Positioner device for use with a fluid valve

Abstract

Methods, apparatus, systems, and articles of manufacture are disclosed for positioner devices for use with fluid valves. An example apparatus includes a fluid valve, an actuator operatively coupled to the fluid valve, and a positioner fluidically coupled to the actuator for controlling a position of the fluid valve via fluid provided from a fluid supply line, the positioner having a first transducer and a second transducer configured to increase or decrease a fluid pressure in the actuator, the positioner for causing the first transducer and the second transducer to change the position of the fluid valve during a safety event.

Description

TECHNICAL FIELD

[0001] The present disclosure relates generally to valves, and more particularly to positioner apparatus for use with fluid valves. BACKGROUND

[0002] Positioners function to facilitate actuation of final control devices from a normal operating state to a safe state (e.g., a tripped state) when used as safety instruments (e.g., when used as safety instruments in fluid valves in process control systems). In some example valves, actuation of the final control device occurs in response to a setpoint signal going from high to low (e.g., de-trip-to-trip (DETT)). In other example valves, actuation of the final control device occurs in response to a setpoint signal going from low to high (e.g., trip-to-trip (ETT)).

[0003] Safety systems in which valves fail or degrade (e.g., components of field devices fail or degrade) can result in the inability of the device to achieve a safe state. Valve failures / degradations during operation can also create undesirable operating conditions for the safety instrument system. By implementing redundant safety instruments in the valve, the likelihood of an undesirable operating condition resulting from a failed valve can be mitigated. SUMMARY

[0004] An example positioner apparatus includes an actuation module for controlling actuation fluid provided to a valve actuator, the actuation module having a first transducer for varying one or more parameters of the fluid, and a trip circuit operably interposed between the actuation module and the actuator to control a position of a fluid valve via the fluid, the trip circuit having a second transducer for varying one or more parameters of the fluid, the positioner for controlling the actuation module and the trip circuit to operate the fluid valve during a safety event.

[0005] An example apparatus includes a fluid valve, an actuator operably coupled to the fluid valve, and a positioner fluidly coupled to the actuator to control a position of the fluid valve via fluid provided from a fluid supply line, the positioner having a first transducer and a second transducer configured to increase or decrease a pressure of the fluid in the actuator, the positioner for enabling the first transducer and the second transducer to vary the position of the fluid valve during a safety event.

[0006] An example method includes receiving, via a valve positioner, a request to trip a fluid control valve, the valve positioner having an actuation module and a trip circuit to control a fluid pressure in a valve actuator operably coupled to the fluid valve, the trip circuit fluidly coupled between the actuation module and the actuator, and in response to receiving the request, controlling the actuation module and the trip circuit to open or close the fluid valve. BRIEF DESCRIPTION OF DRAWINGS

[0007] Figure 1 is a schematic diagram of an example positioner included in a valve assembly in accordance with the teachings of this disclosure.

[0008] Figure 2 is Figure 1 a schematic diagram of a first example implementation of a positioner of

[0009] Figure 3 is Figure 1 a schematic diagram of a second example implementation of a positioner of

[0010] Figure 4 is Figure 1 a block diagram of a third example implementation of a positioner of

[0011] Figures 5-6 is a flowchart representing an example method that can be performed using Figure 1 and Figure 4 example positioners of

[0012] Figure 7 is a block diagram of an example processing platform configured to execute machine-readable instructions to implement Figures 5-6 the method of Figure 1 and Figure 4 example positioners of

[0013] The drawings are not necessarily to scale. Generally, the same reference numbers will be used throughout the drawing and accompanying written description to refer to the same or like parts. DETAILED DESCRIPTION

[0014] Positioners facilitate actuation of a control device from a normal operating state to a safe state (e.g., a tripped state) when used as a safety instrument (e.g., when used as a safety instrument in a fluid valve in a process control system). In some examples, actuation can occur in response to a modulation of a setpoint signal from high to low (e.g., de-energize trip (DETT)). However, in other examples, actuation can occur in response to a modulation of a setpoint signal from low to high (e.g., energize trip (ETT)). Further, as used herein, venting of an actuator corresponds to initiation of a safety function in a DETT application, and charging of an actuator corresponds to initiation of a safety function in an ETT application.

[0015] Process control systems in which valves fail or degrade during operation (e.g., components of field devices fail or degrade) can experience increased periods of downtime. Valve failure / degradation during operation can also create undesirable operating conditions for the process control system. By implementing a redundant safety system in a valve, the likelihood of an undesirable operating condition resulting from a failed valve can be mitigated.

[0016] Although the examples disclosed herein are shown in connection with a positioner, the examples herein can be implemented with various other field devices and instruments that involve control devices such as actuators, actuator assemblies, actuator controllers, actuator positioners, sensors, transmitters, valve assemblies, etc. that can be used throughout a process control system to measure and / or control different aspects of the process control system (e.g., other process control devices). Field devices such as valves (e.g., valve assemblies) can include both electrical and mechanical components. For example, a valve can include electronic components such as a digital valve positioner, a flow rate sensor, a pressure sensor, a travel sensor, a valve controller, etc. In another example, a valve can include mechanical components such as an actuator (e.g., a hydraulic actuator, a pneumatic actuator, etc.), a mechanical housing, process connections, etc.

[0017] In the examples disclosed herein, the positioner (or field device, instrument, etc.) implements with a trip module that includes one or more transducers. In some examples, the trip module is fluidly and / or electrically coupled to multiple subsystems of the positioner.

[0018] For example, the trip module is fluidly coupled to an actuation module (e.g., a servo, a motor, a control element, etc.) that additionally includes one or more transducers (e.g., for regulating pressure supplied to the actuator), and the trip module is electrically coupled to at least a trip input and a trip detection module. In some examples, the transducers can be implemented by solenoid actuated valves (e.g., electrically controlled solenoid actuated valves). The combination of fluidic and electrical coupling of the disclosed trip module adds additional redundancy to the system.

[0019] In a DETT application, the positioner has the technical effect of providing redundancy for the vent function. For example, due to the application of logic one to each of the two vent transducers upon detection of a trip condition (e.g., a safety event), and due to the redundancy of the charge function caused by the two charge transducers being placed in series (e.g., fluidically coupled in series), the charge function is aborted due to a failure (e.g., a malfunction) in one of the charge transducers.

[0020] Alternatively, in an ETT application, the positioner has the technical effect of providing redundancy for the charge function. For example, due to the application of logic one to each of the two charge transducers upon detection of a trip condition (e.g., a safety event), and due to the redundancy of the vent function caused by the two vent transducers being placed in series (e.g., fluidically coupled in series), the charge function is aborted due to a failure (e.g., a malfunction) in one of the vent transducers.

[0021] As will be discussed in greater detail below in accordance with the teachings of the present disclosure, the positioner and / or trip module can have various configurations, which can depend on the type of valve and / or characteristics associated with the process control environment in which the valve is disposed (e.g., whether the valve is for a DETT application or an ETT application). In the examples disclosed herein, these configurations can be varied or altered to optimize the ability of the trip module to accurately and robustly implement safety functions in response to failures and / or malfunctions of components included in the positioner.

[0022] Turning to Figure 1 , the example positioner 100 disclosed herein, including the example trip module 102 (e.g., trip circuit), operates in a process control environment 104 by obtaining valve position information for a valve assembly 106 (e.g., a fluid valve, a fluid control valve, etc.). A first example implementation of the positioner 100 and trip module 102 used in a de-energized trip (DETT) system is further described in connection with Figure 2 , a second example implementation of the positioner 100 and trip module 102 used in an energized trip (EET) system is further described in connection with Figure 3 , and a block diagram of a third example of the positioner 100 and trip module 102 is further described in connection with Figure 4 .

[0023] In the illustrated example, the positioner 100 and trip module 102 are housed in a housing 108 and coupled to an example actuated valve assembly 106 (e.g., a pneumatically actuated valve assembly) that includes at least one actuator 110 (e.g., a fluidic actuator, a valve actuator, etc.) and a valve 112 (e.g., a butterfly valve, a gate valve, etc.).

[0024] However, other valve assemblies, such as electrically actuated valve assemblies, hydraulically actuated valve assemblies, etc., can additionally or alternatively be used. In the illustrated example, the positioner 100 includes an electronic valve controller that measures one or more parameters of the actuator 110 and / or valve 112 (e.g., a position of the valve 112) and / or controls the actuator 110 and / or valve 112.

[0025] Additionally, the positioner 100 can measure one or more parameters, such as a valve travel (e.g., a position of the valve), an actuator pressure, a drive signal, etc. The positioner 100 can control the actuator 110 and / or valve 112 via parameters, such as a command signal or an input signal (e.g., a travel setpoint). The housing 108 of the positioner 100 includes connection points for pneumatic tubing connections 114. In such examples, the positioner 100 can also implement pneumatic control of the actuator 110 via the pneumatic tubing connections 114.

[0026] In the example shown, valve assembly 106 is installed in a fluid process system 116 (e.g., a distribution piping system) within a plant environment or processing system. The fluid process system 116 may be located in an environment that could expose positioner 100 to one or more challenging operating conditions (e.g., extreme vibration, wide temperature range, etc.) and cause premature failure of one or more components of the positioner. For example, positioner 100 may be installed downstream of a positive displacement pump and subjected to extreme vibration. Different failure modes of positioner 100 may occur due to extreme vibration that causes damage and / or deterioration of the electrical components of positioner 100.

[0027] In the example shown, positioner 100 is coupled to an exemplary central facility 120 via network 118. In some examples, network 118 may include one or more data buses (e.g., HART (High-Speed ​​Addressable Remote Sensor) communication networks, Foundation Fieldbus, Profibus (Process Fieldbus), etc.), one or more local area networks (LANs), one or more wireless LANs, one or more cellular networks, one or more private networks, one or more public networks, etc. The central facility 120, communicatively coupled to positioner 100 via network 118, is capable of processing and / or storing one or more parameters generated by positioner 100 (e.g., valve position, valve stroke condition, fault condition causing tripping, etc.).

[0028] Figure 2 It includes Figure 1 The exemplary tripping module 102 and the exemplary positioner 100 are examples of a first exemplary embodiment 200. The first exemplary embodiment 200 is configured for a de-energized tripping (DETT) application. Figure 2 In the illustrated example, the first exemplary embodiment 200 of the locator 100 also includes a trip module 102, an exemplary air supply source 202, an exemplary position setpoint 204, an exemplary trip input 206, an exemplary power input 207, an exemplary position control module 208, an exemplary detection module 210, an exemplary AND gate 212, an exemplary OR gate 214, an exemplary NOT gate 216, an exemplary OR gate 218, an exemplary actuation module 220, one or more exemplary transducers 222A, 222B, 222C, 222D, and an exemplary sensor 226.

[0029] An air supply 202 fluidly coupled to the positioner 100 can provide a constant or adjustable supply pressure (e.g., 10 psi, 30 psi, 80 psi, etc.) of control fluid (e.g., actuating fluid) to the positioner 100. In some examples, when the supply 202 is adjustable, the supply 202 can be adjusted by at least one of a human operator of the valve assembly 106 or a computational algorithm included in the positioner 100. Although in the illustrated example, the control fluid supplied by the supply 202 is air, any other control fluid (e.g., water, hydraulic fluid, oil, etc.) can be used.

[0030] The position setpoint 204 corresponds to a desired position setpoint for the valve assembly 106. In some examples, such as Figure 2 In the illustrated example, the distributed setpoint is a 4-20 mA analog control signal, where 4 mA corresponds to a minimum position set value and 20 mA corresponds to a maximum position set value. In other examples, the position setpoint 204 can additionally or alternatively be a digital setpoint (e.g., a HART protocol signal, a Fieldbus signal, a Profibus signal, etc.).

[0031] The trip input 206 receives a signal indicative of whether a trip condition (e.g., a safety function) is to be implemented by the valve assembly 106. In other examples, the signal at the trip input 206 is manually generated by an operator of the valve assembly 106 via a user input (e.g., a button press, a switch toggle, etc.). However, in other examples, the signal at the trip input 206 is automatically generated by a component of the valve assembly 106 that is different from the positioner 100. Moreover, in some examples, the signal assigned by the trip input 206 is assigned as one of a binary one (e.g., a trip condition to be implemented) or a binary zero (e.g., a trip condition not to be implemented).

[0032] The example power line 207 can utilize a supply voltage (e.g., 5 volts, 12 volts, etc.) to provide electrical power to one or more of the components of the positioner 100. For example, the power line 207 can supply electrical power to at least one of the position control module 208, the detection module 210, the actuation module 220, the sensor 226, and / or the trip module 102. In some examples, the power line 207 can also carry power line communications and can facilitate communication between one or more components of the valve assembly 106 and one or more components of the positioner 100. In some examples, the power line 207 includes two wires (e.g., a pair of wires) including a ground wire and a power supply wire. Additionally or alternatively, the power line 207 can include three wires. In some examples, the example power line 207 does not power the positioner 100, but rather the 4-20 mA control signal of the position setpoint 204 powers the positioner 100.

[0033] The position control module 208 included in or otherwise implemented by the positioner 100 can determine (e.g., control, regulate, etc.) a desired position of the valve assembly 106 based on the position setpoint 204. In some examples, the position control module 208 also converts the received position setpoint signal (which, in some examples, is an analog signal) into a digital pulse (e.g., where the duration and number of pulses correspond to a desired valve position change) to be distributed to at least one of the transducers 222A, 222B via the AND gate 212 and the OR gate 214.

[0034] The detection module 210 included in or otherwise implemented by the positioner 100 can compare the position setpoint 204 signal to a threshold value. In some examples, in response to the received signal satisfying the threshold value, the detection module 210 outputs a logic one. Conversely, in response to the received signal not satisfying the threshold value, the detection module 210 outputs a logic zero. Further, in some examples, the detection module 210 can latch a logic one value (e.g., maintain a logic one output regardless of input to the detection module 210).

[0035] Additionally, the positioner 100 includes a number of logic gates (e.g., devices that determine a logic output (e.g., binary one, binary zero, etc.) based on one or more logic inputs), including the AND gate 212, the OR gate 214, the NOT gate 216, and the OR gate 218.

[0036] For example, the AND gate 212 outputs a logic one signal when each of the input signals (e.g., the two signals in the illustrated example of Figure 2 ) is a logic one signal. Alternatively, the AND gate 212 outputs a logic zero signal when one or more of the input signals is a logic zero signal. Additionally, one or more of the OR gates 214, 218 outputs a logic one signal, for example, when one or more of the input signals (e.g., one of the two signals, both of the two signals, etc., in the illustrated example of Figure 2 ) is a logic one, and outputs a logic zero when both of the input signals are logic zeros. Additionally, the NOT gate 216 outputs a logic one when the input is a logic zero, and outputs a logic zero when the input is a logic one.

[0037] The actuation module 220 included in or otherwise implemented by the positioner 100 can actuate a fluid flow (e.g., a fluid flow from the air supply 202) based on the input signals. In some examples, the actuation module 220 provides the actuated fluid flow directly to the actuator 110. However, in the redundant system disclosed herein, the actuation module 220 is used to provide the actuated fluid flow to the actuator 110 via the trip module 102.

[0038] One or more transducers 222A, 222B, 222C, 222D included in or otherwise implemented by the positioner 100 are capable of converting at least one of a digital signal (e.g., binary signal, logic signal, etc.) or an analog signal (e.g., analog current, analog voltage, etc.) into a pressure value. In some examples, the pressure value is further used to control the position and / or safety functions of the actuator 110 via different pressures corresponding to the opening and / or closing of hardware included in one or more of the one or more transducers 222A, 222B, 222C, 222D.

[0039] An example sensor 226 included in or otherwise implemented by the positioner 100 is capable of determining a fluid pressure of a fluid connection between one of the transducers included in the actuation module 220 (e.g., transducers 222A, 222B) and one of the transducers included in the trip module 102 (e.g., transducers 222C, 222D). In some examples, the output of the sensor 226 can be a second fluid pressure different from the input fluid pressure. Alternatively, the output of the sensor 226 can be one of an analog voltage or current. In each example, a calibration curve is determined to facilitate comparison of the input fluid pressure to the output parameter of the sensor 226.

[0040] In an example operation of the first example implementation 200 of the positioner 100, the positioner 100 receives a supply pressure from the air supply 202, an analog signal (e.g., 4-20 mA current signal) from the position setpoint 204, a logic zero or one from the trip input 206, and a power signal from the power line 207. The position control module 208 and the detection module 210 each receive the analog signal from the position setpoint 204.

[0041] Based on the setpoint signal, the position control module 208 assigns at least one of an increase pulse signal or a decrease pulse signal to the AND gate 212 or the OR gate 214, respectively. Additionally, based on the setpoint signal, the detection module 210 outputs a logic one (and in some examples, latches the logic one value) when the signal exceeds a threshold value and a logic zero when the signal does not exceed the threshold value, and further assigns the determined logic signal to the OR gate 218. Furthermore, the OR gate 218 receives a logic zero (e.g., no manual trip detected) or a logic one (e.g., manual trip detected) from the trip input 206.

[0042] Based on the logic signals received from the detection module 210 and the trip input 206, the OR gate 218 outputs a logic one to each of the OR gate 214, the NOT gate 216, and the transducer 222C when one or both of the signals received from the detection module 210 and the trip input 206 is a logic one. Conversely, the OR gate 218 outputs a logic zero to each of the OR gate 214, the NOT gate 216, and the transducer 222C when each of the signals received from the detection module 210 and the trip input 206 is a logic zero.

[0043] Based on the logic signals received from the OR gate 218, the NOT gate 216 outputs a logic one in response to receiving a logic one and outputs a logic zero in response to receiving a logic zero, effectively inverting the signal received from the OR gate 218. Further, the NOT gate 216 distributes the output signal to the AND gate 212 and the transducer 222C.

[0044] Based on the logic signals received from the position control module 208 (e.g., an increase pulse signal) and the NOT gate 216, the AND gate 212 outputs a logic one to the transducer 222A when each of the signals is a logic one and outputs a logic zero to the transducer 222A when one or more of the signals is a logic zero. The transducer 222A, coupled to the supply 202, converts the signal to a pressure that is distributed to each of the sensor 226 and the transducer 222C, the pressure increases (e.g., charges) when the output of the AND gate 212 is a logic one and does not increase (e.g., does not charge) when the output of the AND gate 212 is a logic zero.

[0045] Based on the logic signals received from the position control module 208 (e.g., a decrease pulse signal) and the OR gate 218, the OR gate 214 outputs a logic one to the transducer 222B when one or more of the signals is a logic one and outputs a logic zero to the transducer 222B when both signals are a logic zero. The transducer 222B converts the signal to a pressure that is distributed to the actuator 110, the pressure decreases (e.g., bleeds) when the output of the OR gate 214 is a logic one and does not decrease (e.g., does not bleed) when the output of the OR gate 214 is a logic zero.

[0046] Transducer 222C coupled to NOT gate 216, one of transducer 222A or sensor 226, and each of transducers 222C outputs pressure to actuator 110. In some examples, pressure increases (e.g., charges) when the output of NOT gate 216 is a logic one and the pressure received from one of transducer 222A and / or sensor 226 indicates a charging function at transducer 222A. Conversely, the output pressure does not increase (e.g., no charge) when the output of NOT gate 216 is a logic zero or the pressure received from one of sensor 226 or transducer 222A does not indicate a charging function. Thus, transducer 222A and transducer 222C are redundantly in series with each other.

[0047] Transducer 222D coupled to OR gate 218 and each of transducers 222D evacuates pressure from actuator 110. In some examples, pressure decreases (e.g., evacuates) when the output of OR gate 218 is a logic one and does not decrease (e.g., no evacuation) when the output of OR gate 218 is a logic zero. Thus, transducer 222D provides exhaust redundancy with transducer 222B.

[0048] Thus, first example implementation 200 of positioner 100 has the technical effect of providing redundancy for an evacuation function due to applying a logic one to each of transducers 222B, 222D (e.g., evacuation transducers) when a trip condition (e.g., a safety event) is detected and redundancy for a charging function due to transducers 222A, 222C being in series (e.g., fluidically coupled in series), thus, interrupting the charging function due to a failure (e.g., a malfunction) of either of transducers 222A, 222C.

[0049] Figure 3 is an example positioner 100 including Figure 1 second example implementation 300 of example positioner 100 of trip module 102, where second example implementation 300 is configured for an energized trip (ETT) application. Second example implementation 300 of positioner 100 also includes trip module 102, air supply 202, position setpoint 204, trip input 206, power line 207, position control module 208, trip detection module 210, AND gate 212, OR gate 214, NOT gate 216, example OR gate 218, actuation module 220, transducers 222A, 222B, 222C, 222D, and sensor 226, each of which are described in connection with first example implementation 200 of positioner 100.

[0050] However, unlike the first exemplary embodiment 200 of the positioner 100 (for a DETT application), the second exemplary embodiment 300 of the positioner 100 is for an ETT application. For example, the operational differences include the OR gate 214 coupled to the transducer 222A (which is coupled to the transducer 222B in the first exemplary embodiment 200) and the AND gate 212 coupled to the transducer 222B (which is coupled to the transducer 222A in the first exemplary embodiment 200). Additionally, the sensor 226 fluidly couples the transducer 224B and the transducer 222D (which is coupled between the transducer 222A and the transducer 222C in the first exemplary embodiment 200), and the air supply 202 is coupled to each of the transducers 222A and 222C (only coupled to the transducer 222A in the first exemplary embodiment 200). Finally, each of the transducers 222A, 222B is directly coupled to the actuator 110.

[0051] Accordingly, the second exemplary embodiment 300 of the positioner 100 has the technical effect of providing redundancy for the charge function due to the application of the logic one to each of the transducers 222A, 222C (e.g., charge transducers) upon detection of a tripped condition (e.g., a safety event) and redundancy for the vent function due to the transducers 222B, 222D (e.g., vent transducers) being in series (e.g., fluidly coupled in series), thus, interrupting the vent function due to a failure (e.g., a malfunction) of one of the transducers 222B, 222D.

[0052] Figure 4 is a block diagram of a third exemplary embodiment 400 of the positioner 100. In some examples, the third exemplary embodiment 400 of the positioner 100 can include the trip detection module 210, the actuation module 220, the sensor(s) 226, and the trip module 102, in some examples, the third exemplary embodiment 400 of the positioner 100 can also include an exemplary actuation module interface 402, an exemplary sensor interface 404, an exemplary threshold calculator 406, an exemplary parameter analyzer 408, an exemplary signal generator 410, and an exemplary database 412.

[0053] The actuation module interface 402, included in or otherwise implemented by the trip module 102, is capable of receiving signals from the actuation module 220 included in the positioner 100. In some examples, the actuation module interface 402 is further used to distribute the received signals to at least one of the threshold calculator 406, the parameter analyzer 408, and / or the database 412.

[0054] The sensor interface 404 included in or otherwise implemented by the trip module 102 is capable of receiving signals from the sensor(s) 226 included in the positioner 100. In some examples, the sensor interface 404 is further used to distribute the received signals to at least one of the threshold calculator 406, the parameter analyzer 408, and / or the database 412.

[0055] In some examples, the actuation module interface 402 and / or the sensor interface 404 can calculate a pressure parameter and a calibration curve that relates an unprocessed analog voltage value to a valve pressure (e.g., 10 psi, 30 psi, etc.) based on unprocessed voltage values received from the actuation module 220 and / or the sensor 226, respectively. Additionally or alternatively, the actuation module interface 402 and / or the sensor interface 404 can calculate a pressure parameter based on unprocessed digital electrical signals (e.g., hexadecimal values based on communication protocol data packets) and a lookup table that relates the unprocessed digital electrical signals to a valve pressure (e.g., 10 psi, 30 psi, etc.).

[0056] The threshold calculator 406 included in or otherwise implemented by the trip module 102 can determine one or more pressure thresholds for the fluid pressure between the actuation module 220 and the trip module 102. In some examples, the threshold calculator 406 can further determine whether satisfaction of a threshold includes a pressure that exceeds the threshold or a pressure that is less than the threshold. In some examples, the pressure threshold(s) between the actuation module 220 and the trip module 102 can be determined automatically by the processor. Additionally or alternatively, the pressure threshold(s) between the actuation module 220 and the trip module 102 can be determined by a user / operator.

[0057] The parameter analyzer 408 included in or otherwise implemented by the positioner 100 is capable of receiving one or more signals including at least one of: a pressure output from the actuation module 220 retrieved by at least one of the actuation module interface 402 and / or the sensor interface 404, a pressure threshold received by the threshold calculator 406, and / or a manual trip input received from the detection module 210.

[0058] Additionally, in some examples, the parameter analyzer 408 can facilitate comparisons between one or more pairs of received pressure parameters. For example, the parameter analyzer 408 can compare a pressure between the actuation module 220 and the trip module 102 received from one of the actuation module interface 402 and the sensor interface 404 to a threshold pressure determined by the threshold calculator 406.

[0059] In some examples, the parameter analyzer 408 can include circuitry, where the circuitry is to sum and / or subtract the received signals corresponding to the pressure parameters to facilitate comparison between the parameters (e.g., to determine a deviation). Additionally or alternatively, the parameter analyzer 408 can include computer-implemented hardware and / or software capable of determining a deviation between the received parameters.

[0060] In response to completing one or more comparisons (e.g., calculating one or more deviations), the parameter analyzer 408 is further to determine whether one or more components of the actuation module 220 are failing (e.g., have failed). In some examples, a failure of one or more components of the actuation module 220 corresponds to a safety event. In such examples, it can be desirable for the positioner 100 to activate a safety state (e.g., a tripped state) of the actuator 110. In response to completing one or more comparisons and determining an operational state of one or more components of the actuation module 220, the parameter analyzer 408 is further to assign at least one of the comparison results and / or the operational state of the one or more components to the signal generator 410. Figure 1

[0061] The signal generator 410 included in or otherwise implemented by the positioner 100 can be capable of providing a control signal to one or more of the transducers 222A, 222B, 222C, 222D based on the comparisons completed by the parameter analyzer 408. In some examples, the control signal can be at least one of a digital voltage signal, a discrete voltage signal, an analog voltage signal, and / or an analog current signal. In some examples, providing the control signal to one or more of the transducers 222A, 222B, 222C, 222D can include a control signal to open one or more of the transducers 222A, 222B, 222C, 222D and / or to close one or more of the transducers 222A, 222B, 222C, 222D. Moreover, in such examples, the opening and / or closing of the one or more transducers 222A, 222B, 222C, 222D can facilitate position control of the actuator 110 and / or apply a safety state to at least one of the actuator 110. Figure 1 Figure 1 Additionally or alternatively, the signal generator 410 can generate a notification of one or more failure modes of one or more components included in the process control environment 104. In such examples, the notification can be assigned to the central facility 120 via the network 118 for display (e.g., to a user and / or operator of the process control environment 104).

[0062] ​​The exemplary database 412 included in or otherwise implemented by the trip module 102 can store pressure values of the fluid between the actuation module 220 and the trip module 102, pressure thresholds calculated by the threshold calculator 406, instances of a manual activation trip state received from the detection module 210, one or more comparisons made by the parameter analyzer 408, one or more safety events, and / or respective activations of safety states determined by the parameter analyzer 408 and initiated by the signal generator 410, among others.

[0063] The database 412 can be implemented by volatile memory (e.g., synchronous dynamic random access memory (SDRAM), dynamic random access memory (DRAM), RAMBUS dynamic random access memory (RDRAM), etc.) and / or non-volatile memory (e.g., flash memory). The database 412 can additionally or alternatively be implemented by one or more double data rate (DDR) memories, such as DDR, DDR2, DDR3, mobile DDR (mDDR), etc. The database 412 can additionally or alternatively be implemented by one or more mass storage devices, such as hard drive(s), optical drive(s), digital versatile disk drive(s), etc. Although the database 412 is shown in the illustrated example as a single database, the database 412 can be implemented by any number and / or type of databases. Moreover, the database 412 can be located in the trip module 102 or in a central location external to the trip module 102 (e.g., the central facility 120 of FIG. 1). Furthermore, the data stored in the database 412 can be in any data format, such as binary data, comma delimited data, tab delimited data, structured query language (SQL) structures, etc. Figure 1

[0064] Although the exemplary manner of implementing the trip module 102 of FIG. 1 is shown in FIG. 1, one or more of the elements, processes, and / or devices shown in FIG. 1 can be combined, divided, rearranged, omitted, eliminated, and / or implemented in any other way. Further, the Figure 4 Figure 1 Although the exemplary manner of implementing the trip module 102 of FIG. 1 is shown in FIG. 1, one or more of the elements, processes, and / or devices shown in FIG. 1 can be combined, divided, rearranged, omitted, eliminated, and / or implemented in any other way. Further, the Figure 4 Figure 4 ​​​The example actuation module interface 402, example sensor interface 404, example threshold calculator 406, example parameter analyzer 408, example signal generator 410, and example database 412, and / or more generally the example trip module 102, can be implemented by hardware, software, firmware, and / or any combination of hardware, software, and / or firmware. Thus, for example, any of the example actuation module interface 402, example sensor interface 404, example threshold calculator 406, example parameter analyzer 408, example signal generator 410, and example database 412, and / or more generally the example trip module 102, can be implemented by one or more analog or digital circuits, logic circuits, programmable processor(s), programmable controller(s), graphics processing unit(s) (GPU(s)), digital signal implementation processor(s) (DSP(s)), application specific integrated circuit(s) (ASIC(s)), programmable logic device(s) (PLD(s)), and / or field programmable logic device(s) (FPLD(s)). When reading any claims into the following description of an apparatus or system before the present disclosure, at least one of the example actuation module interface 402, example sensor interface 404, example threshold calculator 406, example parameter analyzer 408, example signal generator 410, and / or example database 412 is expressly defined to include a non-transitory computer readable storage device or storage disk, such as a memory including software and / or firmware, a digital versatile disk (DVD), a compact disk (CD), a Blu-ray disk, etc. Moreover, Figure 4 The example trip module 102 of Figure 4 may include one or more elements, processes, and / or devices other than or in addition to those shown in

[0065] In Figures 5-6 a flow diagram is shown representing example hardware logic, machine readable instructions, hardware-implemented state machines, and / or any combination thereof for implementing the trip module 102 of Figure 1 The machine readable instructions can be an executable program or portion of an executable program for execution by a computer processor, such as the example hardware logic, machine readable instructions, hardware-implemented state machines, and / or any combination thereof for implementing the trip module 102 of Figure 7The processor 712 shown in the example processor platform 700 discussed above. The program can be embodied in software stored on non-transitory computer readable storage medium such as a CD-ROM, a floppy disk, a hard drive, a DVD, a Blu-ray disk, or a memory associated with the processor, but the entire program and / or portions of it can alternatively be executed by a device other than the processor 712 and / or embodied in firmware or dedicated hardware. Also, although the flow diagrams discussed above show a particular order of execution, alternative embodiments can be practiced where the order of execution is changed, and / or where the block is changed, eliminated, or combined. Additionally or alternatively, any or all of the blocks can be implemented by one or more hardware circuits (e.g., discrete and / or integrated analog and / or digital circuitry, an FPGA, an ASIC, a comparator, an operational-amplifier (op-amp), a logic circuit, etc.) structured and acting in conjunction with, or independent of, software and / or firmware. Figures 5-6 The example processes described above can be implemented using executable instructions (e.g., computer and / or machine executable instructions) stored on a non-transitory computer and / or machine readable medium such as a hard disk drive, a flash memory, read-only memory, an optical disk, a digital versatile disk, a cache, a random access memory, and / or any other storage medium in which information is stored for any duration (e.g., for extended time periods, permanently, for brief instances, for temporarily buffering, and / or the like). As used herein, the term non-transitory computer readable medium expressly excludes propagating signals and excludes transmission media.

[0066] As described above, Figures 5-6 The example processes described above can be implemented using executable instructions (e.g., computer and / or machine executable instructions) stored on a non-transitory computer and / or machine readable medium such as a hard disk drive, a flash memory, read-only memory, an optical disk, a digital versatile disk, a cache, a random access memory, and / or any other storage medium in which information is stored for any duration (e.g., for extended time periods, permanently, for brief instances, for temporarily buffering, and / or the like). As used herein, the term non-transitory computer readable medium expressly excludes propagating signals and excludes transmission media. Figures 5-6 The example processes described above can be implemented using executable instructions (e.g., computer and / or machine executable instructions) stored on a non-transitory computer and / or machine readable medium such as a hard disk drive, a flash memory, read-only memory, an optical disk, a digital versatile disk, a cache, a random access memory, and / or any other storage medium in which information is stored for any duration (e.g., for extended time periods, permanently, for brief instances, for temporarily buffering, and / or the like). As used herein, the term non-transitory computer readable medium expressly excludes propagating signals and excludes transmission media.

[0067] “comprise,” “comprising,” “include,” “including,” “comprising” and “contain” (and any form of these terms) are open-ended terms that are used to describe examples of the disclosure. Therefore, use of any of these terms in the claims section shall not be interpreted as a limitation on the scope or the meaning of the disclosure. The term “and / or” when used in the form “A, B, and / or C” means A, B, C, A and B, B and C, A and C, A, B and C, or any combination of A, B, and C. The use of “and / or” in the description is to be interpreted as an “inclusive OR” rather than an “exclusive OR”. The term “based on” means at least one of the specified conditions is met.

[0068] Used during security incidents Figure 1 The actuator 110 of the exemplary valve assembly 106 trips. Figure 5 The exemplary method 500 begins execution at block 502. At block 502, the trip module 102 (e.g., trip circuit) determines whether to trip from... Figure 4 A tripping request is received in the exemplary detection module 210. In response to the receipt of a request to trip the actuator 110 of the valve assembly 106, the process proceeds to block 510. Conversely, in response to the absence of a request to trip the actuator 110 of the valve assembly 106, the process proceeds to block 504.

[0069] At block 504, sensor interface 404, included in trip module 102, receives pressure between actuation module 220 and trip module 102, determined by sensor 226, each module being included in positioner 100. In some examples, sensor interface 404 further processes the signal received from sensor 226 into a signal (e.g., digital voltage, analog voltage, current, data packet, etc.) that can be read by the rest of the trip module 102.

[0070] Additionally or alternatively, in embodiments of the positioner 100 that do not include sensor 226, the actuation module interface 402 included in the trip module 102 receives pressure directly from the actuation module 220 and processes the pressure signal into a signal (e.g., digital voltage, analog voltage, current, data packet, etc.) that can be read by the rest of the trip module 102.

[0071] At block 506, parameter analyzer 408 compares the pressure of the fluid between actuator module 220 and trip module 102, received by either actuator module interface 402 or sensor interface 404, with the threshold pressure calculated by threshold calculator 406. Processing proceeds to block 508 in response to the calculations required to complete the comparison.

[0072] At block 508, the parameter analyzer determines whether one or more components of actuation module 220 have failed (e.g., have malfunctioned) based on the pressure-to-threshold comparison performed at block 506. In some examples, a component failure can be determined when the pressure exceeds the threshold. Alternatively, in other examples, a component failure can be determined when the pressure does not exceed the threshold. In each example, in response to determining that one or more components of actuation module 220 have failed (e.g., one or more components have malfunctioned), the process moves to block 510. Alternatively, in response to determining that all components of actuation module 220 are functioning normally, the process returns to block 502.

[0073] At box 510, combine Figure 6Further described, signal generator 410 generates a signal to control one or more of transducers 222A, 222B, 222C, and 222D to trip valve assembly 106 via actuator 110. In response to the completion of block 510, Figure 5 The exemplary method 500 ends.

[0074] An exemplary method can be performed to disengage the fluid valve by controlling the valve positioner. Figure 5 (box 510) in Figure 6 As shown in the preceding figures and related descriptions, Figure 6 An exemplary method begins execution at block 602, wherein signal generator 410 commands to enable at least one of transducers 222B and 222D, each of which is configured to reduce the pressure allocated to actuator 110. In some examples, command enable also includes allocating a high signal (e.g., binary 1, power supply voltage, etc.) to at least one of transducers 222B, 222D.

[0075] At block 604, signal generator 410 commands at least one of transducers 222A and 222C to be disabled, each of which is configured to increase the pressure allocated to actuator 110. In some examples, command enable also includes allocating a low signal (e.g., binary zero, ground voltage, etc.) to at least one of transducers 222A, 222C.

[0076] Therefore, via the activation of at least transducers 222B and 222D (each configured to reduce the fluid pressure allocated to actuator 110 (e.g., a fluid actuator)) and the deactivation of at least transducers 222A and 222C (each configured to increase the pressure allocated to actuator 110), in response to determining that a component has failed (e.g., a safety event has occurred), exemplary method 510 provides Figure 1 Redundant tripping of valve assembly 106. In response to completion of block 604, Figure 6 The exemplary method 510 ends and processes the return to Figure 5 The exemplary method 500 ends.

[0077] Figure 7 It is constructed to execute Figures 5-6 Instructions to achieve Figure 4 The block diagram of the trip module 102 is an example of a processor platform 700. The processor platform 700 can be, for example, a server, a personal computer, a workstation, a self-learning machine (e.g., a neural network), or a mobile device (e.g., a mobile phone, a smartphone, such as an iPad). TMsuch as a tablet computer, a personal digital assistant (PDA), an Internet appliance, or any other type of computing device.

[0078] The processor platform 700 of the illustrated example includes a processor 712. The processor 712 of the illustrated example is hardware. For example, the processor 712 can be implemented by one or more integrated circuits, logic circuits, microprocessors, GPUs, DSPs, or controllers from any desired family or manufacturer. The hardware processor can be a semiconductor-based (e.g., silicon-based) device. In this example, the processor implements the example actuation module interface 402, the example sensor interface 404, the example threshold calculator 406, the example parameter analyzer 408, the example signal generator 410, and the example database 412.

[0079] The processor 712 of the illustrated example includes a local memory 713 (e.g., a cache). The processor 712 of the illustrated example, via bus 718, is in communication with a main memory including volatile memory 714 and nonvolatile memory 716. The volatile memory 714 can be implemented by synchronous dynamic random access memory (SDRAM), dynamic random access memory (DRAM), RAMBUS dynamic random access memory (RAMBUS DRAM), and / or any other type of random access memory device. The nonvolatile memory 716 can be implemented by flash memory and / or any other desired type of memory device. Access to the main memory 714, 716 is controlled by a memory controller. Dynamic random access memory and / or any other type of random access memory device. The nonvolatile memory 716 can be implemented by flash memory and / or any other desired type of memory device. Access to the main memory 714, 716 is controlled by a memory controller.

[0080] The processor platform 700 of the illustrated example also includes an interface circuit 720. The interface circuit 720 can be implemented by any type of interface standard, such as an Ethernet interface, a universal serial bus (USB), a Bluetooth interface, a near field communication (NFC) interface, and / or a PCI express interface.

[0081] In the illustrated example, one or more input devices 722 are connected to the interface circuit 720. The input device(s) 722 allow a user to enter data and / or commands into the processor 712. The input device(s) can be implemented by, for example, an audio sensor, a microphone, a camera (still or video), a keyboard, a button, a mouse, a touchscreen, a trackpad, a trackball, isopoint, and / or a voice recognition system.

[0082] One or more output devices 724 are also connected to the interface circuit 720 of the illustrated example. The output devices 724 can be implemented, for example, by display devices (e.g., a light emitting diode (LED), an organic light emitting diode (OLED), a liquid crystal display (LCD), a cathode ray tube display (CRT), an in-place switching (IPS) display, a touchscreen, etc.), a tactile output device, a printer and / or speakers). In this regard, the interface circuit 720 of the illustrated example, in one implementation, includes a graphics driver card, a graphics driver chip and / or a graphics driver processor.

[0083] The interface circuit 720 of the illustrated example also includes a communication device such as a transmitter, a receiver, a transceiver, a modem, a residential gateway, a wireless access point, and / or a network interface to facilitate exchange of data with external machines (e.g., computing devices of any kind) via a network 726. The communication can be via, for example, an Ethernet connection, a digital subscriber line (DSL), a telephone line, a coaxial cable, a satellite system, a

[0084] The processor platform 700 of the illustrated example also includes one or more mass storage devices 728 for storing software and / or data. Examples of such mass storage devices 728 include floppy disk drives, hard drive disks, compact disk (CD) drives, Blu-ray disk (BD) drives, RAID systems, and digital versatile disk (DVD) drives.

[0085] Figures 5-7 Machine executable instructions 732 of the example method, apparatus, and articles of manufacture described herein can be stored on mass storage device 728, volatile memory 714, non-volatile memory 716, and / or removable non-transitory computer readable storage media such as a CD or DVD.

[0086] In light of the forgoing, it can be appreciated that example methods, apparatus, and articles of manufacture have been disclosed that provide a redundant system in a valve assembly via a positioner of the valve assembly to increase the robustness of the assembly against failures that can affect the continuous operation of a process control system. Process control systems that experience failures of components during operation can experience increased downtime, resulting in loss of revenue. Additionally, component failures during operation can also create hazardous operating conditions if the failed component provides erroneous or inaccurate data to the process control system. As such, providing a redundant system in a valve assembly is critical to the successful operation of a process control system.

[0087] Although certain example methods, apparatus and articles of manufacture have been disclosed herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatus and articles of manufacture falling within the scope of the claims.

Claims

1. A positioner for a fluid valve, comprising: an actuation module for controlling actuation fluid provided to a valve actuator, the actuation module having a first transducer for varying one or more parameters of the fluid; and a trip circuit operatively interposed between the actuation module and the actuator for controlling a position of the fluid valve via the fluid, the trip circuit having a second transducer for varying one or more parameters of the fluid, the positioner for controlling the actuation module and the trip circuit to operate the fluid valve during a safety event; wherein portions of the actuation module and the trip circuit are fluidically coupled in series with the actuator; wherein the first transducer and the second transducer are further for varying a pressure of the fluid in the actuator, the second transducer for receiving fluid from the first transducer; and the positioner further comprising a third transducer and a fourth transducer operatively coupled to the actuation module and the trip circuit for varying one or more parameters of the fluid, the first transducer and the second transducer configured to one of increase or decrease the pressure of the fluid in the actuator, and the third transducer and the fourth transducer configured to the other of increase or decrease the pressure.

2. The positioner of claim 1, wherein, the positioner to enable the first transducer and the second transducer while disabling the third transducer and the fourth transducer.

3. The positioner of claim 1, wherein, the positioner for controlling the trip circuit in response to user input provided to the positioner.

4. The positioner of claim 1, further comprising a sensor operatively coupled to the actuation module and the trip circuit to measure a pressure of the fluid, wherein, the positioner for detecting a failure of the actuation module based on a pressure of the fluid, and in response, controlling the trip circuit.

5. The positioner of claim 1, further comprising a housing, the actuation module and the trip circuit disposed in the housing.

6. The positioner of claim 1, wherein, the positioner for receiving a pair of electrical wires for providing power and communication to the actuation module and the trip circuit.

7. An apparatus for a fluid process system, comprising: a fluid valve; an actuator operatively coupled to the fluid valve; and a positioner fluidically coupled to the actuator for controlling a position of the fluid valve via fluid provided from a fluid supply line, the positioner having a first transducer and a second transducer configured to one of increase or decrease a pressure of the fluid in the actuator, the positioner for enabling the first transducer and the second transducer to vary the position of the fluid valve during a safety event; wherein the first transducer and the second transducer also facilitate fluid pressure changes in the actuator; wherein the first transducer, the second transducer, and the actuator are fluidically coupled in series; and the positioner further comprising a third transducer and a fourth transducer configured to the other of increase or decrease the pressure of the fluid.

8. The apparatus of claim 7, further comprising a sensor operatively coupled to the positioner to measure fluid pressure between the first transducer and the second transducer, wherein, The positioner is to detect a failure of the first transducer based on the fluid pressure and, in response, disable the second transducer.

9. The apparatus of claim 7, wherein, The positioner includes a housing in which the first transducer and the second transducer are disposed.

10. The apparatus of claim 9, wherein, The housing is to receive a pair of electrical wires to provide power or communication to the positioner.

11. A method for tripping a valve actuator of a valve assembly during a safety event, comprising: receiving a request to trip a fluid valve via a valve positioner having an actuation module and a trip circuit to control fluid pressure in the valve actuator operatively coupled to the fluid valve, the trip circuit fluidly coupled between the actuation module and the valve actuator; in response to receiving the request, controlling the actuation module and the trip circuit to open or close the fluid valve; and when a respective third transducer and a fourth transducer operatively coupled to the trip circuit are enabled and disabled, a respective first transducer and a second transducer operatively coupled to the actuation module are enabled and disabled, the first transducer and the third transducer are configured to increase fluid pressure in the valve actuator, and the second transducer and the fourth transducer are configured to decrease fluid pressure in the valve actuator.

12. The method of claim 11, further comprising providing command signals or power to the actuation module and the trip circuit via electrical wires coupled to the valve positioner.

13. The method of claim 11, further comprising determining that a component of the actuation module has failed and, in response, controlling the trip circuit.

14. The method of claim 13, further comprising: determining, via a sensor, a pressure of a fluid between the actuation module and the trip circuit; and comparing the pressure of the fluid to a threshold pressure to determine whether a component of the actuation module has failed.

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