B Sai Ramesh, SVP Projects (Retired), Technip India Limited/DVP – ISA APAC.

What are the most significant innovations in industrial valve design over the past five years?

Due to the advent of digitalisation, the Industrial Valve design has been undergoing changes to meet the following needs:

1. Optimisation in sizing

2. Body design including internals

3. Materials suitable for the service

4. Meeting the sustainability requirements (emissions/environmental needs)

5. Customised solutions including operational needs, and

6. Communication & data sciences.

Due to the various government schemes and policies, we see huge markets evolving, especially water & water treatment requirements to provide clean water to the people with reduced waste released to the environment. This has basically forced the valve industry to innovate their design to meet their sustainability goals. We have also seen the usage of sea water treatment facilities to meet the demand for water.

We have also seen Mega Capacity Plants (Oil & Gas, Petrochemicals, Chemicals, Fertilisers and Pharma) which also contributed for the design of Mega Industrial Valves with automation as the operations of the same are possible only through remote. We are also witnessing customised miniaturised automated valves to operate fuel cells, liquid hydrogen, etc., and technologies such as 3D printing that assist the research & development needs.

How are material advancements (e.g., composite materials, coatings) and technologies like additive manufacturing influencing valve durability and performance?

We know that the material suitability for the process is the basic need for the valve operation and sustainability. The advent of new materials and alloys and successful adaptation by the foundries are helping improve valve performance better than ever before. Earlier we used to have very few materials, such as CS, SS and Hastelloy, etc., and had no choice but to select the better one to meet operational requirements. But now foundries can run a batch to meet the industry needs with customised solutions. This has also optimised the cost as well as durability and performance of the valves, thereby increasing the life of the plant itself.

We have also witnessed technologies which help to provide special coatings such as Ceramics, etc., in valves as part of material advancements. These include bioplastics, as well as environmentally friendly and much easier-to-recycle alternative materials such as cassava, sugar cane or corn starch, etc. We have also seen technologies such as 3D printing being implemented in specialised requirements.

Which industries (e.g., oil & gas, water treatment, chemical processing) are driving the demand for advanced valve automation?

As I said earlier, water & waste water, and chemical & pharma industries are driving the demand for advanced valve automation. We have also seen the oil & gas industry (especially FPSOs, well heads and gas separation plants) driving the demand for advanced valve automation in order to operate remotely as well as to ensure environmental safety.

How are energy efficiency and sustainability influencing valve manufacturing and selection?

Valve manufacturing involves casting, which is a highly energy intensive process. As we know every bit of energy saving helps in cost saving and improves operational efficiency. We have also seen digital factories which are data driven with highly efficient CNC machines controlling the entire machining process.

Foundries are also increasing efficiencies by optimising valve design as well as weight optimisation before casting, thereby reducing excess material in castings. Optimising design helps decrease material cost as well as machining time thereby reducing energy consumption, resulting in sustainable operations. Additionally, the adoption of sustainable manufacturing processes, such as recycling and waste reduction, will further contribute to a greener future for the industry.

The innovations facilitate real-time monitoring and predictive maintenance, customised, efficient production with less waste, process optimisation through data analytics, and improved manufacturing accuracy and safety. As a result, companies in the industry are better positioned to respond to changing market demands and maintain a competitive edge in an increasingly dynamic and demanding global environment.

What are the key benefits and challenges of integrating AI and machine learning into valve operations?

We have to split the key benefits and challenges of integrating AI and machine learning into valve operations into the following parts:

1. Valve Manufacturing

In the process of valve manufacturing, today automation and robotics have a significant impact. Most of the processes like precision machining, assembly, and quality control are automated and controlled by advanced robotics, which results in consistency and reduced human error, besides improving productivity and worker safety in hazardous environments.

Example: Neles, a Finnish company that provided valves and valve automation services for process industries, developed a machine for lifting and turning large valves—some of the valves are resembling the size of big cars—stick the valves in the jaws of the PAC-MAN like structure/robot which squeeze it down, and the CNC machine turns it over avoiding the usage of chains and cranes and lifting with people underneath the valves, increasing both efficiency and safety.

2. Valve Automation in Process Industries

Progress in artificial intelligence (AI) will be pivotal in automating industrial valves in demanding environments like oil and gas production and power generation systems. AI and advanced valve connectivity through sensors and actuators present more opportunities for industries to streamline and automate fluid systems. These technological advances will increase the demand for industrial valves in different sectors in 2024.

Advanced technology facilitates innovation in valve manufacturing materials and processes. Industries will have access to specialised valves manufactured from advanced materials like composite polymers capable of handling the most demanding fluid flow conditions. Technologies like digital twins enhance planning and virtual visualisation for the renovation and refurbishment of aging infrastructure and old process valves.

The critical valves in FPSOs such as well head valves, anti surge valves in gas compression, cooling water valves, flow line valves need to be automated extensively as the operations are at sea with very limited resources. It is also essential that these valves are highly reliable in terms of material of construction, design as well as suited for extensive automation.

We should also refer to pharma as well as additive manufacturing plants, where the automation of valves is highly essential. These units are partially batch and partially continuous processes. Batch process needs high quality control and every batch needs to be monitored fully to meet the client requirements. You may be aware that the pharmaceutical industry operates with a combination of drugs, which are run at different times in different batches. The batch operations need different sequences of each batch. All the batches are operated with the same batch reactors but with different recipes based on the drug which is manufactured.

What is the impact of Industry 4.0 on valve manufacturing and operations?

With rapid digitalisation, the process of designing and manufacturing valves has changed dramatically for the better, with the integration of sensors, connectivity, and data analytics, enabled by IIoT. Connectivity in turn provides real-time data on performance, temperature, pressure, and other critical parameters, enabling predictive maintenance, remote monitoring, and optimisation of valve operations. Advanced alloys and composite materials, as noted earlier along with better coatings, significantly extends the lifespan of valves, and improves performance in extreme conditions, especially in industries operating in harsh environments.

(The views expressed in interviews are personal, not necessarily of the organisations represented)

B Sai Ramesh is an experienced technocrat with a demonstrated history of working in the oil & energy industry. Skilled in Petroleum, Gas, Process Control, Power Plants, and Engineering. Strong professional graduated from Loyola Institute Of Business Administration.

B Sai Ramesh is currently heading the Chennai Engineering Division as well as working as IOC Engineering Coordinator. A former SVP Projects at Technip India Limited, he is DVP – ISA APAC, and has 39 years of experience in oil and gas and petrochemicals, heavy chemicals, fertilisers, pharmaceuticals, in basic, FEED and design, detailed engineering, project management, engineering management including that as Dy Project Director in PMC services.

Endowed with excellent leadership qualities, B Sai Ramesh established estimation formats for the onshore engineering and benchmarking of discipline man hours for detailed engineering of onshore/offshore projects. He has varied experience in dealing with international and Indian clients; has excellent organising, communication, presentation and analytical skills; exposure in HSE, Quality and BSC including RMS has an added advantage; handled all discipline leads in terms of quality, productivity as well as coordination interdisciplinary coordination, Project control, project management; and takes care of the profitability and cost control.