Program-controlled valve fault detection alarm system and method thereof
By constructing a multi-module fault detection system, the problem of inaccurate fault diagnosis of programmable valves was solved, and accurate fault identification and rapid location were achieved, thereby improving the operational reliability and maintenance efficiency of the pressure swing adsorption process.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- YUNNAN YUNTIANHUA RED PHOSPHORUS CHEM CO LTD
- Filing Date
- 2023-01-12
- Publication Date
- 2026-06-02
AI Technical Summary
In existing technologies, fault detection of programmable valves relies on a single open-to-close switch, which leads to inaccurate fault diagnosis and untimely maintenance, affecting the normal operation of the pressure swing adsorption process.
The system employs a fault detection module that includes a sequential control program module, a valve open/close output module, a programmable valve module, a valve position detection module, a pressure detection module, a recording and alarm module, an audible and visual alarm module, and an interlocking switching/activation module. Through multiple signal analysis and alarm mechanisms, the system improves the reliability and accuracy of fault diagnosis.
It enables accurate identification and rapid location of faults in programmable valves, improves the operational reliability and maintenance efficiency of the pressure swing adsorption process, and reduces the risk of downtime due to faults.
Smart Images
Figure CN116046378B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of programmable valve fault detection technology, and specifically to a programmable valve fault detection alarm system and method. Background Technology
[0002] Pressure Swing Adsorption (PSA) is a gas separation technology that uses molecular sieves for pressure adsorption and depressurization desorption in a cyclical process. The PSA process is implemented under sequential control, with different valve combinations used at different stages. For example, in a PSA decarbonization (carbon dioxide removal) process, eight adsorption towers are connected by pipelines via 52 programmable valves and four regulating valves. Each tower undergoes the same operating steps, but these steps are staggered in time to achieve continuous processing of the raw gas and output of purified gas. Three sequential control programs have been developed for the eight-tower PSA decarbonization process: 8-3-3 / V, 8-3-2 / V, and 6-2-2 / V, to facilitate manual / automatic process switching in case of valve failure or load changes.
[0003] Because the pressure swing adsorption (PSA) decarbonization process involves numerous valves and frequent periodic switching of valve operating states, solenoid valves and programmable valves operate frequently, resulting in a high failure rate. Currently, the reliability and accuracy of fault diagnosis for programmable valves are low due to the reliance on a single fully open valve check switch. Misdiagnosis or delayed handling of critical programmable valve malfunctions can lead to incorrect or non-switching of the process, and in severe cases, pressure buildup in the adsorption tower, preventing the sequential control process from operating according to the predetermined valve opening and closing sequence and causing the decarbonization process to shut down. Furthermore, the lack of accurate fault detection and location necessitates on-site inspection and testing by maintenance personnel to pinpoint the fault, hindering rapid troubleshooting. Therefore, there is an urgent need to develop a more reliable programmable valve fault detection and alarm system and method. Summary of the Invention
[0004] The purpose of this invention is to provide a fault detection and alarm system and method for programmable valves, which solves the problem that the existing technology of using only one fully open valve switch for fault detection of programmable valves is prone to misjudgment of faults.
[0005] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: a programmable valve fault detection and alarm system, characterized in that: it includes a sequential control program module, a valve open / close output module, a programmable valve module, a valve position detection module, a pressure detection module, a recording alarm module, an audible and visual alarm module, and an interlock switching / activation module. The output of the sequential control program module is connected to the input of the valve open / close output module. One output of the valve open / close output module is connected to the input of the recording alarm module. The other output of the valve open / close output module is connected to the solenoid valve coil of the programmable valve module. The outputs of the open position detection switch F1 and the closed position detection switch F2 of the programmable valve module are both connected to the input of the valve position detection module. The outputs of the solenoid valve inlet air pressure sensor P1, the closed programmable valve pressure sensor P2, and the open programmable valve pressure sensor P3 of the programmable valve module are all connected to the pressure detection module. The outputs of the valve position detection module and the pressure detection module are both connected to the input of the recording alarm module. The output of the recording alarm module is connected to the input of the audible and visual alarm module and the interlock switching / activation module, respectively. The output of the interlock switching / activation module is connected to the input of the valve open / close output module.
[0006] A further technical solution is that the programmable valve module includes a cylinder, an upper sealing ring of the cylinder, a piston sealing ring of the cylinder, and a lower sealing ring of the cylinder which is the dynamic sealing point of the cylinder. The cylinder is equipped with a programmable valve open position detection switch F1 and a programmable valve closed position detection switch F2. The cylinder is connected to a solenoid valve, which is a two-position four-way solenoid valve. The solenoid valve is equipped with an air pressure sensor P1 before the solenoid valve, a pressure sensor P2 for closing the programmable valve, and a pressure sensor P3 for opening the programmable valve.
[0007] A further technical solution is that the sequential control program module contains a sequential control program.
[0008] A further technical solution is the aforementioned audible and visual alarm module, which issues audible and visual alarms according to the settings for input programmable valve opening / closing faults or solenoid valve faults.
[0009] A further technical solution is the interlocking switching / activation module, which interlocks and activates the system to handle input programmable valve opening / closing faults or solenoid valve faults.
[0010] A further technical solution is that the output drive system hardware DO of the valve opening / closing output module adopts a digital output channel. When the line is normal, the quality code DO1 = 1, and when the line is abnormal, the quality code DO1 = 0.
[0011] A further technical solution is that the valve position detection module receives signals from the open position detection switch F1 and the closed position detection switch F2 from the programmable valve module, and outputs a digital input channel to drive the system hardware DI. When the circuit is normal, the quality code F11 of the open position detection switch F1 = 1 and the quality code F21 of the closed position detection switch F2 = 1. When the circuit is abnormal, the quality codes F11 = 0 and F21 = 0. When the programmable valve is open, F1 = 1; otherwise, F1 = 0. When the programmable valve is closed, F2 = 1; otherwise, F2 = 0.
[0012] A further technical solution is that the pressure detection module receives signals from the solenoid valve pre-air pressure sensor P1, the closed-control valve pressure sensor P2, and the open-control valve pressure sensor P3 from the programmable valve module. The output drives the system hardware AI using an analog input channel. When the circuit is normal, the quality code P11=1 for the solenoid valve pre-air pressure sensor P1, the quality code P21=1 for the closed-control valve pressure sensor P2, and the quality code P31=1 for the open-control valve pressure sensor P3. When the circuit is abnormal, the quality codes P11=0, P21=0, and P31=0.
[0013] A further technical solution involves the recording and alarm module analyzing the input signals, determining and alarming for valve malfunctions, and recording and plotting the data as a historical curve on the same time axis; specifically:
[0014] When DO = 1 AND t = 1 AND F1 = 0, a valve not open fault is reported;
[0015] When DO = 1 AND t = 1 AND F1 = 1 AND P1 > P3, a leak is reported in the lower cylinder seal ring;
[0016] When DO = 0 AND t = 1 AND F2 = 0, a valve not closed fault is reported;
[0017] When DO = 0 AND F2 = 1 AND P1 > P2, a leak is reported in the upper cylinder seal ring.
[0018] When (DO=1AND t=1AND F1=1AND P2>0)OR(DO=0AND F2=1AND P3>0), a cylinder piston seal leak is reported.
[0019] When (DO1=1AND DO=1AND F2=1AND P3=P4=0AND P1=P2)OR(DO=0AND F1=1AND P2=P4=0AND P1=P3), a solenoid valve malfunction is reported.
[0020] Where t is the stroke time and P4 is the cylinder exhaust pressure when the valve is opened / closed.
[0021] Compared with existing technologies, the beneficial effects of this invention are as follows: The valve position detection module and pressure detection module respectively acquire the F1 and F2 signals indicating the open / closed positions of the programmable valve, the P1 air pressure before the solenoid valve, the P2 pressure when the programmable valve is closed, and the P3 pressure when the programmable valve is open. The alarm recording module analyzes and judges the DO (digital output) signal from the valve open / close output module, the F1 and F2 signals indicating the open / closed positions from the valve position detection module, and the P1, P2, and P3 pressure signals from the pressure detection module. This information is then presented to operators and maintenance personnel in a direct and effective manner through pop-up information windows, flashing screen markers, and audible and visual alarms, improving the reliability and accuracy of valve fault diagnosis and making sequential control process switching smoother. The above method can accurately distinguish between solenoid valve faults and programmable valve faults and has a certain fault location capability, which is beneficial for maintenance personnel to perform rapid repairs. Attached Figure Description
[0022] Figure 1 This is a schematic diagram of the principle of the present invention.
[0023] Figure 2 This is a schematic diagram of the programmable valve module in this invention.
[0024] In the diagram: 1-Sequential control program module, 2-Valve open / close output module, 3-Programmable valve module, 4-Valve detection module, 5-Pressure detection module, 6-Recording alarm module, 7-Audible and visual alarm module, 8-Interlock switching / activation module, 9-Air pressure sensor P1 before solenoid valve, 10-Solenoid valve, 11-Pressure sensor P2 when closing programmable valve, 12-Pressure sensor P1 when opening programmable valve, 13-Exhaust pressure P4, 14-Open position detection switch F1, 15-Close position detection switch F2, 16-Programmable valve open / close position detection mark, 17-Upper cylinder seal ring, 18-Cylinder piston seal ring, 19-Lower cylinder seal ring, 20-Cylinder. Detailed Implementation
[0025] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
[0026] Figure 1A fault detection and alarm system for a programmable valve is shown in the figure. It includes a sequential control program module (1), a valve open / close output module (2), a programmable valve module (3), a valve position detection module (4), a pressure detection module (5), a recording alarm module (6), an audible and visual alarm module (7), and an interlock switching module (8). The output of the sequential control program module (1) is connected to the input of the valve open / close output module (2). One output of the valve open / close output module (2) is connected to the input of the recording alarm module (6). The other output of the valve open / close output module (2) is connected to the coil of the solenoid valve (10) of the programmable valve module (3). The outputs of the open position detection switch F1 (14) and the closed position detection switch F2 (15) of the programmable valve module (3) are both connected to the input of the valve position detection module (4). The outputs of the air pressure sensor P1 (9) before the solenoid valve, the closed programmable valve pressure sensor P2 (11), and the open programmable valve pressure sensor P3 (12) of the programmable valve module (3) are also connected to the input of the valve position detection module (4). All are connected to the pressure detection module (5); the outputs of the valve position detection module (4) and the pressure detection module (5) are connected to the input of the recording alarm module (6), the output of the recording alarm module (6) is connected to the input of the audible and visual alarm module (7) and the interlocking switching / activation module (8), and the output of the interlocking switching / activation module (8) is connected to the input of the valve opening / closing output module (2); the programmable valve module (3) includes a cylinder (20), an upper cylinder sealing ring (17), and a cylinder piston seal. The cylinder (20) is equipped with a control valve open position detection switch F1 (14) and a control valve closed position detection switch F2 (15). The cylinder (20) is connected to the solenoid valve (10). The solenoid valve (10) is a two-position four-way solenoid valve. The solenoid valve (10) is equipped with a solenoid valve front air pressure sensor P1 (9), a control valve closed pressure sensor P2 (11), and a control valve open pressure sensor P3 (12).
[0027] Specifically:
[0028] The sequence of the sequential control program module (1) described in this embodiment is determined by the specific process and flow. Several sets of running programs can be pre-programmed in a sequential control program module. When the program control valve fails or the process load changes, the process can be switched manually / automatically. The valve opening / closing signal output of the sequential control program module (1) is input to the valve opening / closing output module (2).
[0029] The output drive system hardware DO (digital output) channel of the on / off output module (2) described in this embodiment has a signal loop detection function. When the line is normal, the quality code DO1 = 1, and when the line is abnormal, the quality code DO1 = 0. Maintenance personnel can check the external loop according to the quality code. This channel connects the valve opening / closing (valve open DO = 1 / valve close DO = 0) command to the coil of the solenoid valve (10) of the programmable valve module (3) through a physical cable. Through the electro-pneumatic conversion of the solenoid valve, the opening / closing electrical signal is converted into a pneumatic signal. The pneumatic signal enters the upper and lower air intake (exhaust) ends of the cylinder to realize the opening / closing of the programmable valve. The signals of the programmable valve opening position detection switch F1 (14) and closing position detection switch F2 (15) are connected to the input of the valve position detection module (4). The pressure detection signals of the air pressure sensor P1 (9) before the solenoid valve, the air pressure sensor P2 (11) when the control valve is closed, and the air pressure sensor P3 (12) when the control valve is open are connected to the input of the pressure detection module (5). P4 is the exhaust pressure of the cylinder when the valve is open / closed. After the valve has been open / closed for a stroke time t (t = 1 when the timer expires), P4 = atmospheric pressure = 0 when the valve is fully open / closed. The other output of the open / close output module (2) is connected to the input of the recording alarm module (6). Its function is to start the corresponding timer in the recording alarm module (6) when the open / close command is issued.
[0030] The valve position detection module (4) described in this embodiment drives the system hardware DI (digital input) channel, which has a signal loop detection function. When the line is normal, the quality codes F11=1 and F21=1. When the line is abnormal, the quality codes F11=0 and F21=0. Maintenance personnel can check the external loop according to the quality codes and perform digital filtering on the input valve position detection signal to improve the signal quality. When the programmable valve is open / closed, F1=1 and F2=1. Otherwise, F1=0 and F2=0. The processed signal is connected to the input of the recording alarm module (6) through the output.
[0031] The pressure detection module (5) described in this embodiment drives the hardware AI (analog input) channel of the system and has a signal loop detection function. When the line is normal, the quality codes P11=1, P21=1, and P31=1. When the line is abnormal, the quality codes P11=0, P21=0, and P31=0. Maintenance personnel can check the external loop according to the quality codes, perform digital filtering and range transformation on the input pressure signal, and the processed signal is connected to the input of the recording alarm module (6) through the output.
[0032] The alarm recording module (6) described in this embodiment analyzes the input DO, DO1, F1, F2, P1, P2, and P3 signals to accurately determine and alarm valve faults, and records historical curves on the same time coordinates to facilitate further analysis.
[0033] Under normal circumstances: When the programmable valve is normally open to the end after a stroke time t, the state parameters are DO=1, F1=1, F2=0, P1=P3, P2=P4=atmospheric pressure=0. When it is normally closed to the end, the state parameters are DO=0, F1=0, F2=1, P1=P2, P3=P4=atmospheric pressure=0.
[0034] In abnormal situations: When DO = 1 AND t = 1 AND F1 = 0, a valve not open fault is reported; when (DO = 1 AND t = 1 AND F1 = 1) AND P1 > P3, a lower cylinder seal leakage is reported; when DO = 0 AND t = 1 AND F2 = 0, a valve not closed fault is reported; when (DO = 0 AND F2 = 1) AND P1 > P2, an upper cylinder seal leakage is reported; when ((DO = 1 AND t = 1 AND F1 = 1) AND P2 > 0) OR ((DO = 0 AND F2 = 1) AND P3 > 0), a cylinder piston seal leakage is reported; when (DO1 = 1 AND DO = 1 AND F2 = 1 AND P3 = P4 = 0 AND P1 = P2) OR (DO = 0 AND F1 = 1 AND P2 = P4 = 0 AND P3 = P4 = 0 AND P2 = P2 = P3 = P4 = 0 AND P3 = P4 = P2 = 0 AND P3 = P4 = ... P3 = P3 = P4 = P3 = P3 = P4 = P3 = P3 = P4 = P3 = P3 = P4 = P3 = P3 = P4 = P3 = P3 = P4 = P3 = P3 = P4 = P3 = P3 = P4 = P3 = P3 = P4 = P3 = P3 = P3 = P4 = P3 = P3 = P3 = P4 = P3 = P3 = P3 = P4 = P3 = P3 = P3 When P1 = P3, a solenoid valve malfunction is reported; in addition, the valve jamming situation can be judged based on the final stroke time t1>t when the programmable valve is in the open / closed position and the rate of change of P2 and P3, and a lubrication alarm can be given in time.
[0035] Fault information is displayed centrally in the same window. After the fault is handled, a fault confirmation and reset operation is required to avoid information clutter or omission. The alarm recording module (6) outputs the programmable valve opening / closing fault and solenoid valve fault signals to the input of the audible and visual alarm module (7) and the input of the interlock switching / activation module (8).
[0036] The audible and visual alarm module (7) described in this embodiment emits audible and visual signals according to the settings for input programmable valve opening / closing faults and solenoid valve faults, providing direct and effective alarms to operators and maintenance personnel. The audible and visual alarms will only stop after the reset operation is confirmed.
[0037] The interlocking switching module (8) described in this embodiment performs interlocking switching on / off for input programmable valve opening / closing faults and solenoid valve faults. For preventive maintenance that does not affect the normal operation of the programmable valve, the interlocking can be cut off according to the specific situation to prevent accidental operation during the process. It has a delay function. If the fault can be eliminated in time before the delay time ends, the interlocking switching module will not operate.
[0038] Although the invention has been described herein with reference to several illustrative embodiments, it should be understood that many other modifications and implementations can be devised by those skilled in the art, which will fall within the scope and spirit of the principles disclosed herein. More specifically, various modifications and improvements can be made to the components or layout of the subject matter arrangement within the scope of the disclosure, drawings, and claims. Besides modifications and improvements to the components or layout, other uses will be apparent to those skilled in the art.
Claims
1. A fault detection and alarm system for a programmable valve, characterized in that: The system includes a sequential control program module (1), a valve opening / closing output module (2), a programmable valve module (3), a valve position detection module (4), a pressure detection module (5), a recording alarm module (6), an audible and visual alarm module (7), and an interlock switching module (8). The output of the sequential control program module (1) is connected to the input of the valve opening / closing output module (2). One output of the valve opening / closing output module (2) is connected to the input of the recording alarm module (6). The other output of the valve opening / closing output module (2) is connected to the coil of the solenoid valve (10) of the programmable valve module (3). The programmable valve module (3) has an open position detection switch F1 (14) and a closed position detection switch F1 (14). The output of the detection switch F2 (15) is connected to the input of the valve position detection module (4); the outputs of the solenoid valve front air pressure sensor P1 (9), the closed programmable valve pressure sensor P2 (11), and the open programmable valve pressure sensor P3 (12) of the programmable valve module (3) are all connected to the pressure detection module (5); the outputs of the valve position detection module (4) and the pressure detection module (5) are all connected to the input of the recording alarm module (6), the output of the recording alarm module (6) is connected to the input of the sound and light alarm module (7) and the interlocking switch / start module (8), and the output of the interlocking switch / start module (8) is connected to the input of the valve opening / closing output module (2); The programmable valve module (3) includes a cylinder (20), an upper sealing ring (17), a piston sealing ring (18), and a lower sealing ring (19) of the cylinder as dynamic sealing points of the cylinder. The cylinder (20) is equipped with a programmable valve open position detection switch F1 (14) and a programmable valve close position detection switch F2 (15). The cylinder (20) is connected to a solenoid valve (10). The solenoid valve (10) is a two-position four-way solenoid valve. The solenoid valve (10) is equipped with an air pressure sensor P1 (9) before the solenoid valve, a pressure sensor P2 (11) for closing the programmable valve, and a pressure sensor P3 (12) for opening the programmable valve. The alarm recording module (6) analyzes the input signals, judges and alarms valve malfunctions, and records and plots them as historical curves on the same time coordinate; specifically: When DO=1 AND t=1 AND F1=0, a valve not open fault is reported; When DO=1 AND t=1 AND F1=1 AND P1>P3, a leak is reported in the lower cylinder seal ring; When DO=0 AND t=1 AND F2=0, a valve not closed fault is reported; When DO=0 AND F2=1 AND P1>P2, a leak is reported in the upper cylinder seal ring. When (DO=1 AND t=1 AND F1=1 AND P2>0) OR (DO=0 AND F2=1 AND P3>0), a cylinder piston seal leak is reported. When (DO1=1 AND DO=1 AND F2=1 AND P3=P4=0 AND P1=P2) OR (DO=0 AND F1=1 AND P2=P4=0 AND P1=P3), a solenoid valve malfunction is reported; Where t is the stroke time, and P4 is the exhaust pressure of the cylinder when the valve is opened / closed; the valve opening / closing output module (2) outputs the drive system hardware DO using a digital output channel. When the line is normal, the quality code DO=1, and when the line is abnormal, the quality code DO=0; when the programmable valve is fully open, F1=1, otherwise F1=0; when the programmable valve is fully closed, F2=1, otherwise F2=0.
2. The fault detection and alarm system for a programmable valve according to claim 1, characterized in that: The sequential control program module (1) contains a sequential control program.
3. The fault detection and alarm system for a programmable valve according to claim 1, characterized in that: The audible and visual alarm module (7) issues an audible and visual alarm according to the settings for input programmable valve opening / closing faults or solenoid valve faults.
4. The fault detection and alarm system for a programmable valve according to claim 1, characterized in that: The interlocking switching module (8) performs interlocking switching on or off for input programmable valve opening / closing faults or solenoid valve faults.
5. The fault detection and alarm system for a programmable valve according to claim 1, characterized in that: The valve position detection module (4) receives signals from the open position detection switch F1 (14) and the closed position detection switch F2 (15) from the programmable valve module (3). The output drive system hardware DI adopts a digital input channel. When the line is normal, the quality code F11=1 for the open position detection switch F1 and the quality code F21=1 for the closed position detection switch F2. When the line is abnormal, the quality codes F11=0 and F21=0.
6. The fault detection and alarm system for a programmable valve according to claim 1, characterized in that: The pressure detection module (5) receives signals from the solenoid valve front air pressure sensor P1 (9), the closed programmable valve pressure sensor P2 (11), and the open programmable valve pressure sensor P3 (12) from the programmable valve module (3). The output drives the system hardware AI to use an analog input channel. When the line is normal, the quality code P11=1 for the solenoid valve front air pressure sensor P1, the quality code P21=1 for the closed programmable valve pressure sensor P2, and the quality code P31=1 for the open programmable valve pressure sensor P3. When the line is abnormal, the quality codes P11=0, P21=0, and P31=0.