Valve Testing Control Software

Upgraded control system for valve test rigs

We successfully addressed the challenges associated with control software on a legacy valve test rig by providing a replacement system. The rig is used for extensive performance and qualification testing of specialized valves in the Petrochemical and Natural Gas industries, ensuring compliance with international standards such as API Specification 6A, Appendix F, PR2 level, and ISO10423:2001.

Previously, the valve test rig operated solely in manual mode, despite a previous attempt by another company to upgrade it for automatic operation. This upgrade had failed due to issues with temperature control and inadequate control software. To overcome these limitations, our company supplied a new control system specifically designed to address these issues.

The testing procedures for these valves involve a sequence of operations under varying conditions, including upstream and downstream pressures, valve positions, and ambient and valve body temperatures ranging from -40°C to 160°C. Efficient temperature control is critical, especially considering the significant variation in size and weight among the valves. While ambient air temperature can be controlled directly, the valve body temperature tends to exhibit thermal lag, particularly for larger valves. To achieve precise temperature control without the risk of overheating or underheating, we implemented a dual-loop cascade control system with a thermal head. This innovative approach enables rapid heating or cooling of the valve body, ensuring optimal testing conditions.

Furthermore, our replacement software/control system offers enhanced flexibility and efficiency compared to the previous control system, which relied on an Allen Bradley PLC. We implemented the capability to create multiple test sequence profiles, tailored to each valve type. These profiles can be easily created using a spreadsheet format, stored, and selected for each new test. This streamlined approach allows for more efficient testing and accommodates the wide range of valves tested on the rig.

By successfully implementing the replacement control software, we have achieved fully automatic, unmanned running of the valve test rig. This has not only reduced costs but also simplified the logistical challenges associated with manned testing. With our solution in place, the testing process is now more reliable, efficient, and aligned with industry standards.