Electric valve performance prediction method and system

Abstract

The present invention relates to an electric valve performance prediction method, and a system. The method comprises the following steps: S1, on the basis of basic information and real-time monitoring information of an electric valve, acquiring a current working state of the electric valve; S2, when the current working state of the electric valve is normal, acquiring historical operation data corresponding to the electric valve; and S3, on the basis of the real-time monitoring information and the historical operation data, performing performance trend analysis on the electric valve, so as to obtain a performance change trend of the electric valve. Implementing the present invention can predict the performance of a valve, so as to intervene and perform maintenance in a timely manner before the valve fails, thereby improving the reliability of an entire system.

Description

A method and system for predicting the performance of electric valves Technical Field

[0001] This invention relates to the field of valve reliability research technology, and more specifically, to a method and system for predicting the performance of electric valves. Background Technology

[0002] Valves are widely used equipment in nuclear power units, and some valves perform important safety functions, making it crucial to ensure they are in good condition. Currently, valve performance monitoring and evaluation primarily relies on valve diagnostic technology. However, this technology is mostly implemented during unit shutdown maintenance and cannot cover all valve failure modes. Furthermore, some types of units use a large number of electric valves, and the preventative maintenance and diagnostic testing of these electric valves pose challenges to overhaul windows and manpower. The current state of valve monitoring and maintenance has the following main shortcomings: 1. Limitations of current valve monitoring methods. Current performance monitoring of electric valves relies on electric valve diagnostics, mainly collecting data on valve voltage, current, and thrust / torque on the valve stem. However, it cannot determine if there is internal leakage. Electric diagnostics requires significant time during unit overhauls, and testing valves in radiation areas increases radiation exposure for testing personnel. 2. Preventative maintenance of electric valves. Most nuclear power units currently employ preventative maintenance strategies for electric valves. With a large number of electric valves, this presents significant challenges for maintenance during overhauls, increasing maintenance costs. 3. Lack of intelligent decision-making in predictive maintenance. To address the problems arising from preventative maintenance of electric valves, some power plants and power research institutions have begun predictive research and pilot applications of electric valves. However, predictive maintenance involves tracking electric valve performance trends, failure history, maintenance history, and experience feedback; the large amount of data makes predictive maintenance decisions difficult. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a method and system for predicting the performance of electric valves, addressing the aforementioned technical deficiencies of the prior art.

[0004] The technical solution adopted by this invention to solve its technical problem is: to construct a method for predicting the performance of an electric valve, the method comprising the following steps:

[0005] S1. Obtain the current working status of the electric valve based on its basic information and real-time monitoring information;

[0006] S2. When the current working state of the electric valve is normal, acquire the historical operating data corresponding to the electric valve;

[0007] S3. Perform performance trend analysis on the electric valve based on the real-time monitoring information and the historical operating data to obtain the performance change trend of the electric valve.

[0008] Preferably, in the electric valve performance prediction method of the present invention, the current working state of the electric valve includes whether the operability of the actuator corresponding to the electric valve meets the requirements, whether the mechanical state of the electric valve is good, and whether the electric valve has internal leakage.

[0009] And when the operability of the actuator corresponding to the electric valve meets the requirements, the mechanical condition of the electric valve is good, and there is no internal leakage in the electric valve, the current working state of the electric valve is determined to be normal.

[0010] Preferably, in the electric valve performance prediction method of the present invention, in step S1, obtaining the current working status of the electric valve based on the basic information and real-time monitoring information of the electric valve includes:

[0011] Based on the basic information of the electric valve, obtain the target torque corresponding to the electric valve and the maximum output torque of the corresponding drive mechanism of the electric valve;

[0012] The actual torque corresponding to the electric valve is obtained based on the real-time monitoring information of the electric valve.

[0013] The operability determination result of the actuator corresponding to the electric valve is obtained based on the target torque corresponding to the electric valve, the maximum output torque of the drive mechanism corresponding to the electric valve, and the actual torque corresponding to the electric valve.

[0014] Preferably, in the electric valve performance prediction method of the present invention, obtaining the actual torque corresponding to the electric valve based on the real-time monitoring information of the electric valve includes:

[0015] Obtain the electrical parameters corresponding to the electric valve, and obtain the actual torque corresponding to the electric valve according to the electrical-torque correspondence table corresponding to the electric valve.

[0016] Preferably, in the electric valve performance prediction method of the present invention, in step S1, obtaining the current working status of the electric valve based on the basic information and real-time monitoring information of the electric valve includes:

[0017] Obtain the electrical and torque parameters corresponding to the electric valve, and determine whether the mechanical condition of the electric valve is good based on the electrical and torque parameters corresponding to the electric valve.

[0018] Preferably, in the electric valve performance prediction method of the present invention, in step S1, obtaining the current working status of the electric valve based on the basic information and real-time monitoring information of the electric valve includes:

[0019] Acquire the acoustic emission parameters or temperature parameters corresponding to the electric valve, and determine whether the electric valve has internal leakage based on the acoustic emission parameters or temperature parameters corresponding to the electric valve.

[0020] Preferably, in the electric valve performance prediction method of the present invention, in step S2,

[0021] The historical operating data includes historical monitoring data, historical maintenance data, historical fault data, and historical fault data related to the electric valve.

[0022] Preferably, in the electric valve performance prediction method of the present invention, in step S3, the step of performing performance trend analysis on the electric valve based on the real-time monitoring information and the historical operating data to obtain the performance change trend of the electric valve includes:

[0023] The degree of degradation of the electric valve corresponding to the real-time monitoring information is obtained based on the real-time monitoring information and the preset degradation degree normalization calculation formula.

[0024] Preferably, in the electric valve performance prediction method of the present invention, the method further includes: when the current working state of the electric valve is abnormal, generating maintenance suggestions corresponding to the current working state.

[0025] The present invention also constructs an electric valve performance prediction system, applied to the electric valve performance prediction method described above, the system comprising:

[0026] The first execution unit is used to obtain the current working status of the electric valve based on the basic information and real-time monitoring information of the electric valve;

[0027] The second execution unit is used to acquire the historical operating data corresponding to the electric valve when the current working state of the electric valve is normal.

[0028] The third execution unit is used to perform performance trend analysis on the electric valve based on the historical operating data, so as to obtain the performance change trend of the electric valve.

[0029] The electric valve performance prediction method and system of the present invention have the following advantages: they can predict valve performance so as to intervene in maintenance in time before valve failure and improve the reliability of the whole system. Attached Figure Description

[0030] The present invention will be further described below with reference to the accompanying drawings and embodiments. In the accompanying drawings:

[0031] Figure 1 is a flowchart of an embodiment of the electric valve performance prediction method of the present invention;

[0032] Figure 2 is a flowchart of another embodiment of the electric valve performance prediction method of the present invention;

[0033] Figure 3 is a schematic diagram of the prediction process of an electric valve performance prediction method according to the present invention. Detailed Implementation

[0034] To provide a clearer understanding of the technical features, objectives, and effects of the present invention, specific embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0035] As shown in Figure 1, in a first embodiment of an electric valve performance prediction method of the present invention, the method includes the following steps: S1, obtaining the current working state of the electric valve based on the basic information and real-time monitoring information of the electric valve; S2, when the current working state of the electric valve is normal, obtaining the historical operating data corresponding to the electric valve; S3, performing performance trend analysis on the electric valve based on the real-time monitoring information and the historical operating data to obtain the performance change trend of the electric valve.

[0036] Based on step S1, a basic database corresponding to the electric valve can be constructed to store the basic data of the electric valve. This basic data can be understood as the inherent characteristic data of the valve, such as the structural parameters of the electric valve, the parameters of the actuator used to drive the electric valve's action, and the parameters of the entire system in which the electric valve operates. A monitoring and evaluation module is constructed to acquire real-time monitoring data related to the electric valve when the system corresponding to the electric valve is operating. Based on the obtained real-time monitoring data and the basic information of the electric valve, the current operating status of the electric valve can be confirmed or judged. The process of judging the current operating status of the electric valve can be described as determining whether the electric valve is in a normal operating state.

[0037] Based on step S2, during the above process, when it can be determined that the electric valve is in a normal working state, the historical operating data of the electric valve can be obtained accordingly. In a specific embodiment, a historical data storage module can be constructed to store the historical operating data of the electric valve.

[0038] Based on step S3, the electric valve's performance can be analyzed using the obtained real-time monitoring signal and corresponding historical operating data to determine its performance trend. During trend analysis, the final performance trend can be obtained by fitting a function or curve to the data. In one embodiment, after obtaining the performance trend, the time point at which the electric valve's performance deteriorates can be further determined based on this trend. This allows for the identification of potential anomalies in the electric valve, enabling timely replacement or repair to ensure the overall system reliability.

[0039] In one embodiment, the process of determining the current operating state of an electric valve may include determining whether the operability of the actuator corresponding to the electric valve meets the requirements, whether the mechanical condition of the electric valve is good, and whether the electric valve has internal leakage; and determining that the current operating state of the electric valve is normal when the operability of the actuator corresponding to the electric valve meets the requirements, the mechanical condition of the electric valve is good, and the electric valve has no internal leakage. That is, in the process of determining the operating state of the electric valve, it is necessary to determine the operability of the actuator corresponding to the electric valve to confirm whether the current actuator can be used to drive the electric valve, thus obtaining the operability determination result of the actuator. In addition, it is also necessary to determine the mechanical condition of the electric valve to determine whether the current mechanical condition of the electric valve is normal. For example, determining whether the electric valve can be driven by the actuator to perform the corresponding operation. Furthermore, it is also necessary to determine whether the electric valve has internal leakage to further determine the operating state of the electric valve. That is, only when all three of the above are normal can the current operating state of the electric valve be determined to be normal.

[0040] Optionally, as shown in Figure 2, in step S1, obtaining the current working state of the electric valve based on its basic information and real-time monitoring information includes: S11, obtaining the target torque corresponding to the electric valve and the maximum output torque of the drive mechanism corresponding to the electric valve based on the basic information of the electric valve; S12, obtaining the actual torque corresponding to the electric valve based on the real-time monitoring information of the electric valve; S13, obtaining the operability determination result of the actuator corresponding to the electric valve based on the target torque corresponding to the electric valve, the maximum output torque of the drive mechanism corresponding to the electric valve, and the actual torque corresponding to the electric valve.

[0041] Based on step S11, in the specific determination of the current working state of the electric valve, the target torque of the electric valve and the maximum output torque of the corresponding drive mechanism are first obtained based on the basic information of the electric valve. The maximum output torque of the drive mechanism can be calculated based on the actuator parameters. The actuator parameters involved in the calculation may include the actuator motor output torque, overall reduction ratio, transmission efficiency, application coefficient, motor terminal voltage, torque reduction coefficient, and motor rated voltage. The target torque of the electric valve can be obtained based on the valve parameters and system parameters in the basic information. The valve parameters include multiple parameters such as the electric valve type, sealing surface diameter, valve stem diameter, valve stem thread lead or pitch, valve stem pitch diameter, valve stem material, valve stem friction coefficient, stroke, valve disc wedge angle, and valve disc-sealing surface friction coefficient. Obtaining the valve type specifically determines whether the electric valve is a gate valve, globe valve, ball valve, or butterfly valve. Obtaining the valve disc wedge angle specifically determines whether the electric valve is a C-type, W-type, or V-type gate valve. System parameters may include system design pressure, operating pressure, design temperature, operating temperature, and differential pressure.

[0042] Based on steps S12 and S13, in obtaining the actual torque corresponding to the electric valve, calculations can be performed based on the monitored operating parameters to obtain the actual torque required for the current electric valve to operate. These calculations are then compared to determine whether the current actuator can function as the driving mechanism for the electric valve, i.e., whether the actuator can operate the current electric valve. The monitored parameters include the thrust and torque on the valve stem, the voltage and current of the electric actuator, and the power calculated based on the voltage and current. The main steps involve using a strain sensor to measure the thrust and torque on the valve stem, obtaining a test curve, extracting feature points from the curve, and determining the actual output value of the electric actuator corresponding to the thrust or torque value triggered by the torque switch. Furthermore, the actual output of the electric actuator can also be obtained using the same steps.

[0043] Optionally, the actual torque corresponding to the electric valve is obtained based on the real-time monitoring information of the electric valve; during unit overhaul, the output torque and power of the electric actuator can be collected to obtain the conversion factor between the two. During the daily operation of the system, only the electrical parameters of the electric actuator, such as current and voltage parameters, are collected to calculate the corresponding power, thereby indirectly obtaining the torque output of the electric actuator.

[0044] Optionally, in step S1, obtaining the current working status of the electric valve based on its basic information and real-time monitoring information includes: obtaining the electrical parameters and torque parameters corresponding to the electric valve, and determining whether the mechanical condition of the electric valve is good based on the electrical parameters and torque parameters. Specifically, the process of determining the mechanical condition of the electric valve may include evaluating various components of the electric valve. For example, judging the degree of wear, bending, or thread damage of the valve stem based on whether there are periodic fluctuations in the thrust / torque curve; judging whether the valve disc in the electric valve is deformed or stuck based on whether there are sawtooth fluctuations in the valve stem thrust curve within the valve seating range; judging whether the valve seat in the electric valve is deformed based on whether there are sawtooth fluctuations in the thrust curve within the valve withdrawal range; judging whether the guide rail corresponding to the electric valve is deformed; judging whether the valve stem nut in the electric valve is worn or insufficiently lubricated; and judging whether the thrust bearing in the electric valve is worn, insufficiently lubricated, or deformed. The installation of the actuator and the electric valve can also be assessed to determine if they are properly aligned. For example, it can be determined whether the actuator and the electric valve are aligned, and whether the packing torque exerted by the actuator on the electric valve is too large or too small. The evaluation of each component requires consideration of the electric valve's current electrical and torque parameters. For instance, if the thrust curve formed by the valve's opening and closing exhibits mirror symmetry, it can be inferred that the valve stem is bent or deformed. If the thrust or power curve shows periodic fluctuations, it can be inferred that the valve is eccentric or that the bearing housing is worn.

[0045] Optionally, in step S1, obtaining the current operating status of the electric valve based on its basic information and real-time monitoring information includes: obtaining the acoustic emission parameters or temperature parameters corresponding to the electric valve, so as to determine whether the electric valve has internal leakage based on the acoustic emission parameters or temperature parameters corresponding to the electric valve. Specifically, in the process of determining whether the electric valve has internal leakage, temperature sensors can be installed at appropriate positions upstream and downstream of the electric valve. The judgment is made based on the obtained temperature difference between upstream and downstream. The smaller the temperature difference between upstream and downstream, the greater the possibility of internal leakage in the valve, and the more serious the internal leakage. Acoustic emission sensors can also be installed on the valve body of the electric valve. When the valve has internal leakage, the amplitude (dB) of the collected acoustic emission signal increases, and the degree of internal leakage is determined based on the amplitude. The specific principle is that when the valve has internal leakage, the leaking medium is sprayed downstream through the damaged sealing surface. The acoustic emission signal comes from the impact of the fluid on the pipe wall, which excites the sound signal. The acoustic emission sensors are installed upstream, downstream, and on the valve body. The signals at the corresponding positions are collected using acoustic emission acquisition equipment, and their amplitudes are calculated. By comparing the signal amplitude with the signal amplitude at the same location in history, it can be determined whether the valve has internal leakage and the severity of the internal leakage.

[0046] Optionally, in step S2, the historical operating data includes historical monitoring data, historical maintenance data, historical fault data, and historical fault data related to the electric valve. Specifically, during the acquisition of historical data for the electric valve, historical monitoring data, historical maintenance data, historical fault data, and historical fault data related to the electric valve can be acquired. The starting point for the historical data can be the time point corresponding to each major overhaul.

[0047] Optionally, in step S3, the performance trend analysis of the electric valve based on the real-time monitoring information and the historical operating data to obtain the performance change trend of the electric valve includes: obtaining the degree of degradation of the electric valve corresponding to the real-time monitoring information based on the real-time monitoring information and a preset degradation degree normalization calculation formula. Specifically, each parameter of the electric valve can be monitored, and the corresponding calculation formula can be derived, wherein the degradation degree calculation formula is as follows:

[0048] .

[0049] In one embodiment, as shown in Figure 3, the output torque of the electric actuator at different times is obtained, and a corresponding torque limit value is set according to the basic information of the electric valve. Based on the trend of torque change, the time point when the valve must be repaired when the limit value is reached can be predicted.

[0050] Optionally, the electric valve performance prediction method of the present invention further includes: when the current operating state of the electric valve is abnormal, generating maintenance suggestions corresponding to the current operating state. The process of determining the current operating state of the electric valve can be a judgment on whether the electric valve is in a normal operating state. If it can be determined that the current operating state of the electric valve is abnormal, corresponding maintenance suggestions can be given based on the specific cause of the abnormality.

[0051] Furthermore, the present invention provides an electric valve performance prediction system, applied to the electric valve performance prediction method described above. The system includes: a first execution unit, used to obtain the current operating state of the electric valve based on its basic information and real-time monitoring information; a second execution unit, used to obtain historical operating data corresponding to the electric valve when its current operating state is normal; and a third execution unit, used to perform performance trend analysis on the electric valve based on the historical operating data to obtain the performance change trend of the electric valve. That is, the system has the function of implementing the corresponding steps performed in the above method. Each function can be implemented by hardware or by hardware executing corresponding software. The corresponding hardware or software includes one or more modules or units corresponding to the above functions. That is, a corresponding system is formed by one or more units as described above, in which each unit respectively executes the steps in the above method. The specific cooperative operation between the units can be referred to the specific process of the above method, and will not be repeated here.

[0052] It is understood that the above embodiments only illustrate preferred embodiments of the present invention, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can freely combine the above technical features without departing from the concept of the present invention, and can also make several modifications and improvements, all of which fall within the protection scope of the present invention. Therefore, all equivalent transformations and modifications made with respect to the scope of the claims of the present invention should fall within the scope of the claims of the present invention.

Claims

1. A method for predicting the performance of an electric valve, characterized in that, The method includes the following steps: S1. Obtain the current working status of the electric valve based on its basic information and real-time monitoring information; S2. When the current working state of the electric valve is normal, acquire the historical operating data corresponding to the electric valve; S3. Perform performance trend analysis on the electric valve based on the real-time monitoring information and the historical operating data to obtain the performance change trend of the electric valve.

2. The method for predicting the performance of an electric valve according to claim 1, characterized in that, The current operating status of the electric valve includes whether the operability of the actuator corresponding to the electric valve meets the requirements, whether the mechanical condition of the electric valve is good, and whether the electric valve has internal leakage. And when the operability of the actuator corresponding to the electric valve meets the requirements, the mechanical condition of the electric valve is good, and there is no internal leakage in the electric valve, the current working state of the electric valve is determined to be normal.

3. The method for predicting the performance of electric valves according to claim 2, characterized in that, In step S1, obtaining the current operating status of the electric valve based on its basic information and real-time monitoring information includes: Based on the basic information of the electric valve, obtain the target torque corresponding to the electric valve and the maximum output torque of the corresponding drive mechanism of the electric valve; The actual torque corresponding to the electric valve is obtained based on the real-time monitoring information of the electric valve. The operability determination result of the actuator corresponding to the electric valve is obtained based on the target torque corresponding to the electric valve, the maximum output torque of the drive mechanism corresponding to the electric valve, and the actual torque corresponding to the electric valve.

4. The method for predicting the performance of an electric valve according to claim 3, characterized in that, The step of obtaining the actual torque corresponding to the electric valve based on the real-time monitoring information of the electric valve includes: Obtain the electrical parameters corresponding to the electric valve, and obtain the actual torque corresponding to the electric valve according to the electrical-torque correspondence table corresponding to the electric valve.

5. The method for predicting the performance of an electric valve according to claim 2, characterized in that, In step S1, obtaining the current operating status of the electric valve based on its basic information and real-time monitoring information includes: Obtain the electrical and torque parameters corresponding to the electric valve, and determine whether the mechanical condition of the electric valve is good based on the electrical and torque parameters corresponding to the electric valve.

6. The method for predicting the performance of an electric valve according to claim 2, characterized in that, In step S1, obtaining the current operating status of the electric valve based on its basic information and real-time monitoring information includes: Acquire the acoustic emission parameters or temperature parameters corresponding to the electric valve, and determine whether the electric valve has internal leakage based on the acoustic emission parameters or temperature parameters corresponding to the electric valve.

7. The method for predicting the performance of an electric valve according to claim 1, characterized in that, In step S2, The historical operating data includes historical monitoring data, historical maintenance data, historical fault data, and historical fault data related to the electric valve.

8. The method for predicting the performance of an electric valve according to claim 1, characterized in that, In step S3, the performance trend analysis of the electric valve based on the real-time monitoring information and the historical operating data to obtain the performance change trend of the electric valve includes: The degree of degradation of the electric valve corresponding to the real-time monitoring information is obtained based on the real-time monitoring information and the preset degradation degree normalization calculation formula.

9. The method for predicting the performance of an electric valve according to claim 1, characterized in that, The method further includes generating maintenance suggestions corresponding to the current operating state when the current operating state of the electric valve is abnormal.

10. An electric valve performance prediction system, characterized in that, The system, applied to the electric valve performance prediction method as described in any one of claims 1 to 9, comprises: The first execution unit is used to obtain the current working status of the electric valve based on the basic information and real-time monitoring information of the electric valve; The second execution unit is used to acquire the historical operating data corresponding to the electric valve when the current working state of the electric valve is normal. The third execution unit is used to perform performance trend analysis on the electric valve based on the historical operating data, so as to obtain the performance change trend of the electric valve.

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