Thread Content
The modular product platform is not a new concept, but it has yet to be effectively utilized in many areas of traditional industries. In software development, modularization is already a widely used approach, as combining different subroutines that perform specific functions into a main program has been a common practice for decades. Although modularity is a part of everyday life in terms of software, in the traditional machinery industry it is still easy to approach it with the aim of improving the cost efficiency of a given product merely through simple standardization processes. However, as this article will demonstrate, if the goal is merely to reduce costs, then modularity is too complex and time-consuming. Furthermore, the real advantages of a modular platform lie not in cost, but in versatility and sustainability. An introduction to valve modularization: Simply put, modularization involves identifying standard building blocks and the interfaces between them. These building blocks are called modules. A module can equal one part, but it usually contains several parts that together form a feature or function. The basic rule of modularity is that to create different product variants, one of the modules can be changed while keeping the adjacent modules unchanged. Changing the functionality of an entire modular product usually involves modifying one or several modules, depending on the nature of the desired change. For example, increasing the operating temperature of a valve from 200˚C to 300˚C can be achieved by replacing the valve seat, but if the temperature rises to 600˚C, other components such as the shaft and bearings must also be considered. file:///C:/Users/user/AppData/Local/Temp/msohtmlclip1/01/clip_image002.jpg Figure 1: Neles modular butterfly valves (a universal modular platform that meets all the requirements, from low-temperature applications to other service processes such as those involving abrasive or dirty media). The drivers behind modularity Creating a modular product platform is not a simple or inexpensive task, as it requires careful consideration of customer needs, global engineering standards, and safety regulations. It is necessary to collect data from the market (different industry segments and applications), keep a close eye on international and ** authoritative guidelines and regulations, and be aware of the changes brought about by global trends. Furthermore, these products always inherit the problems from previous generations of models; therefore, extensive research is required on the existing infrastructure and the functions needed. Although integrating all the above requirements into a single new platform is not an easy task, adopting a modular approach is crucial from the perspectives of sustainability and effectiveness. The driving force behind all technological advancements is almost always the pursuit of efficiency, and modularization is an excellent tool to achieve this goal – not only for valve manufacturers, but also for factory owners and operators. The driving force behind all technological advancements is almost always the pursuit of efficiency, and modularization is an excellent tool to achieve this goal – not only for valve manufacturers, but also for factory owners and operators. Without the interchangeability of components and the upgradability of buildings, it is impossible to sustainably meet the demands of increasingly strict regulations, as well as achieve goals of improving efficiency and profitability. Multifunctionality, to meet the needs of different customers as mentioned above, a typical idea associated with modularity is cost reduction. The idea of using mass-produced standard components may seem attractive, but it is not a good starting point for a successful modular platform. The most successful foundation for a broad product platform is customer needs. Customer requirements, such as the functions of the target product, the desired performance levels, and the imposed process conditions, establish boundaries for the identification and classification of modules. One factor that makes modularizing valves a challenging and complex task is the diversity of processes used. This type of valve can be installed in relatively simple water supply systems, where the only key performance criterion relates to the opening and closing of the valve controlled by an automated system. Furthermore, valves must be able to withstand high temperatures, abrasive particles, or toxic media, while ensuring the health and safety of plant operators and the environment. For a platform that serves various needs, finding an intelligent balance among competitiveness, performance requirements, and high quality requires a systematic mapping of functions. On the other hand, it provides factory owners with the option to choose valves from the same product series in order to meet the various requirements of different processes within the factory, while also taking advantage of modularity during maintenance and potential upgrades. file:///C:/Users/user/AppData/Local/Temp/msohtmlclip1/01/clip_image004.jpg Figure 2: The valve is undergoing low-temperature testing. (Designing a reliable valve platform requires the use of modern software for detailed simulations and hundreds of hours of rigorous testing.) Designed for manufacturing and service: Once a successful modular platform is developed based on customer requirements, it is immediately designed with manufacturing in mind (DFM). DFM has been in use as a concept for decades, with the basic idea of making manufacturing and assembly as simple and standardized as possible. DFM can bring benefits to manufacturers and end-users, as long as sustainability is taken into account and valves are not considered disposable products. Valves that are easy to assemble during manufacturing are also easy and quick to repair. Valves that are easy to assemble during manufacturing are also easy and quick to repair. Such valves offer higher disassembly efficiency and faster reassembly, allowing them to return to the production process more quickly and reducing downtime in the factory. During the DFM process, special attention is also paid to safe product handling, assembly-friendly tolerances for parts, and minimizing human errors during the assembly process. This also facilitates maintenance operations. Through careful service and spare parts strategies, the number of different spare parts sets in inventory can be reduced, which facilitates simpler valve maintenance. It facilitates product and cost-efficiency improvements. The use of modular products can greatly contribute to achieving the sustainable development agenda, as it represents an investment in the future with less waste. As Health, Safety, and Environment (HSE) regulations become stricter, modular valves can be easily upgraded thanks to the interchangeability of their components. Using modular products can greatly help achieve the sustainable development agenda, as it represents an investment in the future with less waste. As Health, Safety, and Environment (HSE) regulations become stricter, modular valves can be easily upgraded thanks to the interchangeability of their components. For example, consider short-term emission control. Decades ago, environmental regulations were not very strict, but global warming has changed people’s attitudes. It is now clear that to achieve a carbon-neutral world, emissions must be reduced to a minimum. Currently, the highest level of stringency requirements for emissions is ISO 15848-1 Class B, but future requirements are likely to be ISO 15848-1 Class A, which is 10 times stricter than the current standard. For example, for modular products, a design can be created to support this type of upgrade. It will likely simply involve changing one or two modules, rather than the entire valve. Furthermore, improvements in process efficiency, such as increasing the flow rate or modifying the process to handle less pure input fluid, can usually be achieved by simply upgrading certain key components. Furthermore, for some key process challenges, such as reducing noise or controlling cavitation, the solution may simply involve changing the valve internals. Through these simple examples, it is clear that modularity extends the lifecycle of a single product, thereby directly supporting sustainability and reducing waste. file:///C:/Users/user/AppData/Local/Temp/msohtmlclip1/01/clip_image006.jpg Figure 3: Neles’ next-generation butterfly valves – a new series of universal butterfly valves that simplify valve configuration and are suitable for wide use in all process industries. Opening the door to future needs, reducing greenhouse gas emissions, and transforming processes into renewable raw materials will bring about changes per unit of process. This will lead to the emergence of undeveloped areas and impose new requirements on component manufacturers. Modular products are easier to customize to meet the needs of new customers, as the main structure can remain unchanged, with only certain parts requiring redesign and testing for new functions. This **improves the successful debugging of products, even in completely new applications. The product boasts a solid foundation and certain functions that have been verified in the field; these are then combined with new functions, which can be simulated using finite element analysis (FEA) and computational fluid dynamics (CFD), and tested in the laboratory as separate functions. The development cycle for modular products is usually shorter than that for non-modular products, as the engineering work does not have to start from scratch but can be based on predefined overall design principles. This is digitalization versus traditional product design: for example, if the minimum flange thickness specified by a global valve standard increases. We can implement such improvements very quickly based on the product’s management rules, thereby generating the required manufacturing drawings to guide production. For variants of new products, higher quality can be expected from day one, as early issues have already been resolved in previous versions. Production processes, supply chains, and part tolerances have been proven in many other structures and processes; therefore, one-time products for specific applications can be as reliable as well-designed products. Conclusion In today’s world, the focus is shifting toward sustainable development and overall global profitability, rather than just optimizing performance for the next quarter. Therefore, a modular valve platform that can withstand the test of time and adapt to future unknown process requirements is a valuable asset.