At a Brazilian refinery, ensuring smooth operations and worker safety is a top priority. However, one recurring issue posed both operational inefficiencies and safety hazards: accessing an 8-inch gate valve for the clarifier tank bottom drain. This challenge slowed down processes and increased the risk of accidents. Sofis partner ASELCO stepped in with a solution that transformed how this critical valve operates, delivering safety, efficiency, and reliability.
Valve puts operators at risk
The clarifier tank’s bottom drain valve was in a location that was difficult and dangerous to access. Positioned below ground level, operators had to jump over pipes to reach it, risking slips and falls, especially during rainy conditions. Poor ergonomics added another layer of difficulty, as the valve’s placement made the operation uncomfortable and inefficient. To make matters worse, when weather conditions were unfavorable, valve operation was entirely halted to avoid accidents. This irregularity in operation had a direct impact on the refinery’s processes, limiting the frequency of use to just twice a week and posing a risk to water quality management.
Remote valve operation offers a solution
In close collaboration with ASELCO, the official Sofis partner for Brazil, Sofis installed a FlexiDrive remote valve operator. This setup included a remote operation wheel mounted on a sturdy one-meter pedestal, placed four meters away from the valve itself. By relocating the actuation point to an accessible and ergonomic height, operators could now actuate the valve from a safe distance without navigating hazardous obstacles. As an added layer of safety, Sofis also installed an extended handwheel at the valve station. This dual-safety feature ensured operators could perform maintenance or direct valve operation, if necessary, easily and confidently.
Safety, accessibility, and efficiency
The implementation of the FlexiDrive system dramatically improved safety and efficiency at the refinery. Operators could now access and actuate the valve quickly and safely, without having to jump over pipes or navigate unsafe platforms. The ergonomic pedestal-mounted wheel made operation effortless, even in adverse weather conditions, which had previously halted operations altogether. This improvement allowed the valve to be operated up to twice a day, doubling its frequency and ensuring consistent water management processes. By addressing both accessibility and ergonomic challenges, the solution significantly reduced the risk of accidents while increasing the overall reliability of operations.
A two-fold solution to a complex problem
The operations team at the refinery faced a dual challenge: improving access to a valve located in a fixed, hard-to-reach spot and making its operation ergonomic and efficient. FlexiDrive met these challenges head-on, demonstrating how it can overcome physical constraints without requiring major modifications to existing infrastructure. By improving both safety and operational frequency, the solution has not only enhanced daily workflows but also had a positive impact on the quality of water used in the refinery. The innovative design is now in the process of being fully integrated into the refinery’s operations, marking a significant step forward for the facility.