ValveWatch® is a condition monitoring system for critical valves that delivers proven results. ValveWatch utilizes advanced technology to remotely monitor valves and actuators, detecting problems before they impact p......ValveWatch® is a condition monitoring system for critical valves that delivers proven results. ValveWatch utilizes advanced technology to remotely monitor valves and actuators, detecting problems before they impact production. How It Works The ValveWatch system incorporates sensors attached on or near the valve and actuator assembly to routinely monitor and record their performance. Strain sensors and actuator pressure sensors monitor valve & actuator performance during operation, while dynamic pressure sensors and acoustic sensors monitor the valve for internal seat leaks. Together, these sensors provide operators an automated checkup on the condition of the valve and actuator package. The strain sensor and actuator pressure sensor provide valuable diagnostic data each time the valve strokes. The strain sensor is permanently bonded to the valve yoke adapter and records the force applied to the valve by the actuator during a valve stroke. Problems with valve operation, including damage to certain components, are readily detected using data taken from this sensor. An actuator pressure sensor mounted to the actuator supply line records the change in actuator pressure throughout the valve stroke. Damage to the actuator or a problem with the actuator air or hydraulic supply can be detected using this sensor. The actuator pressure sensor is also used to determine when the valve changes position, causing ValveWatch to initiate a valve stroke test. For ball valve and slab gate valve designs with sealed cavities, dynamic pressure sensors are used to test the valves for leaking valve seats. Unlike other methods of leak detection that require valves to be closed for testing, ValveWatch allows operators to monitor and identify leakage while valves are open and production is flowing. This innovative technology gives operators the ability to trend valve seal performance and proactively plan for maintenance or repair. Two dynamic pressure sensors are used: one installed in the valve cavity and one installed upstream or downstream of the valve. During a typical leak test 60,000 readings are taken from each of these sensors. They record the fluid oscillation in the sealed valve cavity, and compare the frequency and amplitude to the oscillations to those measured in the upstream or downstream flow. As the signals become similar in shape and amplitude operators are immediately warned of a potential seat leak. For valves without a sealed cavity an ultrasonic sensor is installed downstream of the valve. The valve must be stroked closed, and a slight differential pressure is applied across the valve seat to detect a leak. If the valve seats are leaking, high-frequency noise generated by the gas or liquid media passing through the seat will be detected by this sensor. Data is collected from the sensors by the Local Data Acquisition Unit (LDAU) Assembly which consists of an IP66 weather proof box containing several modules installed as close as possible to the valve. The standard system includes two Strain/AC modules and a Communications Module. The strain channel monitors signals from the strain and static pressure sensors, and the AC channels handle the dynamic pressure sensors. The signals are conditioned and converted to digital in the sensor modules and passed to the Communications Module for wireless or data-over-power transmission to a HUB Assembly. The LDAU Assembly and the sensors are intrinsically safe and are certified according to North American and European standards for installation in Zone 0 areas. An additional communications and Ethernet module are housed in the HUB Assembly along with all the power supply, terminal strips, and intrinsically safe barriers. The HUB assembly is rack mounted in a safe area (Zone 2) or equipment room. Each Hub assembly can be configured to monitor up to eight valves. An Ethernet cable connects the HUB to a server where the data is stored, transmitted, and then analyzed for leakage. All the test results and data are stored in a secure Oracle database application. ValveWatch collects data from the dynamic pressure sensors on a scheduled interval or when the valve strokes, while data from the other sensors is recorded only when the valve strokes. For leak tests using dynamic pressure sensors, the system software performs the leakage calculations using patented algorithms that run automatically. The test results are compared to pre-established limits, and alarms warn operators of degrading seal conditions. For valve stroke tests, data taken from each sensor is compiled into a signature and compared against a baseline signature taken under “normal” conditions. Irregularities in valve signatures are identified and analyzed to determine the source of the valve or actuator problem. A simple web interface allows easy access to the system status from any location. Security is provided so that only authorized persons can access the system map, alarm window and system tree to view platform, valve and sensor status. The software provides reports and trending p