Pressure Relief Valve Partial-Stroke Testing for Remote Diagnostics

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Solution Overview

Problem

Existing pressure relief valves lack effective monitoring and autonomous testing capabilities, leading to inadequate proactive maintenance and potential system failures due to excess pressure.

Innovation Solution

A control system for pressure relief valves, including a controller and actuator, conducts partial-stroke tests and operational diagnostics to monitor valve operation, determine set pressures, and provide supplemental loading, using components like solenoid valves, positioners, and electric actuators for remote monitoring and diagnostics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional pressure relief valves are used without monitoring systems, then device complexity is reduced, but reliability deteriorates due to inability to detect wear or malfunction

Engineering Contradiction:

Improvevalve operational reliabilityVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The pressure relief valve performs self-diagnosis through autonomous testing. The valve's own actuator and control system conduct partial-stroke tests and set pressure validations without external intervention, allowing the system to self-monitor its health status and detect wear or malfunction early

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system continuously monitors valve operation through sensors that detect position, pressure, and actuator performance. This feedback enables real-time assessment of valve health, allowing proactive maintenance scheduling based on actual wear indicators rather than fixed time intervals

Inventive Principle:

Principle #23Feedback

2Loss of time

If autonomous testing and continuous monitoring are implemented, then maintenance timing accuracy is improved, but device complexity increases due to additional actuators and sensors

Engineering Contradiction:

Improvemaintenance timing accuracyVSAvoidsystem complexity

Core Design Contradiction:

Loss of timeVSDevice complexity

Solution Approach 1:

The control system serves multiple functions: it operates the valve during normal service, conducts autonomous partial-stroke tests, performs set pressure validations, and monitors valve health. By consolidating these functions into a single control architecture, the patent reduces overall system complexity while achieving continuous monitoring and precise maintenance timing

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The testing and monitoring functions are merged with the normal valve operation system. The same actuator used for valve operation performs testing, and sensors integrated into the existing structure provide both operational data and diagnostic information, eliminating the need for separate dedicated testing components

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If partial-stroke tests and operational diagnostics are conducted, then reliability is improved through early detection of issues, but loss of time increases due to testing procedures

Engineering Contradiction:

Improvevalve operational reliabilityVSAvoidtesting time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

Instead of performing full stroke tests that require complete valve opening and closing cycles, the system conducts partial-stroke tests that move the valve only a portion of the way. This partial action is sufficient to detect sticking or binding issues while significantly reducing the time required compared to full operational tests

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The autonomous testing is performed periodically at scheduled intervals rather than continuously. This periodic action allows the valve to return to normal operation between tests, minimizing disruption to system productivity while still providing regular health assessments to maintain reliability

Inventive Principle:

Principle #19Periodic action

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 continuous monitoring, proactive maintenance, and accurate diagnostic analysis, reducing the need for scheduled testing and ensuring system reliability by providing real-time operational data and reducing operator exposure to hazardous areas.

Implementation Method 1

The actuator can be configured to be connected to the spindle. The controller can be configured to, when the actuator is connected to the spindle, control the actuator to move the disc assembly via the spindle

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Implementation Method 2

a main spring configured to bias the disc assembly toward the valve seat

Methodology Applied

Scientific EffectSpring: Spring

Implementation Method 3

A pressure sensor can be in communication with an inlet of a spring-operated pressure relief valve

Methodology Applied

Scientific EffectPressure measurement:

Data Source

PatentUS20260110370A1Systems and methods for autonomous pressure relief valve testing

Publication Date: 2026.04.23 EMERSON AUTOMATION SOLUTIONS FINAL CONTROL US LP

AI summary

A control system for a pressure relief valve can include a controller and an actuator. The controller can control the actuator to at least partially open a main valve of the pressure relief valve and can determine one or more operational characteristics of the pressure relief valve based on a response of the valve to the controlled movement of the actuator.