Despite the use of personal protective equipment (PPE)—helmets, gloves, goggles, safety shoes—valve operators continue to face significant risks across industries such as petrochemicals, water treatment, energy, and mining.
Why are these operations so hazardous? And how can modern technology like MODEC CONNECT and Portable valve actuators reduce these risks?
Nearly 50% of industrial valves are still operated manually. In many cases, the torque required to open or close a valve exceeds the physical capability of an operator. This is especially true for valves that are blocked due to lack of use, corrosion, or environmental buildup.
Risks:
🔷Handwheel or valve breakage
🔷Musculoskeletal injuries
🔷Incomplete operation due to human fatigue
MODEC Solution: Our portable valve actuators eliminate the need for manual torque, ensuring safe and consistent valve movement—without operator strain.
Without clear feedback, operators often rely on feel alone to determine if a valve is fully open or closed. Over time, as torque profiles change, this can lead to incomplete valve positioning.
Consequences:
🔷Process inefficiencies
🔷Leak risks or pressure inconsistencies
🔷Costly rework or system failures
modec Connect Advantage: With real-time valve monitoring, operators can track position, rotation count, and speed precisely—helping eliminate guesswork.
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In facilities with complex layouts, valves are often installed in hard-to-reach places: above pits, behind pipes, or through barriers. Operators sometimes work in unsafe positions with poor visibility or mobility.
Risks:
🔷Falls or impact injuries
🔷Inaccurate valve operations
🔷Reduced maintenance efficiency
Safe Distance Operation: modec actuators and torque reaction systems are designed to
Certain valves, particularly those with gearboxes, require hundreds of turns to fully open or close. This repetitive action causes:
🔷 Muscle fatigue
🔷Long task durations
🔷Increased error rates
Automated Assistance: modec’s actuators drastically reduce physical effort and operation time—keeping your team efficient and injury-free.
Common mistakes still seen today include:
Extension bars
Homemade actuators
Cable and pulley systems
Oversized valve keys
These solutions may appear cost-effective but often compromise both safety and equipment lifespan. Friction losses, violent backlash, and uncontrolled torque can severely damage valves and injure operators.
At modec, we believe there should be no trade-off between safety, performance, and precision. Our portable valve actuators are engineered for:
✅ Operator safety
✅ Fast, accurate valve operations
✅ Adaptability to harsh environments
When paired with modec Connect, you get a full industrial IoT valve monitoring solution:
📊 Live feedback on valve position and rotation
🚨 Alerts for abnormal torque or motion
🧠 Predictive maintenance support to prevent breakdowns
🌐Compatible with GIS softwares for easy implementation
Result: Fewer risks, less downtime, and a longer lifespan for your infrastructure.
Valve operation is no longer just a manual task—it’s a critical part of industrial safety and efficiency. Outdated or improvised methods expose your teams to avoidable risks.
Now you can equip your operators with the right tools and data to stay safe, work faster, and protect your assets.
👉 Ready to modernize your valve operations? Book a free demo on our website: https://offers.modec.fr/en/schedule_live_demo
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