When it comes to valve diagnostics, unseen issues often have the biggest impact. Inconsistent stroke speeds, calibration drift, or unexpected surges can all indicate underlying mechanical or pneumatic problems that go unnoticed during normal operation.
SofTek Engineering’s Profiler Level 1 Testing is designed specifically for engineers and technicians who need precise, data-backed insight into valve performance. Using our Profiler system, we detect and correct issues that traditional methods often miss — restoring accuracy, repeatability, and control reliability.
Here’s how we do it:
1. Calibration of Positioners (Analog and Digital)
If your valve isn’t hitting setpoints accurately, it’s likely a calibration problem. We verify and recalibrate positioners to ensure exact valve response to control signals, improving loop integrity and process stability.
2. Tuning of Positioners and/or Boosters (Surge Control)
Overshoot or sluggish response often comes down to improper tuning. Our technicians adjust positioner and booster parameters to optimize dynamic response — preventing surge, oscillation, and erratic behavior.
3. Air Leaks in Tubing
Even a minor leak in pneumatic tubing can cause pressure imbalance and erratic stroke performance. Using Profiler diagnostics, we identify and quantify pressure drops indicative of leaks and correct them before they escalate.
4. Blockages in Tubing (Debur)
Burrs and debris restrict airflow and slow actuation speed. We inspect and clean tubing to eliminate restrictions, ensuring consistent and repeatable valve movement.
5. Replace or Repair Positioner Feedbacks (Linkages, Array, or Hall Effect)
Feedback integrity is critical for closed-loop accuracy. We inspect and repair mechanical linkages, feedback arrays, and Hall effect sensors to ensure the control system receives precise position feedback.
6. Fix or Replace Regulators
Unstable regulator output leads to unpredictable actuator performance. We evaluate air supply regulators for stability, pressure control, and responsiveness — repairing or replacing components as needed to maintain consistent supply pressure.
7. Adjust Needle Valves and/or Boosters for Stroke Speed Tests
Properly tuned stroke speeds reduce wear and improve repeatability. Our testing includes fine adjustment of needle valves and boosters to balance speed, response, and mechanical stress.
8. Calibrate I/P Transducers
Accurate signal conversion is critical. We calibrate current-to-pressure (I/P) transducers to ensure control signals translate precisely into pneumatic output, minimizing process variability.
9. Replace I/P Transducers
If calibration can’t restore proper function, we replace faulty I/Ps to ensure reliable communication between control systems and actuators.
Why It Matters
Most of these faults remain hidden until they cause operational issues — erratic control, excessive wear, or full-on failure. The Profiler system allows technicians to see what the valve is actually doing, not just what the control system thinks it’s doing.
SofTek’s Level 1 Testing gives you actionable data, root-cause insight, and verified performance improvements. It’s proactive reliability — not reactive maintenance.
Don’t guess. Just test it.
