Major Oil & Gas multinational

Customer inquiry


Accurate test of safety valves according to the latest safety regulations.

Situation

  • Safety regulations require to test the operation of
    safety valves with a predetermined interval. These
    so-called stroke tests are to be executed in order to
    determine if the safety valve is able to perform its
    safety function (open or close) within the time
    allocated for this.
  • Stroke tests are usually executed by giving open or
    close commands on the DCS system and plant staff
    monitoring the actual time the valve opens or
    closes in the field, sometimes using stopwatches.
  • An (unplanned) upset in the production process
    usually also requires safety valves to operate.
  • It may therefore also be used to reset the test
    interval, provided the actual time the valve used to
    perform its safety function (travel time) has been
    recorded.
  • This is however difficult to achieve during a
    production upset.

Solution

  • Using the open and close limit switch signals it becomes possible to calculate the actual time between
    the shutdown command and the completion of the safety function of the safety valve.
  • These signals are recorded in the data historian system and are used in an application which calculates
    the travel time of the valve.
  • The Magion Application Framework was used to create a web application which shows an overview of all
    valves tested, their actual travel time and the allocated travel time.
  • Various test results of the same valve can be viewed to determine the performance of the valve through
    time.
  • Operations and maintenance personnel can add remarks and determine if the valve should be sent for
    repair before it is no longer able to perform its designated safety function.
  • Calendar functionality has been added to the application which enables operations and maintenance to
    schedule stroke tests of valves within the predetermined test interval.
  • Reminders are sent via e-mail if and when a valve needs testing.

Project results

  • Accurate time measurement of the travel time of the safety valve, without the need of personnel in the field.
  • Every time the safety valve has operated is recorded.
  • Clear overview of the performance of each and every safety-valve through time.
  • Knowing which valve needs maintenance before it fails in an emergency situation.
  • The valve test interval is automatically adjusted during planned stroke tests and unplanned upsets, preventing
    unnecessary stroke tests.
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