{"id":8226,"date":"2026-05-22T16:38:15","date_gmt":"2026-05-22T16:38:15","guid":{"rendered":"https:\/\/www.yunrui-controls.com\/?p=8226"},"modified":"2026-05-22T16:38:41","modified_gmt":"2026-05-22T16:38:41","slug":"control-valve-on-off-valve-fault-tree-analysis-fta","status":"publish","type":"post","link":"https:\/\/www.yunrui-controls.com\/ms\/control-valve-on-off-valve-fault-tree-analysis-fta\/","title":{"rendered":"Panduan Lengkap Analisis Pokok Kerosakan Injap Kawalan \/ Injap Hidup-Mati (FTA)"},"content":{"rendered":"

In industrial automation control systems, control valves<\/strong><\/a> dan on-off valves<\/strong> are critical final control elements. Valve failures not only impact production efficiency but can also create safety hazards. This article presents a systematic Fault Tree Analysis (FTA)<\/strong> approach for pneumatic control valves, electric control valves, solenoid valves, and pneumatic shut-off valves.<\/p>\r\n\r\n\r\n\r\n

\ud83d\udd0d Fault Tree Structure Overview<\/h2>\r\n\r\n\r\n\r\n
\u3010TOP EVENT\u3011\ud83d\udd34 Valve Operation\/Control Abnormality\r\n\u251c\u2500\u3010OR\u3011\ud83d\udd27 Valve Body\/Trim Failure\r\n\u2502  \u251c\u2500 Plug\/Seat wear or corrosion\r\n\u2502  \u251c\u2500 Stem sticking or breakage\r\n\u2502  \u251c\u2500 Body leakage (external\/internal)\r\n\u2502  \u251c\u2500 Packing leakage\/sticking\r\n\u2502  \u2514\u2500 Media crystallization\/scaling causing blockage\r\n\u2502\r\n\u251c\u2500\u3010OR\u3011\u2699\ufe0f Actuator Failure\r\n\u2502  \u251c\u2500\u3010OR\u3011Pneumatic Diaphragm\/Piston Failure\r\n\u2502  \u2502  \u251c\u2500 Diaphragm rupture\r\n\u2502  \u2502  \u251c\u2500 Piston seal aging\/leakage\r\n\u2502  \u2502  \u2514\u2500 Spring breakage or fatigue\r\n\u2502  \u2514\u2500\u3010OR\u3011Electric Actuator Failure\r\n\u2502     \u251c\u2500 Motor burnout\r\n\u2502     \u251c\u2500 Capacitor damage\r\n\u2502     \u251c\u2500 Gear\/screw wear\r\n\u2502     \u2514\u2500 Limit switch malfunction\r\n\u2502\r\n\u251c\u2500\u3010OR\u3011\ud83d\udca8 Air Supply\/Power\/Signal Loop Failure\r\n\u2502  \u251c\u2500\u3010OR\u3011Air Supply Failure\r\n\u2502  \u2502  \u251c\u2500 Insufficient air pressure\r\n\u2502  \u2502  \u251c\u2500 Air line leakage\/blockage\r\n\u2502  \u2502  \u251c\u2500 Filter regulator clogged\r\n\u2502  \u2502  \u2514\u2500 Air supply with water\/oil\/contaminants\r\n\u2502  \u251c\u2500\u3010OR\u3011Power Supply Failure\r\n\u2502  \u2502  \u251c\u2500 24V\/220V power loss\r\n\u2502  \u2502  \u2514\u2500 Voltage fluctuation\r\n\u2502  \u2514\u2500\u3010OR\u3011Control Signal Failure\r\n\u2502     \u251c\u2500 4-20mA signal open\/short circuit\r\n\u2502     \u251c\u2500 DCS\/AO card failure\r\n\u2502     \u2514\u2500 Solenoid valve coil burnout\/plunger stuck\r\n\u2502\r\n\u2514\u2500\u3010OR\u3011\ud83d\udd29 Accessories & Installation Issues\r\n   \u251c\u2500 Positioner failure (I\/P converter, nozzle-flapper)\r\n   \u251c\u2500 Pneumatic booster\/volume booster failure\r\n   \u251c\u2500 Valve limit switch misalignment\r\n   \u2514\u2500 Mounting bracket loose<\/pre>\r\n\r\n\r\n\r\n
\u26a1 Valve Body\/Actuator Basic Events<\/h2>\r\n\r\n\r\n\r\n
\r\n\r\n\r\n\r\n\r\n\r\n\r\n\r\n\r\n\r\n\r\n\r\n
Kod<\/th>\r\nBasic Event Description<\/th>\r\nTypical Symptoms<\/th>\r\n<\/tr>\r\n<\/thead>\r\n
V1<\/code><\/td>\r\nPlug\/Seat wear or corrosion<\/td>\r\nInternal leakage, poor shutoff, degraded control performance<\/td>\r\n<\/tr>\r\n
V2<\/code><\/td>\r\nStem sticking\/breakage<\/td>\r\nValve not moving, delayed response, no feedback signal change<\/td>\r\n<\/tr>\r\n
V3<\/code><\/td>\r\nPacking leakage\/sticking<\/td>\r\nExternal leakage at stem, increased friction causing stick-slip<\/td>\r\n<\/tr>\r\n
V4<\/code><\/td>\r\nDiaphragm rupture<\/td>\r\nPneumatic valve not moving, stuck at one position<\/td>\r\n<\/tr>\r\n
V5<\/code><\/td>\r\nSpring breakage or fatigue<\/td>\r\nValve cannot return to position, insufficient output force<\/td>\r\n<\/tr>\r\n
V6<\/code><\/td>\r\nMotor burnout (electric)<\/td>\r\nElectric valve not moving, no sound or overheating<\/td>\r\n<\/tr>\r\n
V7<\/code><\/td>\r\nLimit switch malfunction<\/td>\r\nOn-off valve not stopping at position, or wrong feedback<\/td>\r\n<\/tr>\r\n<\/tbody>\r\n<\/table>\r\n<\/figure>\r\n\r\n\r\n\r\n
\u26a1 Air Supply\/Power\/Signal\/Accessory Basic Events<\/h2>\r\n\r\n\r\n\r\n
\r\n\r\n\r\n\r\n\r\n\r\n\r\n\r\n\r\n\r\n\r\n\r\n
Kod<\/th>\r\nBasic Event Description<\/th>\r\nTypical Symptoms<\/th>\r\n<\/tr>\r\n<\/thead>\r\n
A1<\/code><\/td>\r\nInsufficient air pressure<\/td>\r\nSlow valve movement, insufficient thrust, cannot fully open\/close<\/td>\r\n<\/tr>\r\n
A2<\/code><\/td>\r\nFilter regulator clogged<\/td>\r\nReduced air flow, slow valve response<\/td>\r\n<\/tr>\r\n
A3<\/code><\/td>\r\nAir supply with water\/oil<\/td>\r\nPositioner\/solenoid valve corrosion, accelerated diaphragm aging<\/td>\r\n<\/tr>\r\n
A4<\/code><\/td>\r\nPositioner failure<\/td>\r\nValve out of control, vibration, delayed response or no movement<\/td>\r\n<\/tr>\r\n
A5<\/code><\/td>\r\nSolenoid valve coil burnout\/plunger stuck<\/td>\r\nOn-off valve not shifting, remains in original position<\/td>\r\n<\/tr>\r\n
A6<\/code><\/td>\r\nControl signal open\/short circuit<\/td>\r\nValve signal loss, stays in hold position or goes to zero<\/td>\r\n<\/tr>\r\n
A7<\/code><\/td>\r\nMedia crystallization\/scaling blockage<\/td>\r\nValve stuck in mid-position, difficult movement<\/td>\r\n<\/tr>\r\n<\/tbody>\r\n<\/table>\r\n<\/figure>\r\n\r\n\r\n\r\n
\ud83d\udee0\ufe0f Control Valve\/On-Off Valve Troubleshooting Guide (By Priority)<\/h2>\r\n\r\n\r\n\r\n
    \r\n
  1. \u2460 Observe Symptoms<\/strong> Is the valve moving? Does it reach position? Any abnormal noise\/vibration? Is feedback signal changing?<\/li>\r\n
  2. \u2461 Check Air\/Power<\/strong> Pneumatic valve: Is air pressure adequate? Is filter regulator clogged? Electric valve: Is power supply normal?<\/li>\r\n
  3. \u2462 Test Signal<\/strong> Use multimeter\/signal generator to inject 4-20mA, observe if valve responds accordingly<\/li>\r\n
  4. \u2463 Inspect Accessories<\/strong> Positioner self-test, solenoid valve shift test, limit switch adjustment<\/li>\r\n<\/ol>\r\n\r\n\r\n\r\n
    \ud83d\udca1 Typical Valve Failure Patterns<\/h2>\r\n\r\n\r\n\r\n
      \r\n
    • No movement<\/strong> \u2192 Check air supply\/power\/signal\/solenoid valve<\/li>\r\n
    • Partial stroke<\/strong> \u2192 Check positioner\/travel\/sticking<\/li>\r\n
    • Vibration\/Stick-slip<\/strong> \u2192 Check positioner gain\/packing friction\/air stability<\/li>\r\n
    • Internal leakage<\/strong> \u2192 Check plug and seat<\/li>\r\n
    • Kebocoran luaran<\/strong> \u2192 Check packing\/gaskets<\/li>\r\n<\/ul>\r\n\r\n\r\n\r\n
      \ud83d\udccb Case Study 1: Pneumatic Control Valve Slow Movement with Stick-Slip<\/h2>\r\n\r\n\r\n\r\n
      Symptoms:<\/strong> A steam pressure control valve showed delayed response after setpoint changes, with stop-start stick-slip behavior during stroke.<\/p>\r\n\r\n\r\n\r\n
      Troubleshooting Process:<\/strong><\/p>\r\n\r\n\r\n\r\n
        \r\n
      1. Checked air pressure: Normal at 0.4MPa (58 psi)<\/li>\r\n
      2. Checked positioner output pressure, variation normal<\/li>\r\n
      3. Checked filter regulator element, found clogged with oil contamination<\/li>\r\n
      4. Replaced element and cleaned filter bowl, valve operation returned to normal<\/li>\r\n<\/ol>\r\n\r\n\r\n\r\n
        \u2705 Root Cause:<\/strong> Filter regulator clogged causing insufficient air flow \ud83d\udccc Preventive Measures:<\/strong> Regularly check air quality, clean or replace filter elements, install FRL unit<\/p>\r\n\r\n\r\n\r\n
        \ud83d\udccb Case Study 2: Solenoid-Operated Valve Cannot Open<\/h2>\r\n\r\n\r\n\r\n
        Symptoms:<\/strong> DCS gave open valve command, but valve did not move, feedback still showing closed position.<\/p>\r\n\r\n\r\n\r\n
          \r\n
        1. Field observation: Solenoid valve indicator light on, but no exhaust sound<\/li>\r\n
        2. Used screwdriver to touch solenoid coil, magnetic force present but plunger not moving<\/li>\r\n
        3. Removed solenoid valve, found plunger stuck with rust particles<\/li>\r\n
        4. Cleaned plunger and installed pre-filter, operation returned to normal<\/li>\r\n<\/ol>\r\n\r\n\r\n\r\n
          \u2705 Root Cause:<\/strong> Rust in air supply caused solenoid valve plunger to stick \ud83d\udccc Preventive Measures:<\/strong> Install precision filter at air inlet, regularly drain air receiver moisture<\/p>\r\n\r\n\r\n\r\n
          \ud83c\udfaf High-Occurrence Minimal Cut Sets (Single Point Failures)<\/h2>\r\n\r\n\r\n\r\n
            \r\n
          • {A1}<\/code> Insufficient air pressure<\/strong> \u2192 Insufficient valve thrust<\/li>\r\n
          • {A2}<\/code> Filter regulator clogged<\/strong> \u2192 Slow movement\/stick-slip<\/li>\r\n
          • {A4}<\/code> Positioner failure<\/strong> \u2192 Loss of control<\/li>\r\n
          • {A5}<\/code> Solenoid valve stuck<\/strong> \u2192 On-off valve not shifting<\/li>\r\n
          • {V2}<\/code> Stem sticking<\/strong> \u2192 Unstable movement<\/li>\r\n<\/ul>\r\n\r\n\r\n\r\n
            \ud83d\udcc8 Field Failure Rate Reference<\/h2>\r\n\r\n\r\n\r\n
            Based on petrochemical industry field statistics:<\/p>\r\n\r\n\r\n\r\n
              \r\n
            • Filter regulator clogged: 5-15%<\/strong> annual occurrence<\/li>\r\n
            • Positioner failure: 3-10%<\/strong><\/li>\r\n
            • Solenoid coil\/plunger failure: 2-8%<\/strong><\/li>\r\n
            • Plug\/Seat wear: 5-20%<\/strong> (depends on service conditions)<\/li>\r\n<\/ul>\r\n\r\n\r\n\r\n
              Note: Actual failure rates significantly affected by air cleanliness, media abrasiveness, and maintenance quality.<\/em><\/p>\r\n\r\n\r\n\r\n
              \ud83d\udcdd Summary<\/h2>\r\n\r\n\r\n\r\n
              Through Fault Tree Analysis (FTA), we can systematically understand failure modes of control valves and on-off valves. Key takeaways:<\/p>\r\n\r\n\r\n\r\n
                \r\n
              • Approximately 70% of valve failures<\/strong> are related to air quality and accessory condition<\/li>\r\n
              • Regular maintenance of filter regulators and air quality checks can significantly reduce failure rates<\/li>\r\n
              • Building a failure case database helps quickly diagnose similar problems<\/li>\r\n
              • For critical valves, consider redundancy or regular preventive maintenance<\/li>\r\n<\/ul>\r\n\r\n\r\n\r\n
                 <\/p>","protected":false},"excerpt":{"rendered":"
                In industrial automation control systems, control valves and on-off valves are critical final control elements. Valve failures not only impact production efficiency but can also create safety hazards. This article presents a systematic Fault Tree Analysis (FTA) approach for pneumatic control valves, electric control valves, solenoid valves, and pneumatic shut-off valves. \ud83d\udd0d Fault Tree Structure […]<\/p>\n","protected":false},"author":1,"featured_media":8228,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"site-sidebar-layout":"default","site-content-layout":"","ast-site-content-layout":"default","site-content-style":"default","site-sidebar-style":"default","ast-global-header-display":"","ast-banner-title-visibility":"","ast-main-header-display":"","ast-hfb-above-header-display":"","ast-hfb-below-header-display":"","ast-hfb-mobile-header-display":"","site-post-title":"","ast-breadcrumbs-content":"","ast-featured-img":"","footer-sml-layout":"","ast-disable-related-posts":"","theme-transparent-header-meta":"default","adv-header-id-meta":"","stick-header-meta":"default","header-above-stick-meta":"","header-main-stick-meta":"","header-below-stick-meta":"","astra-migrate-meta-layouts":"set","ast-page-background-enabled":"default","ast-page-background-meta":{"desktop":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"ast-content-background-meta":{"desktop":{"background-color":"var(--ast-global-color-4)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"var(--ast-global-color-4)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"var(--ast-global-color-4)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"footnotes":""},"categories":[384,1],"tags":[448,449,450,451],"class_list":["post-8226","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-news","category-blogs","tag-control-valve","tag-on-off-valve","tag-fta","tag-fault-tree-analysis"],"acf":[],"yoast_head":"\nControl Valve \/ On-Off Valve Fault Tree Analysis (FTA)<\/title>\n<meta name=\"description\" content=\"Comprehensive fault tree analysis for control valves and on-off valves. 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