If you use valves in your processes – whatever those might be – you rely on their ongoing performance. Beyond basic performance, you count on your valves to operate at an optimal level, providing reliable and predictable output.

Certain challenges in the valve industry have made testing much more of a priority than it might have been in the past. Beyond those undeniable issues, however, virtually every industry and sector that makes use of valves faces a variety of pressing issues for regular valve testing.

The experienced team at SofTek Engineering understands the challenges you face, and we have the solutions you need today.

Challenges in the Valve Industry

Today, fewer and fewer valves are being manufactured in the U.S. That fact, in itself, doesn’t necessarily mean that there is a compromise in quality when using products sourced from overseas. However, it isn’t always possible to know the specific quality standards that were used in the manufacturing process.

International standards for valves can diverge significantly from American manufacturing standards. And, unfortunately, those standards seem to be growing further apart. Finally, not all types of valves are required to include self-contained testing criteria. Although there has been an increasing call for those criteria to be included with all valves, the industry is still a long way from that standard becoming a reality.

Another factor to consider is the changes the valve manufacturing industry has faced with regard to testing standards. The acceptable criteria that previously applied – specifically that no leakage was allowable under hydrostatic testing – no longer applies. Although different testing standards apply to different types of valves, the current applicable criteria does allow for some amount of leakage for certain valve sizes.

Valve Testing Standards & Considerations

Special types of valves require specialized testing procedures. Depending on the specific details, different standards and professional association guidelines apply.

The American Society of Mechanical Engineers (ASME) establishes standards for the testing of pressure seal valves, pressure release valves, and some sizes of steel valves. The American Petroleum Institute (API) is responsible for establishing standards for a variety of testing, including testing for steel ball and steel butterfly valves.

The Fluid Controls Institute (FCI) oversees standards for control valves, in conjunction with the Instrumentation, Systems and Automation Society of America (ISA). ISA has established standards for testing control valves as well, including those for hydrostatic testing. The Manufacturers Standardization Society of the Valve and Fittings Industry (MSS) establishes testing standards for cast iron gates, plugs, checks, and globes as well as bronze globes, gates, and checks.

As you can imagine, it can be challenging to determine which standards apply in certain situations and what the current standards criteria might be.

How Valve Testing Can Help

Valve testing provides a wealth of benefits and advantages, and can help you meet these and other challenges head-on.

No matter what type of valve testing you need – including isolation valve diagnostics, fugitive emissions testing, control valve diagnostics, safety relief valve diagnostics, and block valve diagnostics – you need a comprehensive valve profiler system to ensure optimal results.

If testing demonstrates that your valves don’t meet the established standards criteria, you also need a way to make adjustments inline, in real time. Although you could outsource both testing and correction measures, many people find that the most effective and affordable approach is to have their own valve diagnostics and testing equipment.

Choosing a Valve Profiler System

The most important factors for most customers are reliability, ease of use, and affordability of testing equipment and software. Durability is another critical aspect of choosing valve testing systems.

SofTek Engineering is proud to offer our Profiler, Profiler Mini, and Profiler SRV systems to customers across the United States. We also offer a wide range of accessories that can be used with any of our systems.

This equipment is designed to provide comprehensive testing results in any environment, even in the harshest scenarios. We provide in-depth training for our customers, tailored specifically to your exact needs, so you can get the maximum value from your system.

Contact us today to learn more about how our valve testing equipment can help you comply with established standards and overcome virtually any related challenge you face.

Even a seemingly minor issue with a process control valve can lead to significant problems. Those problems, at best, might involve reduced output or inefficient performance. However, you always run the risk of costly downtime and repair costs. Faulty valve performance can also place the security and safety of your facility and staff at risk.

These are just some reasons why monitoring valve performance is critical to your operation.

Obtaining critical information regarding valve health and performance is vital to your success, but it can be challenging to determine the best way to accomplish that objective. One option is to outsource your valve diagnostics to a third party. But is this the best way to get the actionable information you need?

The Role of Diagnostics in Control Valve Performance

Valve controllers play a critical role in process performance – virtually no matter the specific process—unfortunately, the very nature of any ongoing process places valves and controllers under constant stress. Time and environment both result in wear and tear on equipment.

Without predictive diagnostics, process engineers cannot identify any potential issues that might arise. Even a minor unaddressed issue can lead to significant problems over time. And those problems inevitably lead to shutdowns and the need for costly repairs or replacements.

Automatic control loops make detecting issues very challenging, which can compound problems. The reason for this is that controllers are programmed to compensate for degradation. As the valve continues to fail, you cannot identify the phenomenon – unless you have a way to diagnose the valve in action. Ultimately, complete failure will come as a surprise once it occurs. By that point, you have complete process interruption.

In the time leading up to the valve’s failure, you have likely seen sub-par (and declining) performance, compromising process output and preventing you from achieving your established goals. The irony of this situation is that all of these results could easily be avoided, given a means of obtaining predictive data from valves and controllers. With the correct data, you can perform necessary maintenance on your terms, scheduling it so that processes are not interrupted unexpectedly.

Obtaining Data from Valve Controllers by Outsourcing

Assuming you are not content to wait for total failure to disrupt your processes – or to lose output when you don’t need to – you need a reliable means for obtaining valve performance data. In the past, you might have had to decommission a valve and send it out for testing. However, the drawbacks to this approach are virtually too numerous even to consider.

Another option is outsourcing your control valve diagnostics to a third-party testing company. Periodic valve inspection and testing can go a long way toward providing you with actionable information. However, the schedule upon which you bring in a third-party valve testing expert is critical to providing the data you need for planning.

Budgetary considerations are always at the forefront of your mind – as they should be. Third-party testing consultant fees can quickly increase if you frequently have them onsite. However, unless you schedule valve diagnostics testing frequently enough, you risk missing critical clues that can predict impending failure.

Consider, then, the option of purchasing your own valve diagnostics equipment.

Using Valve Profiler Equipment to Monitor In-House

The preferable alternative to outsourcing valve testing and diagnostics – at least for many organizations – is purchasing a valve Profiler system to obtain actionable information in-house.

SofTek Engineering produces industry-leading advanced control valve diagnostics equipment. We customize our systems and services specific to your needs, ensuring you get the capabilities you need – and that you have those capabilities whenever you need them.

Purchasing a Profiler or Profiler Mini system puts control squarely in your own hands. You can perform testing for troubleshooting anytime, obtaining actionable data in real-time and when needed. Our systems design is extremely rugged and versatile for the harshest environments.

Contact us now to learn more about our company and how we can help you obtain the critical control valve diagnostics you need.

Facilities must run smoothly and efficiently, requiring your processes to remain reliable daily. No matter what industry or sector you operate within, you are also undoubtedly called upon to maximize output, mitigate downtime, reduce repair costs, and improve the safety of your facility.

Proper control valve function helps you achieve all of these objectives.

The first step in optimizing valve operation is obtaining robust diagnostic data. However, receiving data is only as effective as your ability to apply that knowledge. The best control valve diagnostic systems will also allow you to use the information gained through reporting. Application inline and in real-time will help ensure that you get maximum performance – and results – on an ongoing basis.

The Importance of Control Valve Optimization

The benefits of optimizing control valve performance are myriad and significant.

Optimal process performance guarantees maximum output – a critical metric in any scenario. For maximized process performance, every component in the process loop must function within the precise tolerances required.

Beyond the performance factor, however, it also considers the importance of reliability. Optimizing valves ensures that they function as they are supposed to, thereby reducing the risk of potential problems that could take your processes offline. Minimizing downtime also helps mitigate the possible cost of component repairs or replacement.

Safety is the most pressing reason for optimizing valve performance. Maximizing output and reducing downtime and the need for repairs will also improve the safety of your facility and your team members.

Approaches for Optimizing Control Valve Operation

Many of the most effective ways of optimizing valve function are purely mechanical and somewhat intuitive. For example, proper valve design and sizing are critical. But selecting the correct valve and valve controls for the job is only one small part of the overall scenario. Other factors, ranging from a dirty air supply to unwanted (and unexpected) vibration, can also infringe on valves’ ability to perform as desired. Unfortunately, you can only do so much to counteract dirty air or minimize (or eliminate) the vibration caused by other equipment components within the radius of a given valve and controller.

The primary hurdle in this scenario is knowing when and where problems may arise and to what extent those issues may contribute to compromised valve performance.

Comprehensive control valve diagnostics are a critical first step in optimization. Diagnostics provide the necessary predictive intelligence you need to derive actionable input. Even a slight decrease in performance needs to be addressed, as this ensures that you can address any potential issues before they become significant problems.

The Power of a Comprehensive Control Valve Diagnostic Solution

Performing diagnostic checks in a fully operational process scenario can help you quickly and effectively identify performance issues and determine the corrective steps to resolve them.

In an ideal scenario, automated control valve diagnostics tools will allow you to adjust settings and make minor corrections in real time without interrupting process flow. You can then monitor performance further to determine whether those actions have produced the desired results.

An effective diagnostics tool will also give you the power to see into the future – in a manner of speaking – allowing you to schedule and budget for any required downtime for maintenance purposes. The bottom line is that you no longer need to be in a reactive position with the correct valve test system. Instead, you will have everything you need to be proactive in every scenario or situation.

Finding the Best Control Valve Diagnostics System for You

A valve test system will provide critical information when real-time valve testing becomes vital. Otherwise, you put yourself at the mercy of third-party testing companies and their schedule – not to mention pricing.

Suppose you are considering the purchase of a block valve diagnostic system, isolation valve diagnostic equipment, or safety relief valve diagnostic system. In that case, you might have considered another system. However, the Profiler and Profiler Mini systems from SofTek Engineering provide a highly effective solution with multiple advantages over similar options.

Profiler systems are highly valued and regarded for their robust features and functionalities. Our equipment provides maximum durability and power, no matter the conditions you intend to operate within. Our systems are not only highly portable, but they are also simple to set up and use.

As the leading provider of valve diagnostic test systems, SofTek’s team of experts provides exceptional customer service and support. We focus exclusively on valve testing systems, and our dedication to results is apparent in everything we do. For almost 25 years, we have exceeded our client’s expectations by providing the most comprehensive training and support in our industry. Our valve diagnostics software features an intuitive and straightforward interface yet produces various information and results. Profiler systems let you test, report and optimize your valve systems whenever and wherever you need these capabilities.

Contact us today to learn more about how we can assist you in achieving the highest level of control valve optimization at your facility.

In industrial valves, control valves serve various critical process functions. These power-operated devices, such as liquid, steam, or gas, typically regulate or manipulate flow.

Here, we will explore some of the most common types of control valves and their applications. We will also consider the steps necessary to ensure proper valve functioning and performance, including the importance of periodic control valve testing.

How Control Valves Work

Control valves operate under the power of an actuator, the power source of which can be pneumatic, hydraulic, or electric. Depending on the actuator signal, these devices vary the flow opening based on the desired settings specified for an individual process which involves set points for liquid level, temperature, velocity, and pressure. The degree of regulation involved – which can range from fully closed to fully open or modulating (any position in between) – is determined by a valve controller.

Although these devices are typically simple in design, their operation and control can be highly complex. Valve actuators receive signals from outside sources, depending on the process flow design and the specific requirements for the given valve.

Control valves are used in countless applications; these are some of the most common control valves in use today.

Linear Motion Control Valves

Sometimes known as multi-turn valves, these devices achieve flow control via a sliding stem-type mechanism to open and close the device. This simple design offers maximum durability and versatility. Some of the most common types of linear control valves include the following.

Globe Valve

These devices, so named for their spherical-shaped body, function via an internal baffle with a disc or plug that operates to open or close flow within the device. Globe valves are standard in regulating process flow. Some typical applications for these devices include fuel oil systems, boilers, steam vents, water cooling systems, and chemical feed systems.

Gate Valve

Sometimes called a sluice valve, these devices control flow by opening or closing a barrier within the valve’s body, known as a gate. Whereas globe valves typically regulate flow, gate valves are exceptional when the need to stop flow exists. Applications for gate valve use include potable, wastewater, and other neutral liquids.

Rotary Motion Control Valves

Sometimes known as quarter-turn valves, these devices allow fluids to flow through a type of rotating element, which can be used to cut off the flow. Typically used in high-demand environments, these devices are compact and versatile. Some of the most common rotary motion control valves include the following.

Ball Valve

Popular for use in control and shut-off applications, these devices are exceptionally durable and reliable, even after long periods of disuse. Various ball valves are used, depending on the application, including full-bore valves, reduced bore, multiport, cavity filler, and v-port. Although operation remains consistent, ball valves can be composed of a single body, a split body, a top entry body, a three-piece body, or welded body.

Butterfly Valve

Butterfly valves use a rotating disc to control flow, similar to ball valves. Although they can control liquids, gasses, or solids, these devices are primarily in the food and beverage industry, pharmaceuticals, petroleum, and other chemical processing applications. More cost-effective than ball valves, these devices have been widely adopted across various sectors.

Other Types of Control Valves

Control valves that don’t fit into the two primary categories outlined above include the following.

Pinch Valve

Pinch valves use a pinching effect to control flow. Fully ported control valves are found in various applications, including the food and beverage industries, chemical and wastewater applications, and the handling of bulk or solid materials. This approach is beneficial for containing and controlling aggressive materials that might overwhelm other types of valves.

Diaphragm Valve

Sometimes known as membrane valves, diaphragm valves are typically made from durable materials such as steel and brass – although some applications might support heavy-duty plastic materials. These devices are often found in corrosive or abrasive environments where solids or solid-entrained liquids are a part of the process. Diaphragm valves are controlled by manual, pneumatic, hydraulic, and electric actuators. The most common diaphragm valves use pneumatic actuators where air pressure is applied through a pilot valve into the actuator, which raises the diaphragm and opens the valve. This type of valve is used when valve speed is critical.

Hydraulic diaphragm valves are used in high-pressure, low-speed applications. Diaphragm valves are used in pharmaceuticals, mining, wastewater, power, and paper.

Control Valve Testing

Control valve testing is a critical aspect of valve operation. Specifically, periodic, comprehensive testing ensures a valve’s proper and safe operation.

SofTek Engineering offers industry-leading control valve testing equipment and valve profilers. Our valve testing and diagnostics equipment, including Profiler and Profiler Mini, is designed to help you avoid costly downtime. Our valve diagnostic systems perform a full range of performance testing appropriate for more than just control valve diagnostics. Use our systems for isolation valve diagnostics, block valve diagnostics, fugitive emissions testing, and more.

Our valve testing equipment is light and portable, making it ideal for use in virtually any location or application. Our best-in-class training ensures you get the maximum value and return on investment.

Contact us now to learn about control valve testing equipment from SofTek Engineering.

Control valve problems can lead to poor loop performance and, in many cases, complete (and often unexpected) valve failures.

Understanding some of the most common types of valve problems will give you the background you need to address any issues that might arise. However, unless you have the know-how – and the right tools – to troubleshoot valve problems, you could encounter unwanted and costly problems.

Potential Control Valve Problems

Control valves are subject to a wide array of potential problems. The nature and extent of those problems can vary depending on the specific equipment in question, the process loop type, and other factors.

These are some of the most common control valve problems you could encounter.

Hysteresis

Hysteresis refers to the flow difference between the valves up-stroke and down-stroke. Because the valve is trying to maintain desired flow, it will remain in constant motion to reach the desired target. Static friction, among other factors, can be a common cause of hysteresis.

Deadband

Control valve deadband is often considered the opposite of hysteresis. In other words, this phenomenon occurs when there is no movement in the valve, despite the actuator being in motion. This phenomenon occurs due to excess “play” or looseness within the mechanism, incorrect actuator sizing, positioner defects, or valve friction.

Stiction

Stiction, a common term for static friction, generally means something sticking within the valve due to friction. This phenomenon often occurs when the positioner or actuator is not sized correctly. This problem can also develop due to excessive valve wear or if scaling is present. It can also occur due to extreme tightness in the valve stem seal or issues within the positioner.

Why Control Valve Testing Is Important

Many problems described above can also be present in your process without causing substantial concern. Most mechanical devices experience some degree of stiction, for example, without the need to address the issue. Problems occur when you cannot identify the reasons for performance issues; even worse, you may be experiencing an issue without realizing it.

For this reason, regular, comprehensive valve testing is necessary to ensure ongoing, reliable operation.

Automatic valve testing is also essential for maintenance purposes. Getting the proper feedback ensures you can properly tune your valves for optimal performance, reducing the strain on the system and increasing equipment lifespan. You will experience fewer problems, particularly unexpected failures and process interruptions.

Troubleshooting Control Valve Problems

Unfortunately, it can be challenging to determine the specific issue within a control valve – unless you have the knowledge, tools, and technology necessary for comprehensive troubleshooting.

Poorly performing valves call for a practical and affordable valve testing solution. SofTek Engineering has the answers you need today.

Automated control valve diagnostics and testing equipment – including our Profiler and Profiler Mini systems – provides the answers you need for optimal valve performance. Our solutions allow you to conduct your valve testing on-site, returning robust results that don’t require reliance on third-party testing.

Contact us today to learn more about control valve diagnostics and other testing systems (block valve and safety relief valve).