Today factories prefer remote valve monitoring over traditional retrofitted monitoring solutions, which were more costly. Factories like chemical processing, pulp, and paper, water treatment, waste management, etc are using the new IoT technology sensor valves because these are fast and cost-effective. It saves time, and manpower thereby increased productivity with enhanced security.
Reports suggest factories have evidenced around a 90% reduction in retrofitting investment. Industry grade wireless sensors, along with industrial IoT technology have upgraded the operational platforms with enhanced data communication systems.
The global IoT specialist Pretti Kujala who is also the director of Smart Factory Business of Haltian, discussed about retrofit valve monitoring and also explained how the manufacturing companies could reduce the operational cost.
Factories and plants of different manufacturing industries like water treatment, chemical process, food process, etc. used to operate through hundreds of manual valves, until the discovery of IoT sensor valves.
The operation and control process of these manual valves is more difficult as it involves huge manpower. Industrial enterprises need to foster their productivity in order to be in the global competition. The manual technologies have become outdated along with the discovery of automated sensor-controlled devices. The IoT devices are preferred to use for enhanced operational security of the process.
Industrial automation is growing rapidly along with the use of smartphones, tablets, and other wireless devices that are connected through high-speed internet.
Several components are involved in the making of remote valve monitoring, which uses a retrofit sensor device to detect the valve position that is mounted on the hand-operated valve. There are two types of position sensors: the angular position sensors and the linear position sensors that report the position data to the factory central device through the digital format. The whole process is complex it could take hours to operate manually whereas with IoT embedded devices it has become a matter of few clicks, provided a strong connecting network is there.
With the help of an ideal remote monitoring solution, all the valves of the factory can be connected and controlled in no time. The valves can be installed in different positions throughout the factory.
The factories get multiple benefits out of the remote monitoring of process control valves, some of which are:
Among the benefits mentioned above, the most prominent is cost reduction and the second is time-saving which comes hand in hand. Due to the enormous benefits of remote valve monitoring among the recent industry, the 4.0 transformation has pitched the remote monitoring system and result a steady growth with a CAGR of approximately 4.5%. The figure is expected to approach $28 billion by 2023, globally.
Due to the high cost of initial implementation, many factories have delayed remote valve monitoring expansion. However, due to the rapid market growth and dynamic economic benefits many factories are rapidly updating their operational technologies. In retrofitting technology hundreds of valves are involved that are manufactured by different vendors. Also, the overall retrofitting operational method is costly and consumes more time over IoT embedded devices.
Pertti Kujala has mentioned many other issues in retrofitting remote monitoring on the existing valves. Several industrial communication protocols are involved in the field of traditional sensor devices like Profibus, DeviceNet, Foundation Fieldbus, AS-Interface, etc. to communicate with the existing SCADA or SAS System. A few costly software is required in order to interface customization if many different vendors are required to include in the system.
These challenges are serious, and it slows down the operation of the remote valve monitoring solutions in large scale manufacturing factories. Here the game-changing solution came along with IoT. The IoT sensor devices took the technology to a higher level along with wireless technologies.
Angle sensor has developed by Haltian, the product development specialist and leading industrial IoT provider, hand in hand with a global process industry company. It is a smart and wireless sensor for remote valve monitoring. With this solution, big industries can reduce their retrofitting cost as it combines the latest commercial wireless technologies with high-class durable materials. Factories can reduce approximately 90% retrofitting costs with updated IoT sensor valves.
The most interesting part of the wireless sensor is they do not require any cabling, as it can be attached to several manual rotary valves with the help of ball and butterfly valves.
Magnetic and mechanical sensors are present inside of these angle sensor devices that report any position changes through the wireless connection, to the factory’s central control system.
Some of the benefits of the angle sensors are-
Most of the factories have realized the growing benefits of the IoT valves; it not only reduces overall operation cost but also enhances the data security which is essential for smooth running of industry. The new industry-grade angle sensor can modify the overall operation with lower investments, as explained by the Pertti Kujala, director of Smart Factory Business, Haltian.
Sudipto is a Senior Content Developer at IoT Avenue who helped to build the content of the site along with several other sites with his compassionate SEO driven content. He is also a HubSpot, certified Content Marketer. He brings five years of experience to his current role, where he is dedicated to developing the content of different websites.
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