CONTROL VALVE DIAGNOSIS SYSTEM AND METHOD OF OPERATION OF CONTROL VALVE DIAGNOSIS SYSTEM - Patent application

Abstract

The present invention discloses a control valve diagnostic system (100) comprising a smart valve positioner (101) with an integrated accelerometer (101a) and an integrated non-contact position sensor (101b), an actuator (102), a power source (103), and a non-volatile memory (104). The smart valve positioner (101) is pre-loaded with a non-contact position sensor that measures the position of the valve relative to a maximum "G-acceleration" at a time interval of 5-20 milliseconds. The system (100) continuously acquires the "G-acceleration" via the integrated accelerometer (101a), and the system is powered by a 4-20 mA 2-wire loop power supply or a 2-wire fieldbus / profibus (103). The position of the valve at the maximum "G-acceleration" value can be derived by comparing the previous and current "G-acceleration", and the generated data is stored in the non-volatile memory (104).

Description

[Technical field]

[0001] The following specification describes, inter alia, the invention and the manner in which it may be practiced.

[0002] The present invention relates generally to a valve diagnostic system, and more particularly to a smart positioner for controlling and monitoring valve operation in a process control system by continuous "g-force" measurements via an integrated accelerometer. [Background technology]

[0003] A valve positioner is a device that adjusts the position of a valve actuator based on a control signal. Various types of valve positioners are used to control valve operation, where the valve positioner is mechanically connected to the actuator or the valve positioner is integrated into the actuator. The actuator provides the means to physically position the valve, which may be electrical, hydraulic or pneumatic.

[0004] The most common valve positioners used for valve control are pneumatic actuators, which have a piston or a combination of spring and diaphragm to position the valve. The valve positioner is connected to a process control loop through which it receives appropriate signals regarding the desired valve position and the operating power of the positioner. The valve positioner controls the pneumatic actuator, which in turn controls the valve position. For this purpose, smart valve positioners are used, which are microprocessor-based digital valve controllers. Smart valve positioners are electrical current to air pressure conversion devices with internal logic functions that are specially designed to convert electrical current signals into pressure signals for valve operation. These valve positioners are most used in control applications due to their precision.

[0005] European Patent No. 2972624, entitled "Method for Valve Diagnostics," discloses a method and system for developing useful life profiles for process control equipment components, such as valves, which are used to determine the predicted remaining life of the equipment components during operation. The life profiles are developed using actual operating data of similar process control equipment used under substantially the same operating conditions during operation. Profiles are developed for a number of equipment components, from which a predicted life profile for the entire process control equipment is developed. Based on the predicted remaining life, warning notifications are sent to a remote computer and maintenance scheduling is automatically implemented.

[0006] In U.S. Patent No. 9,869,981, entitled "Diagnosis of a Control Device Using an Accelerometer," a diagnostic device is physically connected to a control device in a process control system and includes an accelerometer that determines when the motion or vibration of the control device exceeds a predetermined threshold. When this condition is detected, one or more other components of the diagnostic device (e.g., processor, communication module, etc.) are activated and a distress signal is sent from the diagnostic device using the activated components. As a result, the duty cycle of the components of the diagnostic device is reduced and optimized, resulting in significant power savings. Indeed, in some embodiments, energy harvesting may be sufficient to power the diagnostic device. Furthermore, in some embodiments, the diagnostic device may not require a component processor.

[0007] In U.S. Patent Application No. 20210120477, entitled "Apparatus and Method for Establishing a G Maintenance Route in a Process Control System," generating a maintenance route in a process control system includes generating an initial ordered list of all wireless nodes in direct communication with a wireless gateway, the nodes being ordered by signal strength with the wireless gateway device. Subsequent ordered lists are generated from all nodes in direct communication with a first node in the initial ordered list, the nodes being ordered by signal strength with the first node. The subsequent ordered lists are then added to the initial ordered list after the first node. This process of generating subsequent lists and adding to the initial list is repeated iteratively, each time considering the next node in the added ordered list following the previous iteration, until all nodes have been considered. In the final iteration, the nodes correspond to stop points along the route, and the order corresponds to the route passing between the stop points.

[0008] No. 7,436,797, entitled "Wireless Architecture and Support for Process Control Systems," discloses a wireless communication system for use in a process environment that provides a wireless communication network that can be easily set up, configured, modified, and monitored using mesh, and possibly a combination of mesh and point-to-point communication, making the wireless communication network less expensive, more robust, and more reliable. The wireless communication system allows for the creation and use of virtual communication paths within the process control system in a manner that is independent of the manner in which wireless signals are transmitted between different wireless transceivers within the process plant, thereby operating in a manner that is independent of a particular message or virtual communication path within the process plant. Additionally, communication analysis tools are provided that allow a user or operator to view the operation of the wireless communication network, thereby allowing analysis of the ongoing operation of wireless communications within the wireless communication network.

[0009] Patent application Ser. No. 7,539,560, entitled "Control Valve and Positioner Diagnostics," discloses that a valve positioning system may include one or more components and a controller. These components may include one or more electric-to-pressure output converters, relays, gas sources, and / or actuators. The controller may adjust the position of the valve by sending a signal. The valve positioning system may monitor multiple components individually and determine the status of each individually monitored component. The valve positioning system may determine if a component will fail before a failure occurs and / or if a component will develop a problem before a problem occurs. Summary of the Invention [Problem to be solved by the invention]

[0010] However, existing systems do not continuously monitor for sudden movements of valve components, changes in the dynamics of the fluid flowing through the valve, and damage to the interior of the valve. Furthermore, there are no available systems that can monitor the change in valve position corresponding to maximum "G-force" and continuously monitor the value of G-force acceleration with an integrated accelerometer. Another drawback of existing systems is that there are no systems for analyzing trends in the recorded data regarding the change in valve position corresponding to G-force acceleration, and no systems that can process fluid parameters that can be used to predict problems with the interior of the valve and prevent and diagnose problems that may occur.

[0011] Therefore, there is a need for a system that detects changes in the dynamics of the fluid flowing through the valve and damage associated with the internals of the valve, thereby enabling prediction of problems with the internals of the valve and manipulation of the fluid parameters. [Means for solving the problem]

[0012] The present invention solves the problems of the prior art and provides a control valve diagnostic system. The control valve diagnostic system includes a smart valve positioner having a pre-installed non-contact position sensor for measuring the position of the valve relative to the maximum "gravity acceleration" at a predetermined time interval, for example, every 8 milliseconds. The control valve diagnostic system can continuously obtain the "gravity acceleration" via a built-in accelerometer.

[0013] According to the present invention, the control valve diagnostic system records the position of the valve at the maximum "G-acceleration" value based on a comparison of the previous and current "g", i.e., gravity value. When recording the data, the maximum "G-acceleration" value and the corresponding position are written and stored in a non-volatile memory (NVM). Thus, by monitoring the position of the valve at the maximum "G-acceleration", damage inside the valve can be detected. The generated "G-acceleration" data is recorded, and this recorded diagnostic data can be downloaded to any electronic device, such as a smartphone, via wired means, i.e., a USB cable, or wireless means, such as BLE.

[0014] The present invention includes continuous monitoring of sudden movements of valve parts, which can control sudden changes in the dynamics of the fluid flowing through the valve that can damage the valve's internals. The present invention further monitors the change in the valve's position corresponding to the maximum "G-acceleration" and performs analysis thereof from the recorded data to predict problems with the valve's internals and process the fluid parameters for valve prevention and diagnosis. The updated values ​​can be displayed on the LCD of the smart valve positioner. The stored recorded data can be used to predict trend analysis that can predict problems in the valve control system. [Brief description of the drawings]

[0015] The above-mentioned embodiments and other features of the embodiments will become more apparent from the following detailed description of the embodiments, when read in conjunction with the accompanying drawings, in which like reference numbers refer to like elements and in which: [Figure 1] FIG. 1 shows a control valve diagnostic system according to one embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] Reference will now be made in detail to the subject matter described, one or more examples of which are illustrated in the drawings. Each example is intended to be illustrative, and not limiting, of the subject matter. Various changes and modifications which are apparent to those skilled in the art to which the invention pertains are deemed to be within the spirit, scope and intent of the invention.

[0017] The present invention discloses a control valve diagnostic system, which includes a smart valve positioner pre-installed with a non-contact position sensor for measuring the position of the valve relative to the maximum "gravity acceleration" every 5 to 20 milliseconds. The control valve diagnostic system can continuously obtain the "gravity acceleration" via a built-in accelerometer.

[0018] FIG. 1 shows a control valve diagnostic system according to one embodiment of the present invention.

[0019] The control valve diagnostic system (100) includes a smart valve positioner (101) with an integrated accelerometer (101a) and non-contact position sensor (101b), an actuator (102), a power supply (103), and a non-volatile memory (104). The smart valve positioner (101) is a valve positioner assembly that receives a supply voltage indicative of a desired valve position. The power supply (103) provides 4-20 milliamps or 10-24 volts of power to the smart valve positioner (101), which has an integrated accelerometer (101a) that measures acceleration or vibration for various valve openings. The actuator (102) controls a valve that controls flow within a process, and the non-volatile memory allows for the storage of recorded data at selected time intervals.

[0020] In accordance with the present invention, the smart valve positioner (101) includes an integrated accelerometer (101a) that is used to measure acceleration or vibration for various valve openings, and a non-contact position sensor (101b) that utilizes wear-free technology, which does not include friction on moving parts to eliminate wear, breakage and mechanical failure, and can measure movement or displacement.

[0021] The valve opening can be directly related to the flow through the valve or inversely proportional to the pressure drop at the inlet and outlet of the valve. An integrated accelerometer (101a) measures acceleration from inside the smart valve positioner (101) attached to an actuator (102). The actuator (102) provides pressure and position feedback to the smart valve positioner (101).

[0022] The non-volatile memory (104) disclosed in the present invention can be an EEPROM / Flash / PRAM / FRAM / MRAM located in a microprocessor. The non-volatile memory (104) can store recorded data, i.e., maximum "G-acceleration" values ​​corresponding to the valve position at a selectable time interval. The valve position at the maximum "G-acceleration" value is derived by comparing the previous and current "G", i.e., gravity values. The recorded data is stored in the non-volatile memory (104), and the recorded data can be used to monitor the valve position at the maximum "G-acceleration" value, thereby detecting internal damage to the valve.

[0023] According to the present invention, the process of operation of the smart valve positioner (101) includes powering the smart valve positioner (101) by a 4-20mA 2-wire loop power supply or 2-wire fieldbus / Profibus, which represents a desired valve position. When powered by the power supply, the smart valve positioner (101) provides a pneumatic output to the actuator (102). The actuator (102) controls a valve, which controls the flow of fluid, and also provides pressure and position feedback to the smart valve positioner (101). An accelerometer (101a) located in the smart valve positioner (101) measures acceleration or vibration for various valve openings. The measured acceleration is stored in a non-volatile memory (104) that stores data in a microprocessor, which includes an on-chip program and storage device (EEPROM / Flash / PRAM / FRAM / MRAM).

[0024] Electrically Erasable and Programmable Read Only Memory (EEPROM) uses voltage to erase the memory. The data is stored using floating gate transistors, which require special operating voltages to trap and release charge on an insulated control gate to store the information. The non-volatile memory (104) can save the recorded data at regular intervals that can be selected by the user.

[0025] The present invention relates to continuously monitor the sudden movement of valve components, which can control the sudden change in the dynamics of the fluid flowing through the valve and the damage inside the valve. The control valve diagnostic system (100) further monitors the change in the valve position corresponding to the maximum G-force acceleration, and from the recorded data, performs analysis to predict the problems with the valve's internals, and processes the fluid parameters for valve prevention and diagnosis. The updated values ​​can be displayed on the LCD of the smart valve positioner.

[0026] According to the present invention, the "G-acceleration" data generated by the system is recorded and the recorded diagnostic data can be downloaded to any electronic device such as a smartphone via wired means, i.e. USB cable, or wireless means such as BLE. The smart valve positioner (101) can continuously obtain "G-acceleration" data via the built-in accelerometer (101a) and the valve position at the maximum "G-acceleration" value is recorded. Upon recording, the maximum "G-acceleration" value and the corresponding valve position are stored in a non-volatile memory (104).

[0027] The smart valve positioner (101) is powered by a 4-20 mA 2-wire loop power supply or a 2-wire fieldbus / profibus (103). The smart valve positioner (101) receives its power from a 4-20 mA power supply (103), which supplies the system with the same current throughout the 4-20 mA loop, so any voltage drop caused by a loop-powered smart valve positioner (101) does not affect the current signal. Furthermore, the advantage of using loop power is that it does not require a separate or independent power supply. The 4-20 mA 2-wire loop power supply or the 2-wire fieldbus / profibus are designed to use power from the current flowing in the loop. The smart valve positioner (101) can support a wired or wireless interface for transferring recorded data, including the value of gravitational acceleration, on the available loop power, and does not depend on an external power source.

[0028] The present invention has several advantages, including: The system is powered by 4-20mA 2-wire loop power or 2-wire fieldbus / profibus making the system self-sustaining and not dependent on an external power source. Another advantage of the present invention is that the system can monitor sudden movement of valve components by "G-acceleration" values ​​obtained by an integrated accelerometer. Another advantage of the present invention is that the valve position measurement can be achieved using a non-contact position sensor located in the smart valve positioner. Yet another advantage of the present invention is that the system allows for downloading of diagnostic data using both wired and wireless technologies.

Claims

1. 1. A control valve diagnostic system (100) for determining a valve position relative to a maximum "G-force", comprising: a. A smart valve positioner (101) pre-installed with an accelerometer (101a) and a non-contact position sensor (101b); b. an actuator (102) for controlling said valve; c. a power source (103) for providing power to the control valve diagnostic system (100); d. A non-volatile memory (104) for storing data in the microprocessor; said control valve diagnostic system (100) providing valve position measurement relative to maximum "G-force" in the 5-20 millisecond time range; The control valve diagnostic system continuously acquires the "gravitational acceleration" using a built-in accelerometer (101a).

2. 2. The control valve diagnostic system of claim 1, wherein the smart valve positioner (101) has an integrated accelerometer (101a) that measures acceleration or vibration for various valve openings.

3. 2. The control valve diagnostic system of claim 1, wherein the non-volatile memory (104) is an EEPROM / Flash / PRAM / FRAM / MRAM located on the microprocessor.

4. The power supply (103) is a 4-20 mA two-wire loop power supply or a two-wire fieldbus / Profibus (103); The control valve diagnostic system of claim 1 , wherein the power source (103) enables the control valve diagnostic system to stand alone independent of an external power source.

5. 2. The control valve diagnostic system of claim 1, wherein the non-volatile memory (104) enables storing recorded data for monitoring the position of the valve at maximum "G-forces", which is used to detect internal damage to the valve.

6. A method of operating a control valve diagnostic system (100), comprising: a. powering a smart valve positioner (101) by providing power from a power source (103); b. providing a pneumatic output to an actuator (102) that controls a valve that controls fluid flow and provides pressure and position feedback to the smart valve positioner (101); c. Measuring acceleration or vibration for various valve openings by an accelerometer (101a) located on the smart valve positioner (101); d. Storing the measurement data in a non-volatile memory (104) that stores data in a microprocessor including on-chip program and memory (EEPROM / Flash / PRAM / FRAM / MRAM); e. monitoring the change in valve position corresponding to maximum "G-force" and performing analysis thereof from the recorded data to predict problems within the valve and process the fluid parameters for valve diagnostics; 4. A method of operation comprising:

7. 7. The method of claim 6, wherein the "gravitational acceleration" data generated by the control valve diagnostic system is recorded, and the recorded diagnostic data is downloadable to any electronic device, such as a smartphone, via a wired means, in other words a USB cable, or via a wireless means, such as BLE.

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