Digitization of Swing Check Valve (DoSCV)

Abstract

Overview of the problem background and solution:

Our idea provides the solution for the problem statement such as
1) Prediction of Clapper position & corresponding flow rate:

When cracking pressure (which is the minimum differential upstream

pressure between inlet and outlet at which the valve will operate) is reached the
clapper opens to allow the fluid flow.
The position of the clapper can be measured accurately using a rotary
encoder.
The clapper is fixed at the middle of the rod which can swivel in one of
its axis and other degrees of freedom are restricted. When the clapper plate
swivel, rotary motion is produced in the rod.
Either copper arm of rotary encoder is fixed at one end of the rod or a
rotary encoder module can be coupled at the end to collect the positional data
over a time.
Rotary Encoder Module is an incremental/absolute electro-mechanical
device that converts the angular position or motion of a shaft or axle to digital
code.
The output of absolute encoders provides information about the position
of the shaft, which is typically further processed in Arduino / controllers /
processor into information such as speed, distance, and position.
If the flow rate is an unknown quantity, a pitot tube/ flow meter is used to
obtain the flow rate. The clapper plate angle from the rotatory encoder and flow
rate calculated using Pitot tube / flow meter is used to derive an equation which
relates the clapper angle with flow rate. The equation can be processed to
predict the flow rate for corresponding clapper position of check valve.
2) Prediction of Pressure drops across valve & Valve flow coefficient (Cv):

Two pressure sensors are used to find the inlet and outlet pressure. From
the difference between the inlet and outlet pressure, the pressure drop across the
valve can be predicted.

The valve flow coefficient (CV) can be calculated using the relation,

CV=Q√ (SG/∆P)

Where,
Q- Flow rate (m3/h),
SG-Specific gravity (for water, SG=1),
∆P- Pressure drop in bar.

3) Clapper chattering verification:

When the arm-clapper assembly begins to open slightly and then

immediately closes against the valve seat, repeatedly due to inadequate flow the
angle of clapper tends to increase and drop repeatedly. The values of the rotary
encoder is monitored to verify the clapper chattering.

4) Prevention of Sand erosion:

The sand and clay particles are negatively charge so they are
attracted towards the positive charge and repelled towards the negative charge.
The walls of the valve system are positively charged using external dc supply.
Since the sand particles are in the size of microns to mm, less voltage will be
sufficient to attract the sand particles. The wet sand particles flow down along
the wall and gets collected in the base tank. A release valve operated by
solenoid control DCV, is provided to periodically release the excessive sand
particles collected in the base tank. The sand particles are collected before they
reach clapper plate. The clapper plate is negatively charged so that the sand
particles are repelled from clapper plate which avoid further erosion if any sand
particles present in the flow.

The data’s collected from the rotary encoder and the sand particles
deposited per time is used to predict performance, failures and diagnose
inefficiencies in its life cycle.

5. Sensors used:
SL NAME QUANTITY PURPOSE
NO OF THE
SENSOR
1 Level 1 To measure the flow rate
sensor (if
pitot tube
is used)/
flow meter
2 Pressure 2 To measure the inlet and outlet pressure to
sensor find the pressure difference
3 Rotary 1 To determine the position of the clapper
encoder plate
4 Sludge 1 To detect sand sludge level in sand filter
sensor
6. Layout:

Note: level sensors can be replaced by flow meters

7. Application of IIOT:

1) After obtaining the relationship between the clapper angel and other
parameters (flow rate) the valve with rotary encoder and electrolyte sand
filter is ready to be established in the pipe flow
2) A sludge detector (Eg: ultrasonic sludge detector) can be employed to
find the level of sludge in the base of sand filter
3) The output of rotary encoder and sludge detector is fed into control unit.
4) The control unit (processor) is programmed to indicate the flow
parameters of swing check valve for respective clapper angle and when
there is deflection in angle (say 0 to particular angle and vice versa within
short interval of time) a signal is send to the alarm or indicator which
denotes the clapper chatter.
5) A program to open up the release (relief) valve when sludge sensor
produce signal due to excessive sludge.
8. Conclusion:
This method helps to predetermine the relationship between the
check valve parameters such as pressure drop, flow rate, etc. with the clapper
plate angle. By establishing the relation, the clapper plate angle will be
sufficient to know the parameters of the check valve. The electrolytic based
sand filter and repelling technology prevents the erosion of the clapper thereby
increasing its life time.