Most companies expect the benefits of digital transformation in manufacturing include reduced costs, data visibility and improved reliability, among other things. In other words, success means positive returns, higher efficiencies and increased throughput. Because DT usually relies on incremental changes, the overall success of implementation relies on staying true to a sound strategy.
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Before diving into the details of digitalization, it helps to take a few steps back and understand why it is essential in the first place. Ultimately, DT is a business decision that needs to align with the company’s overall objectives. It is easy to get lost in the world of digitalization, high-tech tools and automated processes, only to end up with a poor bottom line.
For instance, a game-changing type of technology in the arsenal of digital tools is artificial intelligence (AI). A machine that can learn on its own, using massive amounts of data, can grab the attention of any manufacturer. But what does that kind of power really mean for a business?
For starters, wielding such technology can streamline the whole supply chain. Anticipating customer demand no longer relies solely on extrapolated historical information. Instead, a more thoughtful process can utilize algorithms to offer a more predictive outlook to forecast requirements. A valve manufacturer, for example, can link their inventory systems with their customers in the industry. With both sides having visibility on supply and potential constraints, modern systems can precisely identify when to order a new part.
The supply chain is only one of many practical applications of going digital, and there continues to be an abundance of emerging technologies. The challenge for companies is to discern which prospects make the most sense for their business and which ones align with their objectives.
While some DT initiatives can realize value quickly, remember that an entire transformation is a continuous process. It is beneficial to think of DT as a journey that keeps on building upon a series of steps. Therefore, any progress towards digitalization needs to align with a clear vision and a well-founded strategy.
Going through DT is a balancing act of taking significant but practical actions. Taking on things all at once will set teams up for failure, while taking too much time runs the risk of being outpaced by competitors. Putting focus on particular projects over others should be guided by the current capacity of a company. Teams should also have the ability to adapt whenever results are no longer aligning with the overall objective.
The foundations of a strategy involve three key components: products, infrastructure and people. The constant flow of quality products is arguably the most significant — yet practical — challenge to displaying success. A digital transformation strategy needs to consider the continuity of operations and, consequently, the flow of products. Infrastructure refers to the resources a company needs to get to its goal. Preparing for any compatibility issues between transitioning technologies ensures minimal disruptions. Lastly, the people within the organization are the driving force behind the execution throughout the entire journey.
Remember that the actual state of implementation does not always follow a clear and exact path. Instead, you can expect an iteration of the different possible outcomes concerning transformation. A comprehensive strategy allows teams to stay true to the course regardless of the twists and turns along the way.
Acknowledging the evolutionary nature of a DT journey highlights the importance of relying on objective decisions. Expanding on that same analogy, think of data as your compass while navigating through varying terrain. Of course, it is not enough to merely collect and gather data. Equally important is the way teams regard the information and utilize the knowledge.
There are several ways that a data-driven approach can manifest throughout DT. Prioritization of initiatives, for instance, needs to be based on reliable information. Any project that requires new tools and additional resources will incur costs. Companies need to ensure the advantages of taking on a project outweigh the costs within an acceptable timeframe to realize value. Modern systems such as Enterprise Asset Management software or Enterprise Resource Planning programs can tremendously lessen the effort in gathering such data. By having a sense of the current allocation of resources going into existing processes, any improvements can be more readily determined and quantified.
Regardless of how the data lends itself to various aspects of the transformation, companies should recognize the importance of building a data-informed culture. Involving workers from different levels of the organization promotes an environment of awareness about the possibilities and boundaries of data.
While the measure of success can vary for each company, we can all agree that there is significant value in maximizing the potential of current and future assets.
For equipment used in manufacturing, maximizing assets may relate to maintenance and operations to increase reliability and throughput. A traditional approach might employ a preventive maintenance strategy that schedules servicing tasks, preempting breakdowns. A modern approach to the same problem can more precisely identify maintenance needs using software that leverages big data.
Advanced maintenance methods may call for specialized tools and processes. For example, an industrial valve will require several additional sensors, measuring devices and transmitters to gather and collect sufficient information. Additionally, a computing system will need to consolidate the data and perform analysis using a comprehensive algorithm. All these components play a role in the DT journey as the digital maturity of a facility will prescribe the viability of more advanced maintenance strategies.
Infrastructure spending to prepare manufacturing systems for advanced options can comprise a sizable portion of the budget. Decisions about the resources to put into projects come back to comparing investments with the perceived benefits. A practical approach for companies is to identify the critical materials that will realize returns on manufacturing process improvements and specialized maintenance strategies.
As with any business transformation, DT does not just impact physical and virtual tools — but also the users themselves. Planning for the various skill levels throughout the phases of a DT journey requires a dynamic approach to people management. Examples of questions to think about include what support the company needs, what opportunities are there to upskill employees, and what feedback the workers have with any project development.
A common concern for employees is that highly technological tools are often an entirely different scope of work from their usual expertise. A good strategy will be to narrow the gap between the technical requirements of digitalization and the skills of the intended users. Opportunities for training and upskilling will be beneficial to increasing the number of resources that can add value to the transformation. In parallel, management teams should consider selecting user-friendly software alternatives whenever possible.
Preparing for a diverse group of users ensures that the leap to digitalization need not be a shocking event. Instead, it becomes a learning experience that builds on collective knowledge and shared experience.
Transitioning to a more digital world is an inevitable feat in establishing an agile and competitive manufacturing practice. Once a company embarks on its digital journey, the process becomes a continual effort to innovate and improve. Throughout the transformation, a long-term strategy needs to be in place to guide actions toward success.
The inherent design of ball valves makes them ideal for on/off control of a wide variety of media, but what exactly should you expect when it comes to service life? A quick Google search for “ball valve lifespan” turns up a blanket response of 100,000 cycles. If only the real answer was that simple.
The reality is that the lifespan of your ball valves depends on a handful of factors. Ball valves in high-cycle or high-pressure settings will need servicing or replacing more often than those with infrequent operations — and that’s before factoring in any media-specific nuances.
You will see that the majority of ball valve suppliers do set guarantees for the life expectancy of their products because there are so many factors to consider first. Here’s a closer look at five that will impact the longevity of your ball valves.
Ball valves are traditionally used for the on/off control of gases and liquids, including water, oil, air and chemicals.
Media with suspended particulates that are abrasive in nature can cause the valve seals to fail prematurely. This can come in the form of a leak or, depending on the severity of the media characteristics, the ball valve operating torque may rise dramatically ultimately causing actuation failure.
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Takeaways
Use ball valves only for the on/off control of liquids or gases. Avoid abrasive media.
The right materials for your ball valve will depend on the type of liquid or gas flowing through the valve. Some of the most common materials used to manufacture ball valves include stainless steel, PVC, brass and bronze.
The material of both the valve body and the seals must be compatible with temperature and pressure ratings, as well as the chemical makeup of the gas or liquid that will flow through the valve.
Here’s a closer look at material options:
One resource that is commonly used for identifying chemical compatibility is the Cole-Parmer Chemical Compatibility Database. This is a good tool for determining basic chemical compatibility between the valve components and the application media.
Where the materials come from is just as important. Some resellers may source ball valves from manufacturers around the world, so there is always the possibility of design inconsistencies or functionality issues. Valves from domestic manufacturers typically offer more reliable and long-lasting products.
Takeaways
Plastic ball valves are economical but should not be used in high-temperature settings and tend to have shorter lifespans compared to metal options. Pressurized gases should be used with metal valves for maximum safety. It is important to ensure that both the valve body and seal materials are safe for use with the media that will be flowing through the valve.
When determining suitability, it is important to consider both the valve media pressure and temperature, commonly referred to as pressure/temperature rating. In general, as the media pressure increases, the media temperature must decrease, and vise versa.
The pressure/temperature rating will influence the proper materials, valve design and valve seal materials that should be used. This, combined with cycle frequency, are all factors that have a significant affect on the lifespan of a ball valve. A ball valve used in an application that is close to the pressure/temperature rating may last years if the valve is cycled (turned on or off) infrequently. The same valve in the same application may need frequent replacement if the valve is cycled often.
Takeaways
The closer your specific valve media is to the upper limits of the valve pressure/temperature rating, the fewer cycles (on/off) the ball valve will yield. If you still have questions, reach out to the ball valve manufacturer for advice.
There is more than one way to power a ball valve. Manual ball valves are controlled by turning a lever or handle on top of the valve. Since these valves must be powered by an operator, they are not the right choice for high-cycle applications or for valves located in hard-to-reach places.
Actuated ball valves can be automated and controlled remotely through the addition of a power source. You will likely see the following options:
Takeaways
Although pneumatic actuators are the most durable options, in most applications all actuator types (pneumatic, electric, hydraulic) will long outlast the ball valve they operate. Regardless of the actuator that is chosen, it will likely last the lifespan of multiple valves.
With an actuated ball valve, the valve seals are almost always the first component to fail, usually in the form of a leak either from the stem seal or seats noted by downstream leakage when the valve is in the off position. For this reason, it is common to attempt to repair the valve by replacing the soft seals.
If you are planning to maintain the valve in your application, it is important to select a valve that is designed for serviceability, such as a three-piece ball valve. These valves are designed so that the center section and seals of the valve can be easily and safely replaced. One-piece and two-piece ball valves are not designed to be taken apart and should be replaced rather than repaired. The good news is that the replacement ball valve cost is a small percentage of the overall cost of the actuated ball valve assembly. Depending on the brand and quality of the actuator, one actuator will host several ball valves before needing replacement.
Takeaways
An actuator will normally last the lifespan of multiple ball valves, so you should expect to replace the ball valve more frequently than the actuator. In applications where the valve will be subjected to extreme wear and tear, a three-piece ball valve should be considered to allow for serviceability of the valve.
Ultimately, wear and tear are expected no matter the media or application. But with proper installation and the right material construction, you can maximize the time your ball valves spend in service and, in turn, get the most bang for your buck.
George Packard is VP of marketing at Gemini Valve. He manages the creation of digital marketing mediums to facilitate the best user experience with the company's products and services. With previous experience in sales, Packard mentors corporate customer support representatives and is involved in product sales, support and post-sales follow up.
Gemini Valve
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