Valve Predictive Maintenance via Torque-Position Analysis
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Solution Overview
Problem
Current maintenance methods for valves are costly and do not reliably predict future malfunctions, often resulting in unscheduled shutdowns and inefficient maintenance due to lack of reliable data on malfunction causes.
Innovation Solution
A predictive maintenance system using torque and position sensors to record and analyze valve operation data, enabling the detection of behavior patterns that anticipate potential malfunctions before they occur, and automatically sending reports and alarms, which can be adapted for various valve installations including remote locations without internet access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If preventive maintenance is carried out periodically, then breakdowns are prevented, but maintenance costs increase and parts are replaced that are still in good condition
Solution Approach 1:
The system performs preliminary monitoring of valve operations by continuously recording torque and position data during valve maneuvers. This preliminary action enables detection of degradation trends before actual breakdown occurs, allowing maintenance to be scheduled based on actual condition rather than fixed intervals, thus preventing unnecessary replacements while avoiding breakdowns.
Solution Approach 2:
The system implements feedback by analyzing recorded torque-position curves to detect changes in valve behavior patterns. The analysis provides feedback on valve health status, identifying when a valve is degrading and when replacement is actually needed. This feedback mechanism replaces parts based on real condition rather than predetermined schedules, reducing unnecessary maintenance costs while maintaining reliability.
2Loss of energy
If corrective maintenance is performed after breakdown, then economic savings are achieved, but unscheduled shutdowns occur
Solution Approach 1:
The system performs preliminary detection of valve degradation by monitoring torque-position characteristics during operation. By identifying trends indicating upcoming failure, the system enables scheduling of maintenance during planned shutdowns rather than reacting to unexpected breakdowns, thus avoiding unscheduled shutdowns while maintaining economic efficiency.
3Reliability
If valve monitoring is implemented, then future malfunctions can be predicted, but device complexity increases
Solution Approach 1:
The system uses an intermediary approach by placing a monitoring device on the valve spindle that records torque and position data during maneuvers. This intermediary recording mechanism captures operational characteristics without fundamentally altering the valve's primary function. The data is then analyzed to predict malfunctions, achieving reliability improvement with minimal added complexity.
4Measurement precision
If periodic inspection is performed, then wear and tear issues are detected, but maintenance reliability is low due to lack of information on malfunction causes
Solution Approach 1:
The system replaces traditional mechanical inspection methods with electronic sensing and data analysis. Torque sensors and position encoders electronically monitor valve operation, providing precise measurement of operational parameters. The recorded torque-position curves are analyzed to detect wear patterns and identify specific malfunction causes, replacing imprecise visual inspection with accurate electronic measurement and information-rich data analysis.
Data Source
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Figure 2
Figure 3~4
AI summary
The present invention relates to a system and a method for the predictive maintenance of valves for regulating the passage of a fluid, making it possible to detect possible malfunctions while still being maneuverable and to program actions for the repair or replacement thereof preventing unplanned shutdowns, basically comprising a torque sensor for measuring the actuation torque of the valve exerted on the spindle (4), a position sensor (8) for measuring the angular position of said valve, as well as the limit switches that mark the start and end of a maneuver, a sensor board in charge of acquiring and processing the signals from the sensors and a main board that stores and processes the data it receives from the sensor board from which an analysis is made on whether the evolution of the torque-position curves is correct and, if is not, a warning signal is generated.