Valve maintenance support device and support method

Abstract

The invention provides a valve maintenance support device and support method for improving work efficiency of maintenance of an ON-OFF valve. A valve maintenance support device is provided with: an operation command transmission unit (1) that transmits a control command to each of a plurality of switching valves that may be maintenance candidates so as to execute a switching operation for performing an operation check; an operation data reception unit (2) that receives operation data including opening degree measurement value data during the switching operation from each of the plurality of switching valves; a malfunction determination unit (4) that determines, for each of the plurality of switching valves, whether or not there is a possibility that a malfunction has occurred on the switching valves on the basis of the operation data; and a failure condition information presentation unit (5) for presenting the determination result obtained by the failure condition determination unit.

Description

Technical Field

[0001] The present invention relates to a technology for supporting maintenance work, and more particularly to a valve maintenance support device and a support method for realizing efficient work for the maintenance of a switching valve. Background Art

[0002] Valves used in petrochemical facilities etc. (e.g., Figure 6 control valves) must pay special attention to safety, so regular maintenance is carried out. Figure 6 The control valve shown includes: a valve body 100 that opens and closes a passage for fluid flow; a positioner 101 that converts an input electrical signal into air pressure; and an actuator 102 that operates the valve body 100 according to the air pressure supplied from the positioner 101.

[0003] In a facility where many Figure 6 valves shown are provided, in order to improve the efficiency of valve maintenance work, technologies for detecting the occurrence of stick-slip in the sliding part of the valve (refer to Patent Document 1), technologies for determining the hunting state of the valve (refer to Patent Document 2), technologies for detecting the attachment of scale to the valve (refer to Patent Document 3), etc. have been proposed.

[0004] On the other hand, as a valve of a different type from a control valve that can continuously change the opening degree, there is a switching valve that can only take two positions of fully open / fully closed for the opening degree. Figure 7 The switch (ON - OFF) valve 200 shown uses a ball valve and has a structure in which a ball 201 as a valve body is clamped by a seat ring 202 called a ball seat. By rotating the valve stem (valve rod) 203 by 90 degrees by an actuator 204, the valve can be opened or closed. Additionally, depending on the type, it may be an angle other than 90 degrees. As a method for detecting a defective condition with the switching valve as a diagnostic object, technologies for detecting a defective condition using the opening and closing time of the valve as a diagnostic index, or using the maximum operating speed and the minimum operating speed as diagnostic indexes have been proposed (refer to Patent Document 4).

[0005] In the technology disclosed in Patent Document 4, in order to detect a specific defective condition (e.g., the attachment of scale or the wear of a sealing member disclosed in Patent Document 4), it is necessary to make the valve perform an open (fully open) - close (fully closed) action. Therefore, for a switching valve that continuously remains in only one of the open or closed states during the operation of the facility, during regular repairs, irregular repairs, production process switching (when switching production types), etc., it is necessary to specifically perform a switching action (operation check).

[0006] Depending on the facilities, there are facilities that use more than hundreds of switching valves, and there are also switching valves that require careful operation inspection, so improvement of operation efficiency is required.

[0007] [Prior Art Documents]

[0008] [Patent Documents]

[0009] [Patent Document 1] Japanese Patent Publication No. 3254624

[0010] [Patent Document 2] Japanese Patent Publication No. 6200309

[0011] [Patent Document 3] Japanese Patent Publication No. 6216633

[0012] [Patent Document 4] Japanese Patent Publication No. 7265328 Summary of the Invention

[0013] [Problems to be Solved by the Invention]

[0014] The present invention is made to solve the above problems, and an object thereof is to provide a valve maintenance support device and a support method that can improve the operation efficiency of maintenance of a switching valve.

[0015] [Technical Means for Solving the Problems]

[0016] The valve maintenance support device of the present invention includes: an operation instruction transmission unit that transmits a control instruction to each of a plurality of switching valves that may be maintenance candidates to perform a switching operation for operation inspection; an operation data reception unit that receives operation data including an opening measurement value data at the time of the switching operation from each of the plurality of switching valves; a defect condition determination unit that determines, based on the operation data, whether there is a possibility of a defect condition occurring in each of the plurality of switching valves; and a defect condition information presentation unit that presents a determination result obtained by the defect condition determination unit.

[0017] In addition, a structural example of the valve maintenance support device of the present invention further includes a storage unit that stores, in advance for each of the plurality of switching valves, system identification information indicating the system to which the switching valve belongs, and the defect condition information presentation unit identifies the system to which the switching valve determined by the defect condition determination unit belongs based on the system identification information, and presents the determination result obtained by the defect condition determination unit by system.

[0018] In addition, a structural example of the valve maintenance support device of the present invention further includes a malfunction occurrence rate calculation unit that calculates the malfunction occurrence rate for each system based on the system identification information and the determination result obtained by the malfunction determination unit. The malfunction information presentation unit presents not only the determination result obtained by the malfunction determination unit but also the malfunction occurrence rate for each system.

[0019] In addition, a structural example of the valve maintenance support device of the present invention further includes a detailed inspection target setting unit that, when there is a system in which the malfunction occurrence rate exceeds a preset threshold, sets the operation instruction transmission unit and the malfunction determination unit so that the system is inspected a specified number of times more than normal during the next operation inspection.

[0020] In addition, in a structural example of the valve maintenance support device of the present invention, the switching valves of the same system are switching valves provided on the same pipe.

[0021] In addition, in a structural example of the valve maintenance support device of the present invention, the switching valves of the same system are switching valves provided in the same unit.

[0022] In addition, the valve maintenance support method of the present invention includes: a first step of sending a control instruction to each of a plurality of switching valves that may be maintenance candidates to perform a switching operation for an operation inspection; a second step of receiving operation data including the opening measurement value data during the switching operation from each of the plurality of switching valves; a third step of determining, based on the operation data, whether there is a possibility of a malfunction occurring in each of the plurality of switching valves; and a fourth step of presenting the determination result obtained in the third step.

[0023] In addition, in a structural example of the valve maintenance support method of the present invention, the fourth step includes the following steps: referring to the storage unit and, based on the system identification information, identifying the system to which the switching valve determined in the third step belongs, and presenting the determination result obtained in the third step for each system. The storage unit stores in advance the system identification information indicating the system to which each of the plurality of switching valves belongs.

[0024] In addition, a structural example of the valve maintenance support method of the present invention further includes: a fifth step of calculating the malfunction occurrence rate for each system based on the system identification information and the determination result obtained in the third step; and a sixth step of presenting the malfunction occurrence rate for each system.

[0025] In addition, a structural example of the valve maintenance support method of the present invention further includes a seventh step, which, in the case of a system where the incidence rate of the defective condition exceeds a preset threshold, sets the number of times of processing of the first step and the third step so that the system is inspected a specified number of times more than usual during the next operation inspection.

[0026] [Effects of the Invention]

[0027] According to the present invention, by sending control instructions to each of multiple switching valves that may be maintenance candidates to perform switching operations, many switching valves can be operated simultaneously to collect operation data, thus improving the work efficiency of maintaining the switching valves.

[0028] In addition, in the present invention, by identifying the system to which the switching valve determined by the defective condition determination unit belongs and presenting the determination result obtained by the defective condition determination unit by system, the work efficiency of maintaining the switching valves can be further improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 It is a block diagram showing the structure of a valve maintenance support device according to an embodiment of the present invention.

[0030] Figure 2 It is a flowchart for explaining the operation of a valve maintenance support device according to an embodiment of the present invention.

[0031] Figure 3 It is a diagram showing an example of a switching valve on the same piping.

[0032] Figure 4 It is a diagram showing an example of a switching valve in the same unit.

[0033] Figure 5 It is a block diagram showing a structural example of a computer for implementing a valve maintenance support device according to an embodiment of the present invention.

[0034] Figure 6 It is a diagram showing an example of a control valve.

[0035] Figure 7 It is a diagram showing an example of a switching valve.

[0036] [Description of Reference Numerals]

[0037] 1: Operation instruction sending unit

[0038] 2: Operation data receiving unit

[0039] 3: Storage unit

[0040] 4: Defective condition determination unit

[0041] 5: Defective condition information presentation unit

[0042] 6: Defect condition incidence calculation unit

[0043] 7: Detailed inspection object setting unit Detailed implementation mode

[0044] [Principle 1 of the invention]

[0045] In the case of performing an operation inspection on a number of switching valves such as regular maintenance, etc., it is preferable to send an operation instruction from an upper platform such as a facility control system, cause the number of switching valves to act as much as possible simultaneously, and collect information on defect condition detection using the upper platform.

[0046] In the case of pursuing further improvement in operation efficiency, the inventor focused on setting a switching valve in a pipe through which a fluid moves to be processed in a facility.

[0047] Moreover, in the case of switching valves provided in the same system (for example, on the same pipe or in the same unit), since the fluid type or operating state is in the same or similar conditions, the tendency for defect conditions to occur is also likely to be similar. Therefore, from the perspective of the same system, it is reasonable to organize and present the defect condition information of the switching valves. In addition, due to the presence of pipe branches, etc., a specific switching valve may also be presented multiple times as belonging to different pipe systems or units.

[0048] By organizing the switching valve system in this way, even if no defect condition is detected, as long as the valve is located on a pipe or in a unit with many valves having defect conditions, for example, it can be classified as a valve that requires careful multiple operation inspections during the next regular maintenance, etc. If the valve is located on a pipe or in a unit with few valves having defect conditions, it can be classified as a valve that only requires a minimum operation inspection. Therefore, as a result, the operation efficiency can be improved.

[0049] [Principle 2 of the invention]

[0050] From the perspective of the switching valves in the same system, it is preferable to present the defect condition incidence as a numerical value. In addition, it is preferable that in the case where the defect condition incidence exceeds a threshold value, for the switching valves associated with the pipe or the unit, it is automatically set that multiple operation inspections are carefully performed during the next regular maintenance, etc., including the switching valves for which defect condition detection has not been performed.

[0051] [Embodiment]

[0052] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. Figure 1 It is a block diagram showing the structure of a valve maintenance support device according to an embodiment of the present invention. This embodiment is an example corresponding to Principle 1 of the invention and Principle 2 of the invention.

[0053] The valve maintenance support device includes: an operation instruction sending unit 1 that sends control instructions to each of a plurality of switching valves that may be maintenance candidates to perform a switching operation for operation inspection; an operation data receiving unit 2 that receives operation data including opening measurement value data at the time of the switching operation from each of the plurality of switching valves; a storage unit 3 that prestores, for each of the plurality of switching valves, system identification information indicating the system to which the switching valve belongs; a malfunction determination unit 4 that determines, based on the operation data, whether there is a possibility of a malfunction occurring in each of the plurality of switching valves; a malfunction information prompting unit 5 that prompts the determination result obtained by the malfunction determination unit 4; a malfunction occurrence rate calculation unit 6 that calculates the malfunction occurrence rate for each system based on the system identification information and the determination result obtained by the malfunction determination unit 4; and a detailed inspection object setting unit 7 that, when there is a system in which the malfunction occurrence rate exceeds a preset threshold, sets the operation instruction sending unit 1 and the malfunction determination unit 4 to perform a specified number of inspections more than usual on the system during the next operation inspection.

[0054] Figure 2 It is a flowchart showing the operation of the valve maintenance support device of this embodiment. The storage unit 3 stores valve identifiers (IDs) (solid identification information) of a plurality of switching valves that may be maintenance candidates, and system IDs (system identification information) indicating the systems to which the respective switching valves belong. Switching valves with the same system refer to, for example, switching valves provided on the same pipe or in the same unit.

[0055] Switching valves on the same pipe are, for example, Figure 3 as shown, switching valve A1, switching valve A2, and switching valve A3 arranged to process a common fluid. Switching valves in the same unit are, for example, Figure 4 as shown, switching valve B1, switching valve B2, and switching valve B3 applied to the same polymerization kettle 10. Switching valves on the same pipe may have a common malfunction caused by a common fluid. Switching valves in the same unit may have a common malfunction caused by a common installation environment.

[0056] In addition, Figure 3 、 Figure 4 are all schematic diagrams for illustration, and preferably, for many switching valves, the possibility of a common malfunction (design matter) is estimated considering factors such as pipe branching or the distance of the installation position, the systems to which the switching valves belong are classified, and system IDs are assigned in advance. The valve ID is unique solid identification information for each valve, but one valve may sometimes belong to multiple systems, so sometimes multiple system IDs are assigned to one valve.

[0057] At the time of performing an operation check, the operation instruction transmission unit 1 transmits a control instruction to each of a plurality of switching valves that are registered with valve IDs in the storage unit 3 and that may be maintenance candidates, in order to execute a switching operation for the operation check( Figure 2 (step S100). In the present embodiment, it is assumed that a control instruction is provided to a switching valve at a remote location by communication. Therefore, in practice, it can be considered that a control instruction is sent to a controller that controls the switching valve, and an example in which the controller causes the switching valve to perform a switching operation or the like. However, the method of performing the operation check is not limited to such an example, and it can also be implemented by other methods.

[0058] As the timing of the operation check, there are timings such as regular repair, irregular repair, and production process switching (when the product type is switched). The valve maintenance support device can start the operation check, for example, according to an instruction from an operator, or can start the operation check according to predetermined scheduling information.

[0059] The operation data reception unit 2 receives operation data including at least the opening measurement value data when the switching valve operates from each switching valve( Figure 2 (step S101). Each switching valve periodically transmits the opening measurement value data and the valve ID of this device to the valve maintenance support device. The structure of such a switching valve is disclosed, for example, in Patent Document 4. The operation data reception unit 2 adds information on the reception time to the received opening measurement value data.

[0060] In addition, in addition to transmitting the opening measurement value data and the valve ID, each switching valve can also periodically transmit the pressure measurement value data of the operator air supplied to the operator. The structure of such a switching valve is disclosed, for example, in Japanese Patent Laid-Open No. 2021-026268. The operation data reception unit 2 adds information on the reception time to the received pressure measurement value data.

[0061] Based on the operation data received by the operation data reception unit 2, the defect condition determination unit 4 determines, for each switching valve that is registered with a valve ID in the storage unit 3 and that may be a maintenance candidate, whether there is a possibility of a defect condition occurring in the switching valve( Figure 2 (step S102).

[0062] As a technique for determining the defective condition of a switching valve, for example, there is the technique disclosed in Patent Document 4 or Japanese Patent Laid-Open No. 2021-026268. For example, in the technique disclosed in Patent Document 4, the required time TOP from the opening degree of 0% to 100% of the switching valve and the required time TCL from the opening degree of 100% to 0% are calculated, and a switching valve in which at least one of the required time TOP and the required time TCL is above a threshold value is determined as a switching valve that may have a defective condition. Alternatively, the absolute values of the maximum operating speeds VOPmax and VCLmax during the opening operation and closing operation of the switching valve are compared with the corresponding maximum operating speed thresholds, and the absolute values of the minimum operating speeds VOPmin and VCLmin during the opening operation and closing operation are compared with the corresponding minimum operating speed thresholds. A switching valve in which at least one of the operating speeds VOPmax, VOPmin, VCLmax, and VCLmin is above the corresponding threshold value is determined as a switching valve that may have a defective condition.

[0063] In addition, in the technique disclosed in Japanese Patent Laid-Open No. 2021-026268, a switching valve in which the dead zone time from the change in the pressure of the actuator air to the change in the opening degree of the switching valve is above a threshold value is determined as a switching valve that may have a defective condition.

[0064] The defective condition information presentation unit 5 identifies the system to which the switching valve determined by the defective condition determination unit 4 belongs based on the system ID stored in the storage unit 3, and presents the determination result obtained by the defective condition determination unit 4 by system ( Figure 2 Step S103).

[0065] For example, in Figure 3 the case where the switching valves A1, A2, and A3 shown belong to the "first piping system", the determination results of valves A1, A2, and A3 are listed under the item of the "first piping system". In addition, in Figure 4 the case where the switching valves B1, B2, and B3 shown belong to the "second polymerization kettle" system, the determination results of valves B1, B2, and B3 are listed under the item of the "second polymerization kettle". When the switching valve determined by the defective condition determination unit 4 belongs to multiple systems, it is preferable to display the determination results of the valves separately under the items of the multiple systems to which the valves belong in order to observe the tendency of each system.

[0066] Next, the defective condition occurrence rate calculation unit 6 calculates the defective condition occurrence rate for each system based on the system ID stored in the storage unit 3 and the determination result obtained by the defective condition determination unit 4 ( Figure 2Step S104). For example, if there are 20 on-off valves identified as being in the same system and 5 on-off valves are determined to have a possibility of a defective condition occurring (including on-off valves with a defective condition tendency level without emergency), the defective condition occurrence rate of the system is calculated to be 25%.

[0067] The defective condition information presentation unit 5 presents, in addition to presenting the determination result obtained by the defective condition determination unit 4, the defective condition occurrence rate by system ( Figure 2 Step S105).

[0068] In the case where there is a system in which the defective condition occurrence rate exceeds a preset threshold value ( Figure 2 in Step S106, YES), the operation instruction transmission unit 1 and the defective condition determination unit 4 are set so that, at the next operation inspection, the on-off valves of the system, including the on-off valves in which no defective condition has occurred, are inspected a specified number of times more than normal (for example, a detailed inspection of operating multiple times) ( Figure 2 Step S107).

[0069] For example, if the threshold value is 20% and the calculated defective condition occurrence rate is 25%, the operation instruction transmission unit 1 and the defective condition determination unit 4 are set so that, at the next regular repair, irregular repair, production process change (when changing the product type), etc., the on-off valves of the system are inspected a greater number of times than normal for diagnosis.

[0070] At the next operation inspection, the operation instruction transmission unit 1 transmits a control instruction to the on-off valves belonging to the system for which the inspection frequency has been increased, to repeatedly execute the switching operation the increased number of times (Step S100). At the next operation inspection, the defective condition determination unit 4 determines, for each switching operation, whether there is a possibility of a defective condition occurring in the on-off valves belonging to the system for which the inspection frequency has been increased (Step S102).

[0071] The processing of the defective condition information presentation unit 5 is the same as described above, but for the on-off valves belonging to the system for which the inspection frequency has been increased, if it is determined at least once that there is a possibility of a defective condition occurring, the determination result of "defective condition occurred" (or "there is a possibility of a defective condition occurring") is presented by the defective condition information presentation unit 5 (Step S103).

[0072] At the next operation inspection, for the system for which the inspection frequency has been increased, the defective condition occurrence rate calculation unit 6, for example, may use the maximum value or average value of the defective condition occurrence rates calculated for each inspection as the defective condition occurrence rate of the system ( Figure 2 Step S104).

[0073] The valve maintenance support device described in this embodiment can be implemented by a computer including a central processing unit (CPU), a storage device, and an interface, and a program for controlling these hardware resources. An example of the structure of the computer is illustrated in Figure 5 . The computer includes a CPU 300, a storage device 301, and an interface device (Interface, I / F) 302. The I / F 302 is connected to, for example, a valve, a controller, a display, etc. In such a computer, a program for implementing the valve maintenance support method of the present invention is stored in the storage device 301. The CPU 300 executes the processing described in this embodiment according to the program stored in the storage device 301.

[0074] [Industrial Applicability]

[0075] The present invention can be applied to technologies for supporting valve maintenance operations.

Claims

1. A valve maintenance support device, characterized in that, Comprising: An operation instruction sending unit that sends control instructions to each of a plurality of switching valves that may be maintenance candidates to perform a switching action for an operation check; An operation data receiving unit that receives operation data including opening measurement value data at the time of the switching action from each of the plurality of switching valves; A defective condition determination unit that determines, based on the operation data, whether there is a possibility of a defective condition occurring in each of the plurality of switching valves; And A defective condition information prompting unit that prompts the determination result obtained by the defective condition determination unit.

2. The valve maintenance support device according to claim 1, characterized in that It further includes a storage unit that pre-stores system identification information indicating the system to which the switching valve belongs for each of the plurality of switching valves, The defective condition information prompting unit identifies the system to which the switching valve determined by the defective condition determination unit belongs based on the system identification information, and prompts the determination result obtained by the defective condition determination unit by system.

3. The valve maintenance support device according to claim 2, characterized in that It further includes a defective condition occurrence rate calculation unit that calculates the defective condition occurrence rate for each system based on the system identification information and the determination result obtained by the defective condition determination unit, The defective condition information prompting unit not only prompts the determination result obtained by the defective condition determination unit, but also prompts the defective condition occurrence rate by system.

4. The valve maintenance support device according to claim 3, characterized in that It further includes a detailed inspection object setting unit that, when there is a system in which the defective condition occurrence rate exceeds a preset threshold, sets the operation instruction sending unit and the defective condition determination unit to perform a specified number of inspections more than normal on the system during the next operation check.

5. The valve maintenance support device according to any one of claims 2 to 4, characterized in that The switching valves with the same system are the switching valves provided on the same pipe.

6. The valve maintenance support device according to any one of claims 2 to 4, characterized in that The switching valves with the same system are the switching valves provided in the same unit.

7. A valve maintenance support method, characterized in that, Comprising: A first step of sending control instructions to each of a plurality of switching valves that may be maintenance candidates to perform a switching action for an operation check; A second step of receiving operation data including opening measurement value data at the time of the switching action from each of the plurality of switching valves; A third step of determining, based on the operation data, whether there is a possibility of a defective condition occurring in each of the plurality of switching valves; And A fourth step of prompting the determination result obtained by the third step.

8. The valve maintenance support method according to claim 7, characterized in that The fourth step includes the following steps: referring to the storage unit, and based on the system identification information, identifying the system to which the switching valve set as the determination object in the third step belongs, and prompting the determination result obtained from the third step according to the system. For each of the plurality of switching valves, the storage unit prestores the system identification information indicating the system to which the switching valve belongs.

9. The valve maintenance support method according to claim 8, characterized in that, It further includes: a fifth step of calculating the incidence rate of defective conditions for each system based on the system identification information and the determination result obtained from the third step; and a sixth step of prompting the incidence rate of defective conditions according to the system.

10. The valve maintenance support method according to claim 9, wherein it further includes a seventh step. In the case where there is a system in which the incidence rate of defective conditions exceeds a preset threshold, the number of times of processing of the first step and the third step is set so as to perform a specified number of inspections more than usual on the system during the next operation inspection.

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