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When Every Valve in the Process Line Needs Control, the Cabinet Controlling It Needs to Be Designed for the Environment

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Project Background

Chemical production facilities can have dozens or even hundreds of valves of different types. When valves are pneumatically actuated and remotely controlled, their control valves can be centralized in a dedicated JB cabinet, depending on the facility’s control architecture.

In a corrosive industrial environment, particularly where strict safety requirements apply, the design and assembly of such cabinets require careful selection of components, construction materials, and installation methods to meet the environmental conditions and specific requirements of the facility.

In a project we completed for a customer in the chemical industry, we identified an opportunity to simplify the process for the customer by providing a ready-to-install solution, eliminating the need for them to assemble the cabinets themselves.

What is the solution that we have developed for the costumer?

The solution included a JB cabinet equipped with a CAMOZZI D5 Series explosion-protected modular manifold for controlling the valves along the process line, designed to meet the applicable requirements of the working environment.

For the customer, the main benefit was simple but significant: saving assembly time and reducing costs. Instead of investing resources in building the cabinets themselves, they received a complete system, pre-assembled and tailored to the application requirements.

For us, this is exactly where a good engineering solution meets the right service. It is not necessarily about reinventing the wheel, but about identifying an existing need and providing an efficient, accurate solution.

But inside the cabinet, there is another component that brings additional value: the manifold.

The manifold supplied as part of the project is more compact and modular than the previous solution. In addition to saving space and simplifying operation and maintenance, it also provides valve status monitoring through CoilVision® technology, which helps identify deterioration in solenoid performance before a significant malfunction or failure occurs.

For process systems where reliability and availability are integral to day-to-day operations, the ability to detect performance changes at an early stage can make a significant difference.

Advantages of the solution

The cabinet’s construction materials and connections were also selected to suit the environmental conditions. The cabinet is made of polyester reinforced with 30% fiberglass, selected to withstand outdoor conditions and a corrosive environment. Stainless-steel fittings and PTFE tubing were used for the connections, providing a suitable solution for conditions typically found in the chemical industry.

The result is a solution that may initially look like “just a cabinet,” but in practice incorporates several important engineering decisions: adaptation to environmental conditions, compliance with applicable requirements, reduced assembly time, a more compact and modular design, intelligent performance monitoring, and above all – a solution that takes work off the customer’s hands that does not necessarily need to be done on-site.

In facilities with dozens or even hundreds of control cabinets managing different groups of valves across process lines, the benefits of moving to a pre-assembled and ready-to-install solution can quickly add up.

Instead of building each cabinet independently, customers can receive a solution built according to their application requirements and delivered ready for installation and operation.

This project is a good example of how identifying a need in the field can lead to a solution that can also be applied to other customers. In particular, the compact, modular and intelligent manifold can be relevant to a wide range of applications requiring valve control, reliability, adaptation to demanding industrial environments, and the ability to identify performance degradation before a failure occurs.

Do you have process lines with multiple valves or control cabinets that you are still assembling yourself?

You may be able to save assembly time, simplify the installation process, and receive a solution designed in advance to meet your environmental and application requirements.

Want to find out whether this solution is right for your facility? Talk to us.