Digital Valve Positioner Testing for Online Seat Integrity Checks
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing control valves in process control systems often suffer from deteriorated valve seating integrity due to wear and corrosion, necessitating offline evaluation that is costly and time-consuming, especially when the valves are large and operate across vast distances.
Innovation Solution
A method and system for executing online tests of valve seating integrity by queuing test requests and monitoring valve positions, allowing for real-time data collection and analysis without requiring the valve to be taken offline.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If offline evaluation is performed to assess valve seating integrity, then measurement precision is improved, but loss of time and productivity deteriorate due to costly shutdowns and technician travel
Solution Approach 1:
The system performs preliminary actions by continuously collecting sensor data during normal valve operation and pre-processing this data to prepare for integrity assessment. When a test is requested, the evaluation can be executed immediately using pre-collected data, eliminating the need to take the valve offline for data collection.
Solution Approach 2:
The system maintains continuous monitoring of valve operation through sensor data collection during normal workflow. This continuous data collection enables integrity testing to be performed at any time without interrupting valve operation, allowing the useful action of process control to continue uninterrupted while still enabling precise measurements when needed.
2Measurement precision
If offline evaluation with technician on-site is performed, then measurement precision is improved through direct inspection, but loss of time worsens due to technician travel and setup
Solution Approach 1:
The system performs self-service by automatically collecting sensor data, processing it through algorithms, and generating integrity assessments without requiring technician intervention. The digital valve positioner and sensor system autonomously monitor valve operation and can execute integrity tests and generate reports independently, eliminating the need for technician travel and manual inspection.
Solution Approach 2:
The system replaces mechanical inspection methods with electronic sensor-based monitoring and digital data processing. Instead of physical inspection by technicians, the system uses sensors to collect operational data and digital algorithms to assess integrity, substituting mechanical and human processes with automated electronic systems that provide equal or superior measurement precision without the associated time costs.
3Reliability
If valve testing is performed offline, then reliability of test results is improved, but productivity deteriorates due to facility shutdown requirements
Solution Approach 1:
The system transitions from static offline testing to dynamic online monitoring. The sensor system continuously adapts to changing valve operating conditions, collecting data across various positions and loads. This dynamic data collection during actual operation provides reliable integrity assessment that reflects real-world performance, while maintaining full facility productivity throughout the monitoring process.
Data Source
AI summary
Systems and methods may be provided to execute online tests of a valve in a digital valve positioner. The digital valve positioner may receive a request to execute a test of the valve, which specifies a test start point, and queue the request for execution. The digital valve positioner may subsequently receive a new setpoint for the valve. The digital valve positioner may further reposition the valve according to the new setpoint. The digital valve positioner may further, while the valve is being repositioned, compare the test start point to a current position of the valve, and in response to determining that the current position of the valve has reached the test start point, collect sensor data indicative of the operation of the valve, to generate results of the test.