Valve Actuator Force Logging for Local Performance Prognostics
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Solution Overview
Problem
Existing process control systems face limitations in diagnosing valve and actuator issues due to high network capacity demands and processing loads, which restrict the frequency and scope of valve signature data collection and analysis, leading to inadequate detection of potential problems.
Innovation Solution
The system continuously monitors and records actuator force values at predefined position points, creating a high-water mark force log at the actuator level, allowing for real-time analysis and alerting of over/under torque and stick-slip conditions, thereby reducing the burden on the process controller and network.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If valve signature data is continuously collected and transmitted to the process controller for analysis, then diagnostic capability and measurement precision are improved, but network capacity demand and controller processing load increase significantly
Solution Approach 1:
The patent extracts the data analysis function from the central process controller and places it locally at the actuator. The actuator independently analyzes valve signature data and only transmits processed results (alerts, summaries) rather than raw continuous data streams, thereby reducing network capacity demand while maintaining diagnostic capability
Solution Approach 2:
The patent segments the diagnostic system into distributed intelligent actuators that perform local analysis. Each actuator processes its own valve signature data independently, converting a centralized heavy-processing system into multiple lightweight distributed processing units, reducing overall network load
2Measurement precision
If valve signature data collection frequency is increased, then detection capability and measurement precision improve, but controller processing load and network bandwidth requirements increase
Solution Approach 1:
The actuator performs self-diagnosis by independently analyzing its own valve signature data locally. This self-service capability eliminates the need for the process controller to process continuous high-frequency data streams, allowing frequent data collection without increasing controller processing load
Solution Approach 2:
The analysis function is extracted from the process controller and implemented locally in the actuator's firmware. This enables high-frequency local analysis while the process controller only receives periodic alert notifications, dramatically reducing its processing burden
3Measurement precision
If comprehensive valve signature data is transmitted over the process control network, then diagnostic accuracy improves, but network capacity demand increases
Solution Approach 1:
The patent extracts unnecessary raw data transmission by performing analysis locally at the actuator. Only processed diagnostic results and alert notifications are transmitted over the network, extracting the bulk data processing function from the network layer to the edge device layer
Solution Approach 2:
Instead of the conventional approach of transmitting all raw data to the controller for analysis, the patent inverts the workflow: the actuator analyzes data locally and transmits only essential results upward, flipping the traditional data flow direction from centralized analysis to distributed analysis with centralized notification
Data Source
AI summary
An actuator of a process control device continuously monitors actuator force and records high force values at each position point by continuously executing a routine in a processor of the actuator. The routine includes receiving from a position sensor a current position value indicating a position of a valve element in the valve, and from a force sensor a current force value indicating a force applied by the actuator. The routine also includes retrieving, from a memory device coupled to the processor, a previous force value measured at the current position, and comparing the current force values for the current position with the previous force value for the current position. If the current force value for the current position exceeds the previous force value for the current position, the routine replaces the previous force value for the current position with the current force value for the current position in memory.