Solar Powered Electric Actuator for Mainline Valve

Customer Profile

Midstream natural gas operator managing multi-state pipeline assets, with >1B$ in annual revenue and an initiative to lower LOE and OPEX across pipeline operations, with a continual focus on operational reliability and standardized actuation, control, and measurement architecture with centralized data backhaul. 

Project Challenge

The customer was pursuing an initiative to employ alternative valve-actuation methods in Southeastern New Mexico for a mainline valve (MSV) application, driven by availability and cost constraints associated with acquiring line power. The customer was also looking toward future operations and expansion, with a requirement that any new solutions integrate with existing PLC formats and valve sizes. The solution had to be repeatable within strict project timelines, and line gas was ruled out.

Existing Conditions & Customer-Provided Data

Solarcraft’s application was to be centered on a customer-selected Rotork 5 HP electric actuator paired with a 30-inch valve, which is currently deployed in an MSV application. The customer's preferred PLC for this application was an Allen‑Bradley MicroLogix controller with a 4G/LTE data backhaul for RTU/PLC data and remote operations.  The customer also required an emergency shutdown function and local manual control utilizing a pre-programmed HMI.   Customer needed an engineered, turnkey solution to meet their project timeline, with an FAT at the Solarcraft facility and a field commission performed by Solarcraft at the customer’s installation location. The customer elected to free‑issue the PLC hardware to utilize existing internal inventory.  All other material and equipment were to be provided by Solarcraft.  Engineering drawings, data sheets, and instructional handbooks were required to conform to the customer’s RFQ requirements.

Solarcraft requested the following electrical performance data for the actuator, as typically found on motor nameplates and data sheets. The customer supplied the following data:

• Locked Rotor Amps (LRA): 82 A
• Full Load Amps (FLA): 13 A
• Duty Cycle: ESD only; partial stroke test every 90 days
• Actuator voltage: 480V, 3-phase

Solarcraft Solution

Solarcraft’s team validated the feasibility of operating voltage, phase, and communications requirements in a solar/hybrid solution. Based on the provided electrical data and site power requirements, Solarcraft configured an established 45 kVA power system for this particular case.

The solution included a 1600-Watt solar array on skid-mounted solar rack, custom powder coated skid-mounted aluminum electronics enclosure for Allen-Bradley Micrologix controller, separate powder coated, skid-mounted aluminum battery bank enclosure; Cradlepoint cellular modem and router, custom HMI data display, 45 kVA/3-phase power supply, 18.4kW battery bank, and integrated rectifiers and charger inputs.  The RFQ required emergency charging capability and full compatibility with customer‑supplied Allen‑Bradley MicroLogix PLC data structures, and the initial implementation was to include three identical builds for different mainline locations.

Execution Timeline

Initial RFQ/equipment list/electrical data received

• Quote delivered: 2 days
• Engineering drawings returned: 5 days
• Customer approval: 5 days
• Production completion: 9 weeks

Results & Value

Solarcraft’s solution delivered a standards-compatible, solar power system for exclusively electric actuation.  The customer avoided the expenses of bringing local utility grid power to multiple sites. Furthermore, since line gas had previously been ruled out as a solution, the customer expected on-site generators to be their only remaining option for these sites.  Solarcraft offered an alternative to running diesel generators, which are comparatively unreliable and expensive. Ultimately, the Solar Powered Electric Valve Actuator employed in this case benefited the customer by qualifying as depreciable capital equipment.

For the operator’s engineering team, Solarcraft executed a clean data handoff, FAT, documentation, and field commission with a robust electrical design, relieving the vast majority of their internal engineering effort.  For the ongoing procurement and implementation effort, Solarcraft offered a repeatable solution on a quick timeline. This solution has been deployed in various locations across the US, and with minor engineering changes, the scope of applications has been expanded.

In general, this customer and others implementing this system have found it increasingly difficult to obtain start or completion dates from utility companies for line power to their mainline locations. Additionally, when line power becomes available, the cost per mile is prohibitive, and the infrastructure required at each site (transformers/UPS/pads) adds to the already high cost. The Solarcraft solar-powered electric valve actuator replaces all site infrastructure in a single enclosure, which is cooled without HVAC by the enclosure-mounted solar array. Solarcraft reliably delivers this solution within 9-10 weeks from PO, well ahead of line power availability.

Impact on LOE and OPEX

Level of Effort (LOE) and Operating Expense (OPEX) were key considerations for the customer and significantly influenced the overall value of the solution.

From an LOE perspective, the project reduced the customer’s overall effort during project launch and in long-term operations. After the customer supplied electrical data,  Solarcraft independently engineered based on this data, with minimal secondary input from the customer. Our approach reduced engineering back-and-forth and enabled first-pass approval of engineering drawings. Additionally, the hard-spec’ed Allen-Bradley components arrived pre-programmed and ready to join existing data streams via customer-preferred Cradlepoint cellular modem. The build was physically placed on site, mounted on an integrated Solarcraft fork-liftable skid with ballast block system, eliminating any local construction efforts.

Lowered project level-of-effort resulted in lower operating expenditures. Correct electrical sizing minimized thermal stress on components, improved operating reliability, and extended the service life of components and overall systems. The project standardization aspect enabled the customer to simplify maintenance, spare parts inventory, procurement, and troubleshooting, thereby reducing long-term labor costs and downtime. Finally, the delivery of three identical, well-documented systems established a repeatable design that can be referenced for future projects, compounding both LOE and OPEX savings across subsequent deployments. 

A further long-term benefit our customers discovered after deployment was that they no longer needed to acquire line power at these sites.  The solar system had effectively replaced line power as the primary source, and the customer expanded the number of sites using this system rather than purchasing power altogether.

Supplemental Materials to Case Study

Calculations:

Battery Bank Capacity:

FLA, A = 13

Valve Voltage, V = 480

Battery Bank Voltage, V = 48

Stroke Length Minutes, m = 3

3 Phase conversion factor = 1.73

13A x 480V x 1.73 = 10,800W = ~11kW

11kW/48V = 230A

230A x 3m X 1h/60m = 11.5Ah

11.5Ah/440Ah = .026 = 2.6%

Conclusion: One actuation consumes 2.6% of the battery bank.

Supplemental Consideration: Diesel Generator Cold Stacking

In evaluating alternative power strategies, diesel generator solutions are often considered for electric valve actuation applications. However, these applications often operate at low average load with intermittent duty cycles. When diesel generators run for extended periods below approximately 30–40% of rated capacity, they are susceptible to cold stacking, a condition in which incomplete combustion leads to carbon buildup, wet stacking, and accelerated engine wear.

Cold stacking increases maintenance requirements, necessitates periodic load banking, and raises long-term operating expense. For applications such as electric valve actuation—where loads are intermittent and relatively light—these factors can significantly impact reliability and lifecycle cost. By contrast, an electrically engineered power system sized directly to the application avoids minimum load constraints, reduces maintenance complexity, and delivers a more predictable operating profile over the life of the asset.