Mastering Butterfly Valve Control: Mechanical, Pneumatic & Electro-Pneumatic Solutions
Learn about butterfly valve control methods—mechanical, pneumatic, and electro-pneumatic solutions. Explore benefits, key components, and find high-quality parts at Lion Technology
Butterfly valves are essential components in many industrial systems, including pneumatic unloaders for materials like cement, fly ash, bentonite, and barite. Achieving precise control over these valves is crucial for optimizing performance and ensuring reliability. In this blog, we explore the primary methods for controlling butterfly valves—mechanically, pneumatically, and electro-pneumatically—along with the strengths of each approach and the components needed for implementation.
Mechanical Control: Simple and Reliable
Mechanical control of butterfly valves is a straightforward method often used in systems where manual operation is sufficient. The primary mechanical options include:
- Hand Levers: Ideal for small valves and applications requiring infrequent adjustments. Operators can easily open, close, or partially open the valve by hand.
- Handwheels: Suitable for larger valves, handwheels allow operators to make precise adjustments with minimal effort.
- Chainwheels: Perfect for hard-to-reach valves, chainwheels enable operators to control the valve remotely using a chain.
Manual operator / DN100 / Serie 01 Quarter turn lever / SS / EDI
Quarter-turn handle with locking spring and direction pointer for valve disc position indication. Bolted notch plates for resilient and high-pressure valves.
Strengths of Mechanical Control:
- Cost-effective and low-maintenance
- Simple to operate without requiring additional components
- Reliable in environments without power or compressed air availability
Components Needed:
- Butterfly valve
- Hand lever, handwheel, or chainwheel
Pneumatic Control: Efficient and Automated
Pneumatic control offers a more automated solution for butterfly valve operation, using compressed air to power actuators. This method is commonly used in industrial systems requiring frequent adjustments or remote control. The primary components include:
- Pneumatic Actuator: Transforms compressed air into mechanical motion to open or close the valve. Discover the Serie 92 Pneumatic Actuator.
- Solenoid Valve: Directs the flow of compressed air to control the actuator. See the Solenoid Valve NAMUR.
- Activator: Provides position feedback to ensure accurate valve positioning. Check out the Activator BT65A.
- Proximity Sensor: Detects valve position and communicates with the PLC for precise control. Explore the NBN3-F31K Proximity Sensor.
- Adapter Kit: Ensures proper fitting between the actuator and valve, depending on pipeline pressure, medium type, and other specifications. View Adapter Kit Example.
Strengths of Pneumatic Control:
- Reliable and efficient for frequent operations
- Compatible with PLC control systems for automation
- Scalable for small to large valve applications
Components Needed:
- Butterfly valve
- Pneumatic actuator
- Solenoid valve
- Activator
- Proximity sensor
- Adapter kit
- PLC programming
Actuator / 093.0 DD / F07 19mm Serie 92 / Rack and pinion pneumatic actuator / Dubble acting
Styling, strength, compactness, and simplicity of design have been combined to produce the Bray Series 92 direct acting.
Solenoid valve Namur / Combined 5/2 & 3/2 way G¼ / 24 V DC
This Solenoid valve Namur spring return offers SIL 1-3 (IEC 61508:2010) safety certification and IP65 protection.
Electro-Pneumatic Control: The Ultimate in Precision
Electro-pneumatic control combines the efficiency of pneumatic systems with the precision of electronic control. This method uses an electro-pneumatic positioner to manage valve movement with exceptional accuracy.
- Pneumatic Actuator: Transforms compressed air into mechanical motion.
- Electropneumatic Positioner: Precisely controls the actuator’s movement based on PLC signals.
- Feedback Module: Provides analog output signals for monitoring and control.
- Solenoid Valve: Directs the compressed air to the actuator.
- Adapter Kit: Ensures compatibility between the actuator and valve.
Strengths of Electro-Pneumatic Control:
- High precision with degree-specific positioning
- Fail-safe features for enhanced safety during power failures
- Reduced response time and variability compared to pneumatic-only systems
Components Needed:
- Butterfly valve
- Pneumatic actuator
- Electropneumatic positioner
- Feedback module
- Solenoid valve
- Adapter kit
- PLC programming
Electropneumatic positioner - Serie 6A - G1/4 For pneumatic linear and part-turn actuators - Polycarbonate - Fail safe
Electropneumatic positioner Serie 6A for use with pneumatic linear/part-turn actuators. Polycarbonate housing, G¼ connection & M20x1.5 bolt size. Analog 4-20mA, fail safe feature & secure fit for a variety of applications.
Feedback module - IY module Plug-in module for analog current output signal for electropneumatic positioner
Robust and reliable Feedback module for electropneumatic positioners with 4-20mA DC output and eexib explosion protection for added safety. Easy to install and highly accurate.
At www.LionTech.Shop, we specialize in providing high-quality components for pneumatic cement unloaders and other industrial systems. Whether you need a simple hand lever, a robust pneumatic actuator, or an advanced electro-pneumatic positioner, we’ve got you covered. Plus, as the official distributor of Bray Controls, we can source any valve or component not currently listed on our webshop. Contact us for special inquiries or customized solutions.
1. What factors should I consider when choosing a valve control method?
When choosing a valve control method, consider the required precision, as higher accuracy may necessitate advanced actuators like electric or pneumatic options. The frequency of adjustments is also important—automated controls are ideal for frequent changes, while manual options suffice for occasional adjustments. Ensure compatibility with available resources such as compressed air, electricity, or manual operation. Additionally, take environmental conditions into account, as factors like temperature, chemicals, or hazardous areas may influence material and control choices. Finally, balance the upfront costs with long-term expenses, including maintenance, energy consumption, and efficiency, to select the most suitable control method for your application.
2. Can I upgrade my existing system to electro-pneumatic control?
Yes, upgrading is straightforward with the right components, such as the Serie 6A positioner, feedback module, and additional programming. Our engineers are trained and have successfully upgraded valves several times. Contact us for support.
3. Do I need an adapter kit for my pneumatic actuator?
In many cases, yes. Adapter kits ensure proper fitting between the actuator and valve, depending on pipeline pressure, medium type, and other specifications. Please feel free to contact us for guidance.
4. How does a fail-safe feature work in electro-pneumatic systems?
In case of power failure, the system moves the valve to a predefined safety position and depressurises the actuator to protect your equipment.
5. Do you offer components not listed on your webshop?
Absolutely! We have excellent relationships with manufacturers and can source any specific parts or valves you need.
6. Where can I get support for valve control system setup?
Our engineers are available to assist with programming and system integration. Reach out to us for tailored solutions.