IMI's ELE-TRAK actuator: Hydraulic strength, electric intelligence

At the same time, we understand that you, as site operators, face the challenge of maintaining safe, efficient plant performance. Actuation technology lies at the heart of these challenges, controlling valve movement that regulates critical processes across the oil and gas, petrochemical, and power sectors.

To help customers bridge the gap between traditional hydraulic systems and conventional electric actuators, our engineering experts have developed the new ELE-TRAK solution. ELE-TRAK is a fully electric actuator capable of fast, precise control of the valve position and, therefore, your industrial process. The result is technology designed for demanding industrial applications like compressor and steam turbine control, fast processes, and remote installations. This is where performance and operational simplicity are critically important, as are process reliability and fully diagnostic features that support your facility’s preventive maintenance plans.

An actuator is a device that converts energy into mechanical movement to operate equipment such as valves, dampers, and other process-control devices. In industrial facilities, actuators enable operational staff to open, close, or position valves safely and accurately, either locally or remotely. This helps maintain efficient and reliable process control.

Three primary actuator technologies are commonly used across industries worldwide.

Electric actuators are widely used where fast, precise control is not required because ease of installation and low-cost maintenance are the main factors in the decision. Traditional geared electric actuators provide inaccurate positioning because gear friction affects the dead band within the control range.

Pneumatic actuators are commonly used with control valves because of their fast response times and relative ease of installation. They do, however, rely on a continuous supply of compressed air and require numerous accessories, thereby reducing system reliability. Air humidity and premature failure of rubber elements mean operators experience unpredictable shutdowns of the plant.

Hydraulic actuators provide extremely high force output and are widely used in demanding industrial applications. They can also incorporate fail-safe functions, making them suitable for critical duties. However, they also increase system complexity, including hydraulic power units, reservoirs, piping, and associated maintenance requirements.

Hydraulic actuators provide extremely high force output, precise control and fast response. But they also increase system complexity, given that they include hydraulic power units, reservoirs, piping, and associated maintenance requirements. This means they consume high levels of energy and require continuous oil replacement, which degrades their properties very quickly, especially when exposed to high humidity.

Industrial operators often face a difficult choice. Electric actuators offer simplicity but lower performance; hydraulic systems provide exceptional force and precise control, but with lower reliability.

Some actuator manufacturers have tried to improve electric, pneumatic, and hydraulic performances. Unfortunately, the development of a practical combined-power actuator for mainstream industrial applications has remained elusive. The time, complexity, and investment required to develop a reliable solution have traditionally limited customers to costly bespoke systems.

Recognising this challenge, our engineering team identified a clear opportunity to develop a new actuation technology that could combine the strengths of both electric and hydraulic technologies.

The development of ELE-TRAK began when IMI entered discussions with a major oil and gas producer seeking a new approach for anti-surge valve actuation. A previous development programme with another actuation supplier produced a prototype that was not an industrial solution, as it was too tall with a limited proven installation history.

Drawing on our broad expertise in valve engineering and actuation, we proposed a different approach. Our engineering team suggested combining electric actuation with a mechanical spring to deliver the rapid trip-open performance required for anti-surge applications.

The project was closely aligned with the customer's wider engineering strategy, which aimed to replace ageing hydraulic actuator systems with electric alternatives across offshore installations. This transition is becoming increasingly common across the sector as operators seek to reduce maintenance requirements, improve reliability, and simplify asset management

Hydraulic systems have long been valued for their performance, but they often require regular maintenance and are frequently installed in remote or difficult-to-access locations. Electric systems can help reduce this operational burden while eliminating the need for hydraulic fluids, process gas, or instrument air as the primary driving medium.

Traditional geared electric actuators are highly effective in many applications but can struggle in applications requiring very high forces and demanding duty cycles. Linear-drive electric actuators using servomotors offer improvements in force, speed, and accuracy, while hydraulic actuators remain the benchmark for power density.

Our new ELE-TRAK technology brings these strengths together in a single platform. The actuator combines high force output, fast response, precision control, as well as energy efficiency. The system can also incorporate a mechanical spring that enables trip-open or trip-close functionality and tight shut-off performance. It also provides you with manual override capability when required.

One of ELE-TRAK's most significant advantages is its force density. Simply put, it delivers high output force within a compact, self-contained package. Unlike conventional hydraulic systems, it does not require an external hydraulic power unit, a compressor, or any associated piping infrastructure. This simplifies installation at your facility while preserving the performance required for your most demanding valve automation and positioning applications.

Our ELE-TRAK technology is already gaining market traction. Early orders have been secured, including an installation at a major combined-cycle gas turbine power plant in northern Italy.

As industries continue to seek greater efficiency, lower maintenance requirements, and reduced emissions, ELE-TRAK offers a practical new option that combines the strength of hydraulic actuation with the intelligence and controllability of electric systems.

Discover more about IMI’s ELE-TRAK actuation technology.