Local Partial Stroke Testing for Compact Isolation Valve Checks
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Solution Overview
Problem
Existing partial stroke testing systems for emergency isolation valves are complex, sensitive to air quality, consume continuous air and power, require significant space, and often need full stroke calibration, making them impractical for online replacement and operation in industrial settings.
Innovation Solution
A locally-actuated partial stroke testing system using mechanically or electrically operated valves with integrated flow control and position indicators, allowing for manual operation and bidirectional air flow, which simplifies design, reduces space requirements, and enables online replacement without the need for complex computer interfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If computer based PST systems are used, then valve testing capability is provided, but device complexity increases due to complex wiring, multiple input/output lines, voluminous documentation, and numerous design components
Solution Approach 1:
The patent extracts the essential PST functionality from complex computer-based systems and implements it using only three basic pneumatic components: a manually-operated 3/2 or 5/2 valve, a flow control valve, and a position indicator. This eliminates the need for computer interfaces, complex wiring, and multiple I/O lines while retaining the core capability to test valve operation through partial stroke movement.
Solution Approach 2:
The system uses the process air supply already available at the valve location to operate the PST mechanism, eliminating the need for separate power sources or continuous air consumption systems. The manually-operated valve and flow control valve work together with the existing air supply to achieve partial stroke testing without external control systems.
2Reliability
If computer based PST systems are used, then valve testing is enabled, but space requirements increase due to additional height requirements and installation space
Solution Approach 1:
The patent merges the PST testing components directly with the existing valve assembly. The flow control valve is integrated into the pneumatic circuit at the valve location, and the position indicator is mounted in visual proximity to the manually-operated valve. This consolidation eliminates the need for separate control panels, computer equipment, and extensive wiring harnesses, significantly reducing installation space and height requirements.
3Reliability
If computer based PST systems are used, then valve testing functionality is provided, but ease of operation deteriorates due to requirements for full stroke calibration and complex interfaces
Solution Approach 1:
The patent removes the calibration and complex interface requirements by extracting only the essential PST function. The manually-operated valve allows direct mechanical control of the actuator air supply, and the flow control valve provides intuitive flow restriction to achieve partial stroke positioning. The position indicator gives immediate visual feedback without requiring computer interpretation or calibration procedures.
Solution Approach 2:
The system operates autonomously using manual input and visual feedback. The operator manually operates the 3/2 or 5/2 valve to control air flow to the actuator, adjusts the flow control valve to achieve the desired partial stroke position, and observes the position indicator for visual confirmation. This self-contained operation eliminates dependence on computer systems, calibration procedures, and complex interfaces.
4Reliability
If computer based PST systems are used, then valve testing is enabled, but adaptability decreases due to sensitivity to air quality and inability to perform online replacement
Solution Approach 1:
The system uses the existing process air supply directly at the valve location, eliminating sensitivity to air quality variations that affect computer-based systems. The manually-operated pneumatic components and flow control valve work with whatever air is available in the process environment. The compact design allows the entire PST system to be replaced online by simply disconnecting and reconnecting pneumatic lines, without requiring shutdown or special calibration procedures.
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
The system provides a simple, intrinsically safe, and economic solution for testing emergency isolation valves, reducing operational complexity and space needs while allowing for efficient online maintenance and operation, independent of external control systems.
Implementation Method 1
a flow control valve coupled to a vent port of the mechanically-operated valve, the flow control valve being operable to regulate air flow from the vent port
Data Source
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AI summary
Embodiments of the present disclosure describe both mechanically-operated and electrically-operated, locally-actuated partial stroke testing devices and systems for testing operation of an emergency isolation valve.