Valve maintenance support device and support method

Abstract

To improve efficiency of maintenance work of an on-off valve.SOLUTION: A valve maintenance support device includes: an operation command transmission section 1 that transmits a control command to each of a plurality of on-off valves that can become candidates of maintenance to execute an on-off operation for operation inspection; an operation data reception section 2 that receives operation data including opening measurement value data during the on-off operation from each of the plurality of on-off valves; a failure determination section 4 that determines whether or not failure might occur in each of the plurality of on-off valves on the basis of the operation data; and a failure information presentation section 5 that presents a determination result from the failure determination section.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a technique for assisting maintenance work, and particularly to a valve maintenance support device and a support method for realizing efficient work for maintaining an ON-OFF valve.

Background Art

[0002] Valves used in petrochemical plants and the like (for example, the control valve in FIG. 6) require particular attention to safety, and thus are regularly maintained. The control valve shown in FIG. 6 includes a valve body 100 that opens and closes a passage through which a fluid flows, a positioner 101 that converts an input electrical signal into pneumatic pressure, and an actuator 102 that operates the valve body 100 according to the pneumatic pressure supplied from the positioner 101.

[0003] In order to improve the maintenance work efficiency of valves in a plant where a large number of valves as shown in FIG. 6 are installed, techniques for detecting the occurrence of stick-slip in the sliding part of the valve (see Patent Document 1), techniques for determining the hunting state of the valve (see Patent Document 2), techniques for detecting the adhesion of scale to the valve (see Patent Document 3), etc. have been proposed.

[0004] On the other hand, as a type of valve different from a control valve capable of continuously changing the opening degree, there is an ON-OFF valve that can take only two positions of fully open / fully closed for the opening degree. The ON-OFF valve 200 shown in FIG. 7 uses a ball valve and has a structure in which a ball 201 as a valve element is sandwiched between a seat ring 202 called a ball seat, and the valve can be opened or closed by rotating a stem (valve rod) 203 by 90 degrees by an actuator 204. Also, depending on the type, there are those other than 90 degrees. As a method for detecting a defect with an ON-OFF valve as a diagnosis target, techniques for detecting a defect using the opening / closing required time of the valve as a diagnosis index or using the maximum operating speed and the minimum operating speed as diagnosis indexes have been proposed (see Patent Document 4).

[0005] In the technology disclosed in Patent Document 4, it is necessary to operate the valve in the ON (fully open) - OFF (fully closed) state for specific defect detection (for example, scale adhesion or seal component wear disclosed in Patent Document 4). Therefore, for ON - OFF valves that are continuously in either the ON or OFF state only during plant operation, it is necessary to deliberately perform the ON - OFF operation during regular maintenance, irregular maintenance, production process switching (product item switching), etc. (operational inspection).

[0006] Depending on the plant, there may be more than several hundred ON - OFF valves in use, and there are also ON - OFF valves that should be carefully inspected for operation. Therefore, it is required to improve the working efficiency.

Prior Art Documents

Patent Documents

[0007]

Patent Document 1

Patent Document 2

Patent Document 3

Patent Document 4

Summary of the Invention

Problems to be Solved by the Invention

[0008] The present invention has been made to solve the above problems, and an object thereof is to provide a valve maintenance support device and a support method capable of improving the working efficiency of ON - OFF valve maintenance.

Means for Solving the Problems

[0009] The valve maintenance support device of the present invention includes an operation command transmission unit that transmits a control command to execute an ON-OFF operation for an operation inspection for each of a plurality of ON-OFF valves that can be candidates for maintenance, an operation data reception unit that receives operation data including opening measurement value data during the ON-OFF operation from each of the plurality of ON-OFF valves, a defect determination unit that determines for each of the plurality of ON-OFF valves whether there may be a defect in the ON-OFF valve based on the operation data, and a defect information presentation unit that presents the determination result by the defect determination unit. Moreover, one configuration example of the valve maintenance support device of the present invention further includes a storage unit that stores in advance system identification information indicating the system to which the ON-OFF valve belongs for each of the plurality of ON-OFF valves, and the defect information presentation unit identifies the system to which the ON-OFF valve determined by the defect determination unit belongs based on the system identification information, and presents the determination result by the defect determination unit by system.

[0010] Moreover, one configuration example of the valve maintenance support device of the present invention further includes a defect occurrence rate calculation unit that calculates the defect occurrence rate for each system based on the system identification information and the determination result by the defect determination unit, and the defect information presentation unit presents the defect occurrence rate by system in addition to the determination result by the defect determination unit. Moreover, one configuration example of the valve maintenance support device of the present invention further includes a detailed inspection target setting unit that sets the operation command transmission unit and the defect determination unit so that when there is a system in which the defect occurrence rate exceeds a preset threshold value, this system is inspected a specified number of times more than usual during the next operation inspection. Moreover, in one configuration example of the valve maintenance support device of the present invention, the ON-OFF valves with the same system are ON-OFF valves installed on the same pipe. In addition, in one configuration example of the valve maintenance support device of the present invention, the ON-OFF valves in the same system are ON-OFF valves installed in the same unit.

[0011] The valve maintenance support method of the present invention further includes a first step of transmitting a control command to each of a plurality of ON-OFF valves that can be candidates for maintenance so as to execute an ON-OFF operation for an operation inspection, a second step of receiving operation data including an opening measurement value data during the ON-OFF operation from each of the plurality of ON-OFF valves, a third step of determining for each of the plurality of ON-OFF valves whether there is a possibility that a malfunction has occurred in the ON-OFF valve based on the operation data, and a fourth step of presenting the determination result by the third step. In one configuration example of the valve maintenance support method of the present invention, the fourth step includes referring to a storage unit that stores in advance system identification information indicating the system to which the ON-OFF valve belongs for each of the plurality of ON-OFF valves, identifying the system to which the ON-OFF valve determined in the third step belongs based on the system identification information, and presenting the determination result by the third step for each system.

[0012] One configuration example of the valve maintenance support method of the present invention further includes a fifth step of calculating a malfunction occurrence rate for each system based on the system identification information and the determination result by the third step, and a sixth step of presenting the malfunction occurrence rate for each system. One configuration example of the valve maintenance support method of the present invention further includes a seventh step of setting the number of processing times of the first step and the third step so that when there is a system in which the malfunction occurrence rate exceeds a preset threshold value, this system is inspected a specified number of times more than usual during the next operation inspection.

Effect of the Invention

[0013] According to the present invention, by sending a control command to execute an ON-OFF operation for each of a plurality of ON-OFF valves that can be maintenance candidates, a large number of ON-OFF valves can be operated simultaneously to collect operation data. Therefore, the working efficiency of the maintenance of the ON-OFF valves can be improved.

[0014] Further, in the present invention, the system to which the ON-OFF valve determined by the defect determination unit belongs is identified, and the determination result by the defect determination unit is presented for each system, so that the working efficiency of the maintenance of the ON-OFF valve can be further improved.

Brief Description of the Drawings

[0015]

Figure 1

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Embodiments for Carrying Out the Invention

[0016] [Principle 1 of the Invention] When performing an operation inspection on a large number of ON-OFF valves, such as during regular maintenance, it is preferable to send an operation command from a higher-level platform, such as a plant control system, to operate as many ON-OFF valves as possible simultaneously and collect information on defect detection on the higher-level platform.

[0017] When the inventor further pursued improving work efficiency, the inventor focused on the fact that ON-OFF valves are installed in the pipes through which the fluid handled in the plant moves. For ON-OFF valves installed in the same system (for example, on the same pipe or in the same unit), since the fluid type and operating state are the same or similar conditions, the tendency for defects to occur is likely to be similar. Therefore, the inventor came up with the idea that it is reasonable to organize and present the defect information of ON-OFF valves from the perspective of the same system. Note that due to pipe branching and the like, even if a specific ON-OFF valve belongs to different pipe systems or units and may be presented multiple times, it does not matter.

[0018] By organizing the systems of ON-OFF valves in this way, even if no defect has been detected, valves on pipes or within units with a large number of defective valves can be classified as valves that need to be carefully inspected multiple times during, for example, the next regular maintenance, and valves on pipes or within units with a small number of defective valves can be classified as valves that only need to undergo a minimum operation inspection. As a result, work efficiency can be improved.

[0019] [Principle of the Invention 2] It is preferable to present the defect occurrence rate numerically from the perspective of ON-OFF valves in the same system. Also, when the defect occurrence rate exceeds the threshold value, for the ON-OFF valves on the relevant pipe or unit, it is preferably automatically set to carefully perform multiple operation inspections during the next regular maintenance, etc., including ON-OFF valves for which no defect has been detected.

[0020] [Embodiment] Hereinafter, embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a block diagram showing the configuration of a valve maintenance support device according to an embodiment of the present invention. This embodiment corresponds to Principles 1 and 2 of the above invention.

[0021] The valve maintenance support device includes an operation command transmission unit 1 that transmits a control command to execute an ON-OFF operation for an operation inspection for each of a plurality of ON-OFF valves that can be candidates for maintenance, an operation data reception unit 2 that receives operation data including opening measurement value data during the ON-OFF operation from each of the plurality of ON-OFF valves, a storage unit 3 that stores in advance system identification information indicating the system to which each ON-OFF valve belongs for each of the plurality of ON-OFF valves, a defect determination unit 4 that determines for each of the plurality of ON-OFF valves whether there is a possibility that a defect has occurred in the ON-OFF valve based on the operation data, a defect information presentation unit 5 that presents the determination result by the defect determination unit 4, a defect occurrence rate calculation unit 6 that calculates the defect occurrence rate for each system based on the system identification information and the determination result by the defect determination unit 4, and when there is a system in which the defect occurrence rate exceeds a preset threshold value, a detailed inspection target setting unit 7 that sets the operation command transmission unit 1 and the defect determination unit 4 so that a specified number of inspections more than normal are performed on this system during the next operation inspection.

[0022] FIG. 2 is a flowchart for explaining the operation of the valve maintenance support device of this embodiment. The storage unit 3 stores the valve ID (solid identification information) of a plurality of ON-OFF valves that can be candidates for maintenance and the system ID (system identification information) indicating the system to which each ON-OFF valve belongs. The ON-OFF valves with the same system refer to, for example, ON-OFF valves installed on the same pipe or in the same unit.

[0023] The ON-OFF valves on the same pipe are, for example, the ON-OFF valves A1, A2, and A3 installed in an arrangement that handles a common fluid as shown in FIG. 3. The ON-OFF valves in the same unit are, for example, the ON-OFF valves B1, B2, and B3 applied to the same polymerization kettle 10 as shown in FIG. 4. The ON-OFF valves on the same pipe may have common problems caused by the common fluid. The ON-OFF valves in the same unit may have common problems caused by the common installation environment.

[0024] Note that both FIG. 3 and FIG. 4 are schematic diagrams for explanation. In reality, for a large number of ON-OFF valves, it is preferable to estimate the possibility of common problems (design matters) considering factors such as pipe branching and the distance of the installation position, classify the systems to which the ON-OFF valves belong, and assign system IDs in advance. The valve ID is unique solid identification information for each valve, but since one valve may belong to multiple systems, there may be cases where multiple system IDs are assigned to one valve.

[0025] During the operation inspection, the operation command transmission unit 1 transmits a control command to each of the plurality of ON-OFF valves that may be candidates for maintenance and whose valve IDs are registered in the storage unit 3 to execute an ON-OFF operation for the operation inspection (step S100 in FIG. 2). In this embodiment, since it is assumed that a control command is given to the ON-OFF valves at a remote location by communication, in reality, an example is conceivable where a control command is transmitted to the controller that controls the ON-OFF valve, and the controller operates the ON-OFF valve. However, the method of performing the operation inspection is not limited to such an example, and it may be performed by other methods.

[0026] The timings for the operation inspection include timings such as regular maintenance, irregular maintenance, and production process switching (product switching). The valve maintenance support device may start the operation inspection, for example, according to an instruction from an operator, or may start the operation inspection according to predetermined schedule information.

[0027] The operation data receiving unit 2 receives operation data including at least the opening measurement value data during the ON-OFF operation from each ON-OFF valve (step S101 in FIG. 2). Each ON-OFF valve periodically transmits the opening measurement value data and its own valve ID to the valve maintenance support device. Such a configuration of the ON-OFF valve is disclosed in, for example, Patent Document 4. The operation data receiving unit 2 adds information on the reception time to the received opening measurement value data.

[0028] In addition, each ON-OFF valve may be configured to periodically transmit, in addition to the opening measurement value data and the valve ID, the pressure measurement value data of the actuator air supplied to the actuator. Such a configuration of the ON-OFF valve is disclosed in, for example, Japanese Unexamined Patent Application Publication No. 2021-026268. The operation data receiving unit 2 adds information on the reception time to the received pressure measurement value data.

[0029] Based on the operation data received by the operation data receiving unit 2, the defect determination unit 4 determines, for each ON-OFF valve that may be a maintenance candidate and for which the valve ID is registered in the storage unit 3, whether there is a possibility that a defect has occurred in the ON-OFF valve (step S102 in FIG. 2).

[0030] As a malfunction determination technique for an ON-OFF valve, there is, for example, the technique disclosed in Patent Document 4 and Japanese Unexamined Patent Application Publication No. 2021-026268. For example, in the technique disclosed in Patent Document 4, the required time TOP from an opening degree of 0% to 100% and the required time TCL from an opening degree of 100% to 0% of the ON-OFF valve are calculated, and an ON-OFF valve in which at least one of the required times TOP and TCL is equal to or greater than a threshold value is determined as an ON-OFF valve in which a malfunction may have occurred. Alternatively, during the opening operation of the ON-OFF valve, the absolute values of the maximum operating speeds VOPmax and VCLmax during the opening and closing operations are compared with the corresponding maximum operating speed thresholds, and the absolute values of the minimum operating speeds VOPmin and VCLmin during the opening and closing operations are compared with the corresponding minimum operating speed thresholds. An ON-OFF valve in which at least one of the operating speeds VOPmax, VOPmin, VCLmax, and VCLmin is equal to or greater than the corresponding threshold value is determined as an ON-OFF valve in which a malfunction may have occurred.

[0031] Further, in the technique disclosed in Japanese Unexamined Patent Application Publication No. 2021-026268, an ON-OFF valve in which the dead time from when the pressure of the operator air changes until the opening degree of the ON-OFF valve changes is equal to or greater than a threshold value is determined as an ON-OFF valve in which a malfunction may have occurred.

[0032] Based on the system ID stored in the storage unit 3, the malfunction information presentation unit 5 identifies the system to which the ON-OFF valve determined by the malfunction determination unit 4 belongs, and presents the determination result by the malfunction determination unit 4 for each system (step S103 in FIG. 2).

[0033] For example, when the ON-OFF valves A1, A2, and A3 shown in FIG. 3 belong to the valves of the "first piping system", the determination results of the valves A1, A2, and A3 are listed under the heading of the "first piping system". Also, when the ON-OFF valves B1, B2, and B3 shown in FIG. 4 belong to the valves of the "second polymerization kettle" system, the determination results of the valves B1, B2, and B3 are listed under the heading of the "second polymerization kettle". When the ON-OFF valves determined by the defect determination unit 4 belong to multiple systems, in order to see the trends for each system, it is preferable to display the determination results of the valves respectively under the headings of the multiple systems to which the valves belong.

[0034] Next, the defect occurrence rate calculation unit 6 calculates the defect occurrence rate for each system based on the system ID stored in the storage unit 3 and the determination result by the defect determination unit 4 (step S104 in FIG. 2). For example, if there are 20 ON-OFF valves identified as installed in the same system, and 5 ON-OFF valves are determined to have a possibility of defect occurrence (including those with a defect tendency level without urgency), the defect occurrence rate of this system is calculated to be 25%. The defect information presentation unit 5 presents the defect occurrence rate by system in addition to the determination result by the defect determination unit 4 (step S105 in FIG. 2).

[0035] When there is a system whose defect occurrence rate exceeds a preset threshold (YES in step S106 in FIG. 2), for the ON-OFF valves of this system, including the ON-OFF valves without defects, the detailed inspection target setting unit 7 makes settings for the operation command transmission unit 1 and the defect determination unit 4 so that a specified number of inspections more than normal (for example, a detailed inspection with multiple operations) are performed during the next operation inspection (step S107 in FIG. 2).

[0036] For example, if the threshold is 20% and the calculated defect occurrence rate is 25%, for the ON-OFF valves of that system, settings are made for the operation command transmission unit 1 and the defect determination unit 4 so that more inspections than normal are performed and diagnosed during the next regular repair, irregular repair, production process switching (product item switching), etc.

[0037] At the next operation inspection, the operation command transmission unit 1 transmits a control command to the ON-OFF valve belonging to the system in which the increase in the number of inspections is set, so as to repeatedly execute the ON-OFF operation for the increased number of times (step S100). At the next operation inspection, the defect determination unit 4 determines whether there may be a defect for each ON-OFF operation for the ON-OFF valve belonging to the system in which the increase in the number of inspections is set (step S102).

[0038] The process of the defect information presentation unit 5 is the same as above. However, for the ON-OFF valve belonging to the system in which the increase in the number of inspections is set, if it is determined that there may be a defect at least once, the determination result of "defect occurred" (or "possibility of defect occurrence") is displayed by the defect information presentation unit 5 (step S103).

[0039] At the next operation inspection, for the system in which the increase in the number of inspections is set, the defect occurrence rate calculation unit 6 may, for example, use the maximum value or the average value of the defect occurrence rates calculated for each inspection as the defect occurrence rate of the system (step S104 in FIG. 2).

[0040] The valve maintenance support device described in this embodiment can be realized by a computer including a CPU (Central Processing Unit), a storage device, and an interface, and a program for controlling these hardware resources. A configuration example of this computer is shown in FIG. 5. The computer includes a CPU 300, a storage device 301, and an interface device (I / F) 302. For example, valves, controllers, displays, etc. are connected to the I / F 302. In such a computer, a program for realizing the valve maintenance support method of the present invention is stored in the storage device 301. The CPU 300 executes the processes described in this embodiment according to the program stored in the storage device 301.

Industrial Applicability

[0041] The present invention can be applied to a technique for assisting valve maintenance work.

Explanation of Signs

[0042] 1... Actuation command transmission unit, 2... Actuation data reception unit, 3... Storage unit, 4... Defect determination unit, 5... Defect information presentation unit, 6... Defect occurrence rate calculation unit, 7... Detailed inspection target setting unit.

Claims

1. An operation command transmission unit that transmits a control command to execute an ON-OFF operation for an operation inspection for each of a plurality of ON-OFF valves that can be maintenance candidates; An operation data reception unit that receives operation data including opening measurement value data during the ON-OFF operation from each of the plurality of ON-OFF valves; A defect determination unit that determines for each of the plurality of ON-OFF valves whether there may be a defect in the ON-OFF valve based on the operation data; A valve maintenance support device comprising a defect information presentation unit that presents the determination result by the defect determination unit.

2. In the valve maintenance support device according to Claim 1, Further comprising a storage unit that stores in advance system identification information indicating the system to which the ON-OFF valve belongs for each of the plurality of ON-OFF valves, The defect information presentation unit identifies the system to which the ON-OFF valve determined by the defect determination unit belongs based on the system identification information, and presents the determination result by the defect determination unit by system. A valve maintenance support device characterized by the above.

3. In the valve maintenance support device according to Claim 2, Further comprising a defect occurrence rate calculation unit that calculates the defect occurrence rate for each system based on the system identification information and the determination result by the defect determination unit, The defect information presentation unit presents the defect occurrence rate by system in addition to the determination result by the defect determination unit. A valve maintenance support device characterized by the above.

4. In the valve maintenance support device according to Claim 3, When there is a system in which the defect occurrence rate exceeds a preset threshold value, for this system, the operation command transmission unit and the defect determination unit are set so that a specified number of inspections more than normal are performed during the next operation inspection. A valve maintenance support device further comprising a detailed inspection target setting unit for performing the above.

5. In the valve maintenance support device according to any one of Claims 2 to 4, The ON-OFF valves having the same system are ON-OFF valves installed on the same pipe. A valve maintenance support device characterized by the above.

6. In the valve maintenance support device according to any one of Claims 2 to 4, The valve maintenance support device is characterized in that the same ON-OFF valve as the system is an ON-OFF valve installed in the same unit.

7. A first step of transmitting a control command to execute an ON-OFF operation for an operation inspection for each of a plurality of ON-OFF valves that can be candidates for maintenance; A second step of receiving operation data including opening measurement value data during the ON-OFF operation from each of the plurality of ON-OFF valves; A third step of determining, for each of the plurality of ON-OFF valves, whether there is a possibility that a malfunction has occurred in the ON-OFF valve based on the operation data; A valve maintenance support method comprising a fourth step of presenting the determination result by the third step.

8. In the valve maintenance support method according to claim 7, The fourth step refers to a storage unit that stores in advance system identification information indicating the system to which the ON-OFF valve belongs for each of the plurality of ON-OFF valves, and based on the system identification information, identifies the system to which the ON-OFF valve determined in the third step belongs, and presents the determination result by the third step by system. A valve maintenance support method characterized by including steps.

9. In the valve maintenance support method according to claim 8, A fifth step of calculating a failure occurrence rate for each system based on the system identification information and the determination result by the third step; A valve maintenance support method further comprising a sixth step of presenting the failure occurrence rate by system.

10. In the valve maintenance support method according to claim 9, When there is a system in which the failure occurrence rate exceeds a preset threshold value, for this system, the number of processes of the first step and the third step is set so that a specified number of inspections more than usual are performed during the next operation inspection. A valve maintenance support method further comprising a seventh step.

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