Valve Friction Monitoring for Real-Time Abnormality Detection
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Solution Overview
Problem
Current valve abnormality detection technologies in petrochemical plants are not capable of providing real-time fault detection, which is essential for swift safety management, as they rely on week-to-week data collection and are prone to missed detections due to discrete time cycles and statistical analysis.
Innovation Solution
A valve abnormality detecting device and method that includes an opening acquiring portion, pressure acquiring portion, stability-time detecting portion, frictional force detecting portion, and abnormality determining portion to detect frictional force changes at the valve's sliding portion, allowing for real-time abnormality detection by calculating time differences and frequency of index value reductions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If week-to-week data collection is used for valve abnormality detection, then data storage capacity is reduced, but detection timing is delayed and real-time monitoring is not achieved
Solution Approach 1:
The patent extracts only the essential real-time parameters (valve opening value and operating device air pressure) needed for abnormality detection, rather than storing all raw data. This selective extraction enables real-time monitoring while minimizing storage requirements.
Solution Approach 2:
The system performs preliminary calculation of the frictional force index value based on real-time pressure and opening data, preparing the processed information in advance for immediate abnormality assessment without requiring extensive historical data storage.
2Device complexity
If discrete time cycle analysis is used, then device complexity is reduced, but detection precision is insufficient and missed detections occur
Solution Approach 1:
The patent implements continuous feedback by monitoring the frictional force index value against specified thresholds in real-time. When the index value falls below the threshold, the system immediately identifies this as a potential abnormality, ensuring high detection precision without complex periodic analysis.
3Reliability
If statistical analysis of collected data is used, then detection coverage is improved, but response speed is slowed and real-time alerts are delayed
Solution Approach 1:
The patent replaces complex statistical analysis with a simpler threshold-based comparison mechanism. The frictional force index value is directly compared against a specified threshold in real-time, eliminating the need for lengthy statistical computations while maintaining reliable abnormality detection coverage.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables real-time detection of valve abnormalities, such as stick-slip, reducing the likelihood of missed detections and improving safety management by providing timely alerts and reducing storage capacity needs.
Implementation Method 1
a frictional force detecting portion configured to detect a difference between a maximum pressure value and a minimum pressure value of the operating device air in the stable-opening state as an index value indicating a frictional force at a sliding portion of the valve
Data Source
AI summary
A valve abnormality detecting device includes an opening acquiring portion to acquire a valve opening value; a pressure acquiring portion to acquire a pressure value of operating device air of an operating device for a valve; a stability-time detecting portion configured to detect a stable-opening state in which the valve opening value acquired by the opening acquiring portion 1 is substantially constant; a frictional force detecting portion configured to detect a difference between a maximum pressure value and a minimum pressure value of the operating device air in the stable-opening state as an index value indicating a frictional force at a sliding portion of the valve; and an abnormality determining portion configured to determine that an abnormality may have occurred in the valve in a case where a frequency of occurrence of reduction in which the index value falls below a specified value is an abnormal frequency.