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When will your manual valves become a risk you cannot control?
Tank terminals lack
real-time visibility into manual valve positions, leaving operations
exposed to day-to-day preventable risks.
A single undetected valve position can have consequences
across three critical dimensions: operational, financial, and reputational
Critical blind spot
~40% of human-error incidents involve manual valves.
- Incidents and accidents: 2–5x misalignments per week
- Potential injuries and serious safety consequences
- Results in process downtime and interrupted operations
Six-figure losses from a single event.
- Product loss (spills and contamination)
- Cost of cleaning and equipment repair
- Environmental damage and potential regulatory fines
Lost trust means lost customers and lasting reputation damage
It’s not a question of IF.
It’s a question of WHEN.
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The severity varies. So does the probability. But with every manual valve operation, the exposure remains. Even seemingly minor events can quickly escalate into serious consequences.
Calculate the financial impact at your terminal
Every site is different, and so is every business case. To calculate the total cost of an incident, first consider the different cost categories that can contribute to the overall impact:
Then, the overall business impact can be calculated as:
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Why is this so difficult to solve?
More protocols or training won’t eliminate mistakes Administrative controls e.g.: walk the line, 4 eye principles depend on people getting it right every time
Limit switches don’t scale, increased costs and operational inefficiencies.
Hardwired position monitoring is too expensive to scale across thousands of manual valves.
Manual valve blind spots and human error drive recurring incidents and increase operational, financial, and reputational risk. Manual verification doesn’t scale operationally, and hardwired solutions don’t scale economically.
How are leading tank terminals solving this challenge?
By connecting manual valves to their digital environment.
Wireless, non-intrusive, and scalable sensors eliminate blind spots on manual valves.
Real-time valve visibility supports operational efficiency, financial performance, and reputation.
Make your tank terminals safer, more reliable, and more efficient.
Real-time valve insight improves operational efficiency.
Aloxy sensors continuously track valve position and movement, providing open, closed, and intermediate position feedback as a percentage open. Validated data flows directly to your IT and OT systems for faster, informed decisions.
Valve Visibility = Total Operational Control
Financial performance improves with a strongly positive ROI.
Operational excellence builds lasting trust.
Wireless manual valve monitoring is built for brownfield reality.
Aloxy delivers measurable benefits for the world’s leading industry players.
From specialist tank terminal operators to refinery-integrated terminals,
Aloxy helps teams gain real-time visibility into manual valve operations.
"With Aloxy’s valve position sensors, we avoid human errors and make our factories even more efficient, ecological and productive."
Where are the blind spots at your terminal?
Let’s schedule your next Proof of Value meeting with our expert.
