Ball Valve Seat Leak Diagnostics With Integrated Performance Sensing
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Solution Overview
Problem
Industrial ball valves face challenges in detecting malfunction and component failures, particularly in monitoring valve performance and leaks, which can lead to inefficiencies and maintenance issues in industrial plants.
Innovation Solution
A diagnostic and performance monitoring system is integrated into ball valves, utilizing sensors and a logic solver to measure torque, position, leaks, and fluid flow, with features like seat leak detection, pig location tracking, and misalignment assessment, enabling proactive maintenance and improved valve performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional valve monitoring methods are used, then the system is simpler and easier to manufacture, but the ability to detect malfunction and component failures is insufficient
Solution Approach 1:
The patent embeds multiple sensors (torque sensor, position sensor, leak detection sensors, flow sensors) within the valve structure itself, nesting the diagnostic system inside the valve body. This allows comprehensive monitoring functionality to be integrated without significantly increasing external complexity, resolving the contradiction between reliability improvement and device complexity.
Solution Approach 2:
The diagnostic system performs multiple functions simultaneously: torque measurement, position monitoring, leak detection, flow rate measurement, and pig location tracking. By combining these functions into a single integrated system, the patent improves reliability across multiple parameters while avoiding the complexity of multiple separate monitoring systems.
2Difficulty of detecting and measuring
If comprehensive diagnostic sensors are integrated into the valve, then detection capability improves, but manufacturing complexity and cost increase
Solution Approach 1:
The patent divides the diagnostic system into modular sensor components that can be independently manufactured and then assembled into the valve. Each sensor (torque, position, leak, flow) is a separate module, allowing specialized manufacturing processes for each component while simplifying the overall assembly process through standardization.
Solution Approach 2:
The patent introduces a logic solver as an intermediary component that processes signals from multiple sensors and coordinates their operation. This mediator simplifies the manufacturing complexity by providing a centralized intelligence layer that manages the complex interactions between different sensor types without requiring complex direct integration between all components.
3Productivity
If real-time monitoring is implemented, then maintenance efficiency improves, but the system requires more energy and resources
Solution Approach 1:
The patent implements periodic monitoring cycles where sensors take measurements at intervals rather than continuously, reducing energy consumption while still providing timely detection of valve conditions. The logic solver can adjust monitoring frequency based on valve operation states, increasing intensity during critical operations and reducing it during stable periods.
Solution Approach 2:
The diagnostic system automatically analyzes sensor data and generates maintenance alerts without requiring constant human intervention or external processing resources. The logic solver within the valve performs self-diagnosis and can trigger automated responses, reducing the energy and computational resources needed for external monitoring infrastructure.
Data Source
AI summary
A seat leak measurement system for a ball valve is described. The system includes: a ball valve with a cavity drain line, the ball valve including a cavity pressure sensor; a valve seat leak measurement apparatus including: a cable with a connector, the connector having an external grounding cable; an apparatus electronic control system in communication with the valve sensor retrieval fitting and with valves of the valve seat; an fluid inlet line with a quick pipe coupler, the fluid inlet line having an apparatus drain valve and an isolation valve; a pressure indicator transmitter connected to the fluid inlet line, the pressure indicator transmitter in electronic communication with the apparatus electronic control system; a temperature indicator transmitter connected to the fluid inlet line, the temperature indicator transmitter in electronic communication with the apparatus electronic control system; and a flow elements manifold receiving fluid from the fluid inlet line.