Fluid Control Valve Characterization for Seating and Breakout Points

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Solution Overview

Problem

Manual determination and adjustment of seating and breakout points for fluid valves in process control systems are time-consuming, labor-intensive, and prone to operator error, necessitating a more efficient and accurate method for characterizing fluid control valves.

Innovation Solution

A system utilizing sensors and processors to automatically determine and calculate seating and breakout points for fluid valves by monitoring the position, velocity, and acceleration of valve plugs, allowing for precise programming of parameters such as seating force and breakout time, enabling rapid and accurate characterization of multiple valves simultaneously.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual measurements are used to determine valve parameters, then operator control and flexibility are maintained, but the process becomes time-consuming and labor-intensive

Engineering Contradiction:

Improvemanual controlVSAvoidcharacterization speed

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The valve automatically performs self-characterization by using its own actuators to move the valve plug through its range of motion while sensors monitor position, velocity, and acceleration. The processor automatically calculates seating and breakout points from this data, eliminating the need for manual measurement operations while maintaining accurate parameter determination

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical measurement operations are replaced with an automated sensor-based measurement system. Sensors detect valve plug position, velocity, and acceleration, and a processor automatically calculates the required parameters, substituting human operators with an automated electromechanical system that achieves both speed and accuracy

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Device complexity

If manual measurements are used to determine valve parameters, then equipment complexity is reduced, but measurement precision and accuracy deteriorate due to operator error

Engineering Contradiction:

Improvesystem simplicityVSAvoidparameter accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

Sensors continuously monitor valve plug position, velocity, and acceleration during actuator movement, providing real-time feedback data to the processor. This feedback enables automatic calculation of seating and breakout points with high precision, eliminating operator error while the feedback loop ensures accurate parameter determination through multiple measurement points

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

Manual measurement operations prone to human error are replaced with an automated sensor and processor system that objectively measures and calculates parameters. The substitution of human judgment with automated computational analysis significantly improves measurement precision and repeatability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If automated sensor-based characterization is implemented, then productivity and accuracy are improved, but device complexity increases

Engineering Contradiction:

Improvecharacterization speedVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The valve controller is designed with multi-functionality, serving both as the control system for normal valve operation and as the characterization system. The existing actuators are used for both process control and parameter measurement, while sensors serve dual purposes of monitoring valve position during operation and collecting data for characterization, reducing the need for separate dedicated characterization equipment

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The characterization system components are merged with the existing valve control system. Sensors, actuators, and the processor are integrated such that the same hardware infrastructure performs both process control functions and parameter characterization, consolidating system complexity rather than adding to it

Inventive Principle:

Principle #5Merging (Combining)

4Loss of time

If automated characterization is implemented, then labor costs and time are reduced, but initial investment and manufacturing complexity increase

Engineering Contradiction:

Improvecommissioning timeVSAvoidmanufacturing complexity

Core Design Contradiction:

Loss of timeVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

Inventive Principle:

Principle #25Self-service

Data Source

PatentEP3625491B1Apparatus and methods to characterize fluid control valves

Publication Date: 2024.04.24 FISHER CONTROLS INT LLC

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AI summary

Apparatus and methods to characterize fluid valves are disclosed. An example apparatus includes a fluid valve having a valve seat and a flow control member to sealingly engage the valve seat. The apparatus includes a sensor to detect a change in position of the flow control member. The apparatus includes a processor to determine at least one of a seating point or a breakout point corresponding to the flow control member based on the change in position.