A Brazilian site for a global leader in specialty chemicals and paints had to find a solution for operating difficult-to-access 4″ block valves in a thermal oil line, used in the process of coating raw materials. The block valves, four in total, had to be operated every six months during maintenance shutdowns. The only way to access the valves was via a scaffold, which had to be assembled by a third-party supplier. The scaffold platform deck on the scaffolding tower, which is used as the main standing platform for operators to work on, did not allow the operators to access the block valve easily. The ground base was irregular, while wooden support structures were not allowed, due to the fire risk. Three valves were also at awkward angles and it was not possible to equip them with handwheel extenders, to allow operation from the existing catwalk. The awkward angles and limited accessibility made it difficult for operators to safely verify the open or closed state of the valves from within the unit.
Direct valve access without the need for scaffolding
Various options were evaluated, such as a dedicated platform to be built as a permanent structure around the valve. Advised by the official Sofis partner for Brazil, Aselco, the company ultimately installed a FlexidDrive remote valve operator, where the valve operator station was assembled in an existing platform, about four meters from the valve. Compared to building a dedicated platform, FlexiDrive proved to be an even better option ergonomically, improving operator safety and efficiency at the same time. The operator has direct direct access to the block valve from inside the unit, without assuming the risks of working at heights. Being a one-time investment, FlexiDrive saves considerable costs as well.
Operating manual valves from a safe distance
Opting for FlexiDrive proved equally expensive as building a dedicated permanent platform. However, FlexiDrive proved to be the better option from a safety perspective. Using FlexiDrive, the operator can now operate the valve from a safe distance and avoid the heat near the valve (280 degrees Celsius). In addition, FlexiDrive allows the operator to open and close the valve in a better position.