Valve diagnostics using Druck’s UPS4E

In process industries, precise valve control is critical for maintaining safe and efficient operations.

The Masoneillan SVI3 valve positioner ensures accurate valve positioning based on a 4–20 mA control signal from a control panel or DCS (Digital Control System).

During commissioning or troubleshooting, technicians need to verify that the valve responds correctly to these signals and identify any operational issues.

Challenge Traditional methods for simulating control signals often lack precision and automation. Technicians can spend hours manually cycling valves to confirm performance, leaving room for error and consuming valuable time.

Inaccurate signal simulation can mask positioner faults, leading to inefficiencies or costly downtime.

Cycle tests are increasingly becoming an expectation from customers globally due to the efficiency and productivity gains. However, to achieve levels of automation, technicians are having to use more expensive multifunction calibrators, meaning scaling up operations is not possible due to cost.

Druck solution Druck’s UPS4E provides a highly accurate, portable and automated way to simulate 4–20 mA signals for valve diagnostics and commissioning.

The UPS4E allows technicians to detect calibration errors in the positioner quickly. With controlled step cycling from 4 to 20 mA, thousands of test cycles are automated without manual input, saving the customer time and improving productivity.

Cycle management and maintaining safety is also improved when using the UPS4E. Users can set a specific number of cycles and the UPS4E stops automatically after completion of the process. This prevents unnecessary wear and eliminates the risk of valves continuing to cycle unattended.

Druck’s added value: Compared to cheaper alternatives, Druck’s UPS4E offers a more reliable and efficient solution to valve diagnostics.

Through its superior accuracy, the UPS4E enables precise simulation of control signals which allows technicians to assess if the positioner has an error or is out of calibration.

Compared to lower-cost alternatives, the UPS4E delivers superior signal accuracy for reliable diagnostics combined with automated valve cycling, which frees up technician time for other tasks.

The valve commissioning feature in the UPS4E provides a controlled step from 4 to 20 mA with thousands of cycles possible. This enables valve cycling automation and frees up time for a technician to perform other routine tasks.

Automation also creates less “touch-time” for technicians. For industries where prolonged exposure to radiation (for example, nuclear) is present, being able to leave the UPS4E in-situ performing the calibration reduces the impact of exposure.

The size of the UPS4E is also a benefit to users; being the smallest loop calibrator on the market, the UPS4E can fit into the top pocket of an overall, freeing up the hands of the user.