From Manual Inspection to Predictive Maintenance: ATW’s Intelligent Valve Monitoring at Sinopec Zhenhai Refining

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Standards for the service life and seizure levels of program-controlled valves have long been a blank in the industry. However, for valves involved in sequential control—especially high-frequency switching or ESD (Emergency Shutdown) valves—real-time seizure assessment and life expectancy are critical for maintaining continuous production.
[ATW’s Innovation ]
To address this, ATW leveraged modeling, simulation, and extensive experimental data analysis to establish a comprehensive Big Data Analytics Platform. This research led to the launch of our Intelligent Condition Monitor. Unlike traditional position switches that only provide Open/Close signals, ATW’s monitor outputs real-time Seizure Grades and Expected Cycle Life, empowering customers with complete control over their valve assets.
[Field Application]
A key application of this technology is at the Sinopec Zhenhai Refining Polyethylene plant. ATW equipped a high-frequency PDS (Product Discharge System) valve with our Intelligent Condition Monitor. Previously, operators relied on manual inspections to estimate the valve's condition. Now, with real-time, quantified data, the customer can precisely monitor operational health and proactively adjust process operations based on the valve's actual lifespan.
[Conclusion]

By bridging the gap in diagnostic standards, ATW is helping chemical producers transition from reactive maintenance to intelligent, data-driven reliability.

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