Efficiency is no longer just a goal: it has become a requirement for every industrial organization because of the large proportion of operations that are based on automated systems providing precision, safety, and uninterrupted productivity. One such type of equipment that contributes greatly to achieving this level of operation is the actuator, which directs the physical actuation of the valve(s) that regulate fluid flow.

Delval Actuators have made incredible differences within industrial facilities through their precision and reliability. Delval Actuators have become widely accepted in the industrial sector as a means to automate the operation of valves to deliver a more efficient and reliable overall system. Across every industrial sector in the United Arab Emirates, upgrading to a higher level of actuator technology has allowed these organizations to reduce downtime and increase productivity.

In the following article, we will show how we helped to improve efficiency through the use of Delval actuators in an industrial plant, along with an explanation of the challenges, solutions, and quantifiable results.

The Problem: Slow Production Due to Manual Valve Operation

As industrial automation continues to grow, many older industrial sites still use manual valve operations to control production equipment and processes, causing slow production rates and increased operational risk. For example, an industrial facility in the United Arab Emirates experienced a range of operational challenges with their valve system, including the following:

1. Time delays when adjusting valves to support production requirements

2. Instability of flow control resulting in substandard product quality

3. Increased labor for handling and operating valves manually

4. Increased risk of human error when managing valve acts

5. Difficulties integrating valve systems with automated monitoring and control systems

The efficiencies (and consequently added cost) created by the above will impact both the production rate and maintenance costs of this facility and the safety implications.

A recent study on the impact of industrial automation on operational efficiency indicated that industrial plants can improve operational efficiency by up to 25-30% by implementing automation technologies (including automated valve actuators).

The Solution: Install Delval Actuators on Critical Valves for Improved Operational Efficiency

To eliminate the challenges above, the industrial facility decided to upgrade their valve control system to ensure they can maximize the production rate through the installation of Delval actuators on all critical process valves in the facility.

An actuator is a mechanical device used to open and close a valve using one of the following methods: electric, pneumatic, or hydraulic. Delval actuators are designed for industrial applications and provide precise valve control while delivering reliability.

The engineers completed a thorough assessment of the facilities' entire systems. They then proceeded to install actuators in the following areas to control the flow of fluids:

1. Fluid transfer operations

2. Pressure control operations

3. Heating and cooling control operations

4. Safety shut-off valves.

This modification resulted in the conversion of the existing manual valves into a fully automated control system for valve operations.

The installation of the Delval actuators produced significant gains for the plant's operational efficiency.

Automated control of valves permitted operators to change flow rates and/or pressure remotely through a single, centralized control system. Operators no longer needed to adjust valves manually, which caused delays in the operation.

The most notable operational efficiency improvements were

1. Quicker valve response times

2. More accurate control of the fluid flow rates

3. Decreased production stoppages

4. Increased stability of production processes

According to plant engineers, the installation of automated controls improved overall production consistency when compared to using manual controls, specifically during times of increased production demand.

Reduced Maintenance and Downtime

Another major benefit from the installation of Delval actuators is that maintenance costs have been significantly decreased.

Manual valves typically exhibit wear and tear due to being operated frequently by human operators. The use of automated actuators is reducing the amount of physical strain applied to manual valves and aiding in achieving proper operation of the manual valve.

After one year post-installation, the facility recorded:

1. Reduced maintenance-related downtime by 20%

2. Reduced number of valve replacements required

3. Improved reliability of the entire system.

This enabled the maintenance personnel to put more focus on preventive maintenance work instead of having to make emergency repairs.

Improved Safety and Process Control

Facilities across many industries work with potentially dangerous liquids at high pressures and temperatures. As a result, they typically have a priority of safety.

Delval actuators have provided improved safety in many ways:

1. By giving operators the ability to operate a valve from a remote location, the need for workers to enter high-risk areas has been greatly reduced.

2. Automated emergency valve closure mechanisms have improved the speed of the response to emergency situations.

3. The ability to monitor valve status in real time through the integrated monitoring system has allowed for faster reaction times.

According to one of the facility's operations supervisors, "Automation with Delval motors has given us the comfort and confidence of knowing that we can monitor and operate valves at any point in time without having to put personnel into probably hazardous areas."

For this reason alone, the improvement of safety provided through this upgrade was one of the most valuable findings.

Supporting Automation & Smart Industrial Systems

Many industries in the UAE are taking great strides to implement smart industrial technology and automation as part of their modernization plans.

Delval actuators have been specifically designed to work with SCADA and DCS-type digital control systems. The integration has provided plants the ability to monitor their valve performance, identify problems early, and increase overall operational efficiency.

The integration of the actuator into the monitoring system of the plant has provided the process engineers easy access to real-time data with respect to the following:

1. Valves' position status

2. Number of operational cycles

3. Pressure and flow corrections

4. Alerts from the system

Reasons that Make Delval Valves a Preferred Choice for Industrial Applications in the UAE

An increasing number of businesses throughout the United Arab Emirates utilize and install Delval actuators at their industrial operations for a number of reasons:

1. Extremely Reliable for Harsh Industrial Environments

2. Can be used alongside existing automatic control systems.

3. Durable to Provide Long-Term Service

4. Enhanced Safety and Efficiency

Automated valve systems are becoming an important component to maintain competitive and efficient operations at industrial facilities from oil & gas production facilities to desalination plants.

Final Thought 

Automation continues to change the way that industry operates, and when it comes to automation, there are very few devices more important than actuators. Many industrial facilities with automated valve systems can confirm the incredible improvement in efficiency, significant reductions in downtime, and greatly increased safety that Delval actuators provide.

If your facility is considering upgrading its valve automation and control system with dependable and proven actuator technology to realize measurable benefits—including increased production, decreased maintenance costs, and better control of your processes—contact Al Zerwa Trading, a quality industrial valve provider, to help you make the best choice for your application.