Fault simulator and detection for a process control valve

Timo Manninen

    Research output: ThesisDoctoral ThesisMonograph


    In this study a novel fault simulator for a quarter-turn pneumatic control valve is presented. Another contribution of this study is a novel fault detection and diagnosis method for a control valve. It has been possible to analytically model control valve dynamics, despite their inherent nonlinearities for the fault simulator. These nonlinearities of the system have been identified and estimated through selected parameters. The models that were derived have been verified with measurements and the modeling error is found to be acceptable for the fault simulations. Some typical control valve faults have been simulated and the impacts on the internal variables of the flow control loop and control performance analysed. The fault simulator presented here can be used for fault detection and diagnosis, as well as robust control research. On the basis of simulations and test bench test runs it is possible to detect and diagnose typical control valve faults before they have a severe impact on flow control loop performance. This can be done with the online method introduced in this study, which requires low computing power. This means that the method is implementable in an intelligent valve controller and diagnosis can be performed without disturbing the process. The method that is introduced is based on the observation that the internal variable closest to the fault compensates and reacts first to the fault when feedback control is utilised. That leads to an operation point shift for all the internal variables before the fault in the chain of the internal variables in the system. When these operation point changes are being detected, the faults can be detected and diagnosed. This principle can be utilised in all feedback-controlled mechatronic systems. The fault detection and diagnosis method introduced here was verified with the fault simulator and test bench runs and found to be applicable to the detection and diagnosis of all the faults that were tested.
    Translated title of the contributionVikasimulaattori ja vikojen havaitseminen prosessin säätöventtiilistä
    Original languageEnglish
    QualificationDoctor's degree
    Awarding Institution
    • Aalto University
    • Pietola, Matti, Supervisor
    • Pyötsiä, Jouni, Advisor, External person
    Print ISBNs978-952-60-4853-6
    Electronic ISBNs978-952-60-4854-3
    Publication statusPublished - 2012
    MoE publication typeG4 Doctoral dissertation (monograph)


    • fault simulator
    • fault detection
    • fault isolation
    • fault diagnosis
    • process control valve

    Fingerprint Dive into the research topics of 'Fault simulator and detection for a process control valve'. Together they form a unique fingerprint.

    Cite this