Integrated Diagnostic and Health-Index Evaluation System for Control Valves Using Weighted Scoring and Dynamic-Response Analysis

Abstract

Control valves are essential components in steam power generation, ensuring process stability, operational efficiency, and equipment reliability. In many industrial facilities, calibration is still performed manually using separate instruments, resulting in inconsistent measurements, slower diagnostic interpretation, and limited historical traceability. This study develops an integrated system that automates calibration assistance and diagnostic evaluation through a standardized assessment framework. The system applies a scoring-matrix method to quantify key performance indicators, including command–feedback deviation, dead time, stroke duration, overshoot, terminal response integrity, fluid leakage, and abnormal acoustic behavior. Real-time data are visualized through a human–machine interface and stored in a centralized database for web-based historical analysis. A weighted-average algorithm is used to compute a comprehensive Health Index that supports automatic diagnostics and the generation of technical recommendations. Implementation in a steam power plant demonstrates improved consistency across calibration cycles, higher accuracy in condition assessment, and reduced calibration time compared to manual procedures. Web-based access to historical records further enhances traceability and enables more objective, data-driven maintenance decisions. The proposed system strengthens calibration reliability and supports structured diagnostic practices in industrial energy environments.