How to Convert Manual Valve to Electric: A Complete Guide for 2025
Views: 0 Author: Site Editor Publish Time: 2025-04-24 Origin: Site
In today's automated industrial environments, manual valves are increasingly being replaced or retrofitted with electric actuators to enhance efficiency, safety, and remote control capabilities. But how do you actually convert a manual valve into an electric one — and when is it worth doing?
As a professional valve manufacturer with over 20 years of experience, we've helped countless engineers and facility managers navigate this transformation. In this guide, we’ll walk you through the process step by step, explain when to use fixed actuators vs. portable solutions, and help you decide whether retrofitting or replacing the valve is right for your operation.
Why Convert a Manual Valve to Electric?
Converting manual valves to electric is part of a broader industrial shift toward automation. The key benefits include:
Remote operation: No more walking to distant or hard-to-reach valves.
Precise control: Electric actuators enable finer control over flow rates.
Improved safety: Reduce risk by automating valves in hazardous or high-pressure areas.
Data feedback: Many actuators can provide real-time position and diagnostics.
Step-by-Step: How to Convert a Manual Valve to Electric
Here’s how the conversion process typically works:
1. Assess the Existing Valve
Valve type: Is it a ball, butterfly, or gate valve?
Shaft or stem type: You’ll need this to choose the correct coupling or adapter.
Torque requirements: Determine how much force is required to open/close the valve.
Environment: Will the actuator be exposed to moisture, dust, or hazardous gases?
2. Choose the Right Electric Actuator
On/off vs. modulating: Will the valve be simply opened/closed, or will it require position control?
Voltage compatibility: Match with your facility’s power supply (typically 24V, 110V, or 230V).
Smart features: Do you need position feedback, 4-20mA signal control, or fail-safe modes?
3. Prepare the Mounting
Use an ISO 5211 standard flange, if available.
If not, fabricate a custom bracket and coupling that matches the valve stem and body.
Consider anti-rotation brackets and weatherproofing if the actuator is to be used outdoors.
4. Install the Actuator
Remove the manual handwheel or gearbox.
Align and mount the actuator using bolts and the correct flange or bracket.
Wire the actuator according to the manufacturer’s electrical diagram.
Test the system through a full open-close cycle.
Retrofit vs. Replace: Which Is Better?
Scenario
Retrofitting (Keep Existing Valve)
Replacing with Electric Valve
Cost-sensitive
✅ Lower upfront cost
❌ Higher initial investment
Valve in good condition
✅ Ideal
❌ Often unnecessary
Frequent operation
✅ Worth automating
✅ More reliable in long-term
Limited space or odd valve type
❌ May need custom work
✅ Choose optimal configuration
If your valve is aging or non-standard, replacing it with a new electric actuated valve from a trusted manufacturer (like us) may be the smarter, more reliable option.
Real-World Example
In one of our recent projects, a petrochemical client had over 100 manual gate valves. We retrofitted 70% with our HK series electric actuators and replaced the rest with pre-integrated electric valves due to severe corrosion. The client reported a 30% increase in operational efficiency and improved safety compliance.
Our Recommendation
If you’re considering converting manual valves to electric, don’t go it alone. Our engineering team can:
Evaluate your current valve setup.
Recommend the right actuator size and control type.
Supply both actuators and pre-fitted electric valves.
Offer installation kits, technical support, and after-sales service.
Converting a manual valve to electric isn’t just a smart move — it’s an investment in operational efficiency, worker safety, and long-term scalability. Whether you retrofit existing valves or choose to upgrade completely, electric actuation is the future of flow control.
Let us help you make the switch — smoothly, efficiently, and affordably.
