Slide Valve Hot Spot Detection Using Thermocouple Tomography

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Solution Overview

Problem

Equipment in chemical and petrochemical plants, such as slide valves, deteriorate over time due to environmental stresses like temperature extremes, pollution, and abrasion, leading to decreased efficiency and potential failure, necessitating proactive maintenance and monitoring to prevent operational issues.

Innovation Solution

Implementing a system that includes advanced slide valves with refractory linings and electro-hydraulic actuators, combined with a computing platform for sensor data collection, analysis, and predictive analytics to monitor equipment performance and detect potential failures like hot spots, allowing for timely corrective actions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If slide valves operate in harsh petrochemical environments with temperature extremes and abrasion, then they must maintain operational reliability, but their service life decreases due to material deterioration

Engineering Contradiction:

Improveoperational reliabilityVSAvoidservice life

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent applies preliminary action by implementing continuous temperature monitoring and predictive analytics before actual failure occurs. Sensors detect temperature anomalies early, allowing maintenance teams to intervene proactively with corrective actions before the slide valve fails, thus extending service life while maintaining operational reliability.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system employs feedback mechanisms through continuous sensor data collection and analysis. Temperature sensors provide real-time feedback on valve conditions, and the predictive analytics platform processes this feedback to generate maintenance recommendations, creating a closed-loop system that extends equipment life while ensuring reliability.

Inventive Principle:

Principle #23Feedback

2Reliability

If traditional monitoring methods are used for slide valves, then equipment failures are detected only after they occur, but downtime and maintenance costs increase

Engineering Contradiction:

Improvefailure detection capabilityVSAvoiddowntime

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The predictive analytics platform performs preliminary detection of potential failures by analyzing temperature trends and anomalies before actual failure occurs. This allows maintenance to be scheduled in advance, preventing unexpected downtime and reducing the loss of time associated with emergency repairs.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces traditional mechanical monitoring methods with electronic sensor-based monitoring and data analytics. This substitution enables continuous, non-intrusive monitoring that detects failures earlier and more accurately, reducing both downtime and maintenance costs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Temperature

If refractory linings are applied to slide valves, then thermal protection is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvethermal protectionVSAvoidmanufacturing complexity

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The patent applies parameter changes by modifying the thermal properties of the slide valve through refractory linings. The lining material parameters (thickness, thermal conductivity, composition) are optimized to provide adequate thermal protection while minimizing the impact on manufacturing complexity.

Inventive Principle:

Principle #35Parameter changes

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

Enhances the durability and performance of slide valves and other equipment by preventing failures and maintaining optimal operation through real-time monitoring and predictive maintenance, thereby reducing downtime and maintenance costs.

Implementation Method 1

The valve body may be lined with a refractory material to protect the metal structure from the high temperatures

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

A skin thermocouple may be attached near where the stub connects to the wall and/or near the bonnet section

Methodology Applied

Scientific EffectThermocouple effect: Thermocouple

Data Source

PatentUS10684631B2Measuring and determining hot spots in slide valves for petrochemical plants or refineries

Publication Date: 2020.06.16 UOP LLC

AI summary

A plant or refinery may include equipment such as condensers, regenerators, distillation columns, pumps, slide valves, or the like. Different operating methods may impact deterioration in equipment condition, thereby prolonging equipment life, extending production operating time, or providing other benefits. Mechanical or digital sensors may be used for monitoring equipment to determine whether problems are developing. Specifically, sensors may be used in conjunction with one or more system components to predict and detect slide valve hot spots. A shielded, tube skin thermocouple assembly may provide a temperature profile for a slide valve. Tomography may be used to image a slide valve. An operating condition of the plant or refinery may be adjusted to prolong equipment life or avoid equipment failure.