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Improve your process control with smart valves

In almost every production facility where fluid is flowing, valves are used to start, stop, change direction of, or control the amount of liquid or gas flow. In many of these plants, there is no feedback to tell operators and maintenance personnel the health of the valve or whether it is open or closed. Without this basic information, how can you guarantee the quality of your product? More knowledge about the status of your valves leads to increased efficiency and decreased downtime.

  • Eliminate unplanned stops in your process linked to failures of seals on quarter-turn valves.
  • Improve process quality by identifying early failures of critical seals on valves.
  • Reduce environmental risk of media leakage from seal failure on valves.
  • Free up maintenance team to perform value-added work vs. time-based maintenance checks.
  • Reduce inventory of replacement parts and quarter-turn valves.

The MVQ smart valve sensor continuously monitors the actual position of a quarter-turn valve in increments of 0.1 degrees. It is now possible to have a reliable indication of valve open / valve closed. The sensor also has predictive maintenance functions that can indicate valve open / close cycle time and deterioration of the valve seal.

Evolution of valve feedback systems

Valve position feedback systems have evolved over time.  Manufacturing facilities can be anywhere along this evolution process. In fact, different areas of the plant may use different methods of feedback.

  1. No feedback or visual indication only. 
  2. Switchboxes using mechanical limit switches that can stick, break or wear. Maintenance intensive.
  3. Non-contact inductive sensors solve the problems associated with mechanical switches. Generally, just signal open or closed positions.
  4. Continuous position feedback can alert you to potential issues that can be addressed prior to catastrophic failure.

Introducing the MVQ smart valve sensor

The MVQ provides continuous valve position feedback and predictive information alerting to early signs of industrial valve failure. Increase plant effectiveness with the MVQ:

  • Ensure product or ancillary utilities are moving as intended without blockage or leakage.
  • Complement process feedback of pressure, temperature and flow with valve position to have complete operational transparency to factors that affect product quality.

Cost of valve maintenance

Valves wear over time and maintenance is inevitable to keep production running efficiently.  Consider a manufacturing plant with 100 valves operating every day.

Cost of inspection – if all 100 valves are inspected 4 times per year and it takes 20 minutes for each valve and your labor rate is $100/hour…

it costs $13,200 per year just to make sure valves operate correctly.

Cost of valve repair – if a valve requires maintenance and it takes 3 hours for each valve and your labor rate is $100/hour…

It costs $300 per valve to repair. The cost more than doubles if the valves are difficult to reach, since a fork lift and an extra person are likely required. And if the valve must be replaced, add approximately $1000 to the repair cost.

BUT, what is the cost of unplanned downtime compared to the cost of one MVQ sensor?