In-Line Valve Testing for Isolation Leak Detection
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Solution Overview
Problem
Traditional valve testing in process plants requires dismounting, transporting, and remounting valves, leading to costly downtime, risk of damage, and inefficiencies due to the need for offline testing, which can be time-consuming and exposes personnel to hazardous environments.
Innovation Solution
A portable system that allows in-line testing of valves by maintaining fluid connection with upstream and downstream isolation valves using an upstream supply line with a connector, actuator, and sensor, enabling measurement and control without disconnection, and optionally includes a downstream connection for further parameter testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If valves are tested offline by dismounting and transporting them to a workshop or laboratory, then testing can be performed with specialized equipment, but this causes expensive downtime, increases the risk of damage to the valve and pipe connections, and requires significant material handling and labor
Solution Approach 1:
A portable testing system serves as an intermediary between the valve in its installed position and the testing functions previously available only in workshops. The system includes a portable controller with processing unit that can be connected directly to the valve at the installation site, eliminating the need to dismount the valve while providing comprehensive testing capabilities equivalent to workshop equipment
Solution Approach 2:
The testing capability is moved from a fixed location (workshop/laboratory) to a portable unit that can be positioned at the valve's installation site. This dimensional shift from stationary centralized testing to mobile distributed testing allows valves to be tested in-situ without disconnection, reducing downtime and handling requirements
2Reliability
If valves are dismounted for testing, then comprehensive testing can be performed, but this increases the risk of damage to the valve and pipe connections
Solution Approach 1:
The portable testing system acts as an intermediary that enables comprehensive testing functions without requiring the valve to be dismounted. The system connects to the valve through its existing pipe connections and performs all necessary measurements and tests, thereby eliminating the mechanical handling and disconnection/reconnection operations that create damage risk
3Reliability
If traditional offline testing procedures are used, then thorough testing can be conducted, but this requires significant material handling and labor
Solution Approach 1:
The portable testing system is designed to be self-contained with all necessary testing equipment, sensors, and control functions integrated into a single mobile unit. The system automatically performs testing sequences and data analysis, requiring minimal operator intervention and eliminating the need for separate workshop facilities, specialized tooling, and extensive material handling operations
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
This approach reduces material handling, labor, and exposure risks while enabling simultaneous leakage testing of isolation valves, improving testing speed and efficiency by allowing valves to remain connected within the system, thus reducing downtime and potential damage.
Implementation Method 1
an actuator for applying a pressure to the supply line
Implementation Method 2
an upstream sensor on the supply line
Data Source
AI summary
A portable system (100) for testing a valve (3) in a process plant. At least one upstream (102) or downstream (104) connector permits fluid contact to a respective upstream isolation valve (2) or a downstream isolation valve (4). A summation technique enables detection and quantification of a small leakage (20, 40) through either isolation valve (2, 4) during testing or certification of the valve (3). A portable computer (110) runs a controller (120) for automatic testing or certification. The controller (120) supports branching into separate diagnostic routines depending on measurements from sensors (122, 124). A security system (130) ensures reliable and confidential measurement data, and facilitates certification. Areas of use include chemical factories, offshore platforms for producing hydrocarbons and treatment plants aboard ships.