Kyntronics
Innovative Actuation Solutions for Every application
There’s more to valve automation than just opening and closing a valve. As industrial processes continue to become automated, engineers should consider how valve actuation fits within their larger control system, including how the valves are powered, positioned, coordinated, monitored, and integrated with other equipment.
Across oil & gas, chemical processing, water & wastewater treatment, power generation, and industrial manufacturing, valve actuation requirements vary significantly. Some applications need only simple open-and-close operation while others require precise positioning, multiple valve sequencing, remote monitoring, process feedback, etc. Understanding the complete application is critical to selecting an actuation system that provides the right combination of performance, control, reliability, efficiency, and automation.
Pneumatic Actuation: Pneumatic actuators use compressed air to generate valve motion and are commonly used for relatively straightforward open/close, low force valve operation, particularly where a compressed-air supply is already available.
Electromechanical Actuation: Electromechanical actuators convert electrical energy into linear or rotary motion to operate a valve. They use an electric motor and mechanical transmission to deliver precise, fully electric control without the need for a hydraulic system.
Traditional Hydraulic Actuation: Hydraulic systems use pressurized fluid to generate valve motion and provide high power density for applications requiring significant force or torque. These systems typically rely on a hydraulic power unit, along with hoses, reservoirs, piping, and other components.
Hybrid Actuation: Hybrid actuation combines hydraulic power density with electric servo control. Rather than relying on a continuously operating centralized hydraulic power unit, hybrid systems use a servo motor, providing precise control with power-on-demand operation.
Selecting the right actuation technology requires evaluating specific application requirements, from force and motion to control, integration, operating environment, and long-term system performance.
Force and Torque Requirements One of the first considerations is the amount of force or torque required to reliably operate the valve throughout its expected operating range.
Valve type and size, process pressure, friction, breakaway requirements, and operating conditions can all influence actuator sizing. Engineers should consider normal operating loads as well as potential variations, pressure spikes, holding requirements, and other conditions that may affect the force or torque required to move or maintain valve position.
The required force or torque can also narrow the range of practical actuation technologies. Rather than sizing solely around nominal operating conditions, the complete operating profile should be considered when evaluating an actuator and its associated power system.
Motion and Control Requirements For some applications, the primary requirement is simply to move between fully open and fully closed positions. Others require the valve to stop at intermediate positions, regulate a process variable, maintain a commanded position, or repeatedly follow a defined motion profile. Depending on the application, engineers may need to evaluate:
Understanding the required level of control helps determine the best actuator technology. Applications requiring precise positioning, repeatability, or control of variables such as speed, force, pressure, or flow may benefit from a system that uses feedback to continuously monitor and adjust valve operation.
Duty Cycle and Energy Consumption How frequently the valve operates can affect actuator sizing, component life, and overall system energy consumption. Some process valves remain stationary for extended periods and only require power during a change in position. Others cycle frequently or continuously adjust their position as process conditions change.
For frequent cycling or continuously modulating applications, engineers should consider how the duty cycle affects the life expectancy of the actuator. Mechanical screw-type actuators, for example, experience concentrated wear when repeatedly operating within the same range of travel, reducing service life over time.
Duty cycle can also have a significant impact on energy consumption. In applications where valves remain stationary for extended periods, actuation technologies that consume power only when motion is required can reduce unnecessary energy use. For valves that operate more frequently, engineers should consider how the actuation system performs and consumes energy throughout the complete operating cycle.
Multi-Valve Control and Sequencing Applications involving multiple valves require additional consideration of how each valve will operate as part of the overall process. Valves may need to operate independently, follow a defined sequence, or respond to the position or status of other valves and equipment.
Engineers should consider whether multiple valves need to operate from a common power source, how individual valve movement will be controlled, and whether the process requires programmable sequences or coordinated operation. For example, a multi-valve system may require one valve to reach a defined position before another valve can operate. Other applications may require different operating sequences based on the process being performed.
Automation and System Integration As valve systems become more automated, the actuator is increasingly only one component of a larger control strategy. Depending on the application, engineers may need to consider:
Take, for example, a wellhead application in which several valves must operate according to a defined process. The initial requirement may appear to be simply automating valves that were previously operated manually. However, the complete system may need to execute valve sequences automatically, provide operators with valve position and system status, enable remote monitoring, and coordinate valve movement with other process conditions. In applications like these, the engineering question extends beyond how to move the valve. Engineers must determine how that movement will be controlled, coordinated, monitored, and integrated into the overall process.
Existing Infrastructure and Installation Requirements For retrofit applications, engineers should evaluate whether existing hydraulic cylinders, rotary actuators, electrical infrastructure, compressed-air systems, hydraulic plumbing, PLCs, or other control components can be retained. Physical installation requirements should also be considered, including:
In some applications, retaining an existing valve actuator while changing how power and control are provided can offer an alternative to replacing the entire system. For new equipment, considering these requirements early can help simplify system architecture.
Environmental and Safety Requirements Valve actuation systems are frequently installed in demanding environments, making environmental and safety requirements important selection criteria. Depending on the application, engineers may need to account for:
Maintenance, Reliability, and Total Cost of Ownership Initial equipment cost is only one factor when comparing valve actuation technologies. One should consider installation, infrastructure, energy consumption, routine maintenance, expected service life, replacement components, serviceability, and the potential cost of unplanned downtime.
Different actuator technologies introduce different maintenance considerations. Hydraulic systems require attention to pumps, reservoirs, filtration, hoses, piping, seals, and hydraulic fluid. Electromechanical systems have L10 lifecycle considerations associated with mechanical screws, gears, bearings, and other components. Pneumatic systems introduce their own air supply, filtration, leakage, and maintenance requirements.
Hybrid actuation is a strong fit when a valve application requires the power density and durability of hydraulics along with the precision, efficiency, and control capabilities of an electric system. This becomes particularly valuable as valve requirements extend beyond basic open-and-close operation to include precise positioning, programmable operation, process feedback, multi-valve sequencing, or integration with a larger automation system.
Unlike a traditional hydraulic system where a motor-driven pump generates hydraulic power and downstream valves regulate the flow delivered to the actuator or cylinder, Kyntronics hybrid technology uses an electric servo motor to directly control the hydraulic pump. The speed and direction of the servo motor control the operation of the gear pump and the hydraulic flow delivered to the cylinder, while motor torque is controlled to produce the pressure required by the application. This allows the system to provide hydraulic power on demand with rapid response when motion is needed. With position and pressure feedback, the system can provide closed-loop control without relying on proportional or servo valves.
This hybrid approach also enables power-on-demand operation. Hydraulic flow and pressure are generated according to the requirements of the application rather than maintaining a continuously operating hydraulic power source, helping reduce unnecessary energy consumption and heat generation.
Hybrid actuators are a closed hydraulic system with a relatively small volume of fluid, reducing the hydraulic infrastructure and maintenance associated with traditional systems. With no large reservoir or external plumbing, there is less fluid to manage and fewer potential leak points. The closed system also eliminates routine hydraulic fluid and filter changes, helping reduce maintenance requirements, fluid handling, and disposal over the life of the system.
The appropriate hybrid actuation technology depends on the valve, existing equipment, and how the system needs to operate. For applications using existing hydraulic cylinders or rotary actuators, a Kyntronics Compact Power Unit (SPU) combines the motor, hydraulic pump, reservoir, manifold, and control capabilities into a compact power unit. The SPU can integrate with new or existing hydraulic actuators, making it well suited for new equipment as well as hydraulic modernization and hydraulic power unit replacement applications. Existing cylinders, rotary actuators, and mechanical architecture can often be retained while the hydraulic power and control system is modernized, helping reduce the need for extensive machine redesign.
The SPU also provides flexibility for more complex valve automation. The configurable multi-port Power Unit allows multiple valves to operate sequentially or independently from a single system. Combined with PLC, HMI, Fieldbus, sensor, and feedback integration, valve operation can become part of a larger automated process incorporating programmable sequences, process monitoring, diagnostics, data acquisition, and remote operation.
When the valve application needs a fully integrated actuation solution, the Kyntronics Hybrid Linear Actuator (SHA) is an ideal option. The SHA is a self-contained actuation system that integrates a motor, pump, and valving directly onto a cylinder. Unlike traditional hydraulics, there’s no separate hydraulic power unit, no long hoses, and no leak points. The SHA is well suited for new valve designs or applications where the existing hydraulic system is being replaced. Depending on the application requirements, the SHA provides:
Both approaches are based on the same hybrid principle: using an electric servo motor to control hydraulic power based on the demands of the application. The appropriate configuration depends on factors such as valve motion, existing equipment, available installation space, number of valves, control requirements, and how valve operation needs to integrate with the overall automation system.
Kyntronics also provides a complete, integrated valve actuation solution designed to reduce engineering and integration required by the customer. As a single-source supplier, Kyntronics assists with sizing and optimizing the complete system, including the actuator or power unit, motor, drive, controls, and other supporting components. The total solution is assembled, mounted, wired, programmed, and fully tested prior to delivery.
GET EXPERT ACTUATION SUPPORT: Not sure which actuation technology is right for your application? Tell us a little about your application. Once submitted, a Kyntronics engineer will review your information and follow up with recommendations tailored to your specific requirements.
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