the underwater actuator you can rely on -60 °C - Fahlke Control ...

Contents
About Fahlke 4-5
Controls 6-7
Monitoring and safety 8-9
Actuators 10-11
Electrohydraulics
GEHAZ 12-13
SEHAZ 14-15
EHAZ 16-17
Pneumatics
PAZ 18-19
Gas units
GAZ 20-21
Safety shut down valves
SSV 22-23
Regulating <strong>actuator</strong>s
EHAZ-R + PAZ-R 24-25
Underwater <strong>actuator</strong>s
Subsea 26
Low temperature <strong>actuator</strong>s
-60 °C 27
Service
Start-up and maintenance 28
Training 28
Documentation 28
Production
Product development 30
Manufacturing 31
Quality assurance 32
Storage 33
Quality management 34-35
2 3

Modern actua tor technology
by Fahlke
Top quality products
made in Germany
Fahlke Control Systems is one of <strong>the</strong> leading global manufacturers
of high-quality automation solutions for valves. In fact, <strong>the</strong> <strong>actuator</strong>s
and controls we produce in Germany are used all around <strong>the</strong>
world. Our clients are nationally and internationally operating energy
suppliers in <strong>the</strong> gas and oil industry as well as power plants, <strong>the</strong>
chemical and petrochemical industry and water management. This
is for good reason: for every specific requirement, we provide an
innovative, high-performance solution. Quick and efficient. Outstanding
quality. 100% safe.
Feel free to take a look for <strong>you</strong>rselves. With our extensive specialist
knowledge, excellent flexibility and dedicated approach, we are
here to assist <strong>you</strong> with all <strong>you</strong>r requests. Fur<strong>the</strong>rmore, as a family
business, swift decision-making processes and a highly personal
commitment to our clients, make us stand out from <strong>the</strong> rest. This
service benefits <strong>you</strong>. All day - every day.
Performance
Safety
Quality
Service
4 5

Controls by Fahlke –
definitely an optimum solution
A modular concept with a system
For more than 35 years, we have been offering our clients
a variety of tried-and-tested standard controls, accessories
for special functions and custom-made individual solutions.
The selection of controls ranges from simple solenoid
valves to integrated active control components (pressure
pilots, line break detection systems etc) to complex control
functions (central electric hydraulic units, regulating units,
etc.).
All high-pressure controls, whe<strong>the</strong>r <strong>the</strong>y are supplied by
<strong>the</strong>ir own gas or electro-hydraulic, are developed on <strong>the</strong>
Electro-hydraulic control
up to 800 bar
Gas control
up to 200 bar
Control block technology
MCE- Modular Control Elements
The advantages of modular control technology MCE are
particularly evident in its expandability and outstanding
ease of maintenance. Solenoid valves, line break pilots,
hand pumps or o<strong>the</strong>r control elements <strong>can</strong> be easily replaced
in virtually no time at all.
basis of modern MCE technology (modular control elements
technology). They are equally ideal for both simple
and complex automations of different <strong>actuator</strong>s. Control
superstructures for double and single-acting, spring closing
or opening <strong>actuator</strong>s are all available with control pressures
of up to 800 bar.
The Fahlke Plus: in combination with our high-performance
<strong>actuator</strong>s, <strong>you</strong> <strong>can</strong> benefit from perfectly coordinated <strong>actuator</strong>
units that effortlessly meet all requirements of functional
safety (SIL 2 or 3).
Pneumatic control
up to 16 bar
Electrical
control
High-performance central controls
Whe<strong>the</strong>r electrohydraulic or pneumatic – Fahlke’s intelligent central controls, which
<strong>can</strong> be tailored especially to suit <strong>you</strong>r individual needs, greatly simplify both <strong>the</strong> individual
or central operation of multiple controlled <strong>actuator</strong>s. Top priorities for <strong>the</strong> systems
are functionality and quality.
Example:
storage caverns*
In this example, <strong>the</strong> ball valves on <strong>the</strong> cavern
head are controlled; <strong>the</strong> underground
safety shut down valve (USSV) is directly
controlled. The high operating pressure for
<strong>the</strong> USSV is generated directly from <strong>the</strong>
control system by means of a pressure intensifier.
* artificially created cavity in a salt mine
Example:
power plant facility
The control system used in this example
controls <strong>the</strong> Fahlke <strong>actuator</strong>s which aid
<strong>the</strong> safeguarding of a turbine power plant’s
steam circuit. The core functions are “slow
opening and closing” and “quick-acting closure”
as soon as two of <strong>the</strong> three solenoid
valves are actuated.
Example:
leaching facility*
Three hydraulic <strong>actuator</strong>s are controlled by a
control system. Functions: open/close/ESD
and varying closing times.
*Area of application:
salt cavern leaching for storing natural gas
Example:
gas storage facility
Here a Fahlke control system is a technical
element of <strong>the</strong> automation process, which
controls <strong>the</strong> four pneumatic Fahlke <strong>actuator</strong>s
by using two of <strong>the</strong> respective solenoid values
connected in series.
6 7

System monitoring at <strong>the</strong> highest level
Everything in view,
everything under control
Fahlke monitors and secures pipeline systems and
processes at industrial facilities in <strong>the</strong> areas of gas,
oil, water, chemistry and petrochemistry. Our modern
measuring technology and devices were developed
especially to meet <strong>the</strong> challenging demands of <strong>the</strong>
pipeline network. They reliably record when a pipeline
unexpectantly exceeds or falls short of <strong>the</strong> stipulated
pipeline pressure and by doing so, effectively avoid
overloading or damage to <strong>the</strong> pipeline and its components.
Every subtle pressure change is detected directly on
<strong>the</strong> safety-relevant sections of <strong>the</strong> pipeline with utmost
accuracy. Fur<strong>the</strong>rmore, <strong>the</strong> <strong>actuator</strong> unit independently
controls its pipeline valves and opens or closes <strong>the</strong>m
unassisted.
Fields of application or our system monitoring
Transmission pipelines
Valve stations
Compressor stations
Storage facilities
Measurement and control stations
Power plants
Example: High pilot monitoring
Function: Triggers when maximum permitted
pressure drop is exceeded
Setpoint: adjustable from 20 bar to 180 bar
Measurement accuracy: max. 1% deviation
from setpoint (AG 1)
Design temperature: -25 °C to +40 °C
Example: Low pilot monitoring
Function: Triggers when maximum permitted
pressure drop is exceeded
Setpoint: adjustable from 20 bar to 180 bar
Measurement accuracy: max. 2.5% deviation
from setpoint (AG 2.5)
Design temperature: -25 °C to +40 °C
Example: Line Break Control (LBCp)
Function: Triggers when maximum permitted
pressure drop is exceeded
Pressure-drop rate: adjustable from 0.5 to 2.5 bar per minute
Pressure stage: P max. 180 bar
Design temperature: -25 °C bis +40 °C
Example: Line Break Control (LBCe)
Function: Triggers when maximum permitted
pressure drop is exceeded
Pressure-drop rate: adjustable from 0.2 to 3 bar per minute
Pressure stage: P max. 180 bar
Design temperature: -25 °C to +40 °C
Example: Differential pressure pilot
Function: Triggers when maximum permitted
pressure drop is exceeded
Differential pressure: dP adjustable 4–10 bar
Pressure stage: P max. 180 bar
Design temperature: -25 °C to +40 °C
Solar power supply
Function: Supply of self-sufficient
<strong>actuator</strong> systems incl. battery backup
Rated power: as required
8 9

The Fahlke act uator concept –
pioneering technology
Tailored to meet all <strong>you</strong>r requests
Fahlke <strong>actuator</strong>s are an important
component when it comes to <strong>the</strong>
automation of modern process technology.
Due to <strong>the</strong>ir excellent quality
standards and reliability, <strong>the</strong>y are
used for <strong>the</strong> most diverse range of
valves in pipeline systems and industrial
plants (on and offshore)
across <strong>the</strong> globe. Nei<strong>the</strong>r extreme
temperatures nor o<strong>the</strong>r environmental
influences <strong>can</strong> harm <strong>the</strong> robust,
corrosion-proof <strong>actuator</strong> solutions.
Moreover, prolonged downtimes do
not damage <strong>the</strong>ir service life or efficiency
levels.
Standard functions:
Double-acting open/closed
Single-acting spring-force locking
Single-acting spring-force opening
Double-acting regulating
Single-acting regulating, securing by spring
Our delivery programme includes all
pressure ranges and standard types
for pneumatic, gas or hydraulic applications,
as well as modular designs
according to individual customer
specifications. Each <strong>actuator</strong>
is equipped with a pressure safeguard,
a fully-welded working cylinder,
individual limit switch solutions
and a flexible adaptation system. In
summary, with our <strong>actuator</strong>s, <strong>you</strong>
<strong>can</strong> signifi<strong>can</strong>tly cut <strong>you</strong>r operating
costs over <strong>the</strong> entire service life of
<strong>you</strong>r systems and, at <strong>the</strong> same time,
boost system performance.
A brief overview of <strong>the</strong> most important features
Compliance with DIN EN 60529/protection class IP 68 (protection against
permanent immersion) by means of a special hook-on system/annular groove
slot (interlocking slot for fully-welded working and spring cylinders in a two-part
<strong>actuator</strong> enclosure made from resistant spheroidal graphite iron)
Protection against corrosion guaranteed by high-quality nickel coating of <strong>the</strong>
cylinder liner running surfaces and working cylinder pistons
Secure sealing between pistons and cylinders by means of specially-developed
sealing systems
Adjustable limit stops in order to directly capture <strong>the</strong> cylinder forces in a straight
line and torsion-free in <strong>the</strong> cylinder base
Actuator enclosure maintenance-free throughout its entire lifespan
Precise position indicator for valves due to a mechanical position display,
installed as standard
90° Actuators (Scotch Yoke)
Linear Actuators
Features:
Compact robust build
High protection type (IP 68)
High efficiencies
Corrosion-resistant
Actuator sizes and torques:
A 20 – 200 Nm
B 50 – 1,000 Nm
C 1,000 – 4,500 Nm
D 4,000 – 25,000 Nm
E 20,000 – 80,000 Nm
F 70,000 – 150,000 Nm
G 140,000 – 300,000 Nm
Special designs up to 450,000 Nm
Actuator sizes and thrust forces:
A 20 – 200 N
B 200 – 18,000 N
C 15,000 – 50000 N
D 50,000 – 180,000 N
E 180,000 – 300,000 N
F 300,000 – 480,000 N
G 480,000 – 650,000 N
Special designs up to 1,000,000 N
Long service life
Beneficial force transfer
Simple assembly on valves
Functional safety according to IEC 61508 / IEC 61511 (SIL 2/3)
The intelligent Fahlke adaptation system
Every Fahlke <strong>actuator</strong> is manufactured and delivered ready for assembly in accordance with <strong>the</strong> specific adaptation
drawings of <strong>the</strong> valves to be automated. The in-house developed adaptation system consists of an
adaptor flange and a drive sleeve connector, which toge<strong>the</strong>r facilitate quick, easy and cost-effective assembly.
Rotated setup is possible at increments of 45/90 degree angles.
10 11

12
Minimal costs, maximum performance
The extremely small and high-performance GEHAZ ® <strong>actuator</strong> by Fahlke is an integral part of
<strong>the</strong> world‘s most modern <strong>actuator</strong> series for valve automation. The GEHAZ ® <strong>actuator</strong> <strong>can</strong>
be fitted to each valve, it has a variable torque and is explosion-proof. Due to its extraordinarily
compact size, it is perfectly suited to smaller valves (e.g. butterfly and ball valves), to
which it <strong>can</strong> be adapted quickly and easily. Fur<strong>the</strong>rmore, with regard to cost-effectiveness,
<strong>the</strong> small electrohydraulic <strong>actuator</strong> unit certainly does not disappoint. This <strong>actuator</strong> ticks all
<strong>the</strong> boxes when it comes to low installation, operating and maintenance costs.
GEHAZ ® - THE MOST COMPACT
EXPLOSION-PROOF
ELECTROHYDRAULIC ACTUATOR
ON THE MARKET
Technical data:
Double-acting (fail in position)
Spring-return or opening (fail safe close/fail safe open)
Pressure-resistant control casing (Ex de - ATEX, IP 67)
Integrated signalling of <strong>the</strong> end positions (open/closed)
Integrated multi-functional switch (stationary/remote, open/closed)
Motor rated output: 90 W
Solenoid valve for spring return-design: 13 W
Voltage supply: 24 V DC or 230 V AC
Integrated reversing circuit: 24 V DC or 230 V AC
Actuator protection class: IP 68
Temperature range: -40 °C to +60 °C
Options:
Profibus DP
type break torque
(Nm)
GEHAZ double-acting
operating time
open/close (s)
dimensions
L x B x H (mm)
weight
(kg)
GEHAZ-A-1-50 20–200 010 / 020 500 x 300 x 350 30
GEHAZ-B-1-50 50–1,000 010 / 030 600 x 300 x 400 40
GEHAZ-C-1-80 500–4,500 020 / 050 800 x 300 x 450 80
GEHAZ-D-1-125 4,000–20,000 050 / 100 1,200 x 400 x 650 260
GEHAZ single-acting/spring-return
GEHAZ-A-1-50-SR 20–150 015 / 003 750 x 300 x 350 30
GEHAZ-B-1-50-SR 50–700 020 / 005 900 x 350 x 450 60
GEHAZ-C-1-80-SR 500–3,000 040 / 010 1,500 x 350 x 500 120
GEHAZ-D-1-125-SR 3,000–10,000 060 / 020 2,100 x 450 x 650 420
13

14
A valve <strong>actuator</strong> for every occasion
The safety-oriented SEHAZ ® <strong>actuator</strong> combines a highly compact size and low weight, with
maximum safety for automation. It is equipped with up to four integrated safety systems
and <strong>can</strong> be easily fitted to each valve by means of its special adaptation system. Sliders, ball
and butterfly valves are moved. Additional supply connections or complex air compressors
with long supply lines are not necessary. In summary, by using <strong>the</strong> SEHAZ ® <strong>actuator</strong>, <strong>the</strong> installation,
operating and maintenance costs of <strong>you</strong>r automation application are immediately
reduced and <strong>the</strong> field of application expands: <strong>the</strong> SEHAZ ® is approved for both potentially
explosive and non-explosive areas.
SEHAZ ® – SAFETY
REACHES NEW HEIGHTS
Technical data:
Double-acting (fail safe close / fail safe open / fail in position)
Spring-return (fail safe close / fail safe open)
Explosion-proof control casing (Ex de - ATEX, IP 67)
Stainless steel oil tank, Mat. 1.4301
Integrated motor pump unit: max. 250 W
Bladder accumulator for up to 3 spare strokes in case of power failure
Emergency operation by integrated hand pump
Multi-functional switch (stationary/remote, open/closed/off) operable with one hand
Pressure monitoring with system pressure display
Collective fault message (oil level, motor protection switch, runtime monitor)
Control voltage: 24 V DC/220 V DC // 115 V AC/230 V AC, 13 W
Voltage supply: 24 V DC // 115 V AC/230 V AC/380 V AC/400 V AC
Signalling of end positions (open/closed)
Actuator/gear protection type: IP 68
Temperature range: -60 °C to +70 °C
Options:
Functions: ESD/SSV/Regulating
Pressure pilot monitoring (high pilot/low pilot)
Line-Break-System (pneumatic or electronic)
Control on separate assembly
Galvanic separation from <strong>the</strong> cathode-protected pipeline
End-position signal for possible subsea use (IP 68)
Profibus DP or Modbus interface card
type break torque
(Nm)
SEHAZ double-acting
operating time
open/close (s)
dimensions
L x B x H (mm)
weight
(kg)
SEHAZ-A-1-50-SP 20–200 002 500 x 300 x 400 130
SEHAZ-B-1-50-SP 50–1,000 005 600 x 500 x 580 140
SEHAZ-C-1-80-SP 500–4,500 010 800 x 900 x 900 150
SEHAZ-D-1-125-SP 4,000–25,000 010 1,200 x 1,050 x 900 470
SEHAZ-E-1-125-SP 20,000–60,000 030 1,850 x 1,350 x 1,150 950
SEHAZ single-acting/spring-return
SEHAZ-A-1-50-SR-SP 20–200 002 750 x 300 x 400 140
SEHAZ-B-1-50-SR-SP 50–700 020 / 005 950 x 500 x 580 150
SEHAZ-C-1-80-SR-SP 500–3,000 025 / 006 1,200 x 900 x 900 300
SEHAZ-D-1-125-SR-SP 3,000–15,000 035 / 010 2,300 x 1,050 x 900 680
SEHAZ-E-1-125-SR-SP 15,000–30,000 050 / 015 3,500 x 1,350 x 1,150 1,200
15

EHAZ ® – A CUSTOM-MADE
ELECTROHYDRAULIC
ACTUATOR UNIT
Just as customised as <strong>you</strong>r requests
The powerful EHAZ ® and MCE module technology in <strong>the</strong> control system enables Fahlke
to provide <strong>you</strong> with <strong>the</strong> most individually customised electrohydraulic <strong>actuator</strong> units on
<strong>the</strong> market. Every last detail <strong>can</strong> be adapted precisely to suit <strong>you</strong>r processes, so that <strong>you</strong>
achieve exactly <strong>the</strong> individual automation that <strong>you</strong> want quickly and safely. Fur<strong>the</strong>rmore,
<strong>the</strong> EHAZ ® is also available as a regulating <strong>actuator</strong> (EHAZ-R ® ) and a safety shut down
valve (SSV).
Technical data:
Double-acting (fail safe close / fail safe open / fail in position)
Spring-return or regulating (fail safe close / fail safe open)
Control cabinet and oil tank of stainless steel, Mat. 1.4301
Connection terminal box (Ex de - ATEX, IP 65)
Pipe-free high-pressure control block technology
High-pressure accumulator for up to 3 spare strokes
Emergency operation via integrated hand pump
Stationary and remote control (open/closed/off)
Collective fault message (oil level, motor protection alarm)
System pressure monitor (KTI) with pressure display
Motor rated output: max. 1.5 kW, solenoid valves: max. 20 W
Control voltage: 24 V DC (110 / 220 V DC, 115 / 230 V AC)
Voltage supply: 400 V AC (24 V DC, 115 / 230 / 380 V AC)
Signalling of end positions (open/closed)
Actuator protection type: IP 68, control: IP 65
Temperature range: -60 °C to +70 °C
Options:
Functions: ESD/SSV/Regulating
Pressure pilot monitoring (High Pilot and/or Low Pilot)
Line-Break-System (pneumatic/electronic)
Control for separate assembly
Galvanic separation from <strong>the</strong> cathode-protected pipeline
Oil level indicator (Liquiphant Ex ia, SIL 2)
Accumulator pressure monitoring with min. alarm message
Limit switch solution for subsea use IP 68
Profibus DP or Modbus interface card
type break torque
(Nm)
EHAZ double-acting
EHAZ-A-1-50-SP 20–200 002 500 x 300 x 400 140
EHAZ-B-1-63-SP 50–1,000 005 600 x 500 x 800 150
EHAZ-C-1-80-SP 500–4,500 010 800 x 900 x 900 250
EHAZ-D-1-125-SP 4,000–25,000 020 1,200 x 400 x 650 500
EHAZ-E-1-125-SP 20,000–60,000 030 1,850 x 1,350 x 1,500 1,000
EHAZ-E-2-125-SP 60,000–80,000 060 2,230 x 1,350 x 1,500 1,150
EHAZ-F-2-200-SP 80,000–150,000 080 3,150 x 1,600 x 2,000 1,400
EHAZ-G-2-125-SP 150,000–300,000 120 3,950 x 1,700 x 2,300 2,200
EHAZ single-acting/spring-return
EHAZ-A-1-50-SR-SP 20–150 002 750 x 300 x 400 180
EHAZ-B-1-63-SR-SP 50–700 005/002 950 x 500 x 800 200
EHAZ-C-1-80-SR-SP 500–3,000 010/005 1,200 x 550 x 1,200 300
EHAZ-D-1-125-SR-SP 3,000–15,000 025/010 2,000 x 1,000 x 1,200 800
EHAZ-E-1-125-SR-SP 15,000–30,000 040/015 4,500 x 1,600 x 2,000 1,900
EHAZ-F-1-125-SR-SP 30,000–60,000 070/020 5,700 x 1,700 x 2,000 2,500
EHAZ-G-1-160-SR-SP 50,000–100,000 100/025 5,700 x 1,800 x 2,000 4,500
16 17
operating time
open/close (s)
dimensions
L x B x H (mm)
weight
(kg)

type break torque
(Nm)
PAZ double-acting
operating time
open/close (s)
dimensions
L x B x H (mm)
weight
(kg)
PAZ-A-1-80 20–200 002 500 x 400 x 450 50
PAZ-B-1-160 50–1,000 005 600 x 450 x 480 55
PAZ-C-1-250 500–4,500 010 800 x 520 x 650 140
PAZ-D-1-400 4,000–25,000 020 1,200 x 700 x 750 240
PAZ-E-1-400 20,000–60,000 030 1,850 x 910 x 950 650
PAZ-E-2-400 60,000–80,000 060 2,280 x 910 x 950 1,000
PAZ-F-2-500 80,000–150,000 080 3,150 x 1,200 x 850 1,200
PAZ-G-2-300 150,000–300,000 120 4,000 x 1,400 x 850 1,900
PAZ single-acting/spring-return
PAZ-A-1-80-SR 20–150 002 900 x 450 x 480 70
PAZ-B-1-160-SR 50–700 005 / 005 900 x 450 x 480 80
PAZ-C-1-250-SR 500–3,000 010 / 005 1,300 x 520 x 500 200
PAZ-D-1-400-SR 3,000–15,000 020 / 010 2,500 x 700 x 750 580
PAZ-E-1-400-SR 15,000–40,000 040 / 010 3,200 x 910 x 950 1,550
PAZ-F-1-500-SR 50,000–120,000 080 / 020 4,200 x 1,200 x 850 3,500
PAZ-G-1-300-SR
* operating time
100,000–250,000 100 / 025 6,500 x 1,400 x 850 4,400
PAZ ® – RELIABLE AND A WIDE
RANGE OF VARIANTS
Technical data:
Double-acting
(fail safe close / fail safe open / fail in position)
Spring-return closing or opening
(fail safe close / fail safe open)
Stainless steel control cabinet, Mat. 1.4301 (IP 65)
Connection terminal box (Ex e - ATEX, IP 65)
Air connection and block valve of Mat. 1.4571
Maintenance unit consisting of filter,
oiler and pressure controller
Stainless steel manometer
Solenoid valves:
24 V AC or according to customer specification
Pipe work and fittings: Mat. 1.4571
Terminal box for heating and solenoid valve (Ex de)
Actuator protection type: IP 68
End position signal (open/closed)
Temperature range: -60 °C to +70 °C
Sublime automation of 1“–60“ valves
A large selection of working cylinder variants ensures that <strong>the</strong> PAZ ® <strong>actuator</strong>s perfectly
fulfil all automation requirements. The PAZ ® is completely maintenance-free and watertight
according to IP 67 and is suitable for valve sizes ranging from 1“–60“. In addition, <strong>the</strong>
PAZ ® operates in a torque range of 10 to 300,000 Nm. Higher torque levels are possible
on request.
The PAZ ® is also available as a regulating <strong>actuator</strong> (PAZ-R ® ) and a safety shut down valve
(SSV), and <strong>can</strong>, of course, be supplied with a pressure reserve tank and hand pump unit
for emergency operation.
Options:
Functions: ESD/SSV/Regulating
Pressure pilot monitoring (High Pilot and/or Low Pilot)
Pressure reserve tank for up to 3 spare strokes
Selection switch for local or remote control
Line-Break-System (pneumatic/electronic)
Control cabinet with <strong>the</strong>rmal insulation
Heating, <strong>the</strong>rmostat controlled:
max. 100 W, 230 V AC (Ex de – ATEX)
Galvanic separation from <strong>the</strong>
cathode-protected pipeline
Profibus DP or Modbus interface card
18 19

Safe automation
Fahlke gas <strong>actuator</strong>s are used in countless variants in danger zones which demand safe
automation. A core component of <strong>the</strong>ir „safety system“ is a fully-welded, maintenancefree
cylinder technology. The danger of cylinder leakages is <strong>the</strong>refore completely and
effectively eliminated.
Since <strong>the</strong> GAZ ® <strong>actuator</strong>s <strong>can</strong> function without pressure reduction (direct pipeline pressure),
<strong>the</strong>ir design is compact and manageable. The <strong>actuator</strong> units are supplied with high
or low pressure controls and ei<strong>the</strong>r with solenoid valves for easy opening and closing
operation or with pressure pilots for pipeline protection.
Technical data:
Double-acting (fail safe close / fail safe open / fail in position)
Spring-return closing or opening (fail safe close / fail safe open)
Stainless steel control cabinet, Mat. 1.4301 (IP 65)
Connection terminal box (Ex e - ATEX, IP 65)
Pipe-free high-pressure control block technology (max. 200 bar)
Control voltage: 24 V DC (110 / 220 V DC, 115 / 230 V AC)
End position signalling
Actuator protection type: IP 68
Temperature range: -60 °C to +80 °C
Options:
Functions: ESD/SSV/Regulating
Pressure pilot monitoring (high pilot and/or low pilot)
Line-Break-System (pneumatic/electronic)
Control on separate stand
Galvanic separation from <strong>the</strong> cathode-protected pipeline
End-position signal for subsea use (IP 68)
Profibus DP or Modbus interface card
type break torque
(Nm)
GAZ double-acting
operating time
open/close (s)
dimensions
L x B x H (mm)
weight
(kg)
GAZ-A-1-50 20–200 002 500 x 400 x 450 50
GAZ-B-1-63 50–1,000 005 600 x 450 x 480 55
GAZ-C-1-100 500–4,500 010 700 x 500 x 550 140
GAZ-D-1-160 4,000–25,000 020 1,200 x 650 x 800 240
GAZ-E-1-200 20,000–60,000 030 1,850 x 900 x 850 650
GAZ-E-2-200 60,000–80,000 060 2,280 x 900 x 850 1,000
GAZ-F-2-200 80,000–150,000 080 3,200 x 1,250 x 1,400 1,200
GAZ-G-2-200 150,000–300,000 120 3,940 x 1,700 x 1,500 1,900
GAZ single-acting/spring-return
GAZ-A-1-50-SR 20–150 002 750 x 400 x 450 50
GAZ-B-1-63-SR 50–700 005/005 850 x 450 x 480 90
GAZ-C-1-100-SR 500–3,000 010/005 1,400 x 500 x 550 180
GAZ-D-1-160-SR 3,000–15,000 029/015 2000 x 650 x 800 480
GAZ-E-1-200-SR 15,000–60,000 040/025 3,200 x 900 x 850 1,450
GAZ-F-1-200-SR 50,000–120,000 060/030 4,500 x 1,250 x 850 3,000
GAZ-G-1-250-SR 100,000–250,000 090/040 6,500 x 1,400 x 850 4,300
GAZ ® – ADJUSTED TO
HIGH PRESSURE
20 21

Secure protection of <strong>you</strong>r gas line
Fahlke‘s safety shut down valves (SSV) are used around <strong>the</strong> globe by leading suppliers
in <strong>the</strong> gas industry for <strong>the</strong> independent safeguarding of pipeline systems.
In terms of design, fields of application and technology, this innovative system is
ground-breaking and provides perfect protection from overload pressure. This is
ensured by <strong>the</strong> DIN 14382-certified safety shut down units with ball valves. The
advantages: <strong>the</strong> construction of expensive bypass lines is dropped. The system is
launchable. The two independent seals of <strong>the</strong> ball valve make <strong>the</strong> stipulated installation
of two safety shut down valves unnecessary. In comparison with conventional
systems, construction and operating costs are signifi<strong>can</strong>tly reduced. By using
AG-1 pressure pilots, <strong>the</strong> pipeline <strong>can</strong> be safely used to its maximum potential.
SSV – EFFECTIVE AND
Technical data:
Ball valve
Full bore, no pressure loss
Wear -and maintenance free
Fully welded, trunnion mounted
PMSS sealing system
Double Block & Bleed
Fire safe pursuant to BS 6755
Suitable for under-floor installation
Launchable
PIONEERING
Actuator
Spring container with multiple spring technology
High-pressure gas cylinder, fully welded steel, nickel-plated on <strong>the</strong> inside
Gear of GGG 40, grease-filled, water-tight (IP 68), maintenance-free
Control
Stainless steel control cabinet, Mat. 1.4301 (IP 65)
Control in leakage-free Fahlke MCE control block technology
N2 miniature measuring connection for emergency supply
Gas preparation via filter and dryer
Input pressure controller and 2 safety valves
2x high pilots, switching when increasing, accuracy 1% (AG 1,0), SIL 2
1x low pilot, switching when dropping, accuracy 2.5% (AG 2,5), SIL 2
Inspection valve with safety manual shut-off valve
High-pressure quick vent with blow-out pursuant to G 442
Pipe work and fittings Mat. 1.4571
Options:
ESD solenoid valve
Solenoid valves for operational adjustment run
Signalling triggering of a pilot
Heating, <strong>the</strong>rmostat-controlled, max. 100 W, 230 V AC (Ex de – ATEX)
22 23

Exact to a matter of tenths
Using Fahlke‘s modern electrohydraulic regulating <strong>actuator</strong>s (EHAZ ® -R), safe and accurate
set-point controls are guaranteed at all times. In contrast to <strong>actuator</strong>s with opening and
closing controls, <strong>the</strong> controlled valve <strong>can</strong> be set to each desirable position between 0° und
90° at 0.1 degree intervals (for example 0.1° or 0.2°). A plus point that particularly pays off
with larger control ball valves and butterfly valves e.g. in gas control and transfer stations. In
addition, our extremely accurate Scotch-Yoke transmission ensures continuous, high levels
of efficiency: it is designed to suit <strong>the</strong> special mechanical requirements so that frequent
tracking of <strong>the</strong> set value is not longer necessary.
Besides <strong>the</strong> electrohydraulic version, we also supply pneumatic <strong>actuator</strong> units (PAZ ® -R),
including a regulating control.
EHAZ ® -R/PAZ ® -R – WE
REGULATE YOUR PROCESS
Technical data:
Control <strong>actuator</strong> remains in position if <strong>the</strong> control voltage fails
Control voltages: 24 V DC/110 V DC/230 V AC
High resolution of <strong>the</strong> control signal: 0.03 mA = 0.2° = 0.1%
Permissible ambience temperature: -25°C to +50°C
Maintenance-free drive <strong>actuator</strong> (IP 68)
Hydraulic cylinder, steel, fully welded, inside nickel plated
Pipe work and Swagelok fittings, MAT. 1.4571
Endstop adjustable, mat. 1.4305
Free from backlash adapter system pursuant to DIN/ISO
Mechanical position indicator
Stainless steel control cabinet, Mat. 1.4301 (IP 65)
Safety valve/pressure relief valve
Proportional solenoid valve 4/3-directional (Ex de – ATEX)
Block valve 2/2-directional (Ex de – ATEX)
2-fold block valve 2/2-directional (Ex de – ATEX)
Manual operation via control valve 4/3-directional
Connection terminal box (Ex e – ATEX, IP 65)
Position Control Unit, type DHP-SW-006 – Ex de IIB T4, 4-20 mA
Sensor box installed on <strong>actuator</strong> (Ex ia – ATEX, IP 66)
Sensor type: Potentiometer: 4 – 20 mA (Ex ia – ATEX)
24 25

Subsea –
<strong>the</strong> <strong>underwater</strong> <strong>actuator</strong> <strong>you</strong> <strong>can</strong> <strong>rely</strong> on
For depths of up to 250 metres
Already, back in <strong>the</strong> early 1970s, Fahlke
had received <strong>the</strong>ir first orders for <strong>the</strong>
construction of high-quality hydraulic
<strong>actuator</strong>s for <strong>underwater</strong> use. The
challenge: <strong>the</strong>y should carry out <strong>the</strong>ir
work under <strong>the</strong> most difficult of conditions
on offshore platforms in <strong>the</strong> North
Sea or in flood-endangered areas. By
now, our double-acting, spring-closing
or spring-opening subsea hydraulic
<strong>actuator</strong>s are used 100 times more in
individual design around <strong>the</strong> globe.
Both back <strong>the</strong>n and today, <strong>the</strong> subsea
product line stood out for its high
Technical data:
Double-acting
Single-acting/spring return
Torques up to 100,000 Nm
quality: all components in contact with
water are corrosion resistant. An external,
mechanical position display is available.
Equipment fitted with a special
manifold, end position signalling and
an adaptation according to ISO 13628
for emergency operation is available.
Fur<strong>the</strong>rmore, a subsea <strong>actuator</strong> only
leaves our factory when it has been
subject to a comprehensive leak test in
our in-house test chamber. Pressure is
used to perform <strong>the</strong> test; this simulates
<strong>the</strong> given water depths for <strong>the</strong> intended
use.
Options:
Emergency actuation via ISO adapter
End position signalling
Subsea manifold
Electro-hydraulic controls
-60 °C –
Suitable for extreme temperatures below zero
Their field of application is
ice-cold temperatures
When used under extreme temperature conditions, <strong>the</strong> certified low
temperature <strong>actuator</strong>s by Fahlke have already more than passed <strong>the</strong>
test. The robust products are especially designed to actuate pipeline
valves in permafrost areas and guarantee energy suppliers around
<strong>the</strong> globe smooth processes in temperatures of up to -60 °C both
now and in <strong>the</strong> future. This is made possible by specially-designed
components and quality standard tests.
Prior to delivery, all <strong>actuator</strong> types are subject to comprehensive
tests under real conditions in <strong>the</strong> in-house cold chamber. In this way,
we not only ensure a long service life, but also excellent functionality,
which <strong>can</strong> even be guaranteed after prolonged downtimes.
26 27

Our service – always by <strong>you</strong>r side
no matter where <strong>you</strong> are in <strong>the</strong> world
Service – for <strong>you</strong>, we go to every corner of <strong>the</strong> world
Nationally and internationally, <strong>the</strong> service team at Fahlke are here to provide <strong>you</strong>
with all <strong>the</strong> services <strong>you</strong> require prior to and when using our products. These include
comprehensive services in connection with <strong>the</strong> start-up procedure (set-up
and adjustment of <strong>actuator</strong> units), annual inspections, repair work and all tests
which are stipulated by legislators.
Within <strong>the</strong> framework of our service contract, as an operator, <strong>you</strong> have <strong>the</strong> option
of agreeing on individual tests which guarantee <strong>the</strong> highest level of functionality
and safety for <strong>you</strong>r systems.
Training – maintenance and servicing made easy
Worldwide, Fahlke offers its customers both training on site and at <strong>the</strong>ir in-house
training centre in Rotenburg. All trainers are skilled and certified* engineers and
service employees at our company, who are extremely familiar with <strong>the</strong> maintenance
and servicing of every kind of <strong>actuator</strong> and control unit. All training sessions
are documented by providing all attendees with a certificate of participation.
Documentation – so that <strong>you</strong> are always on <strong>the</strong> safe side
As a provider of quality products, for each delivery, we compile individually designed
documentation based on customer wishes. In addition to <strong>the</strong> declaration
of conformity according to directive 94/9/EC, this includes a complete functional
description and detailed instructions for assembly and operation with component
descriptions and all safety instructions and certificates.
* Certification system of Safety Certificate Contractors SSC
28 29

From
development to
series production
Product development
More than 35 years experience and close collaboration with our clients form <strong>the</strong>
basis of modern, high-quality technical automation products at Fahlke. Each
individual order proves that we are experts at what we do. We are constantly
developing a solution which fulfils all desired requirements to <strong>the</strong> highest level.
Our expertise is incorporated into <strong>the</strong> development and maintenance of our
products.
Manufacturing
At Fahlke, all control systems and <strong>actuator</strong>s are manufactured with utmost precision.
For this reason, we have access to modern machines, vastly diverse
manufacturing technology and extremely well-trained employees. The operating
processes are of course subject to <strong>the</strong> quality management system ISO
9001:2008, which guarantees detailed planning and deadline tracking.
Fahlke’s Green Concept
An integral part of engineering and production is <strong>the</strong> “Fahlke Green Concept.”
We place great importance on ecological efficiency, prioritise resource conservation
and pursue <strong>the</strong> sustainability of our products and raw materials used.
30 31

From quality
assurance
to storage
Quality assurance
The durability and reliability of our control systems and <strong>actuator</strong>s <strong>can</strong> be achieved
with simply extremely high quality standards. Our quality and safety standards are
just as comprehensive. The focus of our activities is to outdo even ourselves with
regard to quality and safety. We document and record each stipulated work step.
We carry out thorough manufacturing-related quality controls, regular measuring
and testing equipment controls and functional tests.
Storage
More than 20,000 items at Fahlke are permanently available
in <strong>the</strong> production and spare part storage on demand. This
means that <strong>you</strong> <strong>can</strong> <strong>rely</strong> on flexible production, short delivery
times and an optimum supply of replacement or exchange
parts. In fact, this is our guarantee to <strong>you</strong> for at least 15 years
after delivery at every facility.
32 33

Fahlke – Quality prevails
Safety, performance capacity and reliability
are all indispensable when it comes
to industrial process automation. Therefore,
we have installed a quality management
system early on, which is both
continually monitored via internal audits
and regularly certified by TÜV Rheinland.
We always manufacture our entire product
range to <strong>the</strong> highest quality standards:
<strong>the</strong>se include <strong>the</strong> DIN EN ISO
9001:2008, as well as all <strong>the</strong> relevant
European and international standards.
As a manufacturer of systems, which
are implemented in safety-critical and
potentially explosive environments, it
goes without saying that we are also
ATEX certified (ATEX Product Directive
94/9/EC) and possess an SIL 2 or SIL 3
approval. The CE identification of our
<strong>actuator</strong>s and control systems is obligatory
due to <strong>the</strong> directive to which <strong>the</strong>y
are subject.
34 35

Fahlke worldwide
With our global network of representatives, we offer <strong>you</strong> <strong>the</strong>
best possible service on site.
Do not hesitate to contact us:
Fahlke Control Systems KG
Rudolf–Diesel–Str. 3
27356 Rotenburg
Germany
Tel.: +49 (0) 4261-9143-0
Fax: +49 (0) 4261-9143-143
Email: csg@fahlke.de
Internet: www.fahlke.de
manufacturing plant
representatives