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 sits at the heart of these challenges, controlling the movement of valves that regulate 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 compact electro-hydraulic actuator that combines hydraulic force density with the precision, efficiency, and controllability of electric actuation. The result is a flexible solution designed for your most demanding industrial applications where performance, reliability, and operational simplicity are all of equal importance.

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.

Four primary actuator technologies are commonly used across industries worldwide.

Manual actuators are used where valve operation is infrequent, simple, or required as a backup to automated systems. They provide a practical means of manual override but require human intervention, making them less suitable for remote installations, or for use with large valves, or applications that require rapid operation.

Electric actuators are widely used where precision, automation, and remote control are required. Traditional geared electric actuators provide accurate positioning and straightforward integration with digital control systems. However, stroke speed and force limitations can restrict their suitability for some high-demand applications.

Pneumatic actuators are commonly used with control valves because of their fast response times and relatively simple design. However, they rely on a continuous supply of compressed air and can suffer efficiency losses due to leakage. They also typically offer lower positioning accuracy than electric alternatives.

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.

Industrial operators often face a difficult choice. Electric actuators deliver precision and control, while hydraulic systems provide exceptional force and high-power density. Until now, achieving both characteristics in a single commercially viable technology solution has proven challenging.

Some actuator manufacturers have combined electric, pneumatic, hydraulic, and manual control technologies within broader actuator portfolios. However, 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 involving another actuation supplier had produced a prototype that was never commercialised.

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. As development progressed, hydraulic capability was integrated into the concept, creating the foundation for what would become ELE-TRAK.

The project closely aligned with the customer's wider engineering strategy 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 across many applications, but can struggle where very high forces and demanding duty cycles are required. 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 an electro-cylinder with a hydraulic one to deliver high force output, fast response, precision control, and 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.

ELE-TRAK is not intended to replace every actuator technology. Instead, it fills an important gap between traditional electric and hydraulic solutions for applications where electric actuation alone may not be sufficient, but where a full hydraulic system introduces unnecessary complexity.

You can configure ELE-TRAK with or without the hydraulic element, providing the flexibility to match your specific operational requirements. This versatility reflects the challenges many operators have faced in finding a practical hybrid solution.

Perhaps most importantly, you will no longer need to invest in expensive one-off developments to access the benefits of combined electric and hydraulic performance. ELE-TRAK provides a scalable, commercially available platform built using proven components and engineered by IMI specifically for industrial service.

We are currently developing versions of ELE-TRAK suitable for use in potentially explosive environments and aim to achieve ATEX and IECEx certification for Zone 1/2 Gas IIA/B T4 applications.

The 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. Our engineers are also developing customised ELE-TRAK solutions for fluid catalytic cracking slide valves. A dedicated anti-surge valve version has already attracted interest from a leading gas compressor manufacturer.

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.