Method and system for performing online test of valve seating integrity of control valve

Abstract

Systems and methods may be provided for performing an online test of a valve in a digital valve positioner. A digital valve locator may receive a request to perform a test of a valve, the request specifying a test start point, and queue the request for execution. The digital valve locator may then receive a new setpoint for the valve. The digital valve positioner may also reposition the valve according to a new setpoint. The digital valve positioner may also compare the test start point to a current position of the valve while the valve is repositioned, and in response to determining that the current position of the valve has reached the test start point, collect sensor data indicative of operation of the valve to generate a result of the test.

Description

[0001] This application is a divisional application of the invention application filed on January 18, 2021, with application number 202110064959.1 and entitled "Method and System for Online Testing of Valve Seating Integrity of Control Valve". Technical Field

[0002] This disclosure generally relates to control valves, and more specifically, to methods and systems for performing online testing of valve seating integrity of control valves. Background Technology

[0003] The background description provided herein is for the purpose of generally presenting the context of this disclosure. A portion of the inventors' work is described in the background section, and this portion, and at the time of filing, does not constitute prior art and is neither expressly nor impliedly acknowledged as prior art that would destroy this invention.

[0004] Process control systems typically employ sliding rod valves (such as gate valves, ball valves, diaphragm valves, pinch valves, etc.) to control the flow of process fluids. A sliding rod valve generally includes: a valve body defining a fluid flow passage; a valve seat disposed within the fluid flow passage; a closing element (e.g., a valve plug) engaging the valve seat to close the valve; and a valve stem operatively coupling the closing element to an actuator. In operation, the actuator moves the closing element relative to the valve seat to control the flow of fluid through the fluid flow passage, i.e., closing the valve or opening it to a desired extent. Sliding rod valves typically include a sealing element disposed between the valve seat and the valve body to prevent leakage.

[0005] When these components are properly engaged, proper valve closure occurs, and the valve exhibits satisfactory valveseating integrity. However, through repeated use in the operation of a process control system, valve components may deteriorate due to normal wear, corrosion, and other factors. If the valve seat becomes substantially deteriorated or completely ineffective, the valve will be functionally impaired.

[0006] Furthermore, these valves can be very large and operate across long stretches of piping and other pathways. Taking these systems offline can be very expensive and time-consuming. Simply sending technicians to the site to diagnose, operate, or repair the valves would consume a significant amount of time. However, such assessments are typically only performed when the facility is shut down or offline, or when the valve itself is in bypass mode and isolated from the control system. Therefore, performing preventative or remote testing and maintenance on these valves would greatly benefit the entire system by avoiding costly operational interruptions. Summary of the Invention

[0007] The technology disclosed herein allows for testing valve seat integrity while the valve is online. The system can receive commands (“Test Requests”) to initiate a valve seat integrity test, queue these commands instead of immediately initiating the test, and monitor subsequent commands. When the system receives a command (“Repositioning Request”) to move the valve through a series of positions, including those specified in the test parameters, the system executes the test according to the queued commands. Therefore, by queuing requests to execute valve seat integrity tests, the system can perform the test without taking the valve offline.

[0008] Although the examples below primarily refer to sliding rod valves, the techniques of this disclosure can also be applied to rotary valves (e.g., ball valves, butterfly valves).

[0009] According to one exemplary aspect of this disclosure, a method for performing online testing of a valve in a digital valve positioner is provided. The method may include: receiving, by one or more processors, a request to perform a test on the valve, the request specifying test parameters including a test start point; queuing the request for execution; receiving, after receiving the request to perform the test, a new setpoint for the valve; repositioning the valve according to the new setpoint; and, while the valve is repositioned: comparing the test start point with the current position of the valve; and, in response to determining that the current position of the valve has reached the test start point, collecting sensor data indicating operation of the valve to generate a result of the test. The method may include additional, fewer, or alternative actions, including those described herein.

[0010] According to another exemplary aspect of this disclosure, a system for performing online testing of a valve is provided. The system may include: a position sensor configured to measure the current position of the valve; and a digital valve positioner configured to: receive a request to perform a test on the valve, the request specifying test parameters including a test start point; queue the request for execution; after receiving the request to perform the test, receive a new setpoint for the valve; reposition the valve according to the new setpoint; and, while the valve is repositioned: compare the test start point with the current position of the valve; and, in response to determining that the current position of the valve has reached the test start point, collect sensor data indicating operation of the valve to generate a result of the test. The system may include additional, fewer, or alternative components and / or their functionality, including those described herein.

[0011] According to another exemplary aspect of this disclosure, a computer-readable storage medium is provided that includes non-transitory computer-readable instructions for performing an online valve seating integrity test on a valve. When executed on one or more processors, the instructions cause the one or more processors to perform the following operations: receive a request to perform a test on the valve, the request specifying test parameters including a test start point; queue the request for execution; after receiving the request to perform the test, receive a new setpoint for the valve; reposition the valve according to the new setpoint; while the valve is repositioned: compare the test start point with the current position of the valve; and in response to determining that the current position of the valve has reached the test start point, collect sensor data indicating the operation of the valve to generate a result of the test.

[0012] Furthermore, according to any one or more of the foregoing exemplary aspects of this disclosure, the methods in a system, computer-readable storage medium, or digital valve positioner for performing online testing of a valve may also combine any one or more of the following aspects.

[0013] In one aspect, the request is queued for execution in cooperation with the new setpoint, and wherein comparing the test start point with the current position of the valve further includes: determining at least one of the following: (i) whether the new setpoint corresponds to the closed position of the valve, and (ii) whether the new setpoint corresponds to the open position of the valve; and determining at least one of the following: (i) whether the valve is closed, and (ii) whether the current position of the valve is greater than or equal to the test start point.

[0014] In another aspect, the request is executed in cooperation with the new setpoint when either of the following occurs: (i) the new setpoint corresponds to the valve being closed, and (ii) the current position of the valve is greater than or equal to the test start point; or (i) the new setpoint corresponds to the valve being open, and (ii) the valve is closed; and the request is kept in the queue if either of the following occurs: (i) the new setpoint corresponds to the valve being closed, and (ii) the current position of the valve is less than the test start point; or (i) the new setpoint corresponds to the valve being open, and (ii) the valve is not closed.

[0015] In another aspect, the request also specifies a ramp rate, the new setpoint includes a first new setpoint, and executing the request further includes: receiving a second new setpoint for the current position of the valve; and performing at least one of the following: gradually closing the valve based on the ramp rate until (i) the new setpoint does not correspond to the valve being closed, or (ii) the current position of the valve is static; and gradually opening the valve based on the ramp rate until the current position of the valve is greater than or equal to either (i) the second new setpoint or (ii) the test start point.

[0016] In another aspect, the request also specifies a test frequency, and wherein executing the request further includes: when the new setpoint commands the valve to open, while gradually closing the valve according to the first new setpoint: canceling the request; and requeuing the request for execution according to the test frequency; and when the second new setpoint corresponds to the valve being closed, while gradually opening the valve according to the first new setpoint: canceling the request; and requeuing the request for execution according to the test frequency.

[0017] In another aspect, the method further includes performing at least one of the following: comparing the sensor data with stored data to produce a first result, wherein the stored data represents one or more previous satisfactory requests, and wherein the first result includes information containing at least one of the following: (i) a first slope of the sensor data, (ii) a first smoothness of the sensor data, and (iii) a first seat engagement based on the sensor data; and comparing the sensor data with one or more factory specifications to produce a second result, wherein the one or more factory specifications represent one or more established satisfactory standards, and wherein the second result includes information containing at least one of the following: (i) a second slope of the sensor data, (ii) a second smoothness of the sensor data, and (iii) a second seat engagement based on the sensor data.

[0018] In another aspect, the method further includes generating an alarm based on the first result or the second result, according to the quality of the valve internals.

[0019] In another aspect, the sensor data includes at least the current position of the valve, and at least one of (i) pressure measurement and (ii) force measurement (e.g., using any suitable type of load cell). Attached Figure Description

[0020] The technology of this disclosure can be best understood by referring to the following description taken in conjunction with the accompanying drawings, wherein, in several drawings, the same reference numerals identify the same elements, wherein:

[0021] Figure 1 This is a block diagram illustrating an example of a control valve positioning system configured for online testing of an actuator valve, based on the principles of this disclosure.

[0022] Figure 2A An example valve position value plotted relative to a pressure value is shown, which corresponds to... Figure 1 The valve signature of the control valve.

[0023] Figure 2B It corresponds to Figure 1 The valve seat profile of the control valve. Figure 2A A graph of a subset of the data.

[0024] Figure 3A Examples of valve position values ​​plotted relative to corresponding pressure values ​​in several scenarios are provided to illustrate several exemplary valve seat profiles.

[0025] Figure 3B Examples of a normal valve seat profile and a valve seat profile with excessive "rounding" (which can indicate damage to the valve seat) are shown.

[0026] Figure 3C An exemplary normal valve seat profile and a valve seat profile with potential valve seat engagement problems are illustrated.

[0027] Figure 3D Examples of a normal valve seat configuration and a valve seat configuration with the valve sticking in the seat are illustrated.

[0028] Figure 3E A combination of multiple valve seating integrity tests is illustrated for an exemplary control valve.

[0029] Figure 4 yes Figure 1 The system can present operators with an exemplary graphical user interface (GUI) for configuring test requests.

[0030] Figure 5 It is based on the principles of this disclosure and executes the open. Figure 1 A flowchart illustrating an exemplary method for online testing of valves.

[0031] Figure 6 It is based on the principles of this disclosure and is executed to close. Figure 1 A flowchart illustrating an exemplary method for online testing of valves.

[0032] Figure 7 It is based on the principles and implementation of this disclosure. Figure 1 A flowchart illustrating an exemplary method for online testing of valves.

[0033] Figure 8 It is based on the principles and configuration of this disclosure. Figure 1 A flowchart illustrating an exemplary method for online testing of valves. Detailed Implementation

[0034] Generally, the technology disclosed herein allows systems to effectively perform online valve seating integrity tests on control valves. For clarity, see references... Figure 1 A brief description of an exemplary system is provided, which includes a valve controller that performs a valve seating integrity test according to these techniques. Then, reference is made to... Figures 2A-3E Examples of valve seating integrity testing are discussed, along with references. Figures 4-8 This paper discusses methods for configuring and performing online valve seating integrity tests. Exemplary System

[0035] First refer to Figure 1 The exemplary system 100 includes a valve 102 configured to control fluid flow in process 156. A pneumatic stage 150 may include a pneumatic positioner and actuator or a pneumatic relay and / or actuator. The pneumatic stage 150 generates signals to position a movable closing element of the valve 102 (e.g., valve plug 106), thereby restricting or increasing the flow of process fluid by engaging or disengaging the valve plug 106 from the valve seat 104.

[0036] The digital valve positioner 120 (or simply "valve positioner 120") can control the valve 102 via the pneumatic stage 150. The valve positioner 120 can receive signals indicating pressure and valve stroke from the pressure sensor 152 and the position sensor 154, respectively. Sensors 152 and 154 can be implemented using any suitable components, including those currently known in the art.

[0037] Although the examples in this disclosure mention actuator pressure, generally, the valve positioner 120 can use any suitable force measurement (e.g., pressure multiplied by actuator area) from a suitable load sensor. In some embodiments, the type of load sensor from which the valve positioner 120 receives force measurements depends on the type of valve actuator, such as electric or electro-hydraulic.

[0038] like Figure 1As shown, the valve positioner 120 includes a processor 122, a current-to-voltage (I / P) converter 124, and a memory 126 storing valve seat profile routines 128. The memory 126 may include non-transitory media readable by the processor 122, and the valve seat profile routines 128 may include instructions executable by the processor 122 in any suitable programming language. The memory 126 may also store valve seat profile history 130, such as previous valve seating integrity tests, as described below.

[0039] In this exemplary configuration, workstation 140 is coupled to valve positioner 120 to allow an operator to configure test requests for valve 102, send test requests to valve positioner 120, monitor test progress, etc. Workstation 140 may include one or more processors, memory readable by one or more processors, and a user interface 142 (such as a touchscreen, a conventional screen with a keyboard, etc.). Workstation 140 can communicate with valve positioner 120 via any suitable number of wired or wireless communication links. Exemplary Valve Seating Integrity Test and Analysis

[0040] Figure 2A This is graph 200, which shows the valve position versus actuator pressure, corresponding to the valve characteristics of valve 102. Generally, in this scenario, the valve is initially in a fully open or fully closed configuration. For example, if the valve is initially fully open, the valve positioner 120 gradually moves the valve to the fully closed position and then gradually moves it back to the fully open position. Graph 200 also illustrates a zero-friction line 208, which the valve seat profile routine 128 can use to determine the amount of friction generated by moving the valve plug 106 according to the closed valve seat profile 204 or the open valve seat profile 206.

[0041] In region 202, when valve plug 106 approaches and engages valve seat 104, the valve position and the corresponding actuator pressure value define the valve seat profile. (As in...) Figure 2B The curve 220 (corresponding to) Figure 2AAs best shown in region 202, valve plug 106 approaches and initially contacts valve seat 104 in first region 222. Once valve seat profile 204 closes to first region 222, and, as further discussed below, there is a characteristic pressure drop from first region 222 to second region 224 (a larger change in pressure or force with less or no movement compared to the time prior to first region 222). This characteristic pressure drop is represented by the steep slope of graph 220 between first region 222 and second region 224. First region 222 and second region 224 are both shown approximally and are included in this disclosure for clarity. Second region 224 can, for example, approximately indicate the position where valve plug 106 has fully engaged valve seat 104. Similarly, and as further discussed below, there is a corresponding increase in pressure associated with the start of opening cycle 206 (a significant increase in pressure or force to overcome spring force with less or no movement).

[0042] What will be understood is that the above references Figure 2A and Figure 2B The characteristic pressure changes at the aforementioned locations may not always occur in a substantially similar manner. For example, valve 102 may experience a failed opening condition in which valve plug 106 is in a fully closed configuration (e.g., similar to the position indicated in second region 224), but the actuator pressure may be at its maximum. The actuator pressure may decrease from its maximum value when the valve opens or attempts to open, but in any case may appear inconsistent with... Figure 2A and Figure 2B The overviews shown are largely similar.

[0043] Generally, valve seat profile routine 128 can monitor the slope of the valve seat profile to determine whether the slope remains approximately constant (e.g., within a certain error margin) from the initial contact of valve plug 106 with valve seat 104 until the end of the closing cycle (e.g., closing cycle 204). E (Inside). When the valve seat profile routine 128 determines that the valve seat profile does not exhibit these characteristic rapid increases and decreases in pressure, the valve seat profile routine 128 can identify various potential problems that may be associated with the quality or integrity of the valve seat 104.

[0044] For example, Figure 3AA graph 300, plotted against actuator pressure values, illustrates several exemplary slopes for the valve seat profile under different scenarios. In the first graph 300a, line segment 302 represents the slope of the closed valve seat profile 304. The first slope graph 300a also includes an open valve seat profile 306 and a zero-friction line 308. As shown, line segment 302 corresponds to the “normal” slope of the closed valve seat profile 304 (i.e., the valve plug 106 contacts the valve seat 104 as expected). In other words, the valve seat profile routine 128 can monitor the slope of the closed valve seat profile 304 from the point of first contact between the valve plug 106 and the valve seat 104 to the end of the closed valve seat profile 304, so that the valve seat profile routine 128 can determine that the slope of the closed valve seat profile 304 does not indicate any possible problems with valve seat integrity.

[0045] The end of the closed seat profile 304 (or in fact, any of the seat profiles described below) can be determined when the seat profile routine 128 receives an actuator pressure value higher than / lower than a threshold from the pressure sensor 152, or when the seat profile routine 128 receives a valve position value higher than / lower than a threshold from the position sensor 154, or both. Alternatively or additionally, the end of the closed seat profile 304 can be determined when the seat profile routine 128 determines (e.g., via processor 122) a slope value between two points that are higher than / lower than a threshold for the closed seat profile 304.

[0046] In the second graph 300b, line segment 310 represents the slope of the closed seat profile 312. The second graph 300b also includes an open seat profile 314 and a zero-friction line 316. As shown, line segment 310 corresponds to an “abnormal” slope of the closed seat profile 312 (i.e., the valve plug 106 contacts the valve seat 104 in an unexpected manner). In other words, the seat profile routine 128 can monitor the slope of the closed seat profile 312 from the point of first contact between the valve plug 106 and the valve seat 104 to the end of the closed seat profile 312, so that the seat profile routine 128 can determine whether the slope of the closed seat profile 312 indeed indicates a possible problem with the valve seat integrity.

[0047] In the third curve 300c, line segment 318 represents the slope of the closed seat profile 320. The third curve 300c also includes the open seat profile 322 and the zero-friction line 324. As shown, line segment 318 corresponds to the nearly vertical slope of the closed seat profile 320. In this case, the seat profile routine 128 can monitor the slope of the closed seat profile 320 from the point of first contact between the valve plug 106 and the valve seat 104 to the end of the closed seat profile 320, and determine whether the valve 102 reaches mechanical stop before the valve plug 106 reaches the valve seat 104. For example, mechanical stop might be the valve actuator reaching the bottom of its housing before the valve plug 106 fully engages the valve seat 104. However, it should be understood that the slope of the opening cycle (e.g., opening cycle 206) or closing cycle (e.g., closing cycle 204) for any valve profile can indicate various types of damage to the valve seat or the absence of such damage.

[0048] Furthermore, the slope of the valve seat profile may appear normal, but there may still be a problem with valve seat 104. The relative sharpness of the point of first contact between valve plug 106 and valve seat 104 can indicate various types of potential damage even when the slope is not obviously irregular.

[0049] For example, Figure 3B A graph 326 is a set of valve position values ​​plotted relative to the actuator pressure value, illustrating the rounding of the valve seat profile. The first graph 326a includes the (approaching) region 328, line segment 330, and the closed valve seat profile 332. The first graph 326a also includes the open valve seat profile 334 and the zero-friction line 336.

[0050] Typically, identifying a "smooth" valve seat profile refers to the change in slope X of the valve seat profile analyzed by valve seat profile routine 128 around the initial contact point (e.g., region 328) between valve plug 106 and valve seat 104. For example, valve seat profile routine 128 may simultaneously monitor X with the slope of a line segment (e.g., represented by line segment 330 corresponding to valve seat profile 332) connecting consecutive data points along a particular valve seat profile. If X meets a threshold (e.g., X ≥ 1), then valve seat profile routine 128 may identify the associated point of initial contact as "sharp." In these cases, valve seat profile routine 128 may additionally identify the associated valve seat profile as "healthy," and thus may further identify the associated valve seat 104 as "healthy." Conversely, if X does not meet a threshold (e.g., X < 1), then valve seat profile routine 128 may identify the associated point of initial contact as "smooth." Therefore, valve seat profile routine 128 can additionally identify the associated valve seat profile as "damaged", and thus can further identify the associated valve seat 104 as "damaged".

[0051] To illustrate, in the first curve 326a, region 328 may exhibit a “sharp” corner because the slope change X of the closed valve seat profile 332 around region 328 may meet a threshold. Therefore, valve seat profile routine 128 can additionally identify the closed valve seat profile 332 as “healthy,” and thus can further identify the valve seat 104 corresponding to the closed valve seat profile 332 as “healthy.”

[0052] In contrast, the second curve 326b includes (approaching) region 338, line segment 340, and closed valve seat profile 342. The second curve 326b also includes open valve seat profile 344 and zero-friction line 346.

[0053] Here, region 338 may present a “rounded” corner because the slope change X of the closed seat profile 342 around region 338 may not meet a threshold. Therefore, the seat profile routine 128 may additionally identify the closed seat profile 342 as “damaged”, and thus may further identify the valve seat 104 corresponding to the closed seat profile 342 as damaged.

[0054] An additional indication that valve seat 104 may be damaged is excessively long valve seat engagement, which valve seat profile line 128 can automatically detect based on valve position and pressure readings.

[0055] As used herein, “seat engagement” describes the physical distance Y that the valve plug 106 travels between its first contact with the valve seat 104 and its full engagement with the valve seat 104 (thus stopping the movement of the valve plug 106).

[0056] For example, seat profile routine 128 can monitor the valve position from the initial contact point between valve plug 106 and valve seat 104 (e.g., first region 222) to the end of the seat profile (e.g., second region 224) to determine Y corresponding to valve plug 106 during this process. If Y meets a threshold (e.g., Y < 0.010''), seat profile routine 128 can identify the associated seat profile as "healthy". In these cases, seat profile routine 128 can additionally identify the associated valve seat 104 as "healthy". Conversely, if Y does not meet the threshold (e.g., Y >= 0.010''), seat profile routine 128 can identify the associated seat profile as "damaged", and therefore can further identify the associated valve seat 104 as "damaged".

[0057] Figure 3CThis is a combination of curves 348 showing valve position versus actuator pressure readings, illustrating a valve seat engagement problem associated with an exemplary valve seat profile. The first curve 348a includes displacement 350, pressure depth 352 (force available for shut-off), and a closed valve seat profile 354. The first curve 348a also includes an open valve seat profile 356 and a zero-friction line 358. In this case, the valve seat profile routine 128 can identify the closed valve seat profile 354 as "normal" because displacement 350 meets the threshold. Therefore, the valve seat profile routine 128 can additionally identify the valve seat 104 corresponding to the closed valve seat profile 354 as "healthy."

[0058] The second curve 348b includes displacement 360, pressure depth 362 (force that can be used for shut-off), and a closed seat profile 364. The second curve 348b also includes an open seat profile 366 and a zero-friction line 368. Here, the seat profile routine 128 can identify the closed seat profile 364 as "damaged" because displacement 360 may not meet the threshold. Therefore, the seat profile routine 128 can additionally identify the seat 104 corresponding to the closed seat profile 364 as "damaged."

[0059] So far, seat profile routine 128 has identified potential damage to the valve seat (e.g., valve seat 104) by analyzing the closing cycles of valve characteristic tests (e.g., closing seat profiles 204, 304, 312, 320, 332, 342, 354, and 364). However, it should be understood that seat profile routine 128 can also identify potential damage to the valve seat by analyzing the opening cycles of valve characteristic tests (e.g., opening seat profiles 206, 306, 314, 322, 334, 344, 356, and 366). In addition to the indications discussed above, during the opening cycle (e.g., opening cycle 206), the valve plug (e.g., valve plug 106) may, for example, remain in the valve seat (e.g., valve seat 104).

[0060] When valve positioner 120 opens the valve, the response is slightly delayed due to several factors: filling the actuator volume, overcoming the force required to provide tight shut-off, and overcoming static friction. Therefore, the valve does not move when the force increases. Once the force required for shut-off is met and static friction is overcome, the valve will begin to move. The force required to overcome static friction is greater than the kinetic friction, which can cause the valve to move rapidly beyond the ramp rate due to excessive force and a signal that may lag behind the command. Valve positioner 120 then rapidly reduces the force so that the stroke does not exceed the command signal. All these factors contribute to what is known as a “bubble” in the opening profile. This is normal for most valves. The size of the “bubble” is directly related to the ramp rate, the force required to overcome static friction, and the speed at which the valve controller can correct this situation. Therefore, the size of the bubble is usually directly related to static friction or valve plug stuck in the seat, since the ramp rate and the valve controller’s ability to correct this situation are usually constant. If the valve is stuck in the seat during the initial phase of the opening operation, the bubble may be very noticeable, even forming a “ring.”

[0061] Therefore, as used herein, the term "retention" in the context of a valve seat refers to the valve plug (e.g., valve plug 106) remaining fully engaged with the valve seat (e.g., valve seat 104) to form a larger "bubble" as described above. For example, valve seat profile routine 128 may monitor the length of time Z during which the valve plug remains fully engaged with the valve seat after the start of an opening cycle. If Z exceeds a certain percentage threshold (e.g., 10%, 15%, 20%), valve seat profile routine 128 may identify the associated valve seat profile as "damaged". In these cases, valve seat profile routine 128 may additionally identify the associated valve seat 104 as "damaged". Conversely, if Z does not exceed a certain percentage threshold, valve seat profile routine 128 may identify the associated valve seat profile as "normal", and thus may further identify the associated valve seat 104 as "normal".

[0062] Figure 3D This is a combination of graphs 370 highlighting the valve position versus actuator pressure profile, including the valve plug 106 remaining in the valve seat 104. The first graph 370a includes a closed valve seat profile 372, an open valve seat profile 374, and a zero-friction line 376. Here, the valve seat profile routine 128 can identify the open valve seat profile 374 as "normal" because Z does not exceed a certain percentage threshold. Therefore, the valve seat profile routine 128 can additionally identify the valve seat 104 corresponding to the open valve seat profile 374 as "normal".

[0063] The second curve 370b includes a closed valve seat profile 378, an open valve seat profile 380, a region 382, ​​and a zero-friction line 384. In this case, the valve seat profile routine 128 can identify the open valve seat profile 380 as "damaged" because Z exceeds a certain percentage threshold. Therefore, the valve seat profile routine 128 can additionally identify the valve seat 104 corresponding to the open valve seat profile 380 as "damaged".

[0064] Furthermore, the valve seat profile routine 128 can identify both the open valve seat profile 380 and valve seat 104 as "damaged" based on the valve position and actuator pressure values ​​associated with the open valve seat profile 380. For illustration, region 382 includes consecutive valve position values ​​indicating that the valve plug 106 has moved in the opposite direction to the direction indicated by the command of the valve controller 120. The valve seat profile routine 128 can determine, based on these consecutive valve position values, that the valve plug 106 is stuck on the valve seat 104, and thus indicate that both the open valve seat profile 380 and valve seat 104 are "damaged".

[0065] Taking into account these various indications of potential damage to the valve seat, according to various embodiments of this disclosure, in Figure 3E The document presents an exemplary comparison of several valve seating integrity tests. Figure 3E The curve 386 includes the first composite open valve seat profile 388, the first composite close valve seat profile 392, the second composite open valve seat profile 390, the second composite close valve seat profile 394, and the composite zero friction line 396.

[0066] As further discussed below, seat profile routine 128 can analyze multiple valve characteristic tests, particularly the seat profile, to determine the degree of closeness of the current test to a known "good" test or a factory specification established based on the valve construction. For example, seat profile routine 128 can determine that the seat profiles presented by both the second compound closed seat profile 394 and the second compound open seat profile 390 describe a seat that is damaged when compared to the first compound closed seat profile 392 and the first compound open seat profile 388, respectively. Seat profile routine 128 can make this determination at least in part based on the evaluation and analysis techniques described herein. For Methods for configuring, queuing, and performing online valve seating integrity tests

[0067] Consistent with the systems and analysis points previously described in this disclosure, users may wish to test the seat profile of a process control valve (e.g., valve 102). As described herein, various methods for configuring, queuing, and performing such tests allow for determining the seat profile without taking the valve offline.

[0068] Figure 4This is an exemplary graphical user interface (GUI) 400 for configuring test requests. Generally, GUI 400 allows a user at, for example, a workstation (e.g., workstation 140) to specify certain parameters regarding a valve seating integrity test, which is then uploaded to a valve controller (e.g., valve positioner 120). GUI 400 includes an enable section 402, a test start point section 404, a valve seat profile ramp rate section 406, and a valve seat profile scan time section 410. Enable section 402 may provide the user with options to enable the valve seating integrity test during a closing cycle (e.g., closing valve seat profile 204), an opening cycle (e.g., opening valve seat profile 206), or any combination thereof, by selecting an appropriate box or indicator.

[0069] The test start point section 404 provides the user with the option to input a test start point. The test start point can be based on the amount of travel required to establish an analyzable valve seat profile. For example, it may be necessary to travel the valve plug 106 from at least 10% open to fully closed to obtain an analyzable valve seat profile. In this example, the user can input 10% into the test start point section 404 to allow the system to record or analyze data from when valve 102 is 10% open to when valve 102 is fully closed. Furthermore, the system (e.g., valve seat profile routine 128) can impose unique criteria on the test start point for each type of valve.

[0070] The valve seat profile ramp rate section 406 provides the user with the option to input the valve seat profile ramp rate. This is achieved by employing a pre-established total scan (i.e., as...). Figure 1 The valve profile ramp rate is calculated by determining the scan time and the ramp rate of the total scan (as shown in the valve characteristic test). The established scan time for the valve can be based, for example, on the diaphragm area for spring and diaphragm actuators and the piston area for piston actuators. For example, as shown in the total scan section 408, a typical total scan can run from -5% of the initial valve plug stroke to 105% of the final valve plug stroke. In this example, for an actuator diaphragm area of ​​up to 100 square inches, a total scan can be run with a scan time of 50 seconds. The system (e.g., valve profile routine 128) can then calculate the ramp rate as, for example:

[0071] The valve seat profile scan time section 410 provides the user with the option to input the valve seat profile scan time. Alternatively, the system can automatically fill in the valve seat profile scan time. In either case, the valve seat profile scan time approximately indicates the time required to perform the valve seating integrity test. For example, the system (e.g., valve seat profile routine 128) can calculate the valve seat profile scan time as follows:

[0072] The GUI 400 may also include a test frequency section 412. The test frequency section 412 includes multiple options for the user to select the frequency at which valve seating integrity testing is performed on a specific valve. For example, the test frequency section 412 may have a drop-down menu listing various frequencies (i.e., daily, weekly, monthly, yearly, the next time the valve is closed / opened, etc.). Furthermore, the test frequency section 412 may include an option for the user to select a specific day of the week for valve seating integrity testing. Additionally, the test frequency section 412 may include options for the user to specify the time period for which they prefer to complete the test. For example, if the user knows that the valve is more likely to move on a certain date or time, these options allow the user to more optimally queue the valve seating integrity tests for execution.

[0073] The GUI 400 may also include an upload command 414. The upload command 414 allows the user to download test requests to the valve positioner 120 for queuing and execution according to the parameters described herein.

[0074] Once the valve positioner 120 has been configured and downloaded the parameters for the valve seating integrity test, the valve positioner 120 queues the test for subsequent execution. Figure 5 This is a process flow diagram illustrating an example of a method 500 for performing an online test to close a control valve according to the technology of this disclosure. Method 500 begins at block 502, where valve positioner 120 reads and stores the valve setpoint and valve position. The setpoint may refer to, for example, the end position of the valve plug based on a command request received by valve positioner 120. The valve position may refer to, for example, the current position of valve plug 106, as measured by position sensor 154. The system (e.g., valve positioner 120) may collect and store setpoint and valve position data based on a frequency setting established by a user (e.g., in test frequency section 412).

[0075] At box 504, method 500 includes determining whether the online valve seat profile closure option is enabled. For example, valve positioner 120 may examine a user-submitted test configuration and, more specifically, the option selected in the enable section 402. If the closure option is selected, method 500 proceeds to box 506; otherwise, the method returns to box 502.

[0076] In block 506, method 500 includes determining whether valve positioner 120 is commanding the valve to close by executing a command request specifying a new setpoint for the valve. For example, valve positioner 120 may examine the command request to determine whether valve positioner 120 is commanding the valve to close based on the valve's current position and the setpoint specified in the command request. To illustrate, if the valve is currently positioned at 45% opening and the command request includes a setpoint for 0% opening of the valve, then valve positioner 120 will determine that valve positioner 120 is commanding the valve to close by executing the command request specifying the 0% opening setpoint. If valve positioner 120 is commanding the valve to close, method 500 continues to block 508; otherwise, method 500 returns to block 502.

[0077] At block 508, method 500 includes determining whether the valve position is greater than or equal to the test start point. For example, valve positioner 120 may examine a user-submitted test configuration, and more specifically, the option specified in test start point section 404. Valve positioner 120 may then compare this value with the valve position (e.g., obtained from position sensor 154). If the valve position is greater than or equal to the test start point, method 500 proceeds to block 510; otherwise, method 500 returns to block 502. In some embodiments, block 508 is executed before block 506.

[0078] At block 510, method 500 includes moving the valve to a test start point and then gradually closing the valve based on the valve seat profile ramp rate. As previously described, the test start point can be obtained from the test start point section 404 of the user-submitted test configuration. Similarly, the valve positioner 120 can obtain the valve seat profile ramp rate from the user-submitted test configuration, more specifically, from the valve seat profile ramp rate section 406.

[0079] For illustration, at block 510, valve positioner 120 can execute command requests until the test start point is reached. Once the test start point is reached, valve positioner 120 can continue to gradually close the valve, but at the valve seat profile ramp rate specified by the user in valve seat profile ramp rate section 406. However, it should be understood that the valve controller can gradually close the valve at any suitable rate before and after the valve seating integrity test is completed.

[0080] At block 512, method 500 includes reading and storing the valve setpoint and valve position. Similar to block 502, valve positioner 120 can obtain setpoint data from a command request and valve position from position sensor 154.

[0081] At block 514, method 500 includes determining whether valve positioner 120 is commanding the valve to close by executing a command request specifying a new setpoint for the valve. Similar to block 506, for example, valve positioner 120 may check the command request to determine whether valve positioner 120 is commanding the valve to close based on the current position of the valve and the setpoint specified in the command request. In this way, valve positioner 120 may check whether the command request that initially requested the valve to close is still an operable command request. In other words, if valve positioner 120 receives a subsequent command request specifying a setpoint that will open the valve, while valve positioner 120 is executing a previous command request (i.e., the command request initially received before block 502), the subsequent command request takes priority, and the valve seating integrity test can be terminated. If the valve seating integrity test is terminated in this manner, valve positioner 120 may store data associated with the valve seating integrity test in, for example, the valve seat profile history 130 of the memory 126 of valve seat controller 120. Valve positioner 120 may then mark the valve seat profile data as terminated for a valve seating integrity test, and valve positioner 120 may not be able to perform automatic evaluation, as described herein. If valve positioner 120 commands the valve to close by executing a command request specifying a new set point for the valve, method 500 continues to block 516; otherwise, method 500 continues to block 518.

[0082] At block 516, method 500 includes determining whether the valve position is changing. For example, valve positioner 120 may obtain a reading from position sensor 154 at a first time and again at a second time to determine whether the valve position is changing. If the valve position is changing, method 500 returns to block 512; otherwise, method 500 continues to block 518.

[0083] At block 518, method 500 includes stopping data collection and returning control to the command request. In other words, once the valve seating integrity test has been completed, or, for example, the valve positioner 120 receives a subsequent command request specifying a setpoint to open the valve, the valve positioner 120 can return to operating the valve based on parameters specified in the command request (e.g., ramp rate, scan time, etc.).

[0084] At box 520, method 500 includes comparing valve seat profile data with known “good” data. As previously described and further discussed herein, valve positioner 120 may compare the valve seat profile dataset with known datasets that describe a valve seat in an appropriate functional state (more generally, this analysis may be performed using any suitable hardware and / or software).

[0085] At block 522, method 500 includes determining whether seat profile data obtained during a recent valve seating integrity test execution is statistically comparable to known “good” data, as discussed at block 520. For example, valve positioner 120 may analyze the seat profile data to compare aspects of the seat profile data with known “good” data. Valve positioner 120 may analyze the slope, smoothness, and / or seat engagement of the closing or opening cycle of the seat profile data and compare these values ​​with corresponding values ​​of known “good” data, as discussed herein. Furthermore, valve positioner 120 may analyze the seat profile data to determine whether the valve is stuck in the seat, as discussed herein. It should be understood that valve positioner 120 or other suitable devices may analyze any suitable data to determine whether the seat profile data is statistically comparable to known “good” data, and are not necessarily explicitly limited to the embodiments disclosed herein. If the valve seat profile data is statistically comparable to known “good” data, then method 500 ends; otherwise, method 500 continues to box 524.

[0086] At block 524, method 500 includes setting an alarm. If method 500 reaches block 524, valve positioner 120 or other suitable device may have determined, for example, that the valve seat has been damaged in some way. Therefore, the alarm may correspond to an indication of the quality of the valve seat (e.g., valve seat 104) or valve internals. Furthermore, valve positioner 120 or other suitable device may send the alarm to the user via workstation 140, so that the user can take appropriate action.

[0087] Figure 6 This is a process flow diagram illustrating another example of a method 600 for performing an online test of opening a control valve according to the principles of this disclosure. Method 600 begins at block 602, where valve positioner 120 reads and stores the valve setpoint and valve position. (See previous reference...) Figure 5 The setpoint mentioned above can refer to, for example, the end position of the valve plug based on a command request received by the valve positioner 120. The position sensor 154 measures the valve position, which can refer to, for example, the current position of the valve plug 106. The valve positioner 120 can collect and store this setpoint and valve position data based on a frequency setting established by the user (e.g., in the test frequency section 412).

[0088] At box 604, method 600 includes determining whether the online valve seat profile open option is enabled. For example, valve positioner 120 may examine a user-submitted test configuration and, more specifically, the option selected in enable section 402. If the open option is selected, method 600 proceeds to box 606; otherwise, method 600 returns to box 602.

[0089] At block 606, method 600 includes determining whether the valve is closed. For example, valve positioner 120 may obtain a reading from position sensor 154 to check if the valve is 0% open. If the valve is closed, method 600 proceeds to block 608; otherwise, method 600 returns to block 602.

[0090] At block 608, method 600 includes determining whether valve positioner 120 is commanding the valve to open by executing a command request specifying a new setpoint for the valve. For example, valve positioner 120 may examine the command request to determine whether valve positioner 120 is commanding the valve to open based on the valve's current position and the setpoint specified in the command request. To illustrate, if the valve is currently positioned at 0% opening (e.g., closed), and the command request includes a setpoint for 100% opening of the valve, then valve positioner 120 determines that valve positioner 120 is commanding the valve to open by executing the command request specifying the 100% opening setpoint. If valve positioner 120 is commanding the valve to open, method 600 continues to block 610; otherwise, method 600 returns to block 602.

[0091] At block 610, method 600 includes moving the valve to a test start point based on the valve seat profile ramp rate. As previously described, valve positioner 120 can obtain the test start point from the test start point portion 404 of a user-submitted test configuration. Similarly, valve positioner 120 can obtain the valve seat profile ramp rate from the user-submitted test configuration, more specifically, from the valve seat profile ramp rate portion 406.

[0092] For illustration, at block 610, valve positioner 120 can execute a command request and simultaneously perform a valve seating integrity test. To accurately analyze the valve seat profile, once valve positioner 120 executes the command request, it can gradually open the valve at a ramp rate corresponding to the valve seat profile. Once the valve position reaches the test starting point, valve positioner 120 can further gradually open the valve based on the command request and its associated ramp rate. However, it should be understood that the valve controller can gradually close the valve before and after completing the valve seating integrity test at any suitable rate.

[0093] At block 612, method 600 includes valve positioner 120 reading and storing the valve setpoint and valve position. Similar to block 602, valve positioner 120 can obtain setpoint data from a command request and obtain the valve position from position sensor 154.

[0094] At block 614, method 600 includes determining whether the valve position is less than a setpoint. For example, valve positioner 120 may examine a command request to determine whether the setpoint included in the command request is less than the current position of the valve. In this way, valve positioner 120 may check whether the command request that initially requested the valve to open is still an operable command request. In other words, if valve positioner 120 receives a subsequent command request specifying a setpoint that will close the valve, while valve positioner 120 is executing a previous command request (i.e., the command request initially received before block 602), the subsequent command request takes priority, and the valve seating integrity test can be terminated. If the valve seating integrity test is terminated in this manner, valve positioner 120 may store data associated with the valve seating integrity test in, for example, the valve seat profile history 130 of the memory 126 of valve controller 120. Valve positioner 120 may then mark the valve seat profile data as a terminated valve seating integrity test, and valve positioner 120 may not automatically evaluate the valve seat profile data, as discussed herein. If the valve position is less than the set point, method 600 continues to block 616; otherwise, method 600 continues to block 618.

[0095] At block 616, method 600 includes determining whether the valve position is less than a test start point. For example, valve positioner 120 may obtain a reading from position sensor 154 and compare that reading with a test start point derived from test start point portion 404. If the valve position is less than the test start point, method 600 returns to block 612; otherwise, method 600 continues to block 618.

[0096] At block 618, method 600 includes stopping data collection and returning control to the command request. In other words, once the valve seating integrity test has been completed, or, for example, when valve positioner 120 receives a subsequent command request specifying a setpoint to close the valve, valve positioner 120 can return to operating the valve based on parameters specified in the command request (e.g., ramp rate, scan time, etc.).

[0097] At box 620, method 600 includes comparing valve seat profile data with known “good” data. As previously described and further discussed herein, valve positioner 120 may compare valve seat profile datasets with known datasets that describe a valve seat in an appropriate functional state.

[0098] At block 622, method 600 includes determining whether seat profile data obtained during a recent valve seating integrity test execution is statistically comparable to known “good” data, as discussed at block 620. For example, valve positioner 120 may analyze the seat profile data to compare aspects of the seat profile data with known “good” data. Valve positioner 120 may analyze the slope, smoothness, and / or seat engagement of the closing or opening cycle of the seat profile data and compare these values ​​with corresponding values ​​of known “good” data, as discussed herein. Furthermore, valve positioner 120 may analyze the seat profile data to determine whether the valve is stuck in the seat, as discussed herein. It should be understood that valve positioner 120 or other suitable devices may analyze any suitable data to determine whether the seat profile data is statistically comparable to known “good” data, and are not necessarily explicitly limited to the embodiments disclosed herein. If the valve seat profile data is statistically comparable to known “good” data, then method 600 ends; otherwise, method 600 continues to box 624.

[0099] At block 624, method 600 includes setting an alarm. If method 600 reaches block 624, valve positioner 120 or other suitable device may have determined, for example, that the valve seat has been damaged in some way. Therefore, the alarm may correspond to an indication of the quality of the valve seat (e.g., valve seat 104) or valve internals. Furthermore, valve positioner 120 or other suitable device may send the alarm to the user via workstation 140, so that the user can take appropriate action.

[0100] For understanding, refer to Figure 5 and Figure 6 Both valve positioner 120 or other suitable devices continuously monitor any incoming command requests to indicate changes in the desired control of the valve.

[0101] Figure 7 This is a flowchart illustrating an example of a method 700 for performing online testing of valve 102 in a digital valve positioner according to the principles of this disclosure. Method 700 begins at block 702, where, for example, valve positioner 120 may receive a test request specifying a test start point. Valve positioner 120 may receive the test request from, for example, workstation 140. A user may have used a GUI 400 or other suitable device to input the test start point. In various embodiments, the test request may also specify a ramp rate. In other embodiments, the test request may also specify a test frequency.

[0102] At block 704, method 700 includes queuing test requests for execution. Valve positioner 120 can queue test requests for execution. In various embodiments, test requests can be queued for execution in cooperation with command requests. Furthermore, test requests can be held in the queue until valve positioner 120 receives a command request that enables execution according to, for example... Figures 5 to 6 The illustrated embodiment performs the test. If a test request remains in the queue for an extended period of time due to no command request arriving to meet the requirements, for example, ... Figure 5 and 6 As shown, valve positioner 120 can then send a notification to the user that the valve positioner 120 failed to execute the test request. Additionally, if a previously queued test request has not been executed before the user attempts to enter a second test request, valve positioner 120 can reject the second test request and send a notification to the user regarding the previously queued test request.

[0103] At block 706, method 700 includes receiving a command request. Valve positioner 120 may receive the command request. The command request may include a setpoint for the position of the valve. In embodiments where test requests are queued for execution in cooperation with the command request, a test request may be executed together with the command request if either (i) the command request commands the valve to close based on the setpoint, and (ii) the valve position is greater than or equal to the test start point; or (i) the command request commands the valve to open based on the setpoint, and (ii) the valve is closed. Additionally, in these embodiments, a test request may be retained in the queue if either (i) the command request commands the valve to close based on the setpoint, and (ii) the valve position is less than the test start point; or (i) the command request commands the valve to open based on the setpoint, and (ii) the valve is not closed.

[0104] At block 708, method 700 includes operating valve 102 according to a command request. Valve positioner 120 can operate valve 102 according to a command request. In various embodiments, the command request may include a first command request, and the setpoint may include a first setpoint. Furthermore, in these embodiments, executing the test request may also include: receiving a second command request, wherein the second command request includes a second setpoint for the position of the valve; and performing at least one of the following: gradually closing the valve based on a ramp rate until either (i) the second command request does not command the valve to close, or (ii) the valve position is static; and gradually opening the valve based on a ramp rate until the valve position is greater than or equal to either (i) the second setpoint or (ii) the test start point.

[0105] In other embodiments, executing a test request may further include: when the second command request commands the valve to open, canceling the test request and requeuing the test requests for execution according to the test frequency while gradually closing the valve according to the first command request; and when the second command request commands the valve to close, canceling the test request and requeuing the test requests for execution according to the test frequency while opening the valve according to the first command request.

[0106] At block 710, method 700 includes comparing a test start point with the current position of the valve. Valve positioner 120 may compare the test start point with the current position of the valve. In various embodiments, comparing the test start point with the current position of the valve may further include: determining at least one of: (i) whether a command request commands the valve to close based on a setpoint and (ii) whether a command request commands the valve to open based on a setpoint; and determining at least one of: (i) whether the valve is closed and (ii) whether the valve position is greater than or equal to the test start point.

[0107] In another embodiment, comparing the test starting point with the current position of the valve may further include comparing the observed data with stored data to produce a first result. The stored data may represent one or more previous satisfactory test requests, and the first result may include information containing at least one of the following: (i) a first slope of the observed data, (ii) a first smoothness of the observed data, and (iii) a first valve seat engagement based on the observed data. Additionally, comparing the test starting point with the current position of the valve may further include comparing the observed data with one or more factory specifications to produce a second result. The one or more factory specifications may represent one or more established satisfactory standards, and the second result may include information containing at least one of the following: (i) a second slope of the observed data, (ii) a second smoothness of the observed data, and (iii) a second valve seat engagement based on the observed data. In these other embodiments, the valve positioner 120 may generate an alarm based on the first or second result (e.g., to indicate that the quality of the valve internals does not meet expectations based on previous test results or factory specifications of the valve positioner 120).

[0108] At block 712, method 700 includes observing data on the operation of an indicating valve. Valve positioner 120 can observe data on the operation of an indicating valve (e.g., valve 102). In various embodiments, the observed data may include at least (i) the valve position and (ii) pressure (e.g., actuator pressure).

[0109] Figure 8This is a process flowchart illustrating an example of a method 800 for configuring online testing of valve 102 according to the principles of this disclosure. Method 800 begins at block 802, where, for example, a user enables an online valve seating integrity test. At block 804, method 800 includes inputting the test start point. At block 806, method 800 includes checking the valve seat profile ramp rate based on an established scan time. At block 808, method 800 includes determining the frequency of the online valve seating integrity test. At block 810, method 800 includes downloading the online valve seating integrity test to a positioner. The positioner may be included in valve positioner 120 or any other suitable device. For example, the positioner may be included in pneumatic stage 150. Additional considerations

[0110] The foregoing detailed description is provided for clarity of understanding only, and since modifications thereto will be obvious to those skilled in the art, no unnecessary limitations should be construed as such. Furthermore, throughout the specification, multiple instances may implement components, operations, or structures described as single instances. Although a single operation of one or more methods is illustrated and described as a separate operation, one or more single operations may be performed simultaneously or in an alternative order to the illustrated order. Structures and functions represented as separate components in exemplary configurations may be implemented as combined structures or components. Similarly, structures and functions presented as single components may be implemented as separate components. These and other variations, modifications, additions, and improvements fall within the scope of this document's subject matter.

[0111] Throughout this specification, descriptions of actions (or routines or instructions executed thereon) by processor 122 or other similar devices generally refer to actions or processes by which the processor manipulates or transforms data according to machine-readable instructions. Machine-readable instructions may be stored in and retrieved from a storage device communicatively coupled to the processor. That is, the methods described herein may be embodied by a set of machine-executable instructions stored on a non-transitory computer-readable medium (i.e., on a memory device). When these instructions are executed by one or more processors of a corresponding device (e.g., a server, mobile device, etc.), they cause the processor to perform the method. When instructions, routines, modules, procedures, services, programs, and / or applications are referred to herein as stored or held in computer-readable storage or on a computer-readable medium, the terms "stored" and "held" are intended to exclude transient signals.

[0112] Unless otherwise expressly stated, the use of terms such as “processing,” “computing,” “operating,” “determining,” “identifying,” “presenting,” or “displaying” in this document may refer to the actions or processes of a machine (e.g., a computer) that manipulates or transforms data represented as physical (e.g., electrical, magnetic, or optical) quantities within one or more memories (e.g., volatile memory, non-volatile memory, or combinations thereof), registers, or other machine components that receive, store, transmit, or display information.

[0113] When implemented in software, any applications, services, and engines described herein may be stored in any tangible, non-transitory computer-readable storage medium (e.g., disk, laser disk, solid-state storage device, molecular memory storage device, or other storage medium), in the RAM or ROM of a computer or processor, etc. Although the exemplary systems disclosed herein are disclosed as including software and / or firmware and other components executing on hardware, it should be noted that such systems are illustrative only and should not be considered limiting. For example, it is contemplated that any or all of these hardware, software, and firmware components may be embodied solely in hardware, solely in software, or in any combination of hardware and software.

Claims

1. A method for analyzing valve seating integrity in a digital valve positioner, the method comprising: One or more processors receive sensor data indicating the operation of the valve, wherein the sensor data includes at least one of (i) pressure and (ii) force and the current position of the valve; The one or more processors generate a valve seat profile based on the sensor data, the valve seat profile indicating the pressure or force value of the valve; The quality of the valve seat is determined by the one or more processors based on the valve seat profile and at least one of the following: (a) The slope of the valve seat profile from the point of first contact between the valve plug and the valve seat to the end of the closing cycle; (b) The slope variation of the valve seat profile around the point of first contact between the valve plug and the valve seat; (c) The distance traveled by the valve plug between its first contact with the valve seat and its complete engagement with the valve seat; or (d) The length of time the valve plug remains fully engaged with the valve seat after the start of the opening cycle; and An alarm is generated by one or more processors based on the determination to indicate the integrity of the valve seat.

2. The method of claim 1, wherein, Determining the mass of the valve seat based on the slope of the valve seat profile includes: Determine whether the slope remains approximately constant from the point of first contact between the valve plug and the valve seat to the end of the closing cycle; and When the valve seat profile does not show a pressure threshold increase or decrease, a valve seat integrity problem is identified.

3. The method of claim 1, wherein, Determining the mass of the valve seat includes: Determine that at least one of the following exceeds a corresponding threshold: (i) the slope change of the valve seat profile, (ii) the distance traveled by the valve plug between its first contact with the valve seat and its full engagement with the valve seat, or (iii) the length of time the valve plug remains fully engaged with the valve seat after the start of the opening cycle; and The valve seat is determined to be damaged when at least one of the slope change, the distance, or the length of the time does not meet the corresponding threshold.

4. The method of claim 1, further comprising at least one of the following: The valve seat profile is compared with stored data to produce a first result, wherein, The stored data represents one or more previous satisfactory tests, and wherein the first result includes information containing at least one of the following: (i) a first slope of the valve seat profile, (ii) a first smoothness of the valve seat profile, and (iii) a first valve seat engagement based on the valve seat profile; and The valve seat profile is compared with one or more factory specifications to produce a second result, wherein the one or more factory specifications represent one or more established satisfactory standards, and wherein the second result includes information containing at least one of the following: (i) a second slope of the valve seat profile, (ii) a second smoothness of the valve seat profile, and (iii) a second valve seat engagement based on the valve seat profile.

5. The method according to claim 4, wherein, The alarm is generated based on the first or second result to indicate the quality of the valve internals.

6. The method according to claim 1, wherein, Determining the mass of the valve seat also includes: Based on the slope of the valve seat profile, it is determined that the valve reaches mechanical stop before the valve plug reaches the valve seat.

7. The method according to claim 1, wherein, The size of the bubble in the opening profile of the valve seat corresponds to at least one of the following: ramp rate, force against static friction, or the speed at which the valve controller corrects the valve plug remaining in the valve seat.

8. The method according to claim 1, further comprising determining the mass of the valve seat: The valve plug is determined to remain in the valve seat based on a series of valve position values, the series of valve position values ​​indicating the movement of the valve plug in a direction opposite to that indicated in the command, and wherein the valve plug remaining in the valve seat is associated with the valve plug maintaining full engagement with the valve seat to form a large bubble in the opening profile.

9. The method according to claim 1, wherein, The end of the shut-off cycle corresponds to determining at least one of the following: (i) pressure value, (ii) valve position value, or (iii) the slope value between two points of the valve seat profile that are above or below the corresponding threshold.

10. A system for analyzing valve seating integrity, the system comprising: A position sensor is configured to measure the current position of the valve; as well as A digital valve positioner, which is configured as follows: Receive sensor data indicating the operation of the valve, wherein the sensor data includes at least the current position of the valve, and at least one of (i) pressure and (ii) force; A valve seat profile is generated based on the sensor data, and the valve seat profile indicates the pressure or force value of the valve. The quality of the valve seat is determined based on at least one of the following, according to the valve seat profile: (a) The slope of the valve seat profile from the point of first contact between the valve plug and the valve seat to the end of the closing cycle; (b) The slope variation of the valve seat profile around the point of first contact between the valve plug and the valve seat; (c) The distance traveled by the valve plug between its first contact with the valve seat and its complete engagement with the valve seat; or (d) The length of time the valve plug remains fully engaged with the valve seat after the start of the opening cycle; and An alarm is generated based on the determination to indicate the integrity of the valve seat.

11. The system according to claim 10, wherein, The digital valve positioner is also configured to determine the mass of the valve seat based on the slope of the valve seat profile by performing the following operations: Determine whether the slope remains approximately constant from the point of first contact between the valve plug and the valve seat to the end of the closing cycle; and When the valve seat profile does not show a pressure threshold increase or decrease, a valve seat integrity problem is identified.

12. The system according to claim 10, wherein, The digital valve positioner is also configured to determine the mass of the valve seat by performing the following operations: Determine that at least one of the following exceeds a corresponding threshold: (i) the slope change of the valve seat profile, (ii) the distance traveled by the valve plug between its first contact with the valve seat and its full engagement with the valve seat, or (iii) the length of time the valve plug remains fully engaged with the valve seat after the start of the opening cycle; and The valve seat is determined to be damaged when at least one of the slope change, the distance, or the length of the time does not meet the corresponding threshold.

13. The system according to claim 10, wherein, The digital valve positioner is also configured to perform at least one of the following operations: The valve seat profile is compared with stored data to produce a first result, wherein the stored data represents one or more previous satisfactory tests, and wherein the first result includes information containing at least one of the following: (i) a first slope of the valve seat profile, (ii) a first smoothness of the valve seat profile, and (iii) a first valve seat engagement based on the valve seat profile; and The valve seat profile is compared with one or more factory specifications to produce a second result, wherein the one or more factory specifications represent one or more satisfactory standards to be established, and wherein the second result includes information containing at least one of the following: (i) a second slope of the valve seat profile, (ii) a second smoothness of the valve seat profile, and (iii) a second valve seat engagement based on the valve seat profile.

14. The system according to claim 13, wherein, The alarm is generated based on the first or second result to indicate the quality of the valve internals.

15. The system according to claim 10, wherein, The digital valve positioner is also configured to determine the mass of the valve seat by performing the following operations: Based on the slope of the valve seat profile, it is determined that the valve reaches mechanical stop before the valve plug reaches the valve seat.

16. The system according to claim 10, wherein, The size of the bubble in the opening profile of the valve seat corresponds to at least one of the following: ramp rate, force against static friction, or the speed at which the valve controller corrects the valve plug remaining in the valve seat.

17. The system according to claim 10, wherein, The digital valve positioner is also configured to determine the mass of the valve seat by performing the following operations: The valve plug is determined to remain in the valve seat based on a series of valve position values, the series of valve position values ​​indicating the movement of the valve plug in a direction opposite to that indicated in the command, and wherein the valve plug remaining in the valve seat is associated with the valve plug maintaining full engagement with the valve seat to form a large bubble in the opening profile.

18. The system according to claim 10, wherein, The end of the shut-off cycle corresponds to determining at least one of the following: (i) pressure value, (ii) valve position value, or (iii) the slope value between two points of the valve seat profile that are above or below the corresponding threshold.

19. A computer-readable storage medium including non-transitory computer-readable instructions for analyzing valve seating integrity, wherein, The non-transitory computer-readable instructions, when executed by one or more processors, cause the one or more processors to perform the following operations: Receive sensor data indicating the operation of the valve, wherein the sensor data includes at least the current position of the valve, and at least one of (i) pressure and (ii) force; A valve seat profile is generated based on the sensor data, and the valve seat profile indicates the pressure or force value of the valve. The quality of the valve seat is determined based on at least one of the following: (a) The slope of the valve seat profile from the point of first contact between the valve plug and the valve seat to the end of the closing cycle; (b) The slope variation of the valve seat profile around the point of the first contact between the valve plug and the valve seat; (c) The distance traveled by the valve plug between its first contact with the valve seat and its complete engagement with the valve seat; or (d) The length of time the valve plug remains fully engaged with the valve seat after the start of the opening cycle; and An alarm is generated based on the determination to indicate the integrity of the valve seat.

20. The computer-readable storage medium of claim 19, wherein, The non-transitory computer-readable instructions, when executed by the one or more processors, also cause the one or more processors to determine the mass of the valve seat based on the slope of the valve seat profile by performing the following operations: Determine whether the slope remains approximately constant from the point of first contact between the valve plug and the valve seat to the end of the closing cycle; and When the valve seat profile does not show a pressure threshold increase or decrease, a valve seat integrity problem is identified.

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