Monitoring energy use on a flow control

Abstract

The invention relates to a flow control. The flow control is configured to monitor energy usage. These configurations may include a controller that delivers a signal to pressurize the pneumatic actuator. The controller may have software that may calculate energy usage based on the pressure of the signal and, for example, changes in the position of the valve. This feature may provide real-time data that an operator may use to identify potential problems on its process line. In one implementation, an operator may mark devices exhibiting energy usage tending away from a baseline level. These devices may have inherent problems that may appear as greater, more disastrous problems, potentially leading to quality problems of the final product, or need to operate to completely shut down the production line.

Description

Background Art

[0001] Flow control devices play an important role in many industrial settings. For example, power plants and industrial process facilities use different types of flow control to manage the flow of materials (usually fluids) throughout a vast network of pipes, tanks, generators, and other equipment. These devices may include control valves that provide active control of the flow by exchanging control signals with a central control network.

[0002] Control valves usually have an actuator that is used to regulate convection. The actuator may require a fluid signal in the form of compressed air, for example, flowing into (and out of) the device. Most facilities are provided with a delivery network to provide compressed air to each individual control valve on the process line. The network may include one or more compressors to deliver compressed air at the pressure necessary for pressurizing the actuators used in the system. Of course, these compressors require power as a prerequisite for their operation. This power may come from power plants that typically burn fossil fuels and emit greenhouse gases into the environment. Summary of the invention

[0003] The subject matter of the present disclosure relates to improvement and optimization of process performance. Of particular interest are embodiments that can monitor the energy usage of individual control valves. These embodiments can generate valuable data that can provide operators with insight into the operation of their process lines. This feature can allow operators to make better valve selections, adjust their process loops, or even evaluate the operation of their entire plant. BRIEF DESCRIPTION OF THE DRAWINGS

[0004] Reference will now be made briefly to the accompanying drawings, in which:

[0005] Figure 1 A schematic diagram showing an example of a controller;

[0006] Figure 2 Describes the operation Figure 1 A flowchart of an exemplary method of a controller;

[0007] Figure 3 Depicted with Figure 1 Example performance curves of actuators used with the controller;

[0008] Figure 4 Depicted with Figure 1 Example performance curves of actuators used with the controller;

[0009] Figure 5 Depicted Figure 1 a perspective view of an example of a controller; and

[0010] Figure 6 Depicts the incorporation of Figure 1 A cross-sectional plan view of an example flow control of an example controller.

[0011] Where applicable, like reference numerals indicate identical or corresponding parts and units throughout the several views, which are not drawn to scale unless otherwise indicated. The embodiments disclosed herein may include elements that appear in one or more of the several views or in a combination of the several views. Furthermore, the methods are exemplary only and may be modified by, for example, reordering, adding, deleting, and / or changing various stages.

[0012] The drawings and any description herein use examples to disclose the invention. The examples include the best mode and also enable any person skilled in the art to practice the invention, including making and using any device or system and performing any combined method. Elements or functions described in singular form and beginning with the word "one" or "an" should be understood to not exclude multiple said elements or functions unless such exclusion is explicitly stated. Reference to "one embodiment" or "one specific implementation" should not be understood to exclude the existence of other implementations or specific implementations that also incorporate the described features. DETAILED DESCRIPTION

[0013] Features of the embodiments shown in the above-mentioned figures will now be discussed. These embodiments use readily available data to help operators evaluate their process lines. This feature avoids the need for new or additional hardware. It also provides insights that can be converted into solutions for maintaining quality control, providing timely and appropriate device maintenance, or understanding overall process integrity. As an additional benefit, the proposed design can help reduce power usage across a process line (or plant in general), which can translate into valuable reductions in greenhouse gas emissions. Other embodiments are within the scope of the present disclosure.

[0014] Figure 1 An example of a controller 100 is depicted. The example resides in a distribution network 102, which is generally designed to convey material 104 through a network of conduits 106. The controller 100 may be part of a flow control unit 108 having a valve body 110 to connect in series with the conduits 106. The valve body 110 may house a seat 112 and a closure member 114 that may be moved to a position relative to the seat 112 to regulate the flow of the material 104. A valve stem 116 may connect the closure member 114 to an actuator 118 that includes a piston assembly 120. In one implementation, the controller 100 may have operating hardware 122 that converts an input pneumatic supply signal S1 into an actuator control signal S2 that pressurizes the actuator 118. A feedback mechanism 124 provides data regarding operating conditions or parameters on the flow control unit 108.

[0015] Broadly, the controller 100 can be configured to assess energy usage. These configurations can provide data corresponding to the operation of the pneumatic system in real time, such as those generated in an industrial process facility. The data can reveal anomalies in energy usage, which can occur on a device-by-device basis on a process line. These anomalies, in turn, can lead operators to investigate potential causes and implement appropriate responses. This feature can lead to process improvements or device maintenance or repairs before any problems occur that could reduce output or could cause catastrophic failures or significantly reduce final product yields.

[0016] Distribution system 102 can be configured to deliver or move resources. These configurations can be embodied as a large infrastructure. Material 104 can also include gases, liquids, solids, or mixtures. Conduit 106 can include pipes or pipelines that are typically connected to pumps, boilers, etc. The pipes can also be connected to tanks or reservoirs. In many facilities, the equipment forms a complex network.

[0017] The flow control device 108 can be configured to regulate the flow of the material 104 through the conduits 106 in these complex networks. These configurations can include control valves and similar devices. The valve body 110 in such devices is usually made of cast or machined metal. The structure can form flanges at the openings I, O. Adjacent pipes 106 can be connected to these flanges to allow the material 104 to flow through the device, for example, through the openings in the support 112. The closing member 114 can be embodied as a metal disk or a metal "plug". The valve stem 116 can be embodied as an elongated cylindrical member or rod-shaped member connected to the plug at one end. The other end of the rod-shaped member can be connected to the actuator 118. Typically, the piston assembly 120 in the actuator 118 may include a piston and a spring (or multiple springs) that together generate a load on the valve stem 116. However, in some designs, it is not uncommon for a flexible diaphragm to replace the piston. The resulting load regulates the position of the plug 114, which in turn manages the flow of the material 104 through the support 112 into the pipe 106 downstream of the device.

[0018] The operating hardware 122 may be configured to process and generate signals. These configurations may be connected to a control network (or "distributed control system" or "DCS") that maintains the operation of all devices on the process line to ensure that materials flow according to the process. The DCS may generate control signals with operating parameters that describe or define the operation of the control valve 108 for this purpose. The operating hardware 122 may employ electrical components and computing components (e.g., processors, memory, executable instructions, etc.). These components may also include an electro-pneumatic device that operates the incoming pneumatic supply signal S1. These components ensure that the outgoing actuator control signal S2 to the actuator 118 is suitable for the control valve 108 to supply material 104 downstream according to the process parameters.

[0019] The feedback mechanism 124 can be configured to provide data corresponding to the operation of the flow control 108. These configurations can measure various operating parameters or conditions present on, at, or near the flow control 108. For example, the controller 100 may include a pressure sensor that monitors the pressure of the actuator control signal S2. The feedback mechanism 124 may also include a sensor for monitoring the physical position of a component on the device. The sensor may, for example, monitor the position of the closing member 114. In one implementation, a mechanical linkage may couple the valve stem 116 to a rotatable disk in the controller 100. The disk may rotate in response to the mechanical linkage. This feature changes the position of the magnet relative to the flux sensor, which in turn indicates the position of the closing member 114.

[0020] Figure 2 A flow chart depicting an example of steps of a method 200 for operating a controller 100. The steps may correspond to executable instructions, such as a computer or software program, that configure the controller 100 for certain operations. The instructions may, for example, process data to arrive at values ​​that define operations of the flow control 108. The operations may identify energy consumed, stored, or released by the flow control 108 as part of its use in the process line. In one implementation, the method 200 may include: at stage 202, receiving input or feedback; and at stage 204, determining a value for energy consumption. The method 200 may also include: at stage 206, identifying a relationship between the value and a threshold value. The method 200 may also include: at stage 208, generating an indicator in response to the relationship.

[0021] At stage 202, the controller 100 may receive certain inputs. These inputs may include data regarding the operating parameters of the device. The data may include "actuator pressure" and position information from the feedback mechanism 124. The controller 100 may use this information to make determinations about energy usage or consumption. The controller 100 may also write or store this information into a memory. This feature may save data as an operational history for a flow control 108, or in the case of a process line, save the operational history of multiple flow controls 108 that reside as part of a larger system.

[0022] At stage 204, the controller 100 may calculate the energy used or consumed by the flow control 108 based on inputs including actuator pressure and position. In a spring return device, the spring stores and releases energy as it compresses and relaxes in response to an increase or decrease in actuator pressure. This feature provides a metric for identifying the total energy usage of the flow control 108. In one implementation, the energy usage may correspond to the following equations (1) and (2):

[0023]

[0024] Where E is energy, W is work, and T is a time interval (e.g., for the purposes of this calculation, T is t1-t0). The work W may depend on the configuration or use of the actuator 116. These configurations may include "single-acting" devices and "double-acting" devices.

[0025] Figure 3 The performance curve of an example of a single-acting device is shown. In this device, the actuator pressure acts on the actuator piston in a direction opposite to the force of the spring. The performance curve shows that the change in actuator pressure (P0→P1) compresses the spring (x0→x1). The work W corresponds to the area under the performance curve and can be calculated according to the following equations (3) and (4):

[0026] W=A×P avg ×Δx, Formula (3)

[0027]

[0028] Where A is the effective area of ​​the actuator piston, P avg is the average pressure during the time interval T,

[0029] And Δx is the change in position of the actuator piston.

[0030] Figure 4 The performance curve of an example of a double-acting device is shown. The actuator pressure in this device can act in the same direction as the travel or in the opposite direction to the travel. In this case, the value of the work W can depend on the forces acting on both sides of the actuator piston. This value can be calculated according to the following equations (5) and (6):

[0031] W=[(A a ×Pa avg )-(A b ×Pb avg )]Δx, Formula (5)

[0032]

[0033] Among them A a is the effective area of ​​the "A" side of the actuator piston, A b is the effective area of ​​the "B" side of the actuator piston, Pa avg is the average pressure on the "A" side of the actuator piston during the time interval T, and Pb avg is the average pressure on the "B" side of the actuator piston during time interval T.

[0034] As described above, the energy E over the time interval corresponding to the data point P0,x0→P1,x1 can then be calculated according to equation (2).

[0035] At stage 206, method 200 may compare energy E with a certain threshold value. The relationship between these two values ​​may indicate that there is a problem on the device, or in some cases, a problem with the process or process line. The operator may expect the device to consume a certain baseline amount of energy. Values ​​of energy E that are higher or lower than this expected value may indicate that there is a problem on the device. These problems may also be manifested as cumulative values ​​of energy E that tend to be higher or lower over a specified time period (e.g., a typical operating time period of the process line). These trends may also indicate instabilities in the process, such that to some extent, the device (or the device across the process line) consumes more or less energy than the operator expects to maintain the process parameters at or near a specified level. Operators who are aware of these instabilities or fluctuations can avoid quality control problems, for example, the operator can observe changes in the energy E used by the device, while reducing the quality of the final product.

[0036] At stage 208, the method 200 may generate some type of output corresponding to the energy E. The output may be embodied as an indicator that may change type or delivery as needed. Alarms may be used as a means of drawing attention to field devices in a facility. Indicators may also appear as an email or text message (or similar electronic indicator) on a portable computing device such as a smart phone or tablet.

[0037] This output can also be used as part of a diagnostic system. The system can be embodied as software running on a DCS or an attached computer system. An example of software can generate a user interface, for example, on or through a web browser. The diagnostic software package may find it useful for the user interface to display problematic devices in different colors, fonts, or animations. The user interface can also display drawings or charts of data used to describe the operation of one or more flow controls. These figures can show the trend of energy E over time. If, for example, the trend of energy E increases or decreases away from an expected value or threshold, these trends can guide the operator to identify the problematic device. The operator can use this visual trend data to manually generate an alarm. This action can result in preventive maintenance outside the operator's normal maintenance plan. This feature can prove to be beneficial because it can prevent certain problems from developing into larger problems that affect the entire process line.

[0038] Figure 5A perspective view of an example of a controller 100 is depicted in exploded form. The structure may include a manifold having a manifold body 126, which is typically machined or formed from metal, plastic, or a composite material. The device may include one or more boards 128 having processing hardware disposed thereon. Other hardware may include a current-pressure converter 130 and a relay 132. These devices may generate an actuator control signal S2 that the controller 100 delivers to the actuator 118. As shown, the structure may include an enclosure, which is shown in this example as a cover 134, 136. The cover 134, 136 may be fixed to the manifold body 126 to protect the control components from the conditions of the environment that are prevalent around the flow control unit 108. The cover 136 may include a display 138 and a button input device 140, which may be used as a primary local user interface to allow an end user (e.g., a technician) to interact with the controller 100. This feature may be important for performing periodic maintenance, configuration, and setup, for example, to allow an end user to exit the valve operation mode and step through a menu structure to manually perform functions such as calibration, configuration, and monitoring. In one implementation, the structure may also include one or more gauges 142, 144 that may provide an indication of the flow condition (e.g., pressure, flow rate, etc.) of the fluid, which the controller 100 uses to operate the flow control 108.

[0039] Figure 6 A perspective view of an exemplary structure of a flow control unit 108 is depicted. The valve body 110 may form a flow path 146 having an open end 148 with a flange. The controller 100 may be fastened to a yoke 150 as part of the flow control unit 108 using a bracket 152. Fasteners such as bolts may be used for this purpose. Valve components such as the support 112 and the closing member 114 may reside inside the body 110. In one implementation, the actuator 118 may include a housing 154 coupled to the yoke 150. The housing 154 may enclose a piston 156 and a spring 158 (which together form at least a portion of the piston assembly 120). As described herein, the actuator control signal S2 may pressurize the upper or lower portion of the housing 154 to act on one side (for a single-acting design) or both sides (for a double-acting design) of the actuator piston 156. This feature affects the position of the closing member 114 to regulate the flow through the valve body 110.

[0040] In view of the foregoing, the improvements herein evaluate the energy of a control valve or other flow control device. These embodiments utilize data that is readily available but not typically used for diagnostic purposes. This feature provides operators with important insights into the operation of their devices without adding additional sensors.

[0041] The examples that appear below include certain elements or clauses, one or more of which can be combined with other elements and clauses, describing embodiments contemplated within the scope and essence of the present disclosure. The scope may include and contemplate other examples that occur to those skilled in the art. If such other examples have structural elements that are indistinguishable from the literal language of the claims, or if they include equivalent structural elements that are indistinguishable from the literal language of the claims, these other examples are intended to fall within the scope of the claims.

Claims

1. A flow control component, comprising: a valve assembly including a pneumatic actuator coupled to a closure member; a feedback mechanism configured to generate data corresponding to a position of the closure member and a pressure of an actuation signal for pressurizing the pneumatic actuator; and A controller is coupled to the sensor unit, the controller having operating hardware configured to calculate a value of energy usage based on the data.

2. The flow control of claim 1, wherein the operating hardware is further configured to compare the value to a baseline level.

3. The flow control of claim 1, wherein the operating hardware is further configured to generate an alert in response to the value.

4. The flow control of claim 1, wherein the value represents energy usage over a time interval.

5. The flow control element of claim 1, wherein the value represents energy usage over a specified time period during operation of the process line.

6. The flow control device of claim 1, wherein the value corresponds to energy usage in one direction of travel of the closure member.

7. The flow control device of claim 1, wherein the values ​​correspond to energy usage of the closure member in a first direction of travel and energy usage in a second direction of travel, and wherein the second direction of travel is opposite to the first direction of travel.

8. A flow control component, comprising: valve; a controller configured to regulate a flow of material through the valve; as well as The executable instructions on the controller are used to: The energy usage of the valve is calculated.

9. The flow control device of claim 8, wherein energy usage is based on an input describing operation of the valve.

10. The flow control device of claim 8, wherein energy usage is based on feedback describing a position of the valve.

11. The flow control device of claim 8, wherein energy usage is based on feedback describing the pressure of a signal related to the position of the valve.

12. The flow control device of claim 8, wherein energy usage describes energy usage of a pneumatic actuator coupled to the controller to control a position of a component of the valve.

13. The flow control of claim 8, further comprising a pneumatic actuator coupled to the controller and the valve, wherein energy usage is dependent on the area of ​​a piston in the pneumatic actuator.

14. The flow control of claim 8, further comprising a pneumatic actuator coupled to the controller and the valve, wherein energy usage is dependent on an area of ​​a diaphragm in the pneumatic actuator.

15. The flow control of claim 8, further comprising a pneumatic actuator coupled to the controller and the valve, wherein energy usage is dependent upon the pressure of a signal from the controller for pressurizing the pneumatic actuator.

16. A flow control component, the flow control component comprising: valve, and A controller is configured to determine work performed to maintain flow through the valve within parameters defined by the process.

17. The flow control device of claim 16, wherein the work performed is based on the position of a component in the valve.

18. The flow control device of claim 16, wherein the work performed is based on the pressure of the signal present at the controller.

19. The flow control device of claim 16, wherein the work performed is based on the area of ​​the diaphragm.

20. The flow control device of claim 16, wherein the work performed is based on the area of ​​the piston. in

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