Integrated Valve Control Circuit for Partial Stroke Diagnostics
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Solution Overview
Problem
Current safety systems for pressurized fluid conveying circuits lack comprehensive diagnostic coverage during partial stroke testing, as they exclude the control circuit involved in emergency operations, and require dedicated circuits, leading to inefficiencies and longer testing times.
Innovation Solution
A control and safety system that integrates both partial stroke and emergency operations using a single circuit, involving a pressure reducer, control valve, secondary valve, pressure switch, shuttle valve, flow amplifier valve, and single-acting actuator, ensuring complete diagnostic coverage and reducing testing time by utilizing existing components for both functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dedicated circuit is used for partial stroke testing, then the testing function is isolated and simple, but the control circuit involved in emergency operations is excluded from diagnostic coverage
Solution Approach 1:
The patent merges the partial stroke testing function with the emergency operation control circuit into a single integrated circuit. The same control valve, solenoid valve, and actuator are used for both testing and emergency operations, eliminating the need for separate dedicated circuits while ensuring complete diagnostic coverage of all components involved in safety-critical emergency operations.
Solution Approach 2:
The control circuit is designed with multi-functionality to serve both partial stroke testing and emergency operations. The control valve can be actuated in both test mode (partial closure) and emergency mode (full closure), with the same hardware components performing multiple functions based on control logic differentiation rather than physical separation.
2Reliability
If multiple valves and complex circuitry are used for partial stroke testing, then the testing capability is enhanced, but the execution time increases
Solution Approach 1:
By combining the testing and emergency operation functions into a single circuit path, the patent eliminates the time penalty associated with switching between separate dedicated circuits. The same control valve and actuator are used in both modes, allowing rapid transition between test and emergency functions without the overhead of engaging separate circuitry.
Solution Approach 2:
The system performs preliminary partial closure actions during normal testing that prepare the valve and actuator for full emergency closure. This preliminary action validates the operational readiness of the complete valve kit accessories and control logic under realistic conditions, ensuring that when emergency operations are needed, the system is already warmed up and ready for immediate full-stroke response.
3Reliability
If the valve is tested at speeds comparable to emergency operation, then the test becomes more realistic and convincing, but the process is altered for a longer period
Solution Approach 1:
The patent applies partial action by performing incomplete closure strokes during testing - the valve is closed partially to a predetermined position rather than fully closed. This partial closure is sufficient to validate the operational characteristics of the actuator and control system at emergency-relevant speeds, while avoiding the extended process interruption that would result from complete closure and subsequent full re-opening cycles.
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 integrated system enables thorough diagnostic testing of the actuator-valve-circuit system during partial stroke operations in times comparable to emergency operations, providing enhanced diagnostic coverage and operational efficiency without dedicated circuits.
Implementation Method 1
a pressure reducer (16), a control valve (17)
Implementation Method 2
a flow amplifier valve (21), and a single-acting actuator (22)
Implementation Method 3
a driving element in the form of a pressure switch (19)
Data Source
Figure 1
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Figure 3
AI summary
A control and safety system (100, 200) suitable for conveyance circuits of pressurized fluids provided with at least one process valve, said system having a pressure reducer (16), a control valve (17, 25), a secondary valve (18, 26), a driving element (19, 24), a shuttle valve (20), a flow amplifier valve (21), and a single-acting actuator (22). The system (100, 200) has a single circuit with a supply line of a working fluid, which is directly connected to the pressure reducer (16), to the control valve (17, 25) and to the flow amplifier valve (21); downstream of the pressure reducer (16) is connected the secondary valve (18, 26); the control valve (17, 25) and the secondary valve (18, 26) are both connected to the fast discharge valve (20), which manages the working fluid supply to the pilot of the flow amplifier valve (21 ); the flow amplifier valve (21) connects the single-acting actuator (22) to the working fluid supply line or to a discharge line and is configured to load or discharge the actuator (22) according to the pressure signal that reaches the pilot of the flow amplifier valve (21), so as to actuate a partial stroke maneuver of the process valve.