Hydraulic Actuation System

Application
Hydraulic actuation is typically used for positioning
of control valves which require high stroking speed,
high actuation forces and accurate positioning. The
CCI hydraulic actuation system can develop
actuation forces up to 1200 kN (120 tons), controlled
stroke speeds of up to 250 mm/s and a stable
positioning accuracy of 0.1 mm. With the CCI
hydraulic actuation system combinations of control
functions with additional safe open or close
functions are easy to implement. With additional
accumulators hydraulic energy can be stored for
safe open or close functions.

The system is qualified and type tested to realize

combined control and safety valves according to
TRD 421/EN4126-5.
Fig. 1: Valve, actuator and local controller cubicle
Features
3. Position feedback transmitter with limit switches
• High actuation forces: up to 1200 kN RSG15
4. Positioner for proportional valves PVR10 / 11
• High controlled stroke speed:
up to 250 mm/s 5. 4/3-way solenoid valve APL 6 / 10 for
open/close function
• Stroke up to 330 mm 6. Safety bypass unit SBE 116 / 125 for safety
• Proportional valves and local positioners for valves according to TRD421
fast positioning 7. Safety control unit SSB 10 ... 32 with additional
accumulator
• Up to 3 additional solenoids for independent
8. Hydraulic supply unit HV 80 ... 450
open/close functions
• Safety function according to 4. PVR
TRD421/EN4126-5 possible
• Local or remote positioners
7. SSB
• Hydraulic power units with redundant pumps 5. APL
1. ASM ...
and integrated control and switch gear 6. SBE

• For mineral oil or fire resistant hydraulic

fluids (e.g. Fyrquel EHC-N, Quintolubric 888) P T P T T P

2. PV/BL

Function 3. RSG15

Overview P

T
The Hydraulic Actuation System consists of the 8. HV ..
following Elements:

1. Hydraulic Cylinder GHZ 50-125, ASM 160-320

2. Proportional valve with blocking unit PV4/6/8/10
for positioning function
Fig. 2: Hydraulic diagram (priciple)
Hydraulic Cylinder ASM
Hydraulic actuators are double-acting hydraulic
cylinders. Their piston is moved by the controlled
supply and discharge of hydraulic fluid to either side
of the piston. CCI hydraulic actuators develop
positioning forces of up to 1200 kN combined with
high positioning speeds and accuracy. Eight
different hydraulic cylinders are available with piston
diameters of 50 to 320 mm for forces of up to 1200
kN and with strokes of up to 300 mm.
Fig. 3: Actuator and yoke
Features of ASM-type actuators are the wear-free
bearings of their moving parts and their outstanding
sealing of the piston rod as well as between the
piston chambers. Each actuator can besides a
proportional valve PV be equipped with three
additional safety control units SSB or three safety
bypass units SBE. Thus any combination of
independent safe open and/or close functions can
be realized. For special application hydraulic
actuators can be equipped with additional springs
acting in open or close direction.
Proportional valve PV
The proportional valve is used for fast and precise
positioning of the hydraulic actuators. Three
different sizes of proportional valves (PV4 / PV6 /
PV10) are available. Stroke speeds range from
27mm/s with a PV10 on an ASM 320 to 250 mm/s
for a PV10 on an ASM100. A stable positioning
accuracy of 0.1mm is possible at stroke speeds of
up to 100 mm/s.
Proportional valves are equipped with an additional
blocking solenoid valve which prevents drifting of
the actuator in case of loss of electrical or hydraulic
power (lock in place).
Position feedback transmitter with
limit switches RSG15
The feedback transmitter unit contains a 2-wire
position transmitter SG15 and two SPDT limit
switches. The position transmitter is actually an
angle transmitter with a nominal angel of 60°. A
linkage is converting the linear movement of the
actuator into an angle. The two limit switches are
easily adjustable because of their sliding clutch they
can be adjusted for switching in opening or closing
direction and at any position of the valve stroke.
Feedback transmitter units with 4 limit switches are
also available
Positioner for proportional valves
PVR
The positioner forms together with the proportional
valve and the position feedback transmitter a fast
and accurate position control loop. The possible
positioning accuracy is approx. 0.1% for a stroke
speed of 100% / 1s. The positioner compares
continuously the position demand signal with the
actual position feedback signal and generates the
signals to drive the proportional valve type PV.
Fig. 4: Local controller and laptop with programming
software
The positioner controls also the blocking solenoid
valve. The blocking element is normally energized to
allow oil flow and therefore movement of the
actuator. Upon loss of electrical power as well as
hydraulic fluid pressure the blocking element locks
the hydraulic actuator at its present position (lock in
place). Other fail functions can be realized with the
help of additional open or close control units (SSB).
For failure of the position demand signal or the
position feedback signal the actuator fail position is
programmable. The positioner is adjusted and
operating modes are selected with the help of a PC
connected to the RS232 interface on the positioner.
The PVR10/11 has besides the outputs for the
proportional valve and the blocking solenoid valve
two/three additional outputs to drive additional
solenoid valves APL or SSB. One PVR can
therefore operate one valve with additional safety
control units or one control valve and one
open/close isolation valve with a solenoid valve
APL.
PVR are normally supplied as field mounted boxes
to be installed besides the actuator. Cables to the
actuator are already connected to the field-mounted
boxes. Rack-mounted versions for installation in
cabinets in the electronic room are available.
4/3-way solenoid valve APL and
4/3WEDz
The solenoid valve type APL is normally used for
the operation of open/close valves e.g. isolation
valves. It allows also a stepwise positioning function
which can for slow stroking actuators even provide a
sufficient positioning accuracy. Adjustable orifices
allow to limit the stroke speed independently in each
direction.
Safety bypass unit SBE
The safety bypass unit SBE is used for safety
valves, which have to open without any external
energy. The safety bypass unit SBE provides a
solenoid-operated bypass between the upper and
the lower piston chamber. An open bypass allows
free movement of the actuator and therefore
opening of the main valve by the steam force only.
For a safety valve or a combined bypass and safety
valve according to the German code
TRD421/EN4126-5, the actuator must be equipped
with triple redundant SBE units. The solenoid valves
operate in the mode deenergize to open, which
means they are always energized during normal
operation and deenergize to open the hydraulic
bypass for a safe opening of the main valve. SBE
units are available in two sizes SBE116 and
SBE125
Safety control unit SSB
The safety control unit SSB provides a completely
independent path to open or close the main valve
even if no hydraulic power from the hydraulic power
unit is available. The energy required for this
operation is drawn from an additional hydraulic
accumulator. The accumulator is kept continuously
charged and is located near to the actuator so that
short connection pipes allow a fast stroking speed.
SSB units are available in 4 sizes, SSB6 to SSB32.
Even with the largest actuator ASM 320 a stroke
speed of up to 90 mm/s is possible. With smaller
actuators a stroke speed of up to 700 mm/s
depending on the size of the actuator and the SSB
unit is possible.
Up to three SSB units can be mounted besides a
proportional valve on any hydraulic actuator to
realize even faster stroke speeds, redundant safe
opening or closing functions or safe opening and
safe closing functions on the same valve.
The SSB unit consists essentially of a solenoid
valve and two releasable check valves, which, under
normal operation, keep the pressure line from the
accumulator to the actuator and the return line to the
tank closed. The SSB units can be supplied as
“energize to activate” or “deenergize to activate”.
Hydraulic power unit HV 80 ... 450
The hydraulic power unit (HPU) supplies the
pressurized hydraulic fluid to operate the hydraulic
actuators. Depending on size and system
requirement different hydraulic power units are
available. The smallest HPU HV80 consists
essentially only of a tank, a pump and a hydraulic
accumulator. The pump is sized only to cover
average demand of hydraulic fluid since the peak
demand is taken out of the accumulator. The pump
is running continuously. An accumulator charging
valve is switching the pump into recirculation mode
whenever the accumulator is fully charged. A
pressure reducing valve is keeping the system
pressure on a stable value. The system pressure is
between 8 MPa and 16 MPa depending on the
application.
Fig. 5: HV350 AS with two accumulators
All the larger hydraulic power units HV 200 / 350 /
400 are equipped with redundant main pumps, one
of the two running continuously. These units feature
also a separate filter loop with a continuously
operating filter pump. The filter loop is permanently
cleaning the oil in the tank and therefore preventing
that contaminated oil is entering the piping to the
actuators. In the filter loop there is an oil cooler with
a thermostatically controlled fan. The hydraulic
power units HV200 and HV350 have one or two
accumulators fitted directly at the HPU whereby the
HV450 features distributed accumulators to be
placed near the actuators.
All hydraulic power units can be equipped with a
thermostatically controlled heater for outdoor
operation.
The control and switch gear is an integral part of the Safety control unit SSB
hydraulic power units and is located in a box, which
is mounted directly on the HPU. The HPU is Type Flow
supplied ready to operate. SSB 10Z 80 l/min
SSB 10 100 l/min
Technical Data SSB 16 200 l/min
SSB 32 450 l/min
Actuators
Type Piston area max. force
(push / 16 MPa) Positioners
GHZ 50 19.6 cm2 31 kN Position demand 4 - 20 mA
GHZ 63 31.2 cm2 50 kN Position Feedback 4 - 20 mA
GHZ 80 50.3 cm2 80 kN Supply 24 VDC
GHZ 100 78.5 cm2 126 kN (Converters for other supply
GHZ 125 122.7 cm2 196 kN voltages upon request)
ASM 160 200.0 cm2 322 kN PVR 10 1 PV, 1 Blocking element
2 additional solenoids
ASM 200 314.0 cm2 503 kN
PVR 11 1 PV, 1 Blocking element
ASM 250 491.0 cm2 786 kN
3 additional solenoids
ASM 320 804.0 cm2 1286 kN
Housing Local box
380mm x 380mm x 210mm
Proportional Valves
Protection class IP 66 / NEMA 4
Type Flow
Cable length 5 m / 10 m optional
PV 4 10 l/min
PV 6 30 l/min
PV 8 60 l/min Hydraulic Power Units
PV 10 120 l/min Type Pump flow max. flow
HV80 4.0 l/min 30 l/min
Solenoid valve APL HV200 7.2 l/min 250 l/min
Type Flow HV350 15.5 l/min 2 x 250 l/min
APL 6 30 l/min maximum HV450 20.3 l/min 3 x 250 l/min
APL 10 60 l/min maximum Type Accumulator Tank volume
4/3WEDz 3 8 l/min maximum volume (usable)
4/3WEDz 6 30 l/min maximum HV80 8l 85 l
HV200 21 l 190 l
Safety Bypass unit SBE HV350 42 l 350 l
Type Flow HV450 Up to 84 l 450 l
SBE 116 200 l/min System pressure 8 - 16 MPa
SBE 125 600 l/min Accumulator pressure HV200-450:up to 24 MPa
HV 80:16 MPa
Position feedback transmitter
Angle 60° (max. 70°)
Signal 4 - 20 mA
Limit Switches 4 x SPDT
CCI Switzerland CCI World Headquarter CCI Sweden
Im Link 11 22591 Avenida Empresa Box 602
CH-8404 Winterthur Rancho Santa Margarita SE-661 29
Telephone ++41 52 262 11 66 CA 92688, U.S.A Säffle, Sweden
Telefax ++41 52 262 01 65 Telephone ++1 949 858 18 77 Telephone ++46 533 689 600
Telefax ++1 949 858 18 78 Telefax ++46 533 689 601

CCI Japan CCI Korea CCI Austria

194-2 Shukunosho 26-17, 26 Pungmu-Ri Lembockgasse 63/1
Ibaraki-City, Osaka 567 Kimpo-Eup, Kimpo Gun AT-1233 Vienna, Austria
Japan Kyungi-Do, South Korea Telephone ++43 1 869 27 40
Telephone ++81 726 41 71 97 Telephone ++82 31 985 9430 Telefax ++43 1 865 36 03
Telefax ++81 726 41 71 98 Telefax ++82 31 985 0552

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Rev. 1, 01.10.08