Valve Positioner Emission Detection Using Integrated Optical Sensors

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Solution Overview

Problem

Existing flow control systems in industrial settings struggle to detect and manage small, fugitive emissions of fluids, which can lead to significant regulatory issues and increased operational costs due to the need for manual inspection and potential prolonged emissions.

Innovation Solution

The implementation of a valve positioner system that includes a control unit and a sensor unit capable of detecting fugitive emissions using various detection technologies, such as LIDAR or infrared, and integrating with existing communication infrastructure to alert operators and facilitate pre-emptive maintenance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual inspection methods are used to detect emissions, then detection capability is limited, but labor costs and safety risks increase

Engineering Contradiction:

Improvedetection capabilityVSAvoidlabor costs

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The patent replaces manual mechanical inspection with an automated optical detection system using LIDAR technology. The valve positioner incorporates a LIDAR sensor that automatically detects fugitive emissions by measuring light absorption, eliminating the need for technicians to physically approach and manually inspect valves with hand-held equipment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The valve positioner performs self-diagnosis by continuously monitoring its own operation and detecting emissions autonomously. The system automatically compares actual valve position with commanded position, identifies discrepancies, and detects emissions without requiring external manual intervention, enabling extended maintenance cycles.

Inventive Principle:

Principle #25Self-service

2Reliability

If manual inspection is performed frequently to ensure safety and compliance, then emission detection improves, but operational costs and time consumption increase

Engineering Contradiction:

ImprovesafetyVSAvoidmaintenance time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The LIDAR-based detection system operates continuously during valve operation, providing uninterrupted monitoring of fugitive emissions. Unlike periodic manual inspections, the automated system maintains constant surveillance, immediately detecting emissions as they occur without requiring scheduled maintenance interruptions.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The system implements continuous feedback by comparing the actual valve position sensor data with the commanded position, automatically identifying position discrepancies that indicate potential emissions. This real-time feedback mechanism enables immediate detection and alerting without waiting for manual inspection intervals.

Inventive Principle:

Principle #23Feedback

3Productivity

If automated detection systems are implemented, then labor costs decrease, but device complexity increases

Engineering Contradiction:

Improvelabor efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The valve positioner is designed as a multi-functional device that combines traditional valve positioning control with integrated LIDAR emission detection and diagnostic capabilities. By merging multiple functions into a single device, the system avoids adding separate complex detection equipment, thereby reducing overall system complexity while maintaining high productivity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges the emission detection system with the existing valve positioner hardware and communication infrastructure. The LIDAR sensor, processing unit, and alerting mechanisms are integrated into the valve positioner's existing architecture, leveraging available resources rather than creating entirely new separate systems.

Inventive Principle:

Principle #5Merging (Combining)

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

This solution effectively reduces labor costs and improves safety by automating the detection of fugitive emissions, allowing for extended maintenance cycles and reducing the risk of prolonged emissions and regulatory non-compliance.

Implementation Method 1

capable of detecting fugitive emissions using various detection technologies, such as LIDAR or infrared

Methodology Applied

Scientific EffectLIDAR: LIDAR

Implementation Method 2

capable of detecting fugitive emissions using various detection technologies, such as LIDAR or infrared

Methodology Applied

Scientific EffectInfrared radiation detection: Infrared Radiation

Data Source

PatentUS12345609B2Detecting fugitive emissions with a valve positioner

Publication Date: 2025.07.01 DRESSER LLC

AI summary

A valve positioner that is configured to detect fugitive emissions on a valve. The configuration may include a sensor that resides in proximity to the device. The sensor may connect to a control unit, preferably with operating hardware that can process signals. This arrangement may secure to structure of the valve. In one implementation, the sensor can connect to connections that exist on a circuit board. This feature permits upgrades to devices, including those in assembly or those in the field, with minimal impact to design or performance.