A fault diagnosis system and method for a regulating valve

Abstract

The application discloses a kind of fault diagnosis system and method of regulating valve, system includes power detection module, for obtaining the power parameter of driving execution mechanism;Valve position feedback module, for obtaining the execution parameter of execution structure driving regulating valve;Instruction acquisition module, for obtaining the control instruction of control end, diagnostic test instruction;Diagnostic test instruction is used for valve positioner to execute setting operation;Setting module, for obtaining diagnostic test instruction and executing setting operation, in the process of setting operation, obtain the behavior parameter generated for the fault mapping of diagnosis;Analysis module, for obtaining the response parameter generated when responding control instruction in actual operation, and based on fault mapping comparative analysis obtains fault information.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of regulating valves, and particularly relates to a fault diagnosis system and method for a regulating valve. BACKGROUND

[0002] In process industries such as oil refining, petrochemical, chemical, power, metallurgy, papermaking, pharmaceutical, light industry, etc., regulating valves are used for action execution of process medium (liquid, gas, mixture) flow control to realize automatic regulation of process parameters such as temperature, pressure, flow, liquid level, composition, concentration, etc. The body and control system of the regulating valve mainly consist of the following parts: valve (regulating valve, regulating ball valve, regulating butterfly valve, etc.), actuator (cylinder, piston, diaphragm, fork) for pushing valve opening change, valve positioner for controlling the actuator, and electrical accessories for realizing other functions. The reliability and accurate control performance of the regulating valve are crucial for process safety and production efficiency.

[0003] The regulating valve may be affected by factors such as mechanical action wear, medium corrosion, and temperature and pressure environment aging during long-time operation, resulting in faults of its components, especially failure or performance degradation of core components such as valve positioner, actuator, control gas circuit, valve throttling part, and sealing part. These faults may cause the valve to fail to correctly respond to the instructions of the DCS / PLC master controller or delay the response, which may cause the process parameters to deviate or oscillate, or even cause the equipment to shut down or even production accidents.

[0004] Therefore, it is crucial to monitor and diagnose the health status of each component of the regulating valve in real time, discover potential faults in time, and give early warnings to ensure safe operation of the system and normal process production.

[0005] Currently, fault diagnosis engineering practice of the regulating valve involves, on the one hand, adding some simple fault judgments such as action jamming to the intelligent valve positioner, but this only accounts for a small part of the faults of the regulating valve; on the other hand, more relies on manual inspection to determine the faults. The former cannot determine the performance degradation of specific components and cannot determine more faults, and the latter manual inspection method is limited by technical experience and on-site observation conditions, and it is difficult to discover faults, and it is easy to miss and not timely. SUMMARY

[0006] The purpose of the application is to provide a fault diagnosis system for a regulating valve, which performs overall fault diagnosis on the regulating valve according to multi-directional parameters, gives obvious conclusions of fault positions, and discovers faults in time.

[0007] The technical solution adopted by the application to solve the technical problem is to propose a fault diagnosis system for a regulating valve, which comprises:

[0008] a power detection module configured to acquire power parameters of a driving actuator;

[0009] a valve position feedback module configured to acquire an execution parameter of the actuator driving the regulating valve;

[0010] an instruction acquisition module configured to acquire a control instruction of a control end and a diagnostic test instruction, the diagnostic test instruction being used for a setting operation of the valve positioner;

[0011] a setting module configured to acquire a behavior parameter during the setting operation and generate a fault mapping for diagnosis, the behavior parameter at least including the power parameter and the execution parameter;

[0012] an analysis module configured to acquire a response parameter generated in response to the control instruction in actual operation, and obtain fault information through comparative analysis based on the fault mapping, the response parameter at least including the power parameter and the execution parameter.

[0013] Further, the diagnostic test instruction includes a random signal and a step signal, and the setting operation includes:

[0014] driving the actuator based on the random signal to cause a change in the opening degree of the regulating valve, and acquiring a dynamic behavior parameter, denoted as a dynamic parameter;

[0015] calculating a first parameter feature of the dynamic parameter, and generating a first mapping relationship for diagnosis;

[0016] driving the actuator based on the step signal to cause a change in the state of the regulating valve, and acquiring a steady behavior parameter, denoted as a steady parameter;

[0017] calculating a second parameter feature and a third parameter feature of the steady parameter, and generating a second mapping relationship and a third mapping relationship for diagnosis;

[0018] The fault mapping includes the first mapping relationship, the second mapping relationship, and the third mapping relationship.

[0019] Further, the fault mapping includes an input item, a comparison item, and an output item, the input item being the response parameter, the comparison item being the behavior parameter and the parameter feature, and the output item being the fault information, the parameter feature including the first parameter feature, the second parameter feature, and the third parameter feature.

[0020] Further, the system further includes an acoustic wave acquisition module configured to acquire an ultrasonic wave parameter after the regulating valve.

[0021] a valve flow monitoring module configured to acquire a flow parameter of the valve;

[0022] The behavior parameter further includes the ultrasonic wave parameter and the flow parameter, and the response parameter further includes the ultrasonic wave parameter and the flow parameter.

[0023] Further, the instruction acquisition module is configured to acquire a control instruction of an actual runtime control terminal, or a diagnostic test instruction output by the control terminal or other manual operator to the valve positioner.

[0024] Further, the valve position feedback module comprises a valve position detection unit and a feedback conversion unit, the valve position detection unit is configured to detect a driving stroke of the actuator, and the feedback conversion unit is configured to convert the driving stroke into a feedback signal, and the execution parameter comprises the feedback signal.

[0025] The application further provides a fault diagnosis method of a regulating valve, which is applicable to the fault diagnosis system of the regulating valve.

[0026] The diagnostic test instruction is acquired, the setting operation is performed based on the diagnostic test instruction, the behavior parameter is acquired, the parameter feature of the behavior parameter is calculated, and the fault mapping is generated;

[0027] The response parameter generated in response to the control instruction in actual runtime is acquired, the response parameter is introduced into the fault mapping, and the fault information is output.

[0028] Further, the diagnostic test instruction comprises a random signal and a step signal.

[0029] The diagnostic test instruction is acquired, and specifically comprises:

[0030] The type of the test instruction is judged.

[0031] When the test instruction is a random signal, the behavior parameter acquired in the setting operation is recorded as a dynamic parameter.

[0032] When the test instruction is a step signal, the behavior parameter acquired in the setting operation is recorded as a steady-state parameter.

[0033] Further, the parameter feature of the behavior parameter is calculated, and the fault mapping is generated, and specifically comprises:

[0034] The dynamic parameter is acquired, the first parameter feature of the dynamic parameter is calculated, and the first mapping relationship for diagnosis is generated;

[0035] The steady-state parameter is acquired, the second parameter feature and the third parameter feature of the steady-state parameter are calculated, and the second mapping relationship and the third mapping relationship for diagnosis are generated;

[0036] The first calling condition of the first mapping relationship is identified according to the first parameter feature, the second calling condition of the second mapping relationship is identified according to the second parameter feature, and the third calling condition of the third mapping relationship is identified according to the third parameter feature.

[0037] The first calling condition, the second calling condition and the third calling condition are respectively associated with the first mapping relationship, the second mapping relationship and the third mapping relationship, and are integrated into the fault mapping; the fault mapping comprises the first mapping relationship, the second mapping relationship and the third mapping relationship.

[0038] Further, a response parameter generated when an execution control instruction is acquired is imported into the fault mapping, and fault information is output, and specifically comprising:

[0039] An execution control instruction and a response parameter generated when the control instruction is executed are acquired.

[0040] A mapping relationship suitable for the control instruction is determined.

[0041] When the control instruction meets the first calling condition, the response parameter is imported into the first mapping relationship, and fault information is output.

[0042] When the control instruction meets the second calling condition, the response parameter is imported into the second mapping relationship, and fault information is output.

[0043] When the control instruction meets the third calling condition, the response parameter is imported into the third mapping relationship, and fault information is output.

[0044] In summary, the present application has the following technical innovations and beneficial effects:

[0045] 1. The present application is a relatively independent system, which realizes fault diagnosis of the regulating valve without changing the conventional design specifications of the original regulating valve and the matching electrical accessory selection and configuration, etc. When used alone, it is not limited; it does not interfere with the control work of the original electrical control circuit (valve positioner closed loop control of regulating valve opening degree), and only makes online passive monitoring and fault diagnosis. Therefore, the system function structure has the characteristics of high reliability and high engineering acceptance.

[0046] 2. The fault diagnosis system of the present application finally obtains fault detail information, which covers most of the valve and component faults such as serious faults like refusal to move / stuck / loss of gas and loss of power, and various performance degradation faults of components, overcomes the shortcomings of the existing few intelligent valve positioner fault diagnosis technologies that can only diagnose a small amount of faults, and makes up for the lack of existing technologies in equipment intelligent monitoring and diagnosis.

[0047] 3、The fault diagnosis system of the present application is a relatively independent system, the control function of the valve positioner to the actuator and the detection function of the fault diagnosis device to the actuator are separated from each other, the valve positioner is responsible for the closed-loop control of the valve, and the diagnosis system is passively detected and diagnosed, and the diagnosis reliability of the fault diagnosis device will not be affected by whether the valve positioner has a fault or not; moreover, the valve positioner is one of the objects to be diagnosed, and it is relatively easy to fail during use, and relying on the stability of the valve positioner for fault diagnosis is a principle defect commonly existing in the prior art, which leads to imperfect application objects and low reliability of fault diagnosis; and the fault diagnosis system of the present application overcomes the defect that the fault diagnosis of the existing intelligent valve positioner is severely dependent on the reliability of the valve positioner, not only perfects the application objects of fault diagnosis, but also has higher reliability.

[0048] 4、The fault diagnosis system of the present application finally gives clear fault information such as refusal of each component or performance degradation, which overcomes the defect that some existing intelligent valve positioner fault diagnosis technologies give some performance index data, and the relationship between fault and performance index needs to be judged by experienced engineers.

[0049] 5、The fault diagnosis system of the present application innovatively uses a specific self-tuning excitation to obtain a fault mapping relationship in the diagnosis method, the fault mapping contains various types of fault information of each component of the control valve, and the diagnosis of various types of valve faults is realized.

[0050] 6、The fault diagnosis instrument manufactured based on the system does not change the original design of the control valve (such as the selection and configuration of electrical accessories) when applied, and does not have new sensors that are difficult to implement under engineering conditions, and is not only suitable for new production lines, but especially suitable for intelligent operation and maintenance technology upgrading of original industrial production lines.

[0051] 7、The online fault diagnosis instrument manufactured based on the system is a new type of valve electrical accessory, which can replace the current engineering practice mainly relying on manual inspection, reduce manpower and material resources, and bring major changes to traditional factory operation and maintenance, and change the original regular inspection to predictive planned maintenance. BRIEF DESCRIPTION OF DRAWINGS

[0052] The accompanying drawings, which are incorporated into and constitute a part of the specification, illustrate embodiments of the present application and, together with the description, serve to explain the principles of the present application. In these drawings, like reference numerals are used to represent like elements. The drawings described below are some embodiments of the present application, not all embodiments. For those skilled in the art, other drawings can be obtained from these drawings without creative labor.

[0053] Figure 1A structure diagram of a fault diagnosis system of a regulating valve according to an embodiment of the present application;

[0054] Figure 2 A principle diagram of a fault diagnosis system of a regulating valve according to an embodiment of the present application;

[0055] Figure 3 A flow chart for obtaining a first mapping relationship based on a random signal;

[0056] Figure 4 A flow chart for obtaining second and third mapping relationships based on a step signal;

[0057] Figure 5 A flow chart for fault diagnosis based on a control instruction;

[0058] Figure 6 A flow chart of a fault diagnosis method of a regulating valve according to an embodiment of the present application. DETAILED DESCRIPTION

[0059] The technical solutions of the embodiments of the present application will be explained and described below in combination with the drawings of the embodiments of the present application. However, the following embodiments are only preferred embodiments of the present application and not all, such as various types of valves, actuators, valve positioners, and various air path designs, etc. Various configurations of different regulating valves. Based on the embodiments in the embodiments, other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0060] The terms "first", "second", etc. in the specification and claims in the specification and the above drawings are used to distinguish different objects and are not used to describe a specific order. In addition, the term "includes" and any variations thereof are intended to cover non-exclusive inclusion. For example, a process, method, system, product or device that includes a series of steps or modules is not limited to the listed steps or modules, but can optionally include steps or modules that are not listed, or can optionally include other steps or modules inherent to the process, method, product or device.

[0061] First of all, it should be clear that there are many possible faults of the regulating valve, for example:

[0062] The oil and water impurities contained in the compressed air are not completely filtered, causing the throttle hole inside the valve positioner to be blocked, causing the valve positioner to not respond in time or fail to the main controller DCS / PLC action;

[0063] The feedback rod of the valve positioner is frequently moved for a long time, and the feedback rod is loose, causing the valve positioner to not respond in time or fail to the main controller DCS / PLC action;

[0064] In the actuator and control gas circuit, the air pipe joint is broken, the diaphragm is broken, the diaphragm cover bolt is loose, etc. The gas leakage causes the actuator to not respond in time or fail to the main controller DCS / PLC action.

[0065] The long-term frequent friction of the moving parts causes the packing to break, the sleeve and the valve core to increase in friction, the valve rod to be misaligned, the valve rod to be scratched, etc. The friction abnormalities cause the valve to not respond in time or fail to the main controller DCS / PLC action.

[0066] The valve throttling failure, such as the labyrinth sleeve or the small hole sleeve, causes the throttling failure under the action of high temperature and high pressure medium, such as cavitation, impurity blockage, etc. The process parameters do not meet the expectations or oscillate.

[0067] The valve core and valve seat are damaged by long-term medium scouring, causing internal or external leakage of the sealing surface or sealing element, resulting in medium leakage.

[0068] In a more serious case, when the stuck and refused to move, or the power failure, the control signal is broken, and the compressed air source is lost, the control valve cannot work.

[0069] The control end can be a total control module, which is a digital control module for industrial automation control, and can be realized based on the existing DCS (Distributed Control System) or PLC automation control technology.

[0070] For example, the DCS or PLC can send a control instruction ZC to the valve positioner to control the valve opening change to automatically adjust the medium flow in the pipeline, realizing closed-loop automatic control of the valve; the control instruction will be collected by the instruction collection module of the fault diagnostic device during actual operation, and used for diagnosing the fault of the control valve; before the fault diagnostic device is installed and applied, it needs to be initialized to adapt to the current control valve, at this time, the DCS or PLC or the hand-operated device can send a specific diagnostic test instruction to the valve positioner for setting operation, and the fault diagnostic device obtains the fault mapping relationship adapted to the current control valve.

[0071] According to the fault diagnosis system of the present application, the fault diagnostic device is initialized to obtain the mapping relationship adapted to the current control valve, but the test signal is usually sent by the hand-operated device to the valve positioner, and the valve will move accordingly, and the fault diagnostic device passively obtains the behavior parameters, and then obtains the mapping relationship; in application, the DCS / PLC sends a control instruction to the valve positioner, and the valve moves accordingly, and the fault diagnostic device passively obtains the response parameters to diagnose the fault. The actions of the valve during the diagnostic test operation and actual operation are controlled by the valve positioner, and the fault diagnostic device collects data for passive detection.

[0072] Referring toFigure 1 The regulating valve can include a power device, a valve positioner, an actuator and a valve, wherein the actuator is used to adjust the opening degree of the valve, the power device is used to drive the actuator, and the valve positioner is used to adjust the size of the driving force according to a control instruction, so as to control the opening degree of the valve.

[0073] The fault diagnosis device judges whether the regulating valve has a fault and the fault position by collecting power parameters of the power device and execution parameters of the actuator, and can output clear fault information.

[0074] The main body of the fault diagnosis system is the fault diagnosis device, which can be connected with the control end, the power device, the valve positioner and the actuator to obtain corresponding parameters. Multiple function modules can be configured to realize data collection, comparative analysis and fault diagnosis, and the fault diagnosis device is an integrated body of these function modules.

[0075] The power detection module is used to obtain power parameters of the actuator. The power device takes a gas source Ps as an example, the gas pressure can be adjusted by the valve positioner, the gas pipe between the gas source and the valve positioner is an inlet pipe, the gas pipe between the valve positioner and the actuator is an outlet pipe, an inlet detection unit can be arranged on the inlet pipe, and an outlet detection unit can be arranged on the outlet pipe, so as to obtain the gas pressure parameter P, i.e. the power parameter, which includes the inlet parameter PA and the outlet parameter PB. The values of the parameters can be used as a basis for subsequent fault judgment. The inlet and outlet detection units can adopt gas pressure sensors. Figure 2 The gas pressure sensor A on the inlet pipe is the inlet detection unit, and the gas pressure sensor B on the outlet pipe is the outlet detection unit.

[0076] The valve position feedback module is used to obtain execution parameters of the actuator driving the regulating valve. Since the actuator and the valve are generally mechanically driven, the ratio between the extension stroke of the actuator and the opening degree of the valve is fixed, so that after the driving stroke of the actuator is detected, the opening degree of the valve can be directly converted.

[0077] In this application, the valve position feedback module can be used to detect the driving stroke of the actuator and convert it into the valve opening degree parameter ZT, i.e. the execution parameter.

[0078] Illustratively, the valve position feedback module can include a valve position detection unit and a feedback conversion unit, the valve position detection unit is used to detect the driving stroke of the actuator, and the feedback conversion unit is used to convert the driving stroke into a feedback signal, and the execution parameter includes the feedback signal.

[0079] Specifically, the valve position detection unit can be a diagnostic device valve position feedback rod, and the feedback conversion unit can be a sensor. For example, if the driving stroke of the actuator changes to drive the diagnostic device valve position feedback rod to move synchronously, a displacement sensor can be selected. If the driving stroke of the actuator changes to drive the diagnostic device valve position feedback rod to rotate, an angle sensor or an encoder can be selected.

[0080] It can be understood that the valve positioner and the extension structure of the actuator have a connection relationship, and the diagnostic device valve position feedback rod can be designed based on this connection relationship or designed separately. When designed separately, the diagnostic device valve position feedback rod and the connection relationship do not interfere with each other, and can be arranged on both sides of the extension structure. For example, as shown in FIG. 3, the valve positioner is located on the left side of the extension structure, and the diagnostic device valve position feedback rod is located on the right side of the extension structure, and the connection relationship is established respectively. Figure 1

[0081] The instruction acquisition module is configured to acquire a control instruction and a diagnostic test instruction of the control end. The instruction acquisition module can be implemented based on a circuit. For example, as shown in FIG. 4, the instruction acquisition module can include a current sensor I and a voltage sensor V. Figure 2 The current sensor I can be used to detect the size of the control instruction ZC, and the driving stroke of the actuator can be changed according to the size of the control instruction ZC, so as to correspond to different opening degrees of the valve. For example, when the size of the control instruction ZC is 4 mA, 8 mA, 12 mA, 16 mA, and 20 mA, the opening degree of the valve is 0%, 25%, 50%, 75%, and 100%, respectively. The size range of the control instruction ZC can be adjusted according to actual requirements, such as the identification accuracy of the valve positioner and the adjustment accuracy of the valve. For example, the current sensor I can be a mutual inductor.

[0082] The control instruction is a demand instruction generated during actual operation, and is related to the operation demand of the control valve. The diagnostic test instruction is an operation instruction set by a person, and the purpose is to implement setting operation, that is, to drive the valve positioner to generate corresponding actions based on the diagnostic test instruction, so that the fault diagnosis device can collect the response behavior parameters.

[0083] The fault diagnosis device can collect the control instruction and the diagnostic test instruction based on the same circuit. The control instruction and the diagnostic test instruction do not appear at the same time.

[0084] The opening degree parameter ZT of the valve is directly related to the control instruction ZC. After the fault diagnosis device collects the control instruction ZC, the valve opening degree parameter ZT collected in the steady state after executing the control instruction ZC should correspond to the execution of the control instruction ZC. If they do not correspond, it means that there may be a fault. Therefore, the collected control instruction ZC and the valve opening degree parameter ZT can be used as the basis for subsequent fault judgment. ​

[0085] The diagnostic system of the present application further comprises an acoustic wave acquisition module for acquiring the ultrasonic wave parameter after the regulating valve; a valve flow monitoring module for acquiring the flow parameter of the valve; therefore, the behavior parameter further comprises the ultrasonic wave parameter and the flow parameter, and the response parameter further comprises the ultrasonic wave parameter and the flow parameter.

[0086] The acoustic wave acquisition module is used for acquiring the ultrasonic wave parameter US at the valve, which can be realized by means of continuously receiving ultrasonic waves through an ultrasonic sensor. Specifically, if a leak occurs at the closed position of the valve, the injection of the leaked medium will generate turbulence phenomenon, and the abnormally high-frequency ultrasonic wave signal formed by the turbulence is used for judging the valve leakage information and subsequent setting operation and fault analysis after being received by the ultrasonic sensor.

[0087] The valve flow monitoring module is used for acquiring the pressure difference and medium flow before and after the valve, and a pre-valve pressure detection unit can be arranged before the valve and a post-valve pressure detection unit can be arranged after the valve to obtain the pre-valve pressure parameter PT7 and the post-valve pressure parameter PT8 respectively, and the pressure difference dPT is obtained by calculation; a flow detection unit can be arranged after the valve to obtain the flow detection signal FT; the flow parameter can include the pressure difference dPT and the flow detection signal FT; under normal working conditions, the pressure difference (dPT) of PT7 and PT8 should meet the expected relationship with the valve opening degree (ZT) and the flow (FT), and therefore, it can be used as the basis for subsequent fault judgment.

[0088] The setting module acquires the behavior parameter to generate the fault mapping for diagnosis during the setting operation; the behavior parameter at least includes the power parameter and the execution parameter.

[0089] In the present application, the diagnostic test instruction and the control instruction can be controlled and triggered by the control end, the diagnostic test instruction is used for executing a specific setting operation, and the setting operation is used for acquiring the behavior parameter of the regulating valve (including the power equipment, the valve positioner, the execution mechanism, the valve and other components) under the normal state, so that the response parameter generated in the subsequent actual work of the regulating valve is diagnosed based on the normal behavior parameter.

[0090] During the setting operation, the diagnostic test instruction can be output by the hand controller or the control end, and the output object is the valve positioner, so that the valve positioner generates an action, and the execution mechanism and the valve can be synchronously driven to generate an action, and in this process, the fault diagnostic device acquires the corresponding behavior parameter and acquires the diagnostic test instruction through the instruction acquisition module.

[0091] During the use of the regulating valve, according to different situation requirements, the following three situations can be included: dynamic regulation, closing, and fixed opening degree, therefore, the corresponding diagnostic test instruction should be set to adapt to the three situations, so that the fault diagnosis based on the behavior parameter is more targeted and more accurate and effective.

[0092] The signal types of diagnostic test commands can be divided into random signals and step signals. Dynamic adjustment can be tested using random signals, while steady-state adjustment (closed, fixed opening) can be tested using step signals.

[0093] It should be clarified that when using random signals for dynamic adjustment, the collected behavioral parameters also change dynamically. When using step signals for steady-state adjustment, the collected behavioral parameters are fixed values.

[0094] Therefore, when performing fault diagnosis based on behavioral parameters, this application distinguishes between the two, performs fault analysis separately, and establishes different mapping relationships with fault information.

[0095] In the embodiments of this application, tuning operations can be performed based on the type of test instruction to obtain the behavioral parameters of the corresponding state. Specifically:

[0096] The actuator is driven by a random signal to change the opening of the control valve, and the dynamically changing behavior parameters are obtained and recorded as dynamic parameters.

[0097] Calculate the first parameter feature of the dynamic parameters to generate the first mapping relationship for diagnosis;

[0098] Based on the step signal driving the actuator to change the state of the control valve, the steady-state behavior parameters are obtained and denoted as steady-state parameters.

[0099] Calculate the second and third parameter characteristics of the steady-state parameters, and generate the second and third mapping relationships for diagnosis.

[0100] Fault mapping includes a first mapping relationship, a second mapping relationship, and a third mapping relationship.

[0101] In this application, behavioral parameters include power parameters, execution parameters, etc. During valve adjustment, these parameters are correlated; therefore, under normal conditions, the behavioral parameters exhibit distinct behavioral characteristics, which are termed parameter characteristics. These characteristics can apply to a single parameter or multiple parameters. Based on these parameter characteristics, comparative analysis of the collected response parameters yields corresponding fault information. Alternatively, fault information can be determined experimentally.

[0102] In one possible embodiment, the fault information may include performance degradation information, failure to operate information, malfunction information, power loss information, and gas loss information for each component.

[0103] by Figure 1 Taking the control valve structure as an example, the corresponding fault information can be obtained by comparing and analyzing the collected response parameters based on fault mapping:

[0104] If the control instruction ZC, PA, PB and valve opening parameter ZT are collected and the parameter characteristics are calculated, the corresponding fault information obtained by comparative analysis based on the parameter characteristics can include action failure, such as the failure information of the actuator, such as refusal to act, jamming, etc.; the action failure of the valve positioner, such as air leakage, oil and water blockage, etc.; the action failure of the power equipment, such as air leakage, air loss, etc.

[0105] If the control instruction ZC is not equal to zero, the ultrasonic wave parameter is collected, and the parameter characteristics are calculated, the corresponding fault information obtained by comparative analysis based on the parameter characteristics in the fault mapping can include throttling failure; the parameter characteristics can be the valve flow coefficient.

[0106] If the control instruction ZC is equal to zero, the ultrasonic wave parameter and the flow parameter are collected, and the parameter characteristics are calculated, the corresponding fault information obtained by comparative analysis based on the parameter characteristics in the fault mapping can include leakage failure.

[0107] In one possible embodiment, the fault detailed information includes the leakage information of the valve, wherein the valve leakage can be caused by various factors, such as internal leakage caused by valve core valve seat wear and cavitation, external leakage caused by aging and deformation of valve cover packing or flange sealing, etc. When gas or liquid leakage occurs, gas turbulence phenomenon will occur at the leakage position, and turbulence will form high-frequency ultrasonic wave signals (usually frequency > 20 kHz, beyond the range of human hearing).

[0108] If the valve is in a fully closed state and leakage occurs, the signals are captured by the ultrasonic wave sensor and converted into digital signals that can be processed by the analysis module, which is calculated (by means of noise reduction preprocessing and feature signal extraction in the prior art) and compared with the obtained basic background sound wave parameters in the fault mapping, so that the final leakage information can be determined.

[0109] The sound wave collection module collects two ultrasonic wave parameters US of the valve in the fully open / fully closed state. Under normal circumstances, i.e. without leakage, the above two ultrasonic wave parameters US represent the basic background noise of the valve in the fully open (or 10% opening) / fully closed state, and the parameter diagnosis basis is generated based on the above two ultrasonic wave parameters US. For example, when the valve is in a fully closed position, the valve leakage information can be distinguished and generated based on the collected ultrasonic wave parameter US.

[0110] The above is a comparative analysis example of part of the fault information of the regulating valve, which is realized by comparative analysis of power parameters (such as PA, PB), execution parameters (such as ZT), flow parameters (such as PT7, PT8, dPT, FT), ultrasonic wave parameters (such as US) and control instructions (ZC) and behavior parameters and their parameter characteristics.

[0111] In the present application, a mapping relationship is established based on the behavior parameters and parameter characteristics thereof and the fault information. When the response parameters are collected, they are compared with the behavior parameters and parameter characteristics as input items, and the fault information is output according to the mapping result of the comparison result.

[0112] Taking the three parameters PA, PB and ZT as examples, a mapping relationship with the fault information can be established, wherein PA is the first parameter, PB is the second parameter, and ZT is the third parameter. The mapping result can be obtained by importing the collected response parameters:

[0113] The above three exemplary parameters are imported, and the parameter characteristics are calculated. The parameter characteristics include a plurality of characteristic quantities. Exemplarily, the specific forms of the characteristic quantities can include the change speed of the first parameter, the change speed of the second parameter, the covariance of the first parameter, the second parameter and the third parameter, the mode of the third parameter, the power spectrum, the variance of the first parameter, the second parameter and the third parameter, etc. The number, property, type and correlation of the characteristic quantities can be adjusted and selected as needed.

[0114] Based on the changes of the characteristic quantities in the parameter characteristics, a plurality of mapping structures can be obtained, each or a plurality of mapping structures corresponds to a mapping result, and each mapping result corresponds to an explicit fault information. It can be understood that the changes of the characteristic quantities can be single or multiple.

[0115] It should be clear that based on the changes of the characteristic quantities, accurate and refined fault analysis results can be obtained. The parameter characteristics can include two types, the first type is the property characteristics of a single parameter, and the second type is the correlation characteristics of a plurality of parameters. The plurality of parameters can be any two or three or more parameters that have a correlation. The correlation between the parameters and the correlation between the characteristic quantities can be consistent or related, that is, the correlation between the parameters can affect the selection and calculation method of the parameters in the characteristic quantities.

[0116] In a feasible embodiment, the random signal can cover all values of the valve opening degree from 0% to 100%, so as to obtain the first mapping relationship under the background of adjusting at any opening degree. It should be noted that the random signal can include an initial value and a target value. The initial value is the current valve opening degree, and the target value is the expected valve opening degree.

[0117] In a feasible embodiment, the amplitude of the step signal can be 10%, so as to obtain the third mapping relationship under the background of 10% opening degree. At the same time, the initial amplitude of the step signal can be set to 0%, that is, the valve is fully closed, so as to obtain the second mapping relationship under the background of the fully closed valve.

[0118] Exemplarily, please refer to Figure 3, the diagnostic test instruction is a random signal, the regulating valve is driven to make corresponding controlled action based on the random signal, and the fault diagnoser obtains a first mapping relationship according to the collected behavior data and the first parameter feature; specifically, the content of the first parameter feature can include modal, power spectrum, variance, covariance, change speed, acceleration, etc., and can be calculated based on one parameter or multiple parameters.

[0119] For example, refer to Figure 4 , the diagnostic test instruction is a step signal, the regulating valve is driven to make corresponding controlled action based on the step signal, and the fault diagnoser obtains a second mapping relationship according to the collected behavior data and the second parameter feature; specifically, the second parameter feature can be a valve flow coefficient Kv(ZT), Figure 4 The calculation method of the valve flow coefficient is shown in the table.

[0120] The fault diagnoser obtains a third mapping relationship according to the collected behavior data and the third parameter feature; specifically, the third parameter feature can include valve full-closing background noise US0, i.e., ultrasonic parameters in the valve full-closing background and ultrasonic parameters in the valve 10% opening background. Based on the ultrasonic parameters US0 in the valve 10% opening background, when the ultrasonic parameters US1 in the valve full-closing background are collected, whether the valve is fully closed and whether there is leakage can be judged by comparing US1 and US0.

[0121] The analysis module is used to obtain a response parameter generated in response to a control instruction in actual operation, and to obtain fault information by comparative analysis based on the fault mapping; the response parameter at least includes a power parameter and an execution parameter.

[0122] The analysis module can be used in the normal working state of the regulating valve. In the normal working state (in actual operation), the response parameter is collected for fault diagnosis, the state of the regulating valve is monitored, the function of the regulating valve is ensured to be stable, and fault information is fed back in time.

[0123] Specifically, the analysis module can compare and analyze the collected response parameter based on the fault mapping, and output fault information.

[0124] In a feasible embodiment, a communication unit can be arranged between the analysis module and the control end (specifically, such as DCS or PLC or SCADA), the communication unit can transmit the feedback information (fault information) sent by the analysis module through an analog current signal or a digital signal; or wireless communication can be realized.

[0125] Taking the parallel transmission of analog current signals and digital signals as an example, the communication unit is used to realize the parallel transmission of the analog current signals and the hart digital signals. The 4~20mA analog current signals can transmit the valve position (valve opening) and the indication information of whether there is a fault, and the hart digital signals can transmit the digital fault code representing the detailed fault information (each fault category corresponds to a digital fault code) and the command (control instruction, diagnostic test instruction) of the total control module.

[0126] It should be clear that the control instruction is the real demand of the regulating valve during operation, and the diagnostic test instruction is the test demand, and the contents and forms of the two can be the same, such as both being current signals.

[0127] Referring to Figure 5 After obtaining the fault mapping, in the use process of the regulating valve, the fault diagnostic device can collect various parameters, monitor the state of the regulating valve, and output corresponding fault information.

[0128] The applicable states can include dynamic regulation and steady-state regulation, wherein the dynamic regulation applies the first mapping relationship, and the steady-state regulation is divided into steady-state throttling and valve full-closing states, and respectively applies the second mapping relationship and the third mapping relationship.

[0129] The control instruction ZC can be judged by type, so as to determine the applicable mapping relationship. For example, the current range of dynamic regulation is defined as a dynamic electric signal of 4~24mA, and the current of steady-state regulation is defined as an electric signal of a fixed value. When the control instruction ZC is collected, its type can be directly judged, and then the corresponding mapping relationship is called.

[0130] Of course, the data structure of the control instruction ZC can also be designed, and a recognition code is embedded in the data structure, so as to determine the type of the control instruction ZC, and then the corresponding mapping relationship is called.

[0131] Referring to Figure 6 The application also provides a fault diagnosis method of a regulating valve, which is applicable to the above-mentioned fault diagnosis system of a regulating valve, and the execution subject is a fault diagnostic device, which obtains various parameters of the regulating valve, so as to realize fault diagnosis of the regulating valve and output fault information.

[0132] S101, obtaining a diagnostic test instruction, performing setting operation based on the diagnostic test instruction and obtaining behavior parameters, calculating parameter characteristics of the behavior parameters and generating a fault mapping;

[0133] The diagnostic test instruction includes a random signal and a step signal, the first mapping relationship is obtained based on the random signal, and the second and third mapping relationships are obtained based on the step signal, and the fault mapping includes the first mapping relationship, the second mapping relationship and the third mapping relationship.

[0134] In the embodiments of the present application, when the diagnostic test instruction is acquired, the type thereof is detected, and the parameters collected after execution are distinguished to obtain dynamic parameters and steady-state parameters respectively, specifically including:

[0135] determining the type of the test instruction:

[0136] When it is a random signal, the behavior parameters collected in the setting operation are recorded as dynamic parameters;

[0137] When it is a step signal, the behavior parameters collected in the setting operation are recorded as steady-state parameters.

[0138] In the embodiments of the present application, based on the acquired dynamic parameters, a first parameter feature of the dynamic parameters is calculated, and a first mapping relationship for diagnosis is generated;

[0139] Based on the acquired steady-state parameters, a second parameter feature and a third parameter feature of the steady-state parameters are calculated, and a second mapping relationship and a third mapping relationship for diagnosis are generated.

[0140] When diagnosing, the corresponding mapping relationship should be called according to the type of the control instruction, for example, when the control instruction is dynamic adjustment, the first mapping relationship should be called for diagnosis; when the control instruction is throttle adjustment, the second mapping relationship should be called for diagnosis; and when the control instruction is closing adjustment, the third mapping relationship should be called for diagnosis.

[0141] In the embodiments of the present application, the conditions for calling each mapping relationship can be called, when diagnosing based on the fault mapping, the acquired control instruction is first judged, and the mapping relationship meeting the conditions is called for diagnosis, specifically including:

[0142] According to the first parameter feature, a first calling condition for identifying the first mapping relationship is identified, according to the second parameter feature, a second calling condition for identifying the second mapping relationship is identified, and according to the third parameter feature, a third calling condition for identifying the third mapping relationship is identified;

[0143] The first calling condition, the second calling condition and the third calling condition are respectively associated with the first mapping relationship, the second mapping relationship and the third mapping relationship, and are integrated into a fault mapping.

[0144] The fault mapping includes the first mapping relationship, the second mapping relationship and the third mapping relationship, and corresponds to Figure 5In the embodiment, the fault type output by the first mapping relationship is action failure, and the action failure information can be air leakage or blockage of the air path, oil and water blockage of the valve positioner, loose feedback rod, abnormal friction, power-off, signal interruption, gas loss, stuck or refusal to move, and misoperation; the fault type output by the second mapping relationship is throttling failure, and the throttling failure information can include sleeve cavitation and sleeve blockage; and the fault type output by the third mapping relationship is leakage failure, and the leakage failure information can include valve seat leakage.

[0145] Referring to Figure 5 , the first calling condition is that the control instruction ZC is dynamically changed, for example, a dynamic electric signal; the second calling condition is that the control instruction ZC is stable, and the valve is not closed when ZC≠0, for example, an electric signal representing a fixed value of 20% of the valve opening degree; and the third calling condition is that the control instruction ZC is stable, and the valve is closed when ZC=0, for example, an electric signal representing a fixed value of 0% of the valve opening degree.

[0146] In S102, the response parameter generated when the control instruction is executed is acquired, and the response parameter is introduced into the fault mapping and the fault information is output.

[0147] In the embodiment, the control valve can include any state requirement in use, such as dynamic adjustment, throttling adjustment, and closing adjustment. Therefore, when the fault diagnosis is performed based on the mapping failure, the control instruction should be acquired first, and the corresponding mapping relationship is called based on the control instruction, and then the analysis and comparison of the response parameter are performed, so that the corresponding fault information is output.

[0148] The fault mapping of the application includes a plurality of mapping relationships, each mapping relationship has an independent applicable state, and when the fault diagnosis is performed based on the mapping failure, the specific steps include:

[0149] The control instruction and the response parameter generated when the control instruction is executed are acquired.

[0150] The applicable mapping relationship is determined according to the control instruction.

[0151] When the control instruction meets the first calling condition, the response parameter is introduced into the first mapping relationship, and the fault information is output.

[0152] When the control instruction meets the second calling condition, the response parameter is introduced into the second mapping relationship, and the fault information is output.

[0153] When the control instruction meets the third calling condition, the response parameter is introduced into the third mapping relationship, and the fault information is output.

[0154] In the present application, the control instruction ZC is collected by the fault diagnosis device, the response parameters (ZT, PA, PB, dPT, FT, US) generated by executing the control instruction ZC are collected, the corresponding fault information is obtained through comparative analysis of the mapping relationship, and the state of the regulating valve is fed back in time.

[0155] After obtaining the fault indication, (fault) alarm, (performance degradation) warning, etc. can be performed according to the specific fault details, and meanwhile, each fault information can be numbered, and after obtaining the fault indication, the alarm and data uploading are performed by taking the number as the fault content, so as to facilitate recording.

[0156] It should be emphasized that the integration relationship of the fault diagnosis system proposed in the present application with the actual hardware of the valve, the valve positioner, the actuator and the like is not limited by the above-mentioned embodiments. Any changed hardware implementation scheme due to different configurations of the control valve control gas circuit and electrical accessories, any technical scheme of integrating the fault diagnosis system of the present application with other components of the regulating valve, and any scheme of integrating the setting module and / or the analysis module function into the upper computer or platform, all fall within the protection scope involved in the present disclosure.

[0157] In several embodiments provided in the present application, it should be understood that the disclosed device can be implemented by other ways. For example, the above-described module embodiments are only schematic, for example, the division of the modules is only a logical function division, and actual implementation can have another division manner, for example, a plurality of modules, modules or components can be combined or integrated into another system, or some features can be ignored or not executed. In addition, the coupling or direct coupling or communication connection between the displayed or discussed ones can be indirect coupling or communication connection through some service interface, device or module, and can be electrical or other forms.

[0158] The modules described as separate components can or can not be physically separated, and the components displayed as modules can or can not be physical modules, i.e. can be located in one place or can be distributed to a plurality of network modules. Part or all of the modules can be selected according to actual needs to achieve the purpose of the present embodiment scheme.

[0159] In addition, each functional module in each embodiment of the present application can be integrated in one processing module, or each module can exist physically, or two or more modules can be integrated in one module. The above integrated module can be realized in the form of hardware or in the form of software functional module.

[0160] The above merely describes preferred embodiments of the present application and the principles of the applied technology, and those skilled in the art should understand that the protective scope of the present application is not limited to the technical solutions formed by the specific combinations of the technical features described above, and should also cover other technical solutions formed by the combinations of the technical features described above or equivalent features thereof without departing from the disclosed concept. For example, the technical solutions formed by the mutual replacement of the features described above and the technical features disclosed in the present application (but not limited to) having similar functions.

Claims

1. A fault diagnosis system for a control valve, characterized in that, The system includes a fault diagnostic tool connected to a control unit, a power unit, a valve positioner, and an actuator. The power unit drives the actuator. The fault diagnostic tool is initialized after installation and before application to adapt to the current control valve. A diagnostic test command is sent from the control unit to the valve positioner for adjustment. The fault diagnostic tool obtains a fault mapping adapted to the current control valve. The fault diagnostic tool includes: The power detection module is used to acquire the power parameters of the drive actuator; The valve position feedback module is used to obtain the execution parameters of the actuator driving the regulating valve; The instruction acquisition module is used to acquire control instructions and diagnostic test instructions from the control terminal; the diagnostic test instructions are used by the valve positioner to perform setting operations. The tuning module acquires behavioral parameters during the tuning operation to generate a fault map for diagnosis; the behavioral parameters include at least the power parameters and execution parameters. The tuning operation is used to obtain the behavior parameters of the control valve under normal conditions; The fault mapping is generated based on the behavioral parameters and their characteristics, and the fault information. The behavioral parameters include dynamic parameters and steady-state parameters; the parameter characteristics include the property characteristics of a single parameter and / or the correlation characteristics of multiple parameters. The analysis module is used to obtain the response parameters generated by the control commands during actual operation, and to obtain fault information based on the fault mapping comparison analysis; the response parameters include at least the power parameters and execution parameters.

2. The fault diagnosis system for a regulating valve according to claim 1, characterized in that, The diagnostic test commands include random signals and step signals; the tuning operation includes: The actuator is driven by the random signal to change the opening of the regulating valve, and the dynamically changing behavior parameters are obtained and recorded as dynamic parameters. Calculate the first parameter feature of the dynamic parameters to generate a first mapping relationship for diagnosis; Based on the step signal, the actuator is driven to change the state of the regulating valve, and the steady-state behavior parameters are obtained and recorded as steady-state parameters. Calculate the second and third parameter characteristics of the steady-state parameters, and generate a second and third mapping relationship for diagnosis. The fault mapping includes a first mapping relationship, a second mapping relationship, and a third mapping relationship.

3. The fault diagnosis system for a regulating valve according to claim 2, characterized in that, The fault mapping includes input items, comparison items, and output items. The input items are the response parameters, the comparison items are the behavioral parameters and parameter features, and the output items are the fault information. The parameter features include a first parameter feature, a second parameter feature, and a third parameter feature.

4. The fault diagnosis system for a regulating valve according to claim 1, characterized in that, It also includes: an acoustic wave acquisition module, used to acquire ultrasonic parameters after the control valve; The valve flow monitoring module is used to acquire the valve's flow parameters; The behavioral parameters also include ultrasonic parameters and flow parameters, and the response parameters also include ultrasonic parameters and flow parameters.

5. The fault diagnosis system for a regulating valve according to claim 1, characterized in that, The valve position feedback module includes a valve position detection unit and a feedback conversion unit. The valve position detection unit is used to detect the drive stroke of the actuator, and the feedback conversion unit is used to convert the drive stroke into a feedback signal. The execution parameters include the feedback signal.

6. A method for diagnosing faults in a control valve, characterized in that, The method, applicable to the fault diagnosis system for a control valve as described in claim 1, comprises: Obtain diagnostic test instructions, perform tuning operations based on the diagnostic test instructions and obtain behavioral parameters, calculate the parameter characteristics of the behavioral parameters and generate a fault mapping; Obtain the response parameters generated by the control commands during actual runtime, import the response parameters into the fault map, and output the fault information.

7. A fault diagnosis method for a regulating valve according to claim 6, characterized in that, The diagnostic test commands include random signals and step signals; Obtain diagnostic test instructions, specifically including: Determine the type of the test instruction; When the signal is random, the behavioral parameters collected during the tuning operation will be recorded as dynamic parameters. When the signal is a step signal, the behavioral parameters collected during the tuning operation will be recorded as steady-state parameters.

8. A fault diagnosis method for a regulating valve according to claim 7, characterized in that, Calculating the parametric features of the behavioral parameters and generating a fault map specifically includes: Obtain the dynamic parameters, calculate the first parameter features of the dynamic parameters, and generate a first mapping relationship for diagnosis; Obtain the steady-state parameters, calculate the second parameter features and the third parameter features of the steady-state parameters, and generate the second mapping relationship and the third mapping relationship for diagnosis; The first calling condition of the first mapping relationship is identified by the first parameter feature, the second calling condition of the second mapping relationship is identified by the second parameter feature, and the third calling condition of the third mapping relationship is identified by the third parameter feature. The first calling condition, the second calling condition, and the third calling condition are respectively associated with the first mapping relationship, the second mapping relationship, and the third mapping relationship, and integrated into the fault mapping; the fault mapping includes the first mapping relationship, the second mapping relationship, and the third mapping relationship.

9. A fault diagnosis method for a regulating valve according to claim 8, characterized in that, Obtaining the response parameters generated when executing control commands, importing the response parameters into the fault mapping and outputting fault information specifically includes: Acquire control commands and the response parameters generated when executing the control commands; The applicable mapping relationship is determined based on the control command: When the control command meets the first calling condition, the response parameters are imported into the first mapping relationship, and fault information is output. When the control command meets the second calling condition, the response parameters are imported into the second mapping relationship, and fault information is output. When the control command meets the third calling condition, the response parameters are imported into the third mapping relationship, and fault information is output.

10. A regulating valve, characterized in that, The system includes at least a valve, a valve positioner, a pressure reducing valve, an actuator, and a fault diagnosis system for a regulating valve as described in any one of claims 1-5; the valve, valve positioner, and actuator are all connected to the fault diagnosis system.

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