PowerPoint Presentation

[Audio] Good [morning/afternoon/evening], everyone. It is my pleasure to welcome you all to today's session, proudly hosted by Cair Euromatic Automation Pvt. Ltd., a name synonymous with innovation and excellence in the field of valve automation. I'm Mohammad Safiq, and I'm truly honored to be your speaker for this session. Today, we'll be exploring a crucial and timely topic in our industry — "Retrofit Solutions for Valve Automation."As industries continue to modernize and aim for greater efficiency, retrofitting existing valve systems has emerged as a cost-effective and efficient alternative to complete replacements. Whether you're dealing with aging infrastructure, changing process requirements, or looking to improve performance with the latest automation technologies — retrofitting offers a smart, sustainable path forward..

[Audio] Redefining Valve Automation with Retrofitting Solutions Replace Upgrade Automate MARCH 2025.

[Audio] This session is all about how we at Cair Euromatic are redefining valve automation — with a strong focus on Replace, Upgrade, and Automate. We're not just talking about new installations, but about bringing new life to existing systems — making them smarter, faster, and more reliable with customized retrofitting solutions. In this session, we'll dive into the practical aspects of retrofit solutions — ✅ What they are ✅ Why they matter ✅ How to evaluate your system for retrofit readiness ✅ And the key benefits they bring — especially in terms of cost savings, minimized downtime, and operational reliability. At the end of today's webinar, we'll have a dedicated Q&A session, so please feel free to note down your questions as we go. We're here to make this session as interactive and valuable for you as possible. At Cair, we believe in not just supplying products — but in empowering our partners and clients with the knowledge to make informed decisions. And that's what today is all about. So once again, thank you for joining us. Let's begin this journey of innovation and transformation — together..

[Audio] "This slide showcases the direction industries are moving in — toward fully connected, intelligent, and automated operations. Valve automation plays a key role in this transformation by enabling smarter control, realtime monitoring, and seamless integration with technologies like IoT, predictive analytics, and industrial AR..

[Audio] "Before we dive deeper, let's take a moment to reflect on a few key questions: If your answer is yes to any of these, then you're in the right place. In this session, we'll show you how Cair can help solve these challenges effectively — with proven solutions and real case studies.".

[Audio] Here is the most common Industries chalolanges First, many plants are dealing with aging equipment, which affects overall system performance. This results in reduced efficiency and productivity. There's a common problem of unavailability of spares for old valves and actuators. Leakage and wastage from outdated systems raise environmental concerns. Operating costs are high in systems that use pneumatic, hydraulic, or manual mechanisms. Maintenance costs also go up as equipment gets older. There are safety risks for operators working in hazardous or hard-to-reach areas. And finally, the lack of timely data makes it difficult for management to take quick, informed decisions..

[Audio] The Solutions is Cair services in which We provide retrofit and one-toone actuator replacements without changing the valve. We help in modernizing existing actuators to improve performance. We convert manual valves into actuated valves for automation. We offer complete commissioning at the client site. We ensure strong after-sales support for smooth operation..

[Audio] "Now let's talk about the advantages of retrofitting, automation, and modernizing existing plants. First and foremost, it enables the transformation of traditional plants into smart factories—leveraging technologies like AI, IoT, and Industry 4.0.This leads to a notable boost in efficiency and productivity, while also significantly reducing energy consumption and operating costs. One of the biggest benefits is that we can optimize capital expenditure by upgrading and automating the existing infrastructure, rather than investing in brand new equipment. There's also a reduction in labor costs, thanks to increased automation, and more importantly, it enhances plant safety and operational reliability. The lifespan of existing equipment is also extended, and with real-time data integration, it improves decision-making and predictive maintenance. Overall, this is a smart, future-ready move that adds both technical and financial value to the plant.".

[Audio] we follow a structured approach for retrofitting, automation, and modernization We begin with a pre-supply visit to understand the exact requirement at the site. Wherever possible, we automate the existing valve by adding an actuator without replacing the valve itself— saving time and cost. Our retrofit solutions are tailor-made to match the dimensions of the existing valve or actuator at site. If needed, we also upgrade existing actuators by integrating additional required features. Finally, we offer post-supply support, including commissioning assistance to ensure smooth integration and operation.".

[Audio] We'll look at a few retrofit case studies executed by Cair Automation. These examples demonstrate how we approach different site challenges—whether it's upgrading manual valves or replacing existing actuators— with efficient and customized solutions. Each case study highlights the key technical considerations and outcomes, helping you understand our retrofit capabilities in real applications.".

[Audio] "Let's begin with Case Study 1, where we are converting a manual sluice or gate valve to a motorized valve. To do this retrofit, we need some basic dimensions: The ISO mounting PCD, if available. If not, we take bonnet dimensions to design a mounting bracket or flange. Shaft diameter or square, and thread pitch. Number of turns to open or close the valve. And finally, the extension shaft height – if the valve is in a pit or below ground level. These details help us select the right actuator and design the mount perfectly.".

[Audio] "This slide shows a common real-world scenario – manual valves installed in pits or below ground. In such cases, operators face difficulty in accessing the valve. So, we extend the stem and bring the actuator control above ground level. We also ensure the retrofit can be operated from the platform level, which makes operation safer and easier.".

[Audio] "Here's how we approach the fitment: On the left, we see the original valve inside the pit. In the middle, we add an extended stem to bring the connection to the top. And on the right, we have the fully retrofitted setup – with actuator, headstock, and platform – all aligned and accessible. This is our standard method for handling pit-mounted valves.".

[Audio] "Finally, we have some successful retrofit examples: HMWSSB in Hyderabad Mission Bhagiratha project Amrut 2.0 KWA GWSSB in Gujarat In each of these projects, manual valves were motorized using Cair actuators – improving reliability, safety, and ease of operation.".

[Audio] "Let's now move on to Case Study 2, where we focus on one-to-one replacement of existing imported or reputed make electric actuators. Before executing such replacement, it's critical to gather certain technical inputs from the site: We need to know the actuator torque and RPM. The actuator starter details, I/O specs, and operational philosophy are reviewed, especially if integration with an existing PLC is involved. If a secondary gearbox is present, its torque and gear ratio need to be documented. We also take the valve or damper size and application specifics like media type, pressure, and temperature. Any existing issues with the current setup are assessed to avoid repeat failures. Lastly, mounting details like shaft diameter, height, and actuator PCD – if available – are recorded for perfect fitment.".

[Audio] "With these technical inputs in hand, the next crucial step is collecting dimensional data for mechanical fitment. This slide highlights two main things: On the left, we see that PCD and hole details of the existing actuator and bracket are captured to ensure proper mounting of the replacement actuator. On the right, we see the dimensional needs for designing the actuator foot mounting bracket and connecting arm. This ensures that the new Cair actuator fits seamlessly into the existing setup without extensive modification.".

[Audio] "Here you can see photos of existing actuators from reputed foreign makes. These were installed in critical industrial processes and had either become outdated or had high maintenance and spares costs. Many times, we encounter challenges in sourcing compatible spares, or the actuator no longer supports integration with newer automation systems. This becomes a strong reason to consider reliable Indian alternatives like Cair's actuators.".

[Audio] We've done these retrofits across major industries. Some reference sites include: NMDC Ltd, Bellary JSW Steel Ltd, Bellary BMM Ispat Ltd, Bellary These replacements have provided seamless functionality with reliable torque performance, PLC integration, and local service support – a key advantage over foreign makes.".

[Audio] "Let's look at Case Study 3, which involves converting a pneumatic actuator to an electrical actuator, or the other way around. To do this successfully, we need just two important details: Mounting dimensions, shaft size, and ISO PCD of the existing actuator. The supply voltage and control signals used in the current system. With these, we can select or design a compatible actuator that fits directly – with minimal changes.".

[Audio] "Here you can see the existing valve setup with the pneumatic actuator installed. This is the condition before retrofit. We study how it's mounted and connected so we can plan for the new electric actuator to fit properly in the same position.".

[Audio] "In this slide, we're taking all necessary dimensions for conversion – such as mounting hole spacing, shaft size, and bracket measurements. These measurements are critical to ensure the new actuator can be mounted without any mismatch or modification to the valve.".

[Audio] "And here is the final result – the Cair Electric Actuator successfully installed in place of the pneumatic one. These valves were supplied to Indian Oil Petronas Ltd., Chennai, and are now running smoothly. This shows how Cair can easily retrofit actuators while maintaining full valve functionality and improving control.".

[Audio] "Let's move on to Case Study 4, where we successfully carried out the replacement of a valve without changing the actuator. This type of project requires careful planning and precise measurements to ensure compatibility, especially when reusing existing actuators. For such retrofitting work, we need specific technical details to make the replacement seamless. These include: The existing valve's face-to-face dimensions, flange PCD, and number of holes, ISO mounting PCD and stem diameter or thread details, And lastly, the material of construction and seat material of the existing valve.".

[Audio] "Here, you can see actual images from one of the project sites. These photos show the condition of the existing setup, where the valve was to be replaced while retaining the actuator. It's a common scenario in many plants where the actuator is still functional, but the valve has deteriorated or needs upgrading. Our goal in such cases is to provide a perfect match in dimensions and functionality— without disturbing the actuator mounting.".

[Audio] "This slide highlights the critical dimensions we needed to capture before proceeding with the replacement. You can see our team taking key measurements like the stem details, mounting hole spacing, and flange compatibility. This data is essential to design or select a replacement valve that fits precisely and works reliably with the existing actuator. It's a clear example of how attention to detail at this stage helps avoid alignment issues during installation.".

[Audio] "Based on the collected details, we supplied suitable replacement valves that were directly compatible with the existing actuators. Here are two successful implementations: Yermaras Thermal Power Station, Raichur – Karnataka & SDSTPS, Nellore – Andhra Pradesh The images show our valves installed with the existing actuators, achieving a clean and efficient retrofit. This solution helped the clients save both time and cost while extending the operational life of their systems.".

[Audio] "Let's now take a look at Case Study 5, which focuses on the modification and upgradation of an existing actuator. This case involves Jindal Saw Ltd., Andhra Pradesh, where the client needed to replace a Chinese-make actuator used for a boiler application. The requirement was for a oneto-one replacement using an Indian-make motorized operated valve (MOV). In addition to supplying the MOV, we also upgraded its operation from basic On-Off duty to position feedback type duty—customized and commissioned directly at the site, as per the client's request. We're pleased to share that the client provided positive feedback through a video testimonial, highlighting their satisfaction with the performance and our support throughout the process. Let's take a closer look at the details.".

[Audio] "Let me introduce who we are and what makes us stand out. We are a proudly Indian company, manufacturing a wide range of valves and actuators – all Made in India. We are specialized in valve automation solutions, which means we bring expertise and experience in automating flow control systems across various industries. Our customers enjoy the convenience of a single point of contact for after-sales service, ensuring quick and effective support. We have a qualified team of engineers who handle everything from design and testing to retrofitting of actuators and valves. And finally, with 65+ branch cum service support offices across India, we ensure that we are always within your reach for service and support.".

[Audio] "Let me briefly introduce the range of products we offer at Cair. We manufacture Electric Actuators suitable for various applications including: Multi-turn valves such as Gate Valves and Globe Valves Quarter-turn valves such as Ball Valves and Butterfly Valves Linear Actuators designed for Control Valves Linear Actuators for Diverter Gates and Damper applications with Industry Defined Voltages & along with On-Off & Throttling Applications Electrical Actuator operated Valves Pneumatic Actuator & Accessories like Gearbox, Positioner, Limit Switch Box etc. Our solutions are built to ensure reliable and efficient valve automation across a wide range of industries.".

[Audio] "Thank you all for attending today's webinar. It was a pleasure to speak with you about Retrofit Solutions for Valve Automation. I hope the session gave you a better understanding of how retrofit solutions can help improve system performance, reduce costs, and extend the life of your existing equipment. At Cair Euromatic Automation Pvt Ltd, we are committed to offering dependable and efficient automation solutions to meet your needs. Before we move on to the Q&A session, please take a moment to note the contact details on the slide being displayed. You can reach out to us by email if you have any further questions or would like to discuss a specific project. Now, I would be happy to take your questions. Thank you once again for your time and participation.".