Rotary valves used in pneumatic conveying applications wear and sometimes fail, which can result in the valve’s rotor vanes coming into contact with the valve body. If metal-to-metal contact occurs, metal fragments can break off and contaminate the product, causing costly shutdowns and product rejections. This new Rotor Detection System (RDS) immediately alerts plant operators that metal-to-metal contact has occurred. It monitors the electrical isolation between the rotor and the valve housing. If a rotor vane touches the valve body - even if only for a split second - a warning is sent to personnel via the plant SCADA system and/or the valve is immediately shut down.