Industrial gas turbine packages must deliver efficient and dependable performance with low operating and maintenance costs in order compete in today’s global market place.
Challenge Industrial gas turbine packages must deliver efficient and dependable performance with low operating and maintenance costs in order compete in today’s global market place. In order to accomplish this goal, manufacturers and retrofitters are turning to all electric servo solutions for their actuator needs, eliminating the need for pumps and tubing normally associated with hydro- mechanical or pneumatic designs.Exlar Corporation is a worldwide leader in the design and manufacture of industrial electric servo actuators.
Fuel Control Valve: The use of electric actuated fuel control valves on gas turbines can replace pressure regulator/gas loaders, throttle valves, and associated electrohydraulic actuators. Exlar’s servo electric actuators integrate a high performance servo motor and a specially designed roller screw mechanism for converting electric motor power into linear motion. The roller screw, which consists of multiple threaded helical rollers assembled in a planetary arrangement around a threaded shaft, is capable of carrying heavy loads for thousands of hours even in very arduous conditions. This, combined with high torque servo motor technology, provides a compact and powerful linear actuator solution for fuel valves.
Each Exlar actuator, when supplied with Exlar’s all digital positioner, will respond to command signal changes in less than 5 mSec. The speed of the response combined with the dynamic capability of the all-electric actuator delivers repeatability much greater than typical pneumatic or hydraulic cylinders and allows for end-to-end travel time of a 6 inch stroke actuator of less than 200 mSec. This performance makes Exlar’s actuators the obvious choice for applications such as turbine controls.
Exlar’s FT Series Actuator Performs in Class II Hazardous Location Environment
Coal Diverter Gate /Damper Control
The customer was using an Andco hydraulic actuator to control their coal diverter gate. Due to the actuator’s age, the customer was experiencing difficulties sourcing replacement parts for the unit. The Andco actuator also utilized old technology that the customer wanted to update through the purchase of a new actuator solution. This application required an actuator with a long stroke length that could control the motion of their large coal diverter gate. This application also required a solution that was rated for Class II hazardous locations because of the presence of coal dust in the facility.
The customer had previous experience with Exlar on a turbine application and felt comfortable with the Exlar product. They worked with the local Exlar representative and decided to purchase two FT60 actuators. The actuators provided the necessary stroke length for this challenging application; one actuator with a 12 inch stroke and the other with a 24 inch stroke. Operating in a Class II environment was required for this actuator solution and Exlar’s FT60 combined with a Explosion Proof motor and a Grove gear reducer satisfied this requirement. The customer also required a special trunnion mount and motor support bracket for their application which Exlar willingly designed. This non-standard trunnion mount and custom motor support was easily incorporated on to the FT60 actuator because of Exlar’s immense experience designing and manufacturing custom made actuator solutions for their customers.
Replacing the hydraulics actuators with all electric servo actuators in older steam turbines.
There are hundreds of steam turbines installed throughout the military and process industry that incorporate pre-1970 design. The valves on these turbines are predominantly operated by hydraulic actuators. Maintaining these hydraulic systems is costly with spare parts becoming more and more difficult to find. The control on these turbines in many cases is no longer adequate in today’s marketplace. Many plants that have older steam turbines are now upgrading them with digital controls and replacing the hydraulic actuators with all electric servo actuators from Exlar.
Application Solutions Steam Control Valve Steam turbines incorporate two basic arrangements of control valves: Shell Mounted and Chest Mounted. Shell mounted control valves are attached to the turbine shell. Some are modulated by a rack and cam arrangement. This valve operating method utilizes a common hydraulic cylinder to lift a rack of four to nine poppet valves in sequence. A fulcrum lever is used to multiply actuator force. Exlar directly replaces this main hydraulic actuator with a high performance servo electric actuator and positioner.
Each Exlar actuator, when supplied with Exlar’s all-digital positioner, will respond to command signal changes in less than 5 mSec. The speed of the response combined with the dynamic capability of the all-electric actuator delivers repeatability much greater than typical pneumatic or hydraulic cylinders and allows for end-to-end travel time of a typical 6 inch stroke actuator of less than 200 mSec. This performance makes Exlar’s actuators the obvious choice for applications such as turbine controls.
Wind turbines are constructed to yield energy. The longer it can run trouble-fee, the higher the return on the investment. Integral to the wind turbine is the pitch drives. The pitch drives are located at the base of the blade and provide the motion in turning the blades in the right position. Optimal efficiency is achieved depending on the wind force.
With reliable gearbox components and real-time sensor technology from Wittenstein, the goal can be achieved. The limited space and reliability requirements point to a Wittenstein product. Using either the alpha TP or the alpha SP can provide ultimate sealing and lubrication for a constantly turning blade. Adding the Wittenstein Sensor Technology is the optimal solution for monitoring and diagnosis as well as torque measurement.
Solar tracking systems are constantly aimed at the sun. The more sun exposure, the more energy created. With the ongoing evolution of solar-tracking, the ability to generate solar power at a volume that is a return on investment is more of a reality. Tracking systems can be designed for single-axis and dual-axis designs. Depending on the desired of moving parts, both designs prove to be successful in installations.
Solar Tracker can increased energy production up to 30% over fixed panels.
Efficiency and optimization are key factors in solar energy systems today. Solar design engineers are challenged with developing reliable and cost effective systems that deliver the maximum amount of energy.
Solar tracking systems can increases energy production up to 30% or fixed panels, making the technology very attractive to design engineers.
Saudi Aramco, headquartered in Dhahran, Saudi Arabia, is Saudi Arabia’s national oil company and a fully integrated global petroleum enterprise. Saudi Aramco manages the world’s largest proven crude oil reserves and the world’s fourth-largest gas reserves.
Application Solution Exlar’s GSX60 actuator eliminated the multiple single-point failure vulnerability by replacing the complex hydraulic system with the simple, compact solution shown in the photo at the right. The complete solution includes a fiberglass enclosure, a heavy duty precision trunnion bearing mount system, shock-absorbing minimum travels stops, and a thermoelectrically-cooled servo drive all designed and supplied by LCC. These components ensured the system would require minimal maintenance and trouble-shooting and that the actuator would survive in the desert conditions.
Vertical damper control in an air exchanger system.
A customer historically used pneumatic cylinders to control a vertical damper in their air exchanger systems. They were looking to move away from pneumatic cylinders because of the large amount of noise the cylinders produced and their high power consumption. This application required both high speed and high load in order to move the vertical damper 18 inches from top to bottom. The move also needed to be completed within one second. The customer sought a quieter electric actuator solution that could also offer very high performance and low energy consumption.
Exlar’s FT35 actuator paired with a servo system provided all of the necessary components to solve this customer’s application challenges. The FT35 actuator was able to perform the 18 inch move of a 300 pound load within the required one second cycle time. Not only could Exlar’s FT35 actuator perform this move, but it could perform this move without sacrificing the working life of the actuator. Furthermore, Exlar’s solution eliminated significant noise from the air exchanger system and allowed for better overall system control. Because of Exlar’s ability to deliver a prototype that performed the required functions quietly, the customer decided to replace their existing pneumatic systems with Exlar actuators. They also decided to incorporate Exlar actuators into the future production of this air exchanger system.
Based on its very nature, solar energy isn’t available 24 hours a day. Making the most of our suns energy requires highly efficient solar cells and advanced sun tracking systems. Sun tracking allows the solar cells to face the strongest sunlight while it is available, so they need to be able to detect the strength of sunlight in different directions to determine the best location for the strongest sunlight. The solar plates must be constantly adjusted to the correct angle and direction by the sun tracker system, which requires a multi-axis motion control system.
Because sun tracker systems are installed in outdoor areas in direct sunlight, the devices in the system needed to be able to withstand harsh environments and have wide operating temperatures. This particular system also required a robust DAQ module to measure voltage from different transmitters and a reliable controller with precise stepping control.
System Description: The ADAM-4117 measures the input voltage signal from the sunlight transmitters to detect the direction of the strongest sunlight then informing the result to PEC-3240. PEC-3240 controls the stepper motors of the sun tracker system. If the different strength of the sunlight is detected between two transmitters, the PEC-3240 will calculate the sunlight strength difference to adjust the stepper motors to find the optimal position of the solar cell module. If there is no difference of the sunlight strength between two transmitters, it means the solar cell module is in the optimal direction of sunlight. The system can keep track of the relative data to adjust the stepper motors to control the angle and position of the solar cell module for getting the best performance.
After implementing the PEC-3240 as the control mechanism for this application, the sun tracker system has operated efficiently and reliably without any breakdowns or downtime. This positioning system outlines the inherent strength and benefits of the PEC-3240, which is suitable for many similar motion control applications. Not only can this Embedded Motion Controller simplify existing system architectures to save costs, but its rugged design provides a very reliable solution. Combined with the Advantech ADAM Remote I/O module, the PEC-3240 offers more flexibility for different system requirements.
The Sun is a huge source of abundant power, sending nearly 10,550 EJ of energy to the Earth every day. This is more energy in one hour than all the combined cities of the world use in one year. To try and harness this magnificent power, many countries have been investing in solar technologies for over 30 years. Today’s solar thermoelectric systems include reflectors, mirrors, heat insulating absorbers and advanced motion control technology. Advantech’s own Industrial Wireless Ethernet products are a perfect fit for many such applications due to their great performance, reliability and ruggedness.
Wireless communications are an excellent complement to industrial wired solutions for many applications. In a typical solar thermoelectric control system, a combination of wired and wireless communications can effectively solve problems related to data transmission and field application issues. Two connection modes are supported; Infrastructure and Ad-hoc. When in Ad-hoc mode, the wireless network card does not require a huge network structure and a high-speed, simple network can be built without a lot of end-user effort. In this solar thermoelectric control system, the client required a wireless network with the following requirements: – Industrial grade equipment with high electromagnetic compatibility – Fanless products to operate in extreme environments with high temperatures and humidity – Long MTBF – Easy network management.
WLAN Access Points (AP) are very similar to an Ethernet switch. On one hand, each AP communicates with regular nodes (Clients) regardless if they are fixed nodes or mobile nodes. On the other hand, APs can connect directly to each other through a cable or an independent wireless network, thus realizing communications without the limitations of a wireless network. This solution adopted Advantech’s Wireless AP EKI-6311G and Wireless EKI-1351 Serial Device Server. 100 PLCs have been deployed in the field, and each PLC adopted Wireless mode to transmit information to the host computer. Moreover, these PLCs are far away from the central control room. Therefore, Advantech recommended to the ratio of 1 Wireless AP for every 10 PLCs to guarantee reliable wireless network transmissions. The Wireless APs apply WDS (Wireless Distribution System) technology allowing them to be bridged flexibly, making it easy to transmit data to all of the 100 PLCs through 100 EKI-1351’s and then upload all relevant information to the central control room.