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Improve process control with smart valve sensors

Continuous valve position feedback and predictive information alerting to early signs of industrial valve failure.
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.
Smart valve sensor with solenoid outputs reduces the complexity of wiring networks and the total costs of installation.

Guarantee your product quality

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.

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

  • All valves are inspected 4 times per year
  • Inspection takes 20 minutes per valve
  • Repair takes 3 hours per valve
  • Billable labor is $100/hour
Cost of inspection Cost of repair
100 valves x 4 inspections/year x 20 minutes/valve x $100/hour 3 hours/valve x $100/hour
$13,200 per year inspection cost $300 per valve repair cost

Note: Repair cost more that doubles if the valves are difficult to reach due to forklift and extra labor required. If the valve must be replaced, add $1000 more to the repair cost.

MVQ nearly eliminates the need for inspection

The MVQ smart valve sensor continuously monitors the status of valve seal wear, so maintenance can be planned as needed, rather than a time-based approach when maintenance may not actually be necessary.

Simplify installation, reduce installation cost, and increase efficiency

MVQ201 with solenoid outputs can help you to reduce wiring complexity and simplify cable management in the control cabinet.

  • Reduce installation time and increase machine building efficiency.
  • No more long cables from solenoid pilot valve to the control cabinets throughout the manufacturing plant.
  • The sensor also powers the solenoid directly via the M12 connector.

Assume the following:

  • Cable cost = $3/m
  • Billable labor = $100/hour
  • Average cable run = 10 m
  • 100 valves
  Typical installation Using MVQ201 (direct solenoid connection)
Cable from sensor to control cabinet 10m x $3/m x 100 valves = $3000 10m x $3/m x 100 valves = $3000
Cable from solenoid to control cabinet 10m x $3/m x 100 valves = $3000 0.3m x $3/m x 100 valves = $90
Labor $100/hour x 16 hours = $1600 $100/hour x 8 hours = $800
Total installation cost $7600 $3890

Using MVQ201 results in less downtime and a savings of ~50%!