The members of Rotorks
dedicated Site Services Division have many years
experience of these projects, enabling them
in many cases to organise the total supply of
the work that is required together with project
management services, embracing all of the
project team disciplines in what is called an
extended scope contract.
A major benefit for the customer is the simplified
contractual route that the extended scope
contract enables, by reducing the number of
separate sub-contractor contracts. Extended
scope contracts have become particularly
popular with customers in areas including water,
power and environmental improvement, where
projects can be relatively modest in scale but still
demand a diverse range of engineering skills and
disciplines. A recent Rotork UK contract for the
Environment Agency at the picturesque village of
Buscot in Wiltshire is a good example.
Above: Buscot Weir after the completion
of Rotorks extended scope contract, which
encompassed project management, new valve
actuation and adaptation, a new control panel in
an adjacent building and the installation of a new
walkway platform for inspection and maintenance.
For many years Buscot Weir on the River Thames
had been equipped with electric motors that
were used to adjust the position of two sluice
gates in order to manage the river level and
flow rate during fluctuating weather conditions.
These motors, with the associated valve shafts
and an electrical control panel in an adjacent
building, had become obsolete and required
replacement to safeguard the river banks from
potential flooding in the future.
As well as replacing all the obsolete equipment,
the Environment Agency wished to ensure that
future inspection and maintenance could be
carried out safely. To achieve this it would be
necessary to construct a new access walkway
platform along the length of the weir. Following
the preliminary site survey of the existing
Rotork is well known for
supplying ow control equipment
for new and upgraded industrial
plants and processes on a global
scale. In these contracts, often
involving tens or hundreds of
valve actuators and associated
control equipment, Rotork works
with valvemakers, engineering
companies and end users as one
of several members of a project
team, each with different areas
of expertise and generally all
under the supervision of a
main contractor.
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installation, Rotork Site Services submitted a
contract proposal to the principle contractor
AMCO Engineering which encompassed
project management services and the total
supply of all the elements of the project new
valve actuation, valve adaptation, wiring and
control panel, new walkway platform, removal
of old equipment, installation of new and
commissioning.
Upon acceptance of the proposal, Rotork
engineers returned to site to carry out a detailed
survey to enable the replacement equipment to
be dimensioned, designed and fabricated and
to organise all the other equipment needed
for the installation work such as scaffolding
and temporary access. In this case it included
the provision of pontoons by a company
that specialises in safeguarding working
environments when the presence of water is a
potential hazard.
Rotorks design team was able to replace
the two existing electric motors with a single
IQ3 electric valve actuator to operate both
sluice gates simultaneously, driving through
a combination of new shafting and three
gearboxes supplied by Rotork Gears. The
IQ3 actuator is certified as watertight and
temporarily submersible to IP68, providing secure
environmental protection for long term reliability
in all anticipated ambient conditions. As the
installation is adjacent to a public footpath,
additional security is provided by the fitting of
a vandal-proof cover over the actuators local
control buttons to prevent any unauthorised
operation or interference.
Rotork Site Services co-ordinated the
manufacture and fabrication of all the new
equipment and materials required for the
upgrade. When this was completed, engineers
from Rotork and the sub-contractors were
back on site to remove the old equipment,
install the new actuator and valve shafting with
control panel, wiring, walkway platform and all
associated ancillaries, completing the installation
and commissioning within seven days.
Above: Buscot Weir prior to the upgrade
Close-up of the obsolete sluice gate motor drives. A Rotork engineer confirms the successful operation
of the new control panel during site commissioning.
Installation nearing completion on the new
walkway platform; the IQ3 actuator in the
foreground is fitted with its vandal-proof cover.
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Acquisition expands
Rotorks valve
adaptation business
From its home in Broken Arrow,
Oklahoma, Renfro Associates
has been designing and
manufacturing valve automation
packages encompassing actuators,
gearboxes, instrumentation and
fabricated adaptation for flow
control applications in industries
including oil & gas, water
treatment and food processing
since 1979.
The companys in-house CAD
facilities, combined with a modern
machine shop and welding
equipment, have earned an
impressive reputation for the
manufacture of quality actuated
valve packages of all sizes to meet
the demands of virtually any duty.
When asked about the acquisition,
Rotork Chief Executive Peter
France explained: Renfro is a
long established business with an
excellent reputation for delivering
high quality product and service
to its customers. The acquisition
provides us with the opportunity to
repeat the success of our UK based
Valvekits business by expanding
the Renfro offer across the USA.
The addition of Renfro Associates Inc. to the
Rotork Group heralds the expansion of Renfros
valve adaptation and accessories business to
cover all of the USA.
Rotork adds rack and pinion
actuators to its product range
GT Attuatori was established in 1963 and is
a leading manufacturer of rack and pinion
pneumatic valve actuators. The product range
encompasses single and double acting actuators,
solenoid valves, switchboxes and mounting
accessories, providing packaged valve solutions
for flow control applications in many industrial
processes. For safety critical duties, the actuators
are available with SIL3 certification to IEC
international standards 61508 and 61511.
The GTA Group is based in Italy and Germany,
where the company also has a centre of
excellence. Commenting on the acquisition,

Rotork Chief Executive Peter France said:
The acquisition of GTA brings to the Rotork
family of companies one of the longest
established, best regarded, rack and pinion
actuator manufacturers in our markets. The
acquisition will further enhance the range of
products Rotork offers to our customers.
Rotork recently announced the
acquisition of the GTA Group,
comprising of GT Attuatori Srl, GT
Attuatori Europe GmbH and Max
Process GmbH.
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Rotork Middle East opens purpose-built factory
During the Open Day customers and agents were invited to see the workshops and product presentations
by the Rotork Middle East team.
First orders for Rotorks robust and compact 242 Series manual gear operators
Part of a consignment of Rotork Model 242-30 gearboxes attached to 150 mm
(6 inch) China Valves Hanwei ball valves for a natural gas project.
An Open Day at the end of April
celebrated the opening of Rotork
Middle Easts purpose-built factory
in Dubai. Situated in the Jebel Ali
Free Zone, the new premises contain
ofces and workshops, with initially
15 sales and technical staff and plans
for further expansion.
The new 600 square metre facility provides
increased local support for business in flow
control markets throughout the Middle East,
where Rotork has been active since the 1950s.
A Rotork regional presence was first established
in Abu Dhabi in the 1970s.
Recent projects involving the Middle East oil
and gas industries include the Abu Dhabi Crude
Oil Pipeline linking Habshan and Fujairah, the
Ruwais Refinery expansion and the New Doha
International Airport. Rotork valve actuation and
control technologies are also widely utilised in
the areas water and waste treatment, power
generation, desalination, infrastructure and
environmental improvement industries.
As well as holding stocks of products and
spares locally, the new facility will provide a
full range of valve adaptation, retrofitting,
site service and asset management activity
encompassing electric and fluid power actuators
and associated equipment. A driving force
behind the expansion is the demand for
reduced project downtime, with more scope
for planned, emergency and preventative
maintenance. Rotork Chief Executive Peter
France and Edward Hobart, HM Consul
General in Dubai, performed the ribbon-cutting
ceremony, at which Graeme Mullin, HM Trade
and Investment Advisor in Dubai and Terry
Willis, Regional Director of the Energy Industries
Council, were also present.
When asked about the new factory, Peter
France replied:
The Middle East region has always been an
important market for Rotork. Our success has
been built on the need for high quality products
that will work in some of the most challenging
environmental conditions. The new facility will
enable us to respond to the needs of our local
customer base and provide expanded services
for the complete range of Rotork products.
We look forward to further growth as the
region continues to develop.
The full address for Rotork Middle East is:
Rotork Middle East Fze
R8 OA LC07, Jebel Ali Free Zone,
PO Box 262903
United Arab Emirates 262903
tel: +971 04 887 6408
fax: +971 04 887 6409
email: rme.sales@rotork.com
242 Series manual quarter-turn
gear operators benefit from
the latest design technologies
to provide optimum robustness
and durability with minimal
non-structural mass and reduced
overall size.
Suitable for the operation of
ball, butterfly and plug valves or
other quarter-turn devices in most
general industrial applications, all
242 Series manual gear operators
feature a sturdy cast iron IP67
watertight enclosure, a ductile iron
wormwheel, PTFE thrust washers
and adjustable end stop screws.
A range of five sizes is available
to accept valve stem diameters of
up to 70 mm (or 58 mm square
section) and deliver an output
torque range of up to 2100 Nm.
Built with standard ISO base
dimensions between F05 and F25,
simple and rugged 242 Series gear
operators are ideally suited for low
torque manual applications.
Options include stainless steel
input shafts and fasteners, Namur
and Westlock mountings, an IP68
temporarily submersible enclosure
and a padlock kit.
Rotork Gears reports that international markets have
reacted positively to the introduction of its range of
242 Series manual gear operators and orders have been
received. Signicant activity in China includes an important
order from the valve manufacturer China Valves Hanwei for
a natural gas project.
18
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Schischek launches explosion-proof controller for
decentralised HVAC control structures
Right: The Schischek ExReg is designed for
decentralised control structures in explosion-
proof areas.
Rotork Gears introduces new valve gearbox
with GOST Standard dimensions
The NTBG Series bevel gearbox from Rotork Gears.
GOST Standard output lug drive interface, suitable
for rising or non-rising valve stems.
Rotork Gears has introduced the
NTBG series of bevel gearboxes,
designed specically to comply with
the Russian GOST-R Standard CKBA
062-2009 for valve and actuator
mounting dimensions.
GOST is the predominant standard for
valves in the oil, gas, power generation and
utility industries throughout Russia and its
neighbouring countries.
Developed from the proven and rugged Rotork
IB gearbox range, the NTBG design is intended
for the manual or motorised operation of multi-
turn gate, globe, sluice and penstock valves
where the operating thrust is contained within
the valve itself.
The multi-turn lug drive is suitable for non-
rising and rising valve stems. Housed within an
environmentally sealed ductile iron enclosure,
precision engineered input pinion and output
bevel gears with low friction PTFE hub bearings
provide an extended service life and smooth
operation under high load conditions.
The fully sealed enclosure is grease filled for
life and certified as watertight to IP67 as
standard. IP68 certification is optionally
available for harsh environments including
buried service duty.
Other options include auxiliary spur, bevel
or two-speed input drive reducers, flexible
extensions and high or low temperature trims
beyond the standard -60 to +120 C for
maximum operational adaptability.
The range of four model sizes delivers an
output torque range of 250 to 10,000 Nm.
All models are available with suitably sized
handwheels for manual operation or can be
motorised with electric actuators.
With more and more applications
in the building automation sector
requiring high performance, cost
effective and easy to use explosion-
proof control systems, Schischek
now provides the solution with the
introduction of ExReg.
The ExReg control unit is designed to ensure
smooth operation when controlling HVAC
systems for variable air volume (VAV), pressure,
temperature and humidity by minimising the
number of separate components required.
Developed from the successful ExCos and
ExBin HVAC sensor series used extensively
in hazardous area locations including ATEX
zones 1,2,21 & 22, the new ExReg control unit
features a compact design which incorporates
an internal proportional-integral-derivative
(PID) control structure.
The parameterisation process is easy to use
and automatically achieved for standard
applications. The system provides support,
especially during the start up process, with
many predefined settings and damper
characteristics. Features retained from the
globally established ExCos and ExBin series
include the elimination of intrinsically safe
wiring, digital adjustment, actual value
indication and LED status display. Designed for
electrical and mechanical compatibility with
market standards, the ExReg is suitable for
24 VAC or DC supplies and environmentally
protected to IP66.
The introduction of this exciting development
further expands the Schischek range of market
leading explosion-proof control products,
backed by worldwide support and engineers
experienced in explosion-proof applications.
For over 30 years Schischek has supplied
electric explosion-proof control products
for building automation in a wide range of
industrial sectors including oil & gas, (onshore
and offshore), ship building, chemicals,
pharmaceuticals and water treatment.
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New products from Rotork Fairchild
Allnew low pressure regulator on two week delivery
Increased high pressure capacity for pneumatic regulator range
Innovative high performance polymer pressure regulator
Rotork Fairchild announces
the introduction of the
all-new Model 11 low
pressure regulator.
Available on a 1-to-2 week
delivery, the Model 11
provides a reliable and
highly accurate solution for
very low pressure control
applications.
Designed to handle the most
challenging duties, typical
applications include leak detection
systems, tank blanketing, air and
gas sampling systems, analytical
equipment, soil sampling and
test stands.
Available in a range of five sizes,
the Model 11 features superior
repeatability and sensitivity of 0.05
inches of water column (1.25 mm
WC) for ease of setting. Flow is
critical for most applications and
to meet this demand the Model
11 delivers a flow capacity of 24
SCFM (28 litres/second).
The Model 11 design incorporates
a diaphragm diameter engineered
for optimum performance within
a compact package, offering an
ideal solution when the overall
envelope size must be minimised.
Tamper-proof, screw or standard
knob actuation alternatives
provide versatility and ease of use.
Nitrile or optional fluorocarbon
elastomers enable the Model 11
to work in any environment.
Rotork Fairchild has
increased the high pressure
capacity of its compact leak-
free pneumatic regulators
for instrument and industrial
control applications with the
introduction of a new HPP
range.
A companion to the recently
announced HPD diaphragm style
range of regulators, the new HPP
(High Pressure Piston) range
incorporates a piston design to
manage supply pressures up to 413
Bar (6,000 psi) at temperatures up
to 260 C and deliver high output
pressures between 207 Bar (3,000
psi) and 69 Bar (1,000 psi).
The HPP high pressure performance
complements that of the HPD,
which will also manage supply
pressures up to 413 Bar (6,000
psi) and accurately regulate lower
output pressures down to between
35 Bar (500 psi) and 1.66 Bar
(25 psi).
Constructed with 316 stainless steel
bodies, the HPP and HPD ranges
feature patent pending improved
valve seat sealing that eliminates
the risk of media leakage often
associated with conventional high
pressure regulators. Both ranges
are available with 6 mm ()
ports in either 2 or 4 port
configurations and in multiple
output pressure ranges.
Standard knobs can be replaced
with tamper proof caps for
high temperature and/or non-
adjustment applications.
Rotork Fairchild regulators can be
mounted at the ports, the bottom
surface or in panel mounted
configurations.
A new polymer
pressure regulator with
innovative features
is designed for high
precision pressure
control duties.
The Model 55 pressure regulator
features a non-rising stem
within a small footprint design,
delivering high precision control
in a lightweight and compact
package.
Manufactured entirely from
polymer and stainless steel, the
Model 55 offers compatibility
with medical and scientific gases
such as nitrogen, helium and
oxygen.
Applications include precision
pressure decay and leak
testing, medical ventilators,
respiratory diagnostic systems,
balloon pumps and sterilisation
equipment.
A patent-pending venturi design
compensates for downstream
pressure droop under flow
and provides highly accurate
pressure output control under all
conditions. The separate control
chamber isolates the control
diaphragm from the main flow to
eliminate hunting and buzzing.
With supply capacity up to 150
psi (10 Bar) and flow capacity up
to 10 SCFM (283 litres/minute)
the Model 55 controls output
pressures up to 100 psi (7 Bar)
to within +/- 0.2 psi (14 mBar)
or better, even with fluctuating
or rapidly decreasing supply
pressure. This high pressure
capability, combined with
pinpoint accuracy at low control
pressures of 7.5 psi (0.5 Bar) or
less, sets the Model 55 apart
from conventional regulators for
demanding applications.
The Model 55 is available on a
fast-track two week delivery and
is swiftly available for engineers
seeking a top performance unit to
complete the design and testing
of their new product.
20
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Rotork Valvekits, the specialist valve
mounting kit company in the Rotork
group, is now the ofcial stockist and
distributor for the industry-leading
Pneumatrol Namur range of solenoid
valves and the well established Centork
range of valve positioners.
The Pneumatrol range, formerly known as
RGS Davis, has a long history and excellent
reputation for providing pneumatic solenoid
valve solutions within hazardous and non-
hazardous environments. User markets include
petrochemicals, pharmaceuticals, distilling,
food, beverages and paper making.
Valvekits to stock Pneumatrol solenoid
valves and Centork positioners
With an extensive range of approvals,
Pneumatrol solenoids are the standard
specification within many world class
companies.
Designed for direct mounting on quarter-turn
actuators meeting Namur standards, the valves
are available with a complete range of approved
pilot solenoid operators. The innovative designs
are suitable for operation in a wide range of
temperatures and include valves for high flow
applications.
Hazardous area solenoids are available with
ATEX Category 1, 2 and 3 approvals. Further
international hazardous area approvals include
IEC, FM and GOST.
Commenting on his companys appointment,
Rotork Valvekits General Manager Craig Mellins
said: We are very proud to be appointed as the
stockist and distributor for the world-leading
Pneumatrol Namur range of solenoid valves.
The addition of Pneumatrol further enhances
our product offering as well as enabling off-
the-shelf delivery of these products to our
customers in the valve making, valve actuation
and associated industry areas.
Centork pneumatic positioners are designed for
the operation of quarter-turn or linear actuated
valves in accordance with a proportional control
signal. The design utilises a robust aluminium
enclosure and stainless steel components
for long-term reliability in harsh operating
environments.
Standard features include simple, user-friendly
zero and span settings and NAMUR interfaces
for easy valve and accessory adaptation.
Examples of the Centork
range of positioners,
showing, top-to-
bottom: PR-640 Series
positioner for linear
process control valves
and cutaway diagram of
PR-700 Series positioner
for quarter-turn valve
actuators.
Optional limit switches, position indicators,
gauges for main and control signal pressure
and electronic position transmitters can be
fitted to meet the demands of most operating
requirements, whilst a smart positioner is also
available, incorporating micro-processor based
electronics for valve monitoring and diagnostics.
Excellent operating performance delivers
repeatability of less than 0.3% of full range,
hysteresis of less than 0.5% of full range
and 99% full range linearity. All models are
available with ATEX certification for operation in
hazardous areas.
Examples of the Pneumatrol Namur (formerly RGS
Davis) range of solenoid valves, showing top-to-
bottom: Namur Reflex valve; Namur C1518PP00B
safe area valve; Namur C1518PD00BA EXD 11C T6
ATEX valve, with stainless steel terminal box
coil housing.
Rotork Gears SRL awarded FMC Technologies Global Qualification Certificate for Subsea gearbox
Rotork Gears specialised BGS1 subsea gearbox
has been awarded a three-year Global
Qualification Certificate by FMC Technologies.
Rotork Gears SRL has
been awarded a three-
year Global Qualication
Certicate by FMC
Technologies for a
specialised product from
its range of subsea
gearboxes.
FMC Technologies is a
leading worldwide provider
of solutions for the energy
industry, designing,
manufacturing and servicing
advanced technological
products and systems in areas
including subsea oil and gas
production and processing.
The Global Qualification
Certificate is awarded to
the Rotork BGS1 gearbox, a
specialised product designed
for torque inputs of up
to 3500 Nm at operating
depths of 3000 metres. On
choke valve installations this
1:1 bevel gearbox is a vital
component in the clamp
used for diver-less retrievable
systems. The gearbox is
designed for heavy duty
applications with carefully
selected materials to offer the
highest level of reliability in the
harsh subsea environment.
Rotork Gears SRL General
Manager Roberto Boldorini
speaks on behalf of Rotork
when he says: FMC
Technologies is recognised as
a market leader in the subsea oil
and gas industry, where Rotork
Gears has an extensive reference
list of projects stretching back to
the early 1990s.
To have FMC Technologies as
a customer and to receive a
Global Qualification Certificate
is a proud achievement for
Rotork Gears SRL.
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Rotork Australia has supplied
subsea rack and pinion hydraulic
valve actuators and subsea
gearboxes for an innovative
renewable energy wave
technology project on Garden
Island, near Perth in Western
Australia.
Subsea actuators and gearboxes assist first-
of-kind commercial wave energy project
The patented CETO (Carnegie Wave Energy)
technology converts ocean swells into a
source of energy for power generation and
water desalination plants. Unlike other wave
technology systems, the CETO wave power
converter is fully submerged and produces
high pressure water from the power of waves.
A submerged buoy moving up and down with
the movement of the waves drives a pump
attached to the seabed.
The pump in turn delivers water ashore
through a pipeline at high pressure that enables
zero-emission electricity or fresh water to
be produced.
Due for completion early in 2014, the
Perth Wave Energy Project will be the first
demonstration of a complete grid-connected,
commercial scale CETO power generation
system anywhere in the world.
Rotork actuators and gearboxes have been
ordered by Severn Glocon Australia and include
double-acting hydraulic actuators equipped
with top-mounted diver operated override
gearboxes, controlling subsea ball valves
installed at a depth of 25 metres. The override
gearbox incorporates a lost quadrant system
in the gear pinion, providing a simple but highly
effective mechanism for switching between
hydraulic and manual operation.
All the diver has to do is rotate the handwheel
to the three positions remote (hydraulic), open
(manual) or close (manual) which are visible
through the indicator on top of the gearbox.
Co-operation between Rotork Fluid Systems and
Rotork Gears has enabled a rugged, compact,
well engineered and cost-effective solution to
be delivered for this application.
The patented CETO (Carnegie Wave Energy)
technology.
Rotork equipment includes double-acting hydraulic
actuators equipped with top-mounted diver
operated override gearboxes.
Schischek ExMax explosionproof
actuators have been selected to assist the
production of biogas for district heating
systems in the German city of Munich.
Biogas is produced during the effluent treatment
process at the citys largest waste water plant
Klaerwerk Gut Grosslappen, situated close to
the world famous Munich Allianz Arena, home
to Bayern Munich football club.
The Schischek actuators have been installed
in the digester and fermentation tanks, where
all electrical equipment must be approved
for use in hazardous areas. Built inside four
large towers, the fermentation tanks mix the
waste at a defined temperature to produce the
biogas. For optimum performance the inner
tank temperature must be maintained at 38 C.
Six Schischek actuators are installed in an area
known as the lamp at the top of each tower
for the operation of air dampers to balance the
inside temperature with fluctuating ambient
temperatures on the outside. Factors favouring
the Schischek products for this application
Schischek boosts biogas production at Munich waste water plant
include their compact size, ease of installation,
standardised connections and Zone 1 hazardous
area explosionproof certification. In addition
Schischek, which is now part of the Rotork
Group of flow control companies, has developed
established relationships with the damper
OEM, local engineering companies and the end
user. All Schischek products are manufactured
with colour coding to indicate at a glance the
appropriate hazardous or non-hazardous area of
application. Yellow denotes hazardous zones 1,
2, 21 and 22, red denotes hazardous zones 2 and
22 and green denotes non-hazardous areas only.
One of the four fermentation tank towers at the
Munich waste water treatment works. The Schischek
actuators are installed in the lamp at the top of
each tower.
Schischek ExMax actuator installation on one of the
air dampers.
22
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The 1360 m building houses the
new headquarters for Rotorks
Mexican subsidiary company,
incorporating inside sales,
contracts, after sales and service
departments as well as a training
centre for customers and end
users.
The new factory and warehouse
is a complete service and overhaul
facility equipped with large
overhead cranage capacity and
full electrical, pneumatic, hydraulic
and gas power supplies. The
factory will focus on actuated
valve factory fit operations and
carry comprehensive stocks of
actuators, gearboxes and key spare
parts to provide swift deliveries to
customers.
These include PEMEX, the national
oil company, and CFE, the national
power company.
The number of employees in
Mexico is expected to nearly
double in 2014 as Rotork continues
to increase its market share in the
countrys utilities and industries
including mining, marine and steel.
Contact details for the new
facility are:
Rotork Servo Controles de
Mexico SA de CV
Centeotl #223
Col. Industrial San Antonio C.P.
02760, Delegacion,
Azcapotzalco, Mexico D.F.
Tel: +52 (55) 5559 2959
Team photograph of Rotork staff to commemorate the opening of the
Valve Automation Centre in Mexico City.
Rotork opens Valve Automation Centre in Mexico
Rotork grows into extended head office facilities
Rotork has expanded into new ofce,
workshop and production storage facilities
at its worldwide headquarters in Bath.
The new building will home Rotork PLC, as well
as the southern office for Rotork UK, which
was set up in 2012 to rationalise all of Rotorks
home market electric, fluid power and manual
valve actuation activities under a single banner.
Rotork UKs northern office, actuator and
gearbox factory will be moving into larger new
premises in Leeds early in 2014.
The new Bath offices also house Rotorks
systems sales department, reflecting the
increased demand for Rotorks digital control
network solutions including the advanced
wireless Pakscan system.
Enlarged office and workshop space is also
provided for Rotork Site Services, the companys
specialist retrofit, maintenance, repair and asset
management organisation. Under the same
roof, 872 square metres of new warehouse
space has been created to give additional
support to burgeoning production at the main
electric actuator manufacturing plant, where
IQ3, IQT and CVA actuators are built.
The new facilities have freed up space in
Rotorks original head office building, facilitating
expansion of international sales, marketing,
engineering, research & development and
business development departments, positioning
Rotork for continued growth in Bath for the
foreseeable future.
Rotorks new office, workshop and production storage facilities at Brassmill Lane in Bath. Part of the new Rotork Site Services workshop.
New offices for Rotork UK ready for occupation.
Rotork is proud to announce the opening of its new Valve
Automation Centre in Mexico. Strategically located in Mexico
City, it is the rst full shop facility for Rotork in the country.
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New factory boosts production in Malaysia
The Rotork factory in Malaysia has
relocated to a brand new 5,148
square metre facility in Shah Alam
to increase production and provide
more storage space for nished
goods.
The new offices and production plant,
strategically located close to Kuala Lumpur
and its international airport, feature an
improved manufacturing layout to enable
more production of the AWT range of
actuators without sacrificing prompt
lead times.
Essar introduces IQ actuation training
at its Power Learning Centre
The Power Learning Centre at
the Essar Salaya Power Plant in
the Indian state of Gujarat has
installed a Rotork IQ actuator as
an integral part of its training
programme.
Essar engineers mounted the actuator
on a butterfly valve to create a working
demonstration unit, enabling them to
learn about the technical advantages
and asset management functionality of
IQ intelligent valve actuation, whilst also
getting hands-on experience of setting
up, commissioning and maintaining
the actuators.
Essar is an important energy industry
customer for Rotork in India and
throughout the world. The Power Learning
Centre at Salaya has been established as a
training facility for the engineers at all their
power plants in India.
Pictured here, Mr. KVB Reddy the
head of all Essar power plants in India,
Mr. MG Gupta Chief Executive Officer
of the Salaya Power Plant and Mr. KB
Makadia Chief Executive Officer of the
Vadinar Power Plant inspect the new
IQ demonstration unit with two Essar
engineers.
AWT actuators meet the demand from
worldwide markets for reliable low cost
watertight electric actuators with separate or
integral motor controls and instrumentation.
The new address for Rotork Malaysia is:
Rotork Actuation Sdn. Bhd.
No 32, Jalan Anggerik Mokara 31/47,
Section 31 Kota Kemuning,
40460 Shah Alam
Malaysia
Tel: 03-55251665
Telefax: 03-55253937
Email: rotork@rotork.com AWT actuator
24
UK
Rotork plc
tel +44 (0)1225 733200
fax +44 (0)1225 333467
email mail@rotork.com
USA
Rotork Controls Inc.
tel +1 (585) 247 2304
fax +1 (585) 247 2308
email info@rotork.com
Redefining Flow Control
Rotalk is published and printed by
Rotork Controls Ltd. in the UK.
For more information on ROTALK articles and features contact ROTORK Bath: +44 (0)1225 733200 email: information@rotork.com
www.rotork.com
For the latest news follow
Rotork on twitter @rotork
Rotork Product Selector
Product Selector is now available on the Rotork website.
The Rotork Product Selector is a simple way
to search and compare the Rotork range of
products. The selector has been designed to
enable you to filter your chosen results by
selecting from a drop down list of variants.
You will be able to select the products based on the
following criteria:
Power Source
Valve Type
Duty
Control and Indication
Torque / Thrust
Industry
Enclosure
Control Options
Also, Failsafe, SIL / HIPPS, Partial Stroke and Valve
Monitoring / Diagnostics
You are then able to compare up to 5 products in
the range and from there progress to the product
information page or actuator sizing guide.
The Product Selector currently has 82 Rotork products
listed, and this list will be kept up to date as new
products become available.

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