Manual valve position monitoring for plant operators

Small devices attach to a handwheel or lever and capture movement without altering the fitted mechanism. The processing hub converts that data into opening percentages for remote lineup checks and operation records.

Manual valve position monitoring for plant operators, image 1 of 3Manual valve position monitoring for plant operators, image 2 of 3Manual valve position monitoring for plant operators, image 3 of 3
Aloxy
Connectivity
LoRaWAN, DASH7
Deployment
Public SaaS, On-Premises, Edge/Local
Services
Installation, System Integration

About Manual valve position monitoring for plant operators

Manual isolation monitoring from Aloxy gives plant operators opening-state feedback from valves that otherwise require a walk-around check. Attached motion sensors capture handwheel or lever movements, and software converts the readings into open, closed or intermediate positions. Teams use the results for valve lineup review, maintenance work and investigation of incorrect operations.

Pulse is the sensor that uses three inertial MEMS elements to capture movement. It mounts firmly on the moving valve part without modifying the valve, then transmits raw data over LoRaWAN or DASH7. The IIoT Hub, the processing and device-management platform, calculates the opening percentage and checks network and sensor status. Initial calibration uses device buttons at the current open or closed position.

The opposite position is calibrated after the first full operation when the valve cannot be moved during installation. An Android configuration app uses NFC for firmware changes and remote calibration. Operators review digital valve states and recorded operations rather than repeating every physical position check. Intermediate percentages also show departures from an expected endpoint, providing material for examining valve behaviour and planning maintenance. Cloud hosting and plant-system integration make the calculated positions available to the operating team.

How it works

Sense
Capture handwheel or lever motion with inertial elements
Connect
Transmit movement data over LoRaWAN or DASH7 to the hub
Analyze
Calculate open, closed and intermediate opening percentages
Act
Review valve lineups and investigate incorrect operations

Does it fit your project?

Best suited to

  • Industrial manual isolation valves
  • Tank storage valve lineups
  • Maintenance and turnaround operations

You need

  • Pulse on handwheel or lever
  • LoRaWAN or DASH7 plant network
  • IIoT Hub and operating-system integration

Limitations

  • Requires firm mounting on moving part
  • Requires initial position calibration by buttons

Cost estimate

1 site, 10 assets, United States, in USD
$1,900 – $5,800
$300 – $1,000
Estimated first year, by component
$700 – $2,100$900 – $2,700$300 – $1,000
Hardware$700 – $2,100

Sensors, gateways and spare units

Installation and setup$900 – $2,700

Site survey, mounting, commissioning and configuration

Software and services$300 – $1,000

Platform subscription, connectivity, data and support

This is an estimate by IoT Apps based on comparable deployments, not a quote from Aloxy.
Get an estimate for your own project and invite Aloxy to confirm a price and lead time, on this page. Taxes, shipping, civil works and custom integration are not included. How IoT Apps estimates costs

Similar solutions

See all solutions
Distribution Transformer Condition and Failure Monitoring
Distribution Transformer Condition and Failure Monitoringby CIMCON Intelligence

Review transformer electrical and thermal condition.

Hazardous-Area Valve Position and Tamper Monitoring
Hazardous-Area Valve Position and Tamper Monitoringby SENSAiO

Check valve positions remotely and flag movement.

Legacy Utility Meter Data Collection
Legacy Utility Meter Data Collectionby Urbit Group

Connect legacy utility measurements.

More from Aloxy

Emergency Shower Monitoring
Emergency Shower MonitoringMonitor emergency-shower activation mechanisms.
Valve Position and Wireless Sensor Health Monitoring
Valve Position and Wireless Sensor Health MonitoringCheck valve positions and wireless sensor health.
Line Blind Monitoring
Line Blind MonitoringCheck line-blind position; availability unconfirmed.

Questions and answers

Does a manual valve need modification for the motion sensor?

Pulse attaches firmly to the moving handwheel or lever without altering the valve itself.

Must an installer cycle the valve fully during initial calibration?

The installer calibrates its current open or closed position using device buttons. The opposite position is calibrated after the first full operation when immediate movement is unavailable.

Can the calculated result distinguish partially open valves?

The IIoT Hub provides open, closed and intermediate feedback as a percentage of opening.

How are firmware and calibration settings changed from a phone?

The Android configuration app uses NFC to update firmware and perform remote calibration.

Which radio choices connect the inertial node to the processing hub?

Pulse sends its raw movement data over LoRaWAN or DASH7, and the IIoT Hub calculates the valve position.

What will this deployment cost?

Every page carries a cost estimate by IoT Apps for your own sites and assets; set your budget and invite Aloxy to confirm a price and lead time.

What does a deployment cost?

For 1 site with 10 monitored assets in United States, IoT Apps estimates $1,900 – $5,800 in the first year and $300 – $1,000 every year after. This is an estimate based on comparable deployments, not a quote from Aloxy.

VendorAloxy
MeasuresMotion
ConnectivityLoRaWAN, DASH7
DeploymentPublic SaaS, On-Premises, Edge/Local
ServicesInstallation, System Integration
CertificationsATEX, CE/RED, IECEx, ISO 9001, UL/CSA Hazardous
Hardware modelRequired, Mixed Ecosystem, Gateway-Agnostic
Available inBelgium

Uses this hardware

Mandatory
Aloxy Pulse
Aloxy PulseAloxy · Pulse · Sensor, LPWAN

Have a question for Aloxy?

IoT Apps Enterprise

Not sure this fits your deployment?

Ask the AI Solution Architect: compare this solution against alternatives, check connectivity for your region and get integration guidance. Included with IoT Apps Enterprise.

Ask the Architect
IoT Apps is an independent platform. Listings do not imply endorsement by or partnership with the vendor. Estimates are indicative and based on comparable deployments, not on vendor quotes.