A solenoid valve is an electromagnetic device that is used to open, close, control, and regulate the flow rate of fluids or gases. It is also used in overhead water tanks to control overflow conditions and start or stop a pump after the water reaches above or below the desired level. It offers precise control of the flow of fluid or gases under high pressure. 

Solenoid valves can be controlled remotely and automatically, so they are used in various applications such as water treatment, automotive, food processing, and industrial applications.

Let’s first understand how these valves actually work.

Working Principle Of Solenoid Valve

The solenoid valve needs electric energy to operate. When electricity is applied to the valve, a strong magnetic field is developed inside the valve body. The magnetic field acts to attract or repel the plunger that is connected to the spring.

When the plunger moves upward, it opens the valve, allowing water to flow through it. When the electricity is turned off, the magnetic field disappears, and the spring pushes the plunger back into its original position, sealing the valve and stopping the flow of water.

Common Challenges In Using Solenoid Valves

1. Coil Burning

Coil burning is the most common issue for the solenoid valves. It is caused when the electricity voltage spikes and prolonged operation causes the coil to overheat, leading to insulation damage.

Due to coil burning, the solenoid valve may face problems opening or closing properly, disrupting its operations. To overcome this problem, it is important to regularly inspect the coil for signs of overheating, wear, or insulation damage.

2. Debris Accumulation

Solenoid valves do not work properly when rust, dirt, or sand particles accumulate inside them. These contaminations block the orifice of the valve and affect the internal mechanisms. Regular maintenance is needed to overcome this problem and to extend the valve’s lifespan.

3. Noise

Solenoid valves produce a loud humming and irritating sound. These sounds may be much louder when the nearby equipment is vibrating with the same frequency. A rectifier or power saver module is used to overcome this problem.

4. Abnormality In Pressure And Flow

Solenoid valves are affected by pressure and flow irregularities due to factors such as improper dimensions, faulty installation, or breakdown of valve components. These issues can lead to restricted flow and poor performance of the valve.

It can also lead to a leakage in seals, which is a reason for the poor flow rate. To avoid this problem, you need to select the proper size of the valve, ensure correct installation, perform regular maintenance, and inspect for seal leakage.

5. Damaged Seal

When the seal is worn or broken, it may cause leakage in the valve. A replacement for the broken or worn seal is needed.

Some Alternatives To Solenoid Valve (Based Upon Applications)

1. Motorised Ball Valves

A Motorised ball valve is a cylindrical valve that helps to control the fluid flow through a pipe with a disc-shaped valve. It uses an electric motor, which is an alternative to a solenoid valve for commercial and heavy applications. These valves are more compatible with diverse fluids and effective in regulating the fluids or gases and overcoming the problem of corrosive and abrasive liquids.

Motorised ball valves are commonly used for continuous automatic flow control in domestic, commercial, and industrial purposes, such as in-home water systems, water filters, HVAC, and more.

2. Butterfly Valves (Flotaa)

Butterfly valves are used to regulate fluids and are one of the best alternatives to solenoid valves. It contains a disc that rotates 90 degrees by the shaft or stem.

The stem can rotate manually or by an actuator. When the shaft moves, it helps to rotate the disc; then a gap develops between the seat and the disc, and then the fluid or air passes through it.

Butterfly valves are also less expensive and a cost-effective option for many applications. It is commonly used in flow regulation in large-diameter pipes. It is used in pumping stations, water collection, transmission, and drinking water distribution.

Flotaa offers an advanced level and fully automated smart centralized wireless valve controller, which contains a butterfly valve, actuator, and smart controller. It is an IoT-enabled, Wi-Fi-operated butterfly valve that can operate manually and automatically via a web application. You can control this valve remotely.

It also contains an IP67 enclosed actuator unit and an LED for status monitoring, and it needs 220-volt AC electricity.

3. Autonomous Mechanical Valve (Flotaa)

An autonomous mechanical valve works as a differential-level water valve to control the water level without electricity and a switch float. It is a direct alternative to the solenoid valves in domestic and commercial applications.

An autonomous mechanical valve made by Flotaa is suitable for clean water applications to control the water level automatically in tanks. It has a high flow rate of 150-450 L/min and the capability to save electricity and extend pump life. 

It also has a soft closing feature that prevents water hammering. It can be used as a top rainwater harvesting valve and is also fully serviceable.

4. Pneumatic Valves

Pneumatic valves are used to control the flow of fluid and gases with the help of compressed air and pressure into the seal chamber. It is a better alternative to the solenoid valve in terms of the torque needed for high-force applications such as pipelines. To operate, it needs a proper actuation.

Pneumatic valves are initially expensive, reliable in different conditions, simple in design, and more, making them a better alternative to solenoids in many applications.

5. Diaphragm Solenoid Valves

Diaphragm valves use a flexible membrane to control the flow of fluids or gases. It is not a direct alternative to the solenoid valve but is a combination of solenoid and diaphragm valves. It has a diaphragm made of rubber, which moves up and down against the hard seat of the valve to open or close the path of fluid. 

The diaphragm solenoid valve is an effective valve for many applications, such as water treatment, medical equipment, food and beverage, and more.

Conclusion

If you’re searching for alternatives to solenoid valves, chances are you’ve faced issues like coil burning, debris accumulation, loud humming sounds, or frequent wear and tear. These common problems have led many to look for more reliable and efficient options.

From butterfly valves to pneumatic valves, there are several alternatives that can enhance your system’s performance. When making the switch, consider factors like temperature, pressure, flow rate, and environmental conditions to ensure the best fit for your needs.

Upgrading to a better alternative not only improves efficiency but also ensures smart water management and long-term reliability. We have listed the best available options mentioned above. Choose the one that best suits your application. For further help, you may contact Flotaa.