Recent research on online condition monitoring for control valves in fluid control has achieved interim results, with in-valve diagnostic solutions for process industries moving into application.

Based on built-in sensor modules, the solution continuously collects parameters such as valve stroke, actuator air supply pressure and operating friction, identifying early abnormal signals including cavitation, internal leakage, jamming and seal wear, and uploads them to the control system to support condition-based maintenance and reduce unplanned downtime.

The R&D team optimized the valve plug flow passage structure and surface protection process to improve erosion resistance and noise reduction under high pressure differentials, and optimized low-emission sealing structures to meet environmental leakage control requirements. Prototypes have completed multiple rounds of hot-state and fatigue tests and are adaptable to chemical, hydrogen and air separation applications.

Industry sources say control valves are transforming from single executing components into perceptive, traceable measurement and control units. Digital diagnostics, materials resistant to harsh media and low-leakage structures are key research directions that will support stable operation and energy consumption control of process units.