How AVK Positioner Technology Transforms Reservoir Valve Control
United Utilities faced a common challenge: maintaining precise water levels without risking safety or overburdening staff. Manual adjustments were inconsistent, labour-intensive, and limited the potential for future automation.
Background
United Utilities manages a reservoir where water levels are regulated using an AVK DN150 gate valve. Traditionally, this valve has been manually operated, with technicians adjusting it two to three times per week. The system does not include a float valve - commonly used for automatic water level control – because of health and safety concerns. Instead, the team relies on manual adjustments to maintain optimal water levels.
Challenge
Variability: The primary challenge was ensuring consistent and accurate valve operation across different technicians. Manual adjustments introduced variability, as interpretations of valve turns (e.g., "half-turn" or "full-turn") could differ.
Labour-Intensive: Frequent manual intervention raised concern about long-term sustainability and cost-effectiveness.
Future Readiness: Lack of automation limited scalability and long-term optimisation.
Solution
By integrating an AVK Positioner into the existing manual valve, every adjustment becomes measurable and repeatable, with the device recording the number of valve turns and the exact timing of each change. This data not only enhances current operational visibility but also strengthens the long-term case for installing an automatic actuator to further reduce labour costs and improve consistency. Ultimately, the Positioner’s insights support more efficient day to day performance while building a clear roadmap for future automation, increased reliability, and more informed strategic decision making.
Left hand image above shows before, and right hand image shows after, with the positioner installed.
Technical Details
- Valve Type: AVK DN150 gate valve
- Control Method: Manual operation with Positioner feedback
- Data Captured: Number of valve turns and timestamps of adjustments
- Frequency of Use: 2–3 times per week
- Automation Status: No float valve; actuator installation under consideration
- The Positioner ensures that each valve adjustment is precise and repeatable, regardless of the technician performing the task
Outcome and Impact
- Consistency Achieved: Every adjustment is precise and repeatable
- Data-Driven Decisions: Reliable insights support future automation planning
- Strategic Advantage: A cost-effective step today that unlocks efficiency tomorrow
Image above: AVK Smart Positioner for Gate Valves
Conclusion
By incorporating a Positioner into a manually operated valve system, United Utilities has enhanced operational accuracy and laid the groundwork for future automation. This approach balances immediate cost-effectiveness with long-term strategic planning, demonstrating how incremental improvements can lead to significant operational benefits.
Innovation
This case study demonstrates how small steps towards incremental innovation can pave the way for transformative change. By starting with smart monitoring, this project is laying the foundation for a fully automated, future-ready water management system.
Your Gateway to Smart Water Networks
AVK Positioners offer utility providers a smart, wireless solution for monitoring valve activity across the water distribution network. By transmitting data via NB-IoT or LoRa® to cloud platforms or third-party systems, these battery-operated devices enable real-time visibility and control. When paired with other Smart Water sensors, they provide comprehensive insights into pressure, flow, temperature, and water levels helping utilities optimise performance, extend asset life, and make data-driven decisions for future improvements.
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