Pressure Safety Valve Monitoring for Leak and Pop Detection
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Solution Overview
Problem
Current monitoring systems for Pressure Safety Valves (PSVs) face issues with accuracy and effectiveness, generating nuisance alarms due to acoustic noise and requiring costly, specialized data analysis, while existing maintenance methods are inefficient and time-consuming.
Innovation Solution
A system and method utilizing sensors and a microcontroller to monitor PSVs for abnormal conditions, including leak detection, wear, and pressure deviations, with real-time data storage and wireless communication to external systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If continuous on-line monitoring with accelerometers and vibration detectors is used, then monitoring coverage is improved, but data analysis complexity and cost increase significantly
Solution Approach 1:
The patent extracts only the essential diagnostic information needed for PSV maintenance from the continuous monitoring data, rather than analyzing all raw data. This is achieved by implementing specific evaluation criteria that focus on key parameters such as valve opening/closing events, vibration patterns during critical phases, and pressure differential changes, thereby reducing data analysis complexity while maintaining monitoring effectiveness
Solution Approach 2:
The monitoring system segments the continuous data stream into discrete evaluation intervals corresponding to specific valve operational phases (closed state, opening transition, open state, closing transition). Each phase has tailored evaluation criteria, which simplifies the overall analysis by breaking down the complex continuous monitoring task into manageable segments with focused analysis requirements
2Reliability
If preventive maintenance is performed at predefined intervals, then equipment reliability is maintained, but maintenance time and costs increase
Solution Approach 1:
The patent changes the maintenance decision parameter from time-based (fixed intervals) to condition-based (actual valve state). By continuously monitoring parameters such as vibration characteristics, pressure differential, and acoustic emissions, the system determines maintenance needs based on actual valve condition rather than predetermined schedules, allowing extensions between maintenance events when valves remain in good condition
Solution Approach 2:
The monitoring system enables the PSV to effectively monitor its own condition and signal when maintenance is needed, replacing the external time-based scheduling system. The valve's operational parameters self-report their status, allowing maintenance to be triggered by actual need rather than external calendar schedules, thereby reducing unnecessary maintenance interventions
3Loss of information
If acoustic noise sources are monitored, then comprehensive data collection is improved, but false alarm rate increases due to turbulence and ambient noise
Solution Approach 1:
The patent converts the harmful effect of ambient acoustic noise into a beneficial diagnostic tool by using noise filtering and pattern recognition techniques. Instead of treating all acoustic signals as potential faults, the system learns normal noise patterns from the specific operating environment and distinguishes them from actual valve anomalies, thereby utilizing the acoustic field comprehensively while rejecting false alarm sources
Solution Approach 2:
The system implements feedback mechanisms where alarm conditions are evaluated against historical data and operational context. When acoustic anomalies are detected, the system cross-references them with current process conditions, valve position, and pressure differentials to determine if the signal represents a true fault or normal operational variation, thereby reducing false alarms through contextual feedback evaluation
Data Source
AI summary
A system for detecting safe operating conditions and maintained integrity in a Pressure Safety Valve (PSV) the valve comprising an inlet, an outlet, a valve disc controlling fluid flow between the inlet and outlet, a stem connected to the valve disc, a spring washer, and a spring in communication with the valve disc and the spring washer, a vibration sensor which detects vibration in the valve disc, an inlet pressure sensor which detects the static pressure in the inlet, a position sensor which detects the position of the valve disc transferred through the stem, a compression load cell sensor which detects the dynamic force applied on the valve spring washer by the spring, an outlet pressure sensor which detects the pressure in the outlet, a separate shock sensor adapted to determine if the PSV has popped and then activate a microcontroller.