Self-Diagnosing Control Valve Positioner for Early Fault Detection

Solution Overview

Problem

Control valve and positioner malfunctions in fluid control systems often go undetected until they cause process deterioration, leading to increased production costs and inefficiencies, as existing systems can only detect issues after problems occur, requiring downtime for diagnosis and potentially harming the process.

Innovation Solution

A self-diagnosing valve positioning system that includes a controller and various components like electric-to-pressure output converters, relays, and actuators, equipped with sensors to monitor and compare input and output signals, allowing for early detection of component failures and problems before they occur, enabling on-line monitoring and reducing downtime.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional detection methods are used to identify control valve and positioner problems, then the system can detect issues after they occur, but the process has already been adversely affected and downtime is required for diagnosis

Engineering Contradiction:

Improvedetection accuracyVSAvoiddowntime

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system performs preliminary diagnostics by continuously monitoring component conditions and comparing actual performance against expected performance models. This allows the system to detect potential failures before they occur, enabling maintenance to be scheduled during planned downtime rather than requiring unplanned shutdowns for diagnosis and repair.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The diagnostic system segments the control valve assembly into individual monitorable components (positioner, actuator, valve body, seals). Each component can be independently diagnosed by monitoring specific parameters, allowing precise identification of the problematic component without requiring complete system shutdown or disassembly.

Inventive Principle:

Principle #1Segmentation

2Difficulty of detecting and measuring

If the control valve is brought off line for diagnosis, then the source of the problem can be identified, but the process is interrupted and production efficiency decreases

Engineering Contradiction:

Improveproblem identificationVSAvoidproduction efficiency

Core Design Contradiction:

Difficulty of detecting and measuringVSProductivity

Solution Approach 1:

The system implements continuous feedback monitoring of component conditions through sensors that measure parameters such as position, pressure, and electrical signals. This feedback loop enables real-time detection of deviations from normal operation, allowing problem identification while the valve remains online and the process continues uninterrupted.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The diagnostic system enables the control valve assembly to self-diagnose its own condition by continuously monitoring its performance parameters and comparing them against expected values. This self-service capability eliminates the need for external diagnostic equipment or system shutdown to identify problems, maintaining production efficiency while enabling thorough problem identification.

Inventive Principle:

Principle #25Self-service

3Productivity

If on-line detection is implemented, then the valve can remain operational during monitoring, but problems are only detected after failure or irregular operation occurs

Engineering Contradiction:

Improveoperational continuityVSAvoidearly problem detection

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system performs preliminary diagnostics by continuously monitoring component conditions and comparing actual performance against expected performance models. This allows the system to detect potential failures before they occur, enabling maintenance to be scheduled during planned downtime rather than requiring unplanned shutdowns for diagnosis and repair.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements continuous feedback monitoring of component conditions through sensors that measure parameters such as position, pressure, and electrical signals. This feedback loop enables real-time detection of deviations from normal operation, allowing problem identification while the valve remains online and the process continues uninterrupted.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS7890216B2Control valve and positioner diagnostics

Publication Date: 2011.02.15 DRESSER LLC

AI summary

Valve positioning systems may include one or more components and a controller. Components may include one or more electric-to-pressure output converters, relays, gas supplies, and/or actuators. A controller may adjust a position of a valve by sending a signal. The valve positioning system may individually monitor components and determine the condition of each component being individually monitored. The valve positioning system may determine if a component will fail prior to failure and/or determine if a problem will occur in a component prior to the problem occurring.