“Industry 4.0”, i.e. the digital factory of the future, will be characterized by its adaptability, resource efficiency, ergonomic design and the integration of customers and business partners into business and value generating processes. The underlying technology is based on research into cyber-physical systems and the “Internet of Things”. In order to achieve full system control, however, all the important components need to be capable of providing systemcritical information in real-time. KLINGER Schöneberg is focusing its power of innovation on intelligent valves – in the course of the project “SMART Valve – INTECtalk”.
Creating the digital factory of the future is an ambitious and at the same time a complex undertaking. Adhering to the principle of ‘information is key’, all the relevant parts need to be able to report their current status at any given time. For operators of process technology plants, this means no longer having to rely on specifications provided by manufacturers or the results of complex and costly inspections, which only deliver momentary data on the basis of the current setting. While valves may not be at the forefront of the drive towards ‘Industry 4.0’, every plant operator will readily agree that they play a most important role when it comes to avoiding leakages and the subsequent potential for damage to man, machine and the environment. Enter the valve specialist, KLINGER Schöneberg.
The importance of being ‘smart’
A smart system, such as the one proposed, must be able to log and analyze all relevant data. This not only covers information on the process itself, e.g. temperature of the medium or its pressure, but also data on the function and status of the valve. At present, obtaining function logs is a highly complex undertaking and comes with major cost attached. Any plant operator who has had his emission values audited in order to prove compliance with applicable emission threshold values, i.e. the German Clean Air Act regulation – generally well-known as “TA Luft” as well as the standard DIN EN ISO 15848 (fugitive emission), will be very much aware of this fact.
Talking about INTEC
Launched in 2014 by KLINGER Schöneberg, the “SMART Valve – INTECtalk” project aims at significantly improving the quality of information regarding valve utilization. Together with its customers, the company has identified three relevant target areas to be addressed in the course of the project: The actual seal tightness of the valve towards its surrounding environment, the tightness in the port as well as its operational status. Furthermore, the to be developed systems must be utilizable with all 90° valves with flange connections for drives in accordance with the standard DIN EN ISO 5211. And last but not least, the accumulated data must also enable operators to carry out prognostic assessments with regard to future availability, maintenance scheduling and replacement.
The future of leak detection
Following its completion, the revolutionary smart system will permanently detect leakages by means of a sensor system positioned directly at the operating stem port. For this purpose, a shielded chamber will be installed over the head flange and capture the leakage from the valve. The highly sensitive system will subsequently measure the leakage and its amount, allowing for subsequent analysis by means of a downstream evaluation electronic system. In this manner, the system will be capable of measuring the amount of leakage without having to fall back on indirect measurement methods, for example by means of sealing pressure reduction. Monitoring the compliance with leakage threshold values will therefore be possible during standard operation and online. Furthermore, the solution will also allow for a prognosis of the remaining lifetime of the valve. Also of great importance to operators: The leak detection innovation will not be limited to KLINGER products, but will be utilizable in tandem with every 90° valve by means of flange connections on both sides in accordance with DIN EN ISO 5211.
Monitoring of the actuation torque
With regard to valve utilization during standard operation, KLINGER Schöneberg is in the process of completing a sensor-based system, which will be inserted in automated INTEC products between the valve itself and the drive. The highly sensitive sensor unit, which is media-shielded, will measure and analyze the force generated by each movement of the drive. The torque will be permanently assessed with regard to the specific reference torque of the valve and will thus ensure a positive and early fault detection.
Winning features
“With INTECtalk we will be able to significantly contribute to increasing the ‘mean time between shutdown’ (MTBS) and at the same time avoid costs which would be incurred by maintenance, substitution or downtime,” explains Samuel Weber, in charge of R&D at KLINGER Schöneberg, and adds: “Next to costsaving, INTECtalk will offer its users a wide range of additional advantages: Among these are permanent status monitoring, independence from manufacturer certificates, the ability to plan costs and last but not least, a massive increase in plant safety – of great importance to both man and the environment.”