Solenoid Valve Testing via Positioner for Non-Disruptive Emergency Valves
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Solution Overview
Problem
Existing methods for testing emergency valves, such as partial stroke tests, often disrupt system operations and fail to detect solenoid valve deterioration, leading to potential failures in hazardous conditions due to infrequent testing and lack of precise control over actuation.
Innovation Solution
A method and apparatus using a valve positioner with a processor to conduct solenoid valve tests independently or concatenated with emergency valve tests, allowing for regular testing of solenoid valves without affecting the actuator or shutdown valve, and automatically scheduling partial stroke tests based on solenoid valve functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If partial stroke tests are conducted on emergency valves, then the emergency valve actuation capability is verified, but system operations are disrupted and solenoid valve deterioration is not detected
Solution Approach 1:
The testing process is segmented into two independent tests: a solenoid valve test that can be conducted frequently without disrupting operations, and a partial stroke test that verifies emergency valve actuation. The solenoid valve test monitors pressure changes in the actuator chamber to detect deterioration, while the partial stroke test is performed separately to verify full actuation capability. This segmentation allows frequent reliability checking without continuous system disruption.
Solution Approach 2:
The solenoid valve test serves as a preliminary action that detects potential deterioration before it leads to failure. By monitoring pressure changes in the actuator chamber during solenoid valve operation, the system can identify degradation trends and schedule maintenance proactively, preventing unexpected failures while minimizing disruption to operations.
2Measurement precision
If solenoid valve testing is performed independently, then frequent testing is enabled and deterioration detection is improved, but the position of the actuator and shutdown valve is affected
Solution Approach 1:
A positioner acts as an intermediary device that controls the actuator position during solenoid valve testing. The positioner receives commands from the control system and adjusts the actuator position to maintain the shutdown valve in its current position while allowing pressure changes in the actuator chamber to be monitored. This intermediary control enables precise measurement of solenoid valve functionality without affecting the actual valve position.
Solution Approach 2:
The testing method monitors pressure changes in the actuator chamber as a parameter indicator of solenoid valve functionality. By measuring pressure differential changes rather than directly observing actuator position changes, the system can detect solenoid valve deterioration with high precision while maintaining ease of operation through non-intrusive measurement.
3Reliability
If traditional emergency valve testing methods are used, then system safety is maintained, but testing frequency is low and potential failures are not detected timely
Solution Approach 1:
The system implements continuous feedback monitoring of pressure changes in the actuator chamber during normal operation. The control system analyzes pressure differential data to detect trends indicating solenoid valve deterioration. This feedback mechanism enables frequent assessment of solenoid valve health without requiring frequent full emergency valve tests, reducing detection time while maintaining system safety through proactive maintenance scheduling.
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 frequent testing of solenoid valves and emergency valves, detecting potential failures more promptly, reducing the risk of system disruptions and improving safety by ensuring timely detection of solenoid valve deterioration without interrupting system operations.
Implementation Method 1
The solenoid valve is in fluid communication with an actuator to enable the actuator to actuate an emergency valve
Implementation Method 2
determining a functionality of the solenoid valve by measuring, via a valve positioner, a maximum pressure change of a pressure chamber of the actuator
Data Source
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AI summary
Methods and apparatus of testing a solenoid valve of an emergency valve via a positioner are disclosed. An example method includes conducting a solenoid valve test by initiating a pulse duration and a monitoring duration for the solenoid valve test. Conducting the solenoid valve test further includes instructing a solenoid valve to transition from a first state to a second state during the pulse duration. The solenoid valve is in fluid communication with an actuator to enable the actuator to actuate an emergency valve. Conducting the solenoid valve test further includes determining a functionality of the solenoid valve by measuring, via a valve positioner, a maximum pressure change of a pressure chamber of the actuator during the monitoring duration. The example method includes, upon determining the solenoid valve is in a functioning state, conducting a partial stroke test of the emergency valve via the valve positioner.