Check Valve Leak Testing Using Pressure-Based Self-Diagnosis
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Solution Overview
Problem
Existing check valves in fluid supply systems, such as water supply systems, are difficult and inconvenient to test for leaks and malfunctions, often leading to undetected failures that can cause backflow and property damage.
Innovation Solution
A check valve testing system with electronically actuated inlet, outlet, and drain valves, a pressure sensor, and a controller that automatically performs leak detection by monitoring pressure changes during controlled valve closures and openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual testing of check valves is performed, then testing can be done with simple equipment, but testing is time consuming and inconvenient particularly when the valve is located in a hard to reach location
Solution Approach 1:
The check valve testing system performs self-testing automatically without requiring manual intervention. The controller automatically actuates the inlet valve, outlet valve, and drain valve in sequence, monitors pressure changes through the pressure sensor, and determines valve functionality autonomously, eliminating the need for manual testing operations
Solution Approach 2:
The system replaces manual mechanical testing operations with an automated electronic control system. The controller electronically actuates the valves and automatically processes test results, substituting the manual mechanical testing process with an automated electromechanical system that reduces time and improves convenience
2Reliability
If check valves are not tested frequently, then maintenance costs are reduced, but undetected failures can cause backflow and property damage
Solution Approach 1:
The testing system integrates multiple functions into a single device: the pressure sensor monitors pressure changes, the controller coordinates valve actuation sequences, and the system performs both leak detection and functionality assessment. This multi-functional integration achieves reliable detection without proportionally increasing system complexity
Solution Approach 2:
The pressure sensor acts as an intermediary that indirectly detects valve functionality by monitoring pressure changes in the fluid system. Instead of directly testing the valve mechanism, the system uses pressure variations as a mediator to infer valve status, simplifying the detection process while maintaining reliability
3Extent of automation
If a simple testing method is used, then the testing system is easier to implement, but it cannot provide automated remote testing capabilities
Solution Approach 1:
The system merges the testing functions with the existing valve infrastructure by integrating the pressure sensor and controller into the fluid supply system's existing valve assembly. The inlet valve, outlet valve, and drain valve are combined with the sensing and control components to form an integrated automated testing system that achieves high automation without excessive complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables convenient and frequent testing of check valves without manual intervention, promptly identifying leaks and ensuring proper functionality, thereby preventing backflow and reducing maintenance costs.
Implementation Method 1
a pressure sensor that is configured to detect a fluid pressure downstream of the check valve
Data Source
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AI summary
Check valve testing systems and leak detection methods using the same are disclosed. In embodiments the check valve testing system includes a check valve assembly and a pressure sensor. The check valve assembly includes a first pressure zone upstream of the check valve and a second pressure zone downstream of the check valve. An inlet valve and a drain valve may be fluidly coupled to the first pressure zone, an outlet valve may be fluidly coupled to the second pressure zone. The pressure sensor is configured to detect a fluid pressure in the second pressure zone. The controller is configured to communicatively couple to the pressure sensor, and is configured to determine whether there is a leak through the check valve, a leak downstream of then outlet valve, or a leak through the outlet valve when the inlet valve, drain valve, and outlet valve are in various conditions.