FIELD OF THE INVENTION
The present invention generally relates to a manually or electrically operated
valve to start, stop or regulate the flow of a gas, liquid, slurry, loose dry material
and any combination in a technical process. More particularly, the invention
relates to a process for accurate setting of technical parameters and conducting
detailed functional testing of electrically operated motor valves. The invention
further relates to a device for parameter setting and functional testing of
electrically operated motor valves.
BACKGROUND OF THE INVENTION
A typical valve contains a body, a bonnet, a disc, a seat, multiple ports, gaskets
and a handle. A motorized valve additionally comprises an electrical actuator
mounted on the valve.
The electrical actuator consists of a motor, a gear arrangement, a stem nut for
connection to the stem, position limit switches, torque limit switches, a dial
indicator, and terminals for connection and other protective/operating devices as
required.
Motorized valves are used in many industries for automizing the process, and
controlling from remote. Higher sizes motorized valves are used for larger
process control. For an effective and trouble free operation of motorized valves,
it is necessary that some of the protective

and operating devices disposed on the valve actuators are pre-set and reset
according to the design parameters.
According to the prior art, during manufacture of the valves, the mechanical
assembly of the valve is completed and then the motorized actuator is assembled
with the valve. After assembly of the electrical actuator with the valve, some of
the components of the actuator are to be pre-set on the actuators so that the
valve is operated correctly without any damage. These components are position
limit switches, torque limit switches, dial indicator, position feedback transmitter.
The parameter values to be set vary with respect to type, design, size and rating
of the valve. Presently, these settings are manually done by skilled person based
on the design data. During the setting process, the testing person operates the
valves and positions it at required locations for setting the devices. This
positioning is done either through a hand wheel or by operating a motor. The
accuracy and correctness of the setting depends on the skill and knowledge of
the operator and the data available with the operator. Subsequently the
performance and life of the valve and the connected equipment also
corresponding depends on these factors.
According to prior art, functional testing of the valves is generally done based on
the instantaneous values for example current (for motor healthiness) and
operating time (for achievement of both extreme ends).
Further, the valve-settings are done manually by trained persons based on the
design data. During the setting process, the valve is moved to the required
locations and required limit settings are done. The accuracy of the test results
depends on the operator skill and knowledge.

OBJECTS OF THE INVENTION
It is therefore an object of the invention to propose a process for accurate
setting of technical parameters and conducting detailed functional testing of
electrically operated motor valves.
Another object of the invention is to propose a device for parameter setting and
functional testing of electrically operated motor valves.
SUMMARY OF THE INVENTION
Accordingly, the present invention in a first aspect provides a process for
accurate setting of technical parameters and conducting detailed functional
testing of electrically operated motor valves. In a second aspect of the invention,
there is provided a device for parameter setting and functional testing of
electrically operated motor valves.
The present inventions allows a detailed testing of electrical motor operated
valves, which captures important operating data continuously over the entire
operating period and provide the captured data for further analysis. To make the
data analysis easier, the invention uses a knowledge based predictive current
curve for comparison. Accordingly, the setting of the valves for functional testing
can be accurately done by eliminating the human discretion and errors.
By making the functional test analysis and setting the valves more accurately,
the failures of the valves during operation are avoided, and the performance and
life of the valve is improved.

BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS
Figure 1 Block diagram for a device for parameter setting and functional
testing of electrically operated motor valves, according to the
invention.
DETAIL DESCRIPTION OF THE INVENTION
The block diagram in figure 1 illustrates a device for setting and testing of
electrical motor operated valves, comprising a processor, a storage device, a
display device, and an input device like key board etc. The device is provided
with connecting cables for power supply and data feed back.
Initially all the technical parameters of all types valves to be tested are stored in
to the testing device. The valve to be set is operably connected to the testing
device. After a start command is given, the testing device operates the valve
automatically to check that the input data match with that of the connected
valve, once matched, the valve is moved to an assigned position and the
operator is given a clearance to set the switches, dial indicator, feedback sensors
to the respective points. At every point, the setting done by the operator is
automatically checked and the next operation is allowed only after the prior
setting is found to be correct.
After the setting is completed, the detailed testing of the remaining technical
parameters of the valve are tested and the test results are displayed. The test
data is also stored in the system and can be referred for further performance
analysis in the future.

According to the invention, electric current curve of the motor over the total
operating time of the valve is continuously captured, and used for functional
testing, wherein the continuous electric current curve represents the torque
requirement. Further, the current curve is used for identifying any abnormality in
operation/design of the valve. A knowledge based predictive current curve for
each type of valve is generated by collecting a plurality of current curves from
successful tests, wherein said plurality of current curves are averaged to obtain
an average predictive current curve. This predictive current curve ise is used in
the functional test to evaluate the valve function.
The valve position corresponding to the operating time is mapped based on the
operating speed and the total time of operation as the parameters, and the
limiting position of the switches is located. By this way, the physical
measurement of the switch position can be replaced with an automated location
identification for setting the switch by the use of a computer apparatus and data
stored in such computer.
The above improvement ensures the optimal setting and accurate setting of the
electrical motor operated valves for example, flow-control valves to prevent
damage to the valves including other connected equipment.

WE CLAIM :
1. A process for accurate setting of technical parameters and conducting
detailed functional testing of electrically operated motor valves, the
process comprising the steps of:
- generating a continuous electric current curve by capturing data during
entire operation of the valve in a testing process, the generated curves
representing required torque valves and adapted for functional testing of
the valve;
- providing a testing device having at least one computer apparatus with
storage device, and a signal interface, the storage device incorporating at
least an average predictive current curve developed from a plurality of
known predictive current curves relating to different types and capacities
of motor valves and averaging the data of said plurality of predictive
current curves;
- operably connecting the valve with the testing device through said
interface and comparing the technical parameters of the physical valve
with stored parameters in the memory;
- determining a limiting position of electrical switches provided in the
testing device for operating the valve during testing, the location of the
switches being automatically selected on the basis of the valve position
evaluated upon the parametric values of operating speed and total
operational time of the valve;
- conducting the functional test without allowing human intervention
towards matching or otherwise of the valve with designed parameters and
right-positioning of the switch limiters; and
- displaying the output data on a display positioned on the testing device.

2. A device for parameter setting and functional testing of electrically operated
motor valves, comprising :
- a computer apparatus having a memory means;
- a plurality of electrical switches for operating the valve during testing
process;
- a plurality of sensor means to capture physical including operating data of the
valve;
- a power source to operate the device; and
- a power and signal interface interfacing the testing device and the valve;
wherein the memory means having stored with knowledge based average
current curve.