Valve diagnostics and repair
Valve diagnostics enable the elimination of emergency shutdowns due to unexpected equipment failure, improve the efficiency of planned preventive maintenance, and allow for rational spare parts management.
Our clients gain the ability to plan shutdowns more effectively, prevent accidents, detect premature wear of valve components, and reduce maintenance costs.
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Information on diagnosed valve models is being collected and prepared (pre-diagnostic phase).
DS Controls will prepare a proposal and provide the estimated timelines for the diagnostics.
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The work is being performed (positioners are being tested for correct operation, adjusted as required, and diagnostic graphs are subsequently captured).
A report on the completed work will be issued.
Following the report, repair recommendations are provided.
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If required: a technical and commercial proposal for spare parts for repair and/or a repair proposal is prepared.
The repair timeline at the service center is coordinated based on the lead times for specific spare parts.
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The period for conducting the works is defined in consultation with the customer (during this period, the valves must be decommissioned: for equipment repair or switched to ByPass).
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The timing of repairs at the service center is coordinated according to the availability of specific spare parts.
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Refurbished valves come with an extended manufacturer's warranty. A note is made in the valve's passport.
Currently DS Controls can perform
- Diagnostics of Masoneilan® valves
- Diagnostics and repair of control valves by Masoneilan, Samson, Fisher, Neles, Metso, and RUST
- Diagnostics of valves from other manufacturers with Masoneilan® control instruments
Diagnostic method using a mobile diagnostic complex is implemented in many factories, requires minimal customer investment, and can be deployed at any time.
Intelligent diagnostic controller
Designed for control and diagnostics of on-off valves, this unit features an integrated microprocessor with configurable software. This ensures compatibility with all actuator types available on the market, including pneumatic, hydraulic, rotary, linear, spring-return, and double-acting models.
It is now possible to diagnose the valve during operation. A partial stroke test, coupled with comparative analysis against standard characteristics, enables the verification of individual actuator and valve component functionality, current setting values, and the execution of corrective actions as needed.
The controller can perform
- Partial stroke test
- Full stroke test
- Emergency shutdown test for valve
- Solenoid valve test
All displayed graphs show the valve's position and the actuator's pressure. This enables identification of the operating conditions of the valve.
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The following parameters are used for diagnosing potential valve malfunctions
- Response time (start of movement)
- Stroke time
- Set pressure (start of movement)
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Possible problems to be identified
- Slow response or sticking of the solenoid valve
- Slow valve movement or sticking
- Excessive stem/shaft friction
- Broken springs in the actuator
- Long response time to control signal
Valve repair
DS Controls service centers offer equipment repair services, including an extended warranty. The availability of our own spare parts warehouse allows for prompt work execution.
DS Controls provides its customers with comprehensive repair services for control, on-off and control, on-off, and safety valves, as well as digital displacer level transmitters. These services are available at our production facility in Veliky Novgorod, at the premises of our regional service centers, and on customer locations.
