Emergency shutdown valve reliability function test by automated Partial Stroke Testing System

Partial stroke testing (PST) is a technique that is regularly practiced in oil and gas industries to test the emergency shutdown (ESD) valve by closing a certain percentage of the valve position and stop any flow through the pipeline. Generally, it only functions when there is an emergency occurring in the production system. When the ESD valve remains in one position for a long period, there is a risk and potential of fail on demand which is, the ESD valve fail to operate during the emergency shutdown. This testing can reveal approximately 75 of unrevealed failures in valves. It can also provide predictive maintenance data that can contribute to the extension of the preventive maintenance for the ESD valve. The objectives of this paper are to design, simulate, build and test the performance of the automated PST system based on PLC. Four guidelines and methodology are used in this work. First, understanding the operation of the PST system. Then, the utilization of the capability of MATLAB-Simulink software as the simulation tool for the PST design system. Next, designing the PST automated system based on PLC design and lastly, testing the performance of the PST design system using lab scale PST system prototype that has been built. Results of the project shows that the PST system is successfully designed and simulated via MATLAB-Simulink and the PLC programming is working in the correct order as performed on the prototype