In many industrial operations, discharge valves for tanks are located in areas that pose significant safety hazards. At a refinery in Spain, discharge valves were installed in a channel pit under a pipe rack, which qualifies as a confined space. Confined spaces are notoriously dangerous for operators, especially when combined with the hidden, hard-to-access nature of the area. Operators face risks like restricted airflow, limited mobility, and potential exposure to hazardous materials or sudden accidents. Performing routine tasks such as valve operation can become a serious hazard. For this refinery, ensuring operator safety while maintaining operational efficiency is paramount, leading them to seek a suitable solution to address this priority.
Remote operation of manual valves
Sofis partner for Spain, SETEC, was approached by the refinery for advice on the best way to address their safety priority. SETEC offered an innovative and practical solution by installing FlexiDrive remote valve operators. FlexiDrive units were installed from the discharge valves in the confined pit, extending out into an open area where operators can remotely control the valves. By allowing operators to work from a safe, open space rather than entering the confined pit, using FlexiDrive eliminated the need for workers to enter hazardous environments, thus drastically improving safety. The FlexiDrive remote valve operation system uses durable, flexible cables that connect the valves from the confined area, passing under the pipe rack to a control point in a safer, open space. This straightforward mechanical solution allows for reliable remote operation without the need for motorized systems, which can be costly in capital expenditure (CAPEX) and ongoing maintenance.
Extra handwheel for emergency operations
An important safety enhancement is the inclusion of an additional handwheel for emergency operations. This feature plays a critical role in maintaining process safety, as it ensures operators have manual control over the valves, allowing them to intervene swiftly and effectively during unforeseen situations. By providing this extra level of control, the handwheel helps prevent potential hazards, safeguarding both the system and personnel in emergency scenarios.
Safer, more cost-effective valve operations
Introducing FlexiDrive has transformed manual valve operation, delivering multiple benefits. Firstly, the operator no longer has to enter the confined space, greatly reducing the risk of accidents. By opting for a mechanical solution instead of motorizing the valves, the refinery also saved significantly on both CAPEX and future maintenance expenses. The additional handwheel ensures that operators are fully prepared for any emergency that requires direct valve access. After almost 300 FlexiDrive units have been installed at the refinery’s facilities, FexiDrive has proven itself to be an effective and reliable problem-solver for customers facing hazardous valve operation scenarios.
FlexiDrive under gas spheres
The versatility of the FlexiDrive system extends beyond confined spaces. In another application, FlexiDrive units were installed on manual valves located under gas spheres across five different sites. These spheres, typically equipped with valves positioned at a height of 1 meter or less, are surrounded by firefighting pipework. This makes access to the valves difficult. FlexiDrive provided a safer, more ergonomic solution for valve operation in this challenging environment. The successful installation of FlexiDrive under these gas spheres has paved the way for more units to be installed.
A broad range of applications
While FlexiDrive is primarily known as a remote valve actuator system for hard-to-reach or inaccessible valves, its applications are far more extensive. In addition to solving issues with confined spaces, it is equally effective for accessible valves in hazardous areas or situations where ergonomics and safety are critical concerns. This wide range of applications makes FlexiDrive a valuable tool across various industries, helping to ensure both safety and efficiency in valve operation. For industries dealing with confined spaces, hazardous environments, or difficult valve access, FlexiDrive offers an innovative, cost-effective, and reliable solution.