System and method for detecting safe operating conditions and maintained integrity in a pressure safety valve

A method for detecting safe operating conditions in a pressure safety valve, the pressure safety valve including an inlet and an outlet, a valve disc controlling fluid flow between the inlet and the outlet, a position sensor for detecting the position of the valve disc, a vibration sensor for detecting vibration in the valve disc, and an inlet pressure sensor for detecting the inlet pressure in the inlet, the method comprising:

• a) comparing the inlet pressure with a predefined value, and if the inlet pressure is above the predefined value,
• generating a valve-stuck alarm,
• storing sensor data, and
• terminating the method;
• b) if the inlet pressure is below the predefined value, computing a time series of frequency magnitudes for sensor data from the vibration sensor and inlet pressure sensor, and comparing the computed time series of frequency magnitudes with a corresponding stored condition data set of time series of frequency magnitudes, and if the computed time series of frequency magnitudes is outside of an acceptable range:
• generating a check-movement alarm,
• storing sensor data, and
• terminating the method;
• c) if the computed time series of frequency magnitudes is within the acceptable range, comparing the time series of frequency magnitudes with a corresponding stored pop data set of time series of frequency magnitudes reflecting a fast opening of the valve, and if the computed time series of frequency magnitudes conforms to the stored pop data set:
• estimating a flow volume through the valve,
• logging that a pop has occurred,
• storing sensor data and the flow volume, and
• terminating the procedure;
• d) if the computed time series of frequency magnitudes does not conform to the stored pop data set, comparing the time series of frequency magnitudes for the vibration sensor with a corresponding stored leak data set of time series of frequency magnitudes reflecting a leaky valve, and if the time series of frequency magnitudes for the vibration sensor conforms to the stored leak data set:
• estimating leak flow volume through the valve,
• logging that the valve is leaking,
• storing sensor data and the leak flow volume, and
• terminating the procedure;
• and
• e) if the computed time series of frequency magnitudes does not conform to the stored leak data set, terminating the procedure.

A method for detecting safe operating conditions in a pressure safety valve, the pressure safety valve including an inlet and an outlet, a valve disc controlling fluid flow between the inlet and the outlet, a position sensor for detecting the position of the valve disc, a vibration sensor for detecting vibration in the valve disc, and an inlet pressure sensor for detecting the inlet pressure in the inlet, the method comprising:

• a) comparing the inlet pressure with a predefined value and, if the inlet pressure is above the predefined value, generating a valve-stuck alarm;
• b) computing a time series of frequency magnitudes for sensor data from the vibration sensor and inlet pressure sensor,
• c) comparing the computed time series of frequency magnitudes with a corresponding stored condition data set of time series of frequency magnitudes, and, if the computed time series of frequency magnitudes is outside of an acceptable range, generating a check-movement alarm,
• d) comparing the time series of frequency magnitudes with a corresponding stored pop data set of time series of frequency magnitudes reflecting a fast opening of the valve and, if the computed time series of frequency magnitudes conforms to the stored pop data set, developing a log that a pop has occurred;
• and
• e) comparing the time series of frequency magnitudes for the vibration sensor with a corresponding stored leak data set of time series of frequency magnitudes reflecting a leaky valve and, if the time series of frequency magnitudes for the vibration sensor conforms to the stored leak data set, developing a log that the valve is leaking.

A system for detecting operating conditions in a valve, comprising:

• an inlet and an outlet;
• a valve disc controlling fluid flow between the inlet and the outlet;
• a stem connected to the valve disc;
• a biasing device in communication with the valve disc;
• a position sensor for detecting the position of the valve disc via the stem;
• a vibration sensor for detecting vibration in the valve disc;
• an inlet pressure sensor for detecting the static pressure in the inlet;
• and
• a microcontroller in communication with the position sensor, the vibration sensor, and the inlet pressure sensor;
• and
• wherein the microcontroller computes a time series of frequency magnitudes based on sensed data from at least one of the vibration sensor and the inlet pressure sensor and, in response to the sensed data, generates operating-condition output data.

A method for detecting operating conditions in a valve, the valve including an inlet and an outlet, a valve disc controlling fluid flow between the inlet and the outlet, a position sensor for detecting the position of the valve disc, a vibration sensor for detecting vibration in the valve disc, and an inlet pressure sensor for detecting the inlet pressure in the inlet, the method comprising:

• a) comparing the inlet pressure with a predefined value, and if the inlet pressure is above the predefined value,
• generating a valve-stuck alarm,
• storing sensor data, and
• terminating the method;
• b) if the inlet pressure is below the predefined value, computing a time series of frequency magnitudes for sensor data from the vibration sensor and inlet pressure sensor, and comparing the computed time series of frequency magnitudes with a corresponding stored condition data set of time series of frequency magnitudes, and if the computed time series of frequency magnitudes is outside of an acceptable range:
• generating a check-movement alarm,
• storing sensor data, and
• terminating the method;
• c) if the computed time series of frequency magnitudes is within the acceptable range, comparing the time series of frequency magnitudes with a corresponding stored pop data set of time series of frequency magnitudes reflecting a fast opening of the valve, and if the computed time series of frequency magnitudes conforms to the stored pop data set:
• estimating a flow volume through the valve,
• logging that a pop has occurred,
• storing sensor data and the flow volume, and
• terminating the procedure;
• d) if the computed time series of frequency magnitudes does not conform to the stored pop data set, comparing the time series of frequency magnitudes for the vibration sensor with a corresponding stored leak data set of time series of frequency magnitudes reflecting a leaky valve, and if the time series of frequency magnitudes for the vibration sensor conforms to the stored leak data set:
• estimating leak flow volume through the valve,
• logging that the valve is leaking,
• storing sensor data and the leak flow volume, and
• terminating the procedure;
• and
• e) if the computed time series of frequency magnitudes does not conform to the stored leak data set, terminating the procedure.

A method for detecting operating conditions in a valve, the valve including an inlet and an outlet, a valve disc controlling fluid flow between the inlet and the outlet, a position sensor for detecting the position of the valve disc, a vibration sensor for detecting vibration in the valve disc, and an inlet pressure sensor for detecting the inlet pressure in the inlet, the method comprising:

• a) comparing the inlet pressure with a predefined value and, if the inlet pressure is above the predefined value, generating a valve-stuck alarm;
• b) computing a time series of frequency magnitudes for sensor data from the vibration sensor and inlet pressure sensor,
• c) comparing the computed time series of frequency magnitudes with a corresponding stored condition data set of time series of frequency magnitudes, and, if the computed time series of frequency magnitudes is outside of an acceptable range, generating a check-movement alarm,
• d) comparing the time series of frequency magnitudes with a corresponding stored pop data set of time series of frequency magnitudes reflecting a fast opening of the valve and, if the computed time series of frequency magnitudes conforms to the stored pop data set, developing a log that a pop has occurred;
• and
• e) comparing the time series of frequency magnitudes for the vibration sensor with a corresponding stored leak data set of time series of frequency magnitudes reflecting a leaky valve and, if the time series of frequency magnitudes for the vibration sensor conforms to the stored leak data set, developing a log that the valve is leaking.