From self-driving vehicles to ChatGPT for writing, the world is becoming more reliant on automation than ever. The same is true for many industrial processes that rely on fluid flow to make ends meet. Many industries, such as wastewater treatment, agriculture, food and beverage, and more, utilize water on an everyday basis.
In addition to having reliable filters, pipes, and strainers, industrial processes that utilize water also need excellent control valves. Control valves determine fluid pressure and flow. Traditionally, manual valves have been the only option. However, automated valves are quickly becoming the industry standard, due to the many advantages they offer.
This article will delve into how automated valves work, how they're different from manual ones, and the advantages of using them. We'll also examine the different types of actuated valves and how to choose the right one for your needs.
What is the Role of Automated Valves and How Do They Work?
An automated valve is any type of valve that relies on an actuator for control. This means the actuator attaches to the valve stem and can open and close valves as needed. While different types of automated valves have different operating mechanisms, the general concept is that they receive signals based on water pressure, air pressure, and electricity telling them when to open and close.
Different Types of Automated Valves and Where to Use Them
In general, there are three basic types of automated valves used by industrial processes. The type of valve is based on how it receives control signals and opens and closes.
Electric Actuators
Electric actuators are one of the most reliable and precise type of valve actuators on the market. They operate using a two-way electric motor which offers variable speed control, powerful torque, and easy operation. They open and close based on electrical signals they receive from their control system, which analyzes air and water pressure.
While electric actuators regulate fluid flow with accuracy and efficiency, they are susceptible to vibrations. They also require a constant, uninterrupted power supply, which means they're limited to places with power availability. Fluid flow rates are also slower with electric actuators, which means they aren't ideal for high pressure or flow situations.
Pneumatic Actuators
While electric actuators operate using electricity, pneumatic actuators rely on air pressure for operation. Air enters the entry port on the valve actuator, builds up to a set point, and then triggers the valve to open. Once the air pressure recedes, the valve closes and the process repeats.
Pneumatic actuators offer a simple design, easy operation, and little maintenance. Because they operate using compressed air, they are very cheap to operate and rarely have issues. They are one of the most widely used types of actuators for industrial processes and are especially useful in environments with high temperatures.
Hydraulic Actuators
Hydraulic actuators are very similar to pneumatic actuators, but with one major difference. Rather than using compressed air as control mechanisms, hydraulic actuators use hydraulic fluid. The fluid builds up pressure within the valve and forces it to open and close as needed. Because they use hydraulic fluid, hydraulic actuators are commonly used in the construction industry or to operate heavy machinery.
How Are They Different From Manual Valves?
While each automated valve has different control mechanisms, the one thing they have in common is that they don't require human intervention to operate. This is in stark contrast to manual valves that a person must open and close on their own. Manual valves are often manipulated by twisting a knob, pulling a lever, or turning a wheel.
Industries That Rely on Actuated Valves for Flow Control
Because opening and closing valves manually requires extra manpower and often comes with safety risks, valve automation is quickly becoming the industry standard. This is especially true in industrial applications where multiple valves are constantly opening and closing, and some are too large to operate manually, including:
- Agriculture
- Wastewater Treatment
- Manufacturing
- Energy Production
- Food and Beverage
- Textiles
- Many more!
Benefits of Actuated Valves for Automated Flow Control
Now that you know the different types of automated control valves and how they operate, let's examine their many benefits over manual valves.
Increased Efficiency
The biggest advantage of automated valves is that they offer increased efficiency and production output. Automated valves open and close at exactly the right time, resulting in minimal waste and less energy use. This results in optimal energy efficiency, less maintenance, and maximum production efficiency.
Remote Operation
You can also monitor automated valves from remote locations, rather than having someone on site. This means one person can oversee numerous valves, which drastically cuts down on manpower.
Accuracy and Precise Control
Because automated valves open and close exactly when they need to, they offer more accuracy and precision than manual valves. You can also adjust the parameters of automated valves according to your specific needs.
Improved Safety
Valves are often located in dangerous environments, which means that people will be put in harm's way if you have manual valves. Because automated valves can be controlled remotely, you don't need someone on-site and placed in jeopardy just to open and close the valve body.
Automated valves are also less likely to break, burst, or experience problems, which means increased product quality and safety.
Cost Savings
Although they're more expensive to install than manual valves, automated valves are bound to save you money for a number of reasons.
1. Reduced equipment downtime due to repairs and issues.
2. Increased energy conservation and efficiency.
3. Less manpower is necessary for operation.
4. Less waste due to increased control and accuracy.
Integration With Control Systems
One of the more recent advantages of automated valves is that you can integrate them with advanced control systems. Certain programs, such as Distributed Control Systems, Programmable Logic Computers, and others offer system-wide control over many operations. You can integrate your automated valves with these programs, resulting in maximum precision and performance.
Predictable Maintenance
With manual valves, you need to perform maintenance on them as needed based on how often you use them. With automated valves, however, you have a better idea of how often they will open, close, and move. As such, you can better predict when they will require maintenance, tune-ups, and repairs.