What Are Sample Valves and How Are They Used in Industrial Applications?

Testing is an essential part of manufacturing and quality control. From food and beverage creation to chemical manufacturing, each system requires a way to test the material during production to ensure safety and quality. This is the purpose of sample valves.

Sample valves allow for testing without interrupting processes and equipment. They make it possible to draw a small amount of liquid or gas from a tank or line without interrupting or contaminating the ongoing process. This ensures that manufacturers can test for quality, consistency, temperature, and safety in the middle of a process, with time to make adjustments before the process is complete.  They can be manual or automated depending on the workflow and purpose of each processing system.

Through this function, sample valves are an essential part of quality control, safety, and regulation compliance for a wide range of industries and processes involving liquids or gases. In essence, sample valves contribute to quality control and process efficiency by providing the ability to quickly identify and test fluids that pass through the valve. 

What Are Sample Valves?

Sample valves are a special type of valve that takes a small or measured sample portion of liquid or gas. The purposes of a sample valve are typically for identification, testing for quality control, and ensuring regulatory compliance. Sample valves allow the current process to continue efficiently by drawing the sample without interrupting the running equipment or risking contamination of the contents within.

In this way, sampling valves can maintain process integrity and efficiency without disrupting operations when a sample is taken for testing.

Popular Sample Valve Types

Depending on both the material and the process being sampled, it is possible to choose the ideal type of sample valve.There are several varieties of sample valves based on the mechanism used to draw out the sample.

• Needle Valves - The needle valve has a very small port paired with a needle-shaped plunger. This allows for precise regulation flow and very small samples to be taken. Needle valves are often used with gasses and in situations that require delicate pressure regulation.
• Ball Valves - Ball valves are actuated with a pivoting ball to control the flow of fluid or gas. Ball valves can be manual or, when automated, provide a measured sample with one full rotation. Ball valves are considered ideal for oil, gas, and plumbing.
• Diaphragm Valves - A diaphragm valve has two or more ports and a flexible diaphragm in the middle. The diaphragm can be used to restrict, isolate, or close the flow of fluids through specific ports. Diaphragm valves are often used when dealing with liquids that include solid particulates, such as food or paper production.

Understanding the types of valves can help you select the best valve for each application. McKenzie Valve can help make the right selection.  

Key Components of Sample Valves

The components of a sample valve determine its function and the specific processes that it is capable of sampling. Each sample valve has a valve body, seal, actuator, and port. However, these designs vary quite widely to accommodate different materials, environments, and sampling procedures.

‍Valve Body

‍The valve body is the exterior casing of the valve which houses the internal components. It defines the shape and overall durability. Valve bodies are typically made with highly durable materials like stainless steel, Monel, or Inconel to ensure the sample valve can withstand conditions like pressure, temperature, and thousands of uses over years of performance.

‍Seal

‍The valve seal ensures that there is no risk of leaks or contamination. The seal is broken to take a sample and reconnected when the sampling process is complete. Seals are always made of an appropriate sealing material such as PTFE or EPDMbased on the material, temperature, and pressure they are designed to handle based on sampling conditions. Seals are essential for sterile and flawless sample taking, and integrity between samples.

‍Actuator

‍The valve actuator determines how the sample valve opens, closes, and regulates the flow of the material during a sampling. Each process calls for a specific sampling procedure which determines the best type of actuator for the task.Types of valve actuators include manual, electric, pneumatic, and hydraulic.

• Manual actuators are used to perform an action that does not require automation, but the system still needs to know their position. 
• Automated actuators can be electric, pneumatic, or hydraulic.
  
  • Electric actuators require electricity to function. 
  • Pneumatic actuators require air pressure to function.
  • Hydraulic actuators require fluid pressure to function.

‍Sample Port

‍The sample port is where the liquid or gas sample is dispensed. The port size must be considered when selecting a sampling port, particularly if you require a hose of a specific length. Sample ports and hoses interface with manual or automated sampling machinery.

‍Cleaning Systems

‍Some sample valves come with an integrated cleaning mechanism such as steam cleaning or clean-in-place (CIP). These systems may be essential in industries like food & beverage or pharmaceuticals, where contamination must be prevented at all times. These systems ensure that processes continue to run efficiently, cleanly, and up to industry standards.

‍Chemical Compatibility and Material Selection

‍Sample valves can be customized with a range of materials to meet the specific needs of your industrial or manufacturing process. Chemical composition, temperature, pressure, and usage frequency are all factors that must be considered. Choosing the right materials is crucial for both the safety and efficiency of your sampling process.

Examining how different materials handle various chemicals, pressures, and temperatures can help you make the right selection.

• Stainless Steel: Stainless steel has a high oxidation and corrosion resistance. It works well in high-pressure and high-temperature uses.
• Monel: Monel has high corrosion resistance and performs well in seawater, salt, and other saline uses.
• Inconel: Inconel has a high oxidation and corrosion resistance. It works well in extreme pressures and extreme heat uses.

‍The Importance of Temperature and Pressure Ratings

‍Always select valves that meet the appropriate temperature and pressure rating requirements for your process. This will ensure durability and performance under the specific process conditions where the valve will be operating. Choose the right valve body, component, and seal materials to withstand the chemical, temperature, pressure, and usage conditions. 

Using Sample Valves in Various IndustriesSample valves serve a vital role in many different industries. Quality and safety are paramount priorities whether you are manufacturing food, medicine, chemicals, or fuel. Let's take a more detailed look at how sample valves are used in each of these essential industries.

‍Pharmaceuticals

‍In the pharmaceutical industry, sample valves are used during the production of medications to ensure product consistency. Chemical testing confirms that the medications being produced meet the exact molecular design to provide safe, desired effects when distributed to patients. Sample valves also ensure the ability to maintain strict regulation compliance and ensure hygienic manufacturing conditions at all times.

‍Food & Beverage

‍In food and beverage manufacturing, hygiene and safety are paramount. Sampling allows manufacturers to ensure that food remains at optimal quality without contamination or spoilage during the production process. It also allows for quality control with time to make adjustments to ensure optimal consistency, quality, and flavor.Oil & GasIn the oil and gas industry, sample valves make it possible to monitor and adjust the chemical composition of fuel in real time. This ensures safe and stable formulas that meet regulatory and quality standards.

‍Chemical Processing

‍Sample valves are essential in safely handling corrosive and hazardous substances during chemical processing. Chemicals are delicate compounds that require very precise processing, and sample valves help to ensure each stage of the process is safe, minimizing the risk of both process flaws and harmful consequences. 

The Benefits of Sample Valves

Incorporating sample valves into your manufacturing process provides critical benefits that can enhance the efficiency and reliability of your operations. Sample valves allow you to ensure that the products meet specific standards at each stage of the process, with time to make corrections before a batch is ruined by slight variations in tank conditions.

The benefits of sample valves include:

• Quality Control - Regular sampling helps you check product quality and maintain high product standards. In many processes, early sampling can allow you to adjust conditions to maintain product quality if variations are detected.
• Process Optimization - Sample valves offer real-time data analysis at each stage of the process, which can allowyou to improve efficiency and reduce waste. This may involve real-time adjustments to the process or over-time improvements to your manufacturing design to achieve higher quality and more consistent products.
• Safety - Sample valves enhance operator safety and provide environmental protection. A reliable sampling system allows for regular safety checks while providing a safe way to take those checks manually or through routine automation.
• Cost Efficiency - Well-designed sample valves minimize downtime and operational costs through early detection of process deviations.

The Right Sample Valve for Your Needs

How do you choose the best sample valve for each stage of your manufacturing process? Every sampling condition is unique, and your valve design should match those conditions for safe and efficient sample operations.

Factors to consider when choosing your sample valve include the process requirements, valve features, and customization options.

Assess the specific needs of your sample valve based on your industry and the system the valve will be installed into.Consider additional features that may provide a benefit such as self-draining, self-cleaning and sterilization capabilities, and ease of regular maintenance.

Lastly, explore options for customization including tailored solutions that perfectly meet your unique industrial conditions and process challenges. 

Make the Right Selection of Sample Valve for Your Needs

Sample valves play a vital role in industrial processes. If you need a sample valve or to design a unique sample valve system for your manufacturing assembly, you can find everything you need at McKenzie Valve. Explore our selection of sample valves and consult with our valve experts to design custom solutions to meet your industrial needs.

‍Contact McKenzie Valve and we'll make sure the valve you choose gives you the efficient, precise process you expect.