JP6978252B2 - Valve maintenance support device and method - Google Patents

Description

The present invention relates to a valve maintenance support device and method for supporting valve maintenance work for regulating fluid flow.

Conventionally, valves used in petroleum and chemical plants need to pay particular attention to safety, and for this reason, regular maintenance is performed. FIG. 9 shows an example of a valve (control valve) used in petroleum and chemical plants.

The valve 100 includes a valve body 101, a positioner 102, and an actuator 103. The actuator 103 has a spring-type diaphragm structure, and the valve shaft (valve shaft (diaphragm) 103a of the actuator is displaced against the force of the spring 103b according to the air pressure Po supplied from the positioner 102. The stem) 104 is moved up and down to adjust the opening degree of the valve (the gap between the valve body 105 and the seat ring 106). The positioner 102 detects the lift position of the valve shaft 104, that is, the actual opening of the valve from the rotation angle position of the feedback lever 107 connected to the valve shaft 104, and determines the difference between the detected actual opening and the set opening. The corresponding air pressure Po is supplied to the actuator 103.

Although the valve 100 shown in FIG. 9 uses a reverse actuating actuator as the actuator 103, a normal actuating actuator may be used in some cases. The reverse actuating actuator urges the valve opening in the closing direction by the force of the spring, and the forward actuating actuator urges the valve opening in the opening direction by the force of the spring. Further, in the valve 100 shown in FIG. 9, the actuator 103 is operated by air pressure, but there is also a type in which the actuator 103 is operated by hydraulic pressure.

In plants where such valves are installed, it is necessary to efficiently maintain a large number of valves, and in order to improve the efficiency of the maintenance work, valve stick slip detection (see, for example, Patent Document 1) and valves Methods such as hunting detection (see, for example, Patent Document 2) and valve scale adhesion detection (see, for example, Patent Document 3) have been proposed.

Japanese Patent No. 3254624 Japanese Unexamined Patent Publication No. 2015-114942 Japanese Unexamined Patent Publication No. 2015-114943

However, there is no complete or sufficient upper limit for safety and efficiency of maintenance work. Since many valves are used in petroleum and chemical plants, further improvement in the efficiency of maintenance work is required.

The present invention has been made to solve such a problem, and an object thereof is to improve the efficiency of valve maintenance work, especially when the valve operator is subject to maintenance. To provide valve maintenance support devices and methods that can be used.

In order to achieve such an object, the present invention is a valve maintenance support device (200) that supports maintenance work of a valve (100) that regulates a fluid flow, and measures a valve opening degree (θ). It is transmitted from the pressure measuring unit (22) that measures the opening measurement value data (D1) transmitted from the opening measuring unit (21) and the fluid pressure (Po) supplied to the valve operator (103). Information on the valve operating amount based on the measured value data storage unit (1) that stores the incoming pressure measured value data (D2) and the opening measurement value data stored in the measured value data storage unit is used as the valve operating amount. Based on the calculated pressure measurement value data stored in the measured value data storage unit, information on the fluid pressure supplied to the valve operator is calculated as the operator pressure, and the calculated valve operating amount and operator pressure are calculated. It is provided with a diagnostic index calculation unit (3) that calculates the product of and as a valve diagnostic index (S) and a diagnostic index presentation unit (4) that presents the valve diagnostic index calculated by the diagnostic index calculation unit. It is a feature.

In the present invention, the measurement value data storage unit stores the opening measurement value data from the opening measurement unit and the pressure measurement value data from the pressure measurement unit. The diagnostic index calculation unit calculates information on the valve operation amount as the valve operation amount based on the opening measurement value data stored in the measurement value data storage unit. For example, the number of valve operations within the diagnosis target period is calculated as the valve operation amount, or the sliding distance of the valve shaft of the valve within the diagnosis target period is calculated as the valve operation amount. Further, the diagnostic index calculation unit calculates information on the fluid pressure supplied to the valve operator as the operator pressure based on the pressure measurement value data stored in the measurement value data storage unit. For example, the average value of the fluid pressure supplied to the valve actuator within the diagnosis target period is calculated as the actuator pressure. Then, the diagnostic index calculation unit calculates the product of the calculated valve operating amount and the actuator pressure as the valve diagnostic index. The calculated valve diagnostic index (product of valve operating amount and actuator pressure) is presented to the operator.

In the above description, as an example, the components on the drawing corresponding to the components of the invention are shown by reference numerals in parentheses.

As described above, according to the present invention, the product of the valve operating amount calculated based on the opening measurement value data and the operator pressure calculated based on the pressure measured value data is calculated as a valve diagnostic index. Therefore, a more reliable diagnostic index that takes into account not only the amount of operation of the valve but also the fluid pressure supplied to the valve operator is presented to the operator, and in particular, the valve operator is maintained. It becomes possible to improve the efficiency of valve maintenance work in the case of the target.

FIG. 1 is a block diagram showing a configuration of a main part of the valve maintenance support device according to the first embodiment of the present invention. FIG. 2 is a flowchart showing how the opening measurement value data and the pressure measurement value data are accumulated in the measurement value data storage unit of the valve maintenance support device. FIG. 3 is a diagram illustrating changes in the valve opening degree θ and the air pressure Po in one vertical movement when the valve actuator is a reverse operation actuator. FIG. 4 is a diagram illustrating changes in the valve opening degree θ and the air pressure Po in one vertical movement when the valve manipulator is a normal operating device. FIG. 5 is a flowchart for explaining the operation of this valve maintenance support device. FIG. 6 is an image diagram showing an example of valve arrangement of a plant to be maintained. FIG. 7 is a diagram showing a display example of a diagnostic index of a valve that is a maintenance candidate. FIG. 8 is a diagram illustrating a configuration (implementation example of the first embodiment) of the plant and its equipment management system according to the second embodiment of the present invention. FIG. 9 is a diagram showing an example of a control valve.

[Principle of invention]
In the conventional valve diagnosis, the area around the sliding portion of the valve has received particular attention, and therefore the number of operations and the sliding distance are adopted as control indexes. However, with respect to the valve operator, especially in the diaphragm of the operator having a spring type diaphragm structure, the accumulation (accumulation) of the load differs depending on the base pressure (pneumatic pressure).

The inventor should use an integral that takes into account the pressure of the fluid supplied to the actuator, not simply the number of operations or the sliding distance, for the actuator with a spring-type diaphragm structure. I focused on. Then, by presenting information such as "valve operating amount x operating device pressure", for example, "number of operations x operating device pressure", "sliding distance x operating device pressure" to the operator as a diagnostic index, the operator can be used. I came up with the idea of being able to estimate the deterioration of the diaphragm.

As a result, a more reliable diagnostic index that takes into account not only the amount of operation of the valve but also the fluid pressure supplied to the valve operator is presented to the operator, and in particular, the valve operator is subject to maintenance. In this case, the efficiency of valve maintenance work can be improved.

[Embodiment 1]
Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 is a block diagram showing a configuration of a main part of the valve maintenance support device according to the first embodiment of the present invention. Here, for the sake of brevity, the example of the valve ID (identification information) will be simpler than that used in an actual plant.

The valve maintenance support device 200 of the present embodiment is realized by hardware including a processor and a storage device, and a program that realizes various functions in cooperation with these hardware, and includes a measured value data storage unit 1 and a storage unit 1. It includes a valve ID storage unit 2, a diagnostic index calculation unit 3, a diagnostic index presentation unit 4, a determination unit 5, a threshold storage unit 6, and a determination result presentation unit 7.

In the valve maintenance support device 200, the measured value data storage unit 1 is transmitted from the opening measurement value data D1 and the pressure measuring unit 22 transmitted from the opening measurement unit 21 of the valve 100 used in the plant. The incoming pressure measurement value data D2 is stored.

That is, the valve 100 used in the plant includes an opening degree measuring unit 21 for measuring the opening degree θ of the valve and a pressure measuring unit 22 for measuring the air pressure Po supplied to the operator of the valve. There is. The opening degree measuring unit 21 transmits the measured valve opening degree θ as the opening degree measurement value data D1 to the valve maintenance support device 200, and the pressure measuring unit 22 uses the measured air pressure Po as the pressure measurement value data D2 to support valve maintenance. It is transmitted to the device 200.

When the valve maintenance support device 200 receives the opening degree measurement value data D1 from the opening degree measuring unit 21 (YES in step S101), as shown in the flowchart in FIG. 2, the valve maintenance support device 200 receives the received opening degree measurement value data D1. When the measured value data storage unit 1 stores the measured value data (step S102) and the pressure measured value data D2 from the pressure measuring unit 22 is received (YES in step S103), the received pressure measured value data D2 is stored in the measured value data storage unit 1. Is stored in (step S104).

FIG. 3 illustrates changes in the valve opening θ (opening measurement value data D1) and air pressure Po (pressure measurement value data D2) in one vertical movement when the valve 100 actuator is used as a reverse operation controller. Then, in FIG. 4, changes in the valve opening θ (opening measurement value data D1) and air pressure Po (pressure measurement value data D2) in one vertical movement when the valve 100 actuator is used as a normal operation controller. Is illustrated.

In the present embodiment, the opening measurement value data D1 and the pressure measurement value data D2 are periodically transmitted from the opening degree measuring unit 21 and the pressure measuring unit 22 of the valve 100 to the measured value data storage unit 1. It shall be accumulated as time series data. Further, in the present embodiment, a large number of valves 100 are installed in the plant, and the opening measurement value data D1 (D1 _{1 to D1 N} ) and the pressure from these valves 100 (100-1 to 100-N) are installed. It is assumed that the measured value data D2 (D2 _{1 to D2 N} ) is stored in the measured value data storage unit 1 in association with the ID of the valve.

Hereinafter, the operation of the valve maintenance support device 200 will be specifically described with reference to the flowchart shown in FIG. 5, with the functions of each part.

The operator targets the valves 100-1 to 100-N installed in the plant as the measurement target, determines the maintenance candidate valves from the measurement target valves 100-1 to 100-N, and determines the maintenance candidate valves. Register the valve (step S201). In this case, the ID of the valve registered as the valve as a candidate for maintenance (hereinafter, also referred to as a valve ID) is stored in the valve ID storage unit 2 of the valve maintenance support device 200.

For example, assuming that there are 26 valves 100 in the plant, these 26 valves 100 have "A", "B", "C", ..., "M", ..., "X", "", respectively. It is assumed that unique IDs "Y" and "Z" are assigned in advance. When valves A, M, and C are defined as candidate valves for maintenance, the operator inputs "A", "M", and "C" as valve IDs. In this embodiment, it is assumed that valves A, M, and C are selected as the highest priority maintenance target in a specific periodic plant maintenance.

FIG. 6 is an image diagram showing an example of valve arrangement of a plant to be maintained. In the present embodiment, the valves 100-A (valve A) and 100-M (valve M) having valve IDs "A" and "M" are arranged in the flow path 11-1 having the flow path ID "1". It is assumed that the valve 100-C (valve C) of the valve ID “C” is arranged in the flow path 11-3 of the flow path ID “3”. In FIG. 6, 12-A, 12-C, and 12-M are flow rate measuring instruments, 13 is a tank, and 14 is a pressure transmitter. In FIG. 6, the description is omitted for valves whose valve IDs are other than "A", "C", and "M".

When the diagnostic index calculation unit 3 receives an instruction to calculate the diagnostic index (YES in step S202), the maintenance candidate valve IDs “A”, “C”, and “M” stored in the valve ID storage unit 2 (Step S203), and the opening measurement value data D1 and the pressure measurement value data D2 stored in the measurement value data storage unit 1 in association with the read valve IDs “A”, “C”, and “M”. Is read (step S204). In this case, the entire usage period of the valve is set as the diagnosis target period, and the opening measurement value data D1 and the pressure measurement value data D2 of the valves A, C, and M within this diagnosis target period are read out. In this example, the entire usage period of the valve is set as the diagnosis target period, but the entire usage period of the valve does not necessarily have to be the diagnosis target period.

Then, the diagnostic index calculation unit 3 calculates information on the operation amounts of the valves A, C, and M as the valve operation amount based on the opening measurement value data D1 read from the measurement value data storage unit 1 (step S205). Based on the pressure measurement value data D2 read from the measurement value data storage unit 1, information on the air pressure Po supplied to the operators of the valves A, C, and M is calculated as the operator pressure (step S206), and this calculation is performed. the product of the valve operation amount and the operating device pressure (valve operation amount × operating device pressure) the valve a, C, diagnostic of _{M S (S a, S C} , S M) is calculated as (step S207).

In the present embodiment, as an example, in step S205, the number of operations of valves A, C, and M within the diagnosis target period is calculated as the valve operation amount, and in step S206, the valves A, C, and M within the diagnosis target period are calculated. The average value of the air pressure Po supplied to the actuator is calculated as the actuator pressure. In this case, in step S207, the product of the number of operations and the operating device the pressure in the diagnosis period (operation times × operating device pressure) valve A, C, M diagnostic index S of (S _A, S _C, S _M) Is calculated as.

In the present embodiment, as another example, in step S205, the sliding distance of the valve shafts of the valves A, C, and M within the diagnosis target period is calculated as the valve operating amount, and in step S206, within the diagnosis target period. The average value of the air pressure Po supplied to the actuators of the valves A, C, and M is calculated as the actuator pressure. In this case, in step S207, the sliding distance and operating device pressure and the product (sliding distance × operating device pressure) valve A in the diagnostic period, C, diagnostic of _{M S (S A, S C} , S Calculated as _M).

Diagnostic index calculated by the diagnostic index calculator _{3 S (S A, S C} , S M) is sent to the diagnostic index presenting unit 4. The diagnostic index presentation unit 4 presents the diagnostic index S from the diagnostic index calculation unit 3 to the operator (step S208). For example, as shown in FIG. 7 as the display area of the diagnostic index as # 1, the IDs “A”, “C”, “” of the maintenance candidate valves are associated with the maintenance candidate valves A, C, and M. in association with the M ", and displays the calculated diagnostic index calculation unit 3 diagnostic indicator S _a, S _C, the value of S _M to the display.

At this time, as shown in the presentation area of the diagnosis target portion in FIG. 7 as # 2, diagnostic index S _A being presented (displayed) on the presentation area # 1 of the diagnostic index, S _C, S _M is the valve A, C , By presenting (displaying) that the maintenance of the diaphragm of the actuator that drives the valve shaft of the M is targeted, the operation is performed for the operator who lacks knowledge about the necessity of maintenance of the diaphragm of the actuator. Since the necessity of paying attention to the diaphragm of the vessel is quantitatively shown, the risk of omission of the check of the diaphragm of the actuator can be reduced.

Diagnosis calculated index calculation unit 3 diagnostic indicator _{S (S A, S C,} S M) is also sent to the determination unit 5. The upper limit value of the normal range with respect to the diagnostic index S is stored in the threshold storage unit 6 as the diagnostic index threshold Sth. When the diagnostic index S is sent from the diagnostic index calculation unit 3, the determination unit 5 reads out the diagnostic index threshold Sth stored in the threshold storage unit 6 (step S209), and the diagnostic index from the diagnostic index calculation unit 3. S is compared with the diagnostic index threshold Sth (step S210). In this case, the diagnostic indicator S _A from the diagnostic index calculation unit 3, S _C, for each of S _M, is compared with the diagnostic indicator threshold Sth.

Here, when the diagnostic index S from the diagnostic index calculation unit 3 is equal to or higher than the diagnostic index threshold value Sth (YES in step S210), the determination unit 5 determines that the valve is a valve requiring maintenance (step). S211). For example, determining the diagnostic indicator S _A, S _C, of the S _M, if diagnostic index S _M was a diagnostic indicator threshold Sth or more, the valve M maintenance is valve required. The determination unit 5 sends this determination result to the determination result presentation unit 7.

The determination result presenting unit 7 presents the determination result from the determination unit 5 to the operator (step S212). For example, when it is determined that the valve M is a valve requiring maintenance among the valves A, C, and M that are candidates for maintenance, the valve ID and the diagnosis of the valve M in the diagnostic index presentation area # 1 shown in FIG. to display the index S _M in red. In this case, the other valves are displayed in black. At this time, the diagnostic index threshold value Sth used at the time of determination may be displayed in the diagnostic index presentation area # 1.

In this embodiment, the diagnostic index of the valve that is a candidate for maintenance and the judgment result of whether or not the valve requires maintenance are displayed on the display, but it may be printed out by a printer or the like, and it may be output by voice. You may let them know.

Further, in this embodiment, the diagnostic index calculation unit 3 calculates the diagnostic index S only for the maintenance candidate valves (valves A, C, M), but all the valves to be measured (valve A). The diagnostic index S may be calculated for ~ Z). In this case, in the diagnostic index presentation unit 4, the valve IDs of all the valves to be measured are associated with the diagnostic index, for example, the valve that is a candidate for maintenance is blue, and the valve that is not a candidate for maintenance is black. Valves that are determined to require maintenance should be displayed separately, such as in red.

[Embodiment 2]
Next, the valve maintenance support device according to the second embodiment of the present invention will be described. The second embodiment explains the implementation example of the first embodiment. FIG. 8 is a diagram showing the configurations of the plant and its equipment management system, and the same configurations as those in FIG. 6 are designated by the same reference numerals.

Petroleum and chemical plants are provided with an equipment management system 8 that controls and manages each equipment of the plant. Since the measured value data storage unit 1, the valve ID storage unit 2, the diagnostic index calculation unit 3, the determination unit 5, and the threshold value storage unit 6 described in the first embodiment handle a huge amount of plant-specific information, the equipment management system It is preferably mounted on the 8 side.

On the other hand, the diagnostic index presentation unit 4 and the determination result presentation unit 7 provide, in principle, particularly necessary processing when determining valve maintenance. In addition, the maintenance performer (the person in charge of the work of the maintenance contractor) is generally outsourced by the plant owner company to carry out the maintenance of the plant. Therefore, assuming that an unspecified number of plants are targeted, the diagnostic index presentation unit 4 and the determination result presentation unit 7 are mounted on the portable computer 9 carried by the worker (operator) of the maintenance contractor. It is preferable to do so.

The computer 9 includes a CPU (Central Processing Unit), a memory, and an interface. The equipment management system 8 of the plant and the computer 9 are temporarily connected to each other by using a communication function such as Ethernet (registered trademark) when performing maintenance work.

When the operator starts the application software on the computer 9, the CPU of the computer 9 executes the process according to the program stored in the memory, sends a calculation instruction of the diagnostic index to the device management system 8, and registers it in the device management system 8. For the maintenance candidate valves that have been performed, the diagnostic index is calculated and it is determined whether or not maintenance is necessary. The diagnostic index of the valve that is a candidate for maintenance calculated by the device management system 8 and the determination result of whether or not maintenance is necessary are displayed on the display of the computer 9.

In this example, it is assumed that the maintenance candidate valves are already registered in the device management system 8, but the operator can also register or change the maintenance candidate valves from the computer 9.

Based on the diagnostic index of the valve as a candidate for maintenance displayed on the display of the computer 9 and the determination result of whether or not maintenance is necessary, the operator confirms the valve that should pay particular attention to the inspection of the diaphragm of the actuator. After confirmation, the operator disconnects the computer 9 from the device management system 8.

In this way, the valve maintenance support device 200 described in the first embodiment can be applied to an actual plant.

[Extension of Embodiment]
Although the present invention has been described above with reference to the embodiments, the present invention is not limited to the above embodiments. Various changes that can be understood by those skilled in the art can be made to the structure and details of the present invention within the scope of the technical idea of the present invention.

1 ... Measurement value data storage unit, 2 ... Valve ID storage unit, 3 ... Diagnostic index calculation unit, 4 ... Diagnostic index presentation unit, 5 ... Judgment unit, 6 ... Threshold storage unit, 7 ... Judgment result presentation unit, 21 ... Open Degree measurement unit, 22 ... Pressure measurement unit, 100 (100-1 to 100-N) ... Valve, 101 ... Valve body, 102 ... Positioner, 103 ... Operator, 103a ... Diaphragm (diaphragm of operator), 103b ... Spring , 104 ... Valve shaft, 200 ... Valve maintenance support device.

Claims (8)

A valve maintenance support device that supports valve maintenance work that regulates fluid flow.
The opening measurement value data transmitted from the opening measurement unit that measures the opening of the valve and the pressure measurement value data transmitted from the pressure measuring unit that measures the fluid pressure supplied to the valve operator. The measured value data storage unit to be stored and
Based on the opening measurement value data stored in the measured value data storage unit, information regarding the valve operating amount is calculated as the valve operating amount, and the pressure measured value stored in the measured value data storage unit. Based on the data, information on the fluid pressure supplied to the valve operator is calculated as the operator pressure, and the product of the calculated valve operating amount and the operator pressure is calculated as the valve diagnostic index. Department and
A valve maintenance support device including a diagnostic index presenting unit that presents a diagnostic index of the valve calculated by the diagnostic index calculating unit. In the valve maintenance support device according to claim 1,
A threshold storage unit that stores the upper limit of the normal range for the diagnostic index as a diagnostic index threshold, and
A determination unit that determines that the valve is a valve that requires maintenance when the diagnostic index of the valve calculated by the diagnostic index calculation unit is equal to or higher than the diagnostic index threshold value.
A valve maintenance support device including a determination result presenting unit that presents a valve that is determined to require maintenance by the determination unit. In the valve maintenance support device according to claim 1 or 2.
The diagnostic index calculation unit is
A valve maintenance support device characterized in that the number of times the valve is operated within the diagnosis target period is calculated as the valve operating amount. In the valve maintenance support device according to claim 1 or 2.
The diagnostic index calculation unit is
A valve maintenance support device characterized in that the sliding distance of the valve shaft of the valve within the diagnosis target period is calculated as the valve operating amount. In the valve maintenance support device according to any one of claims 1 to 4.
The diagnostic index calculation unit is
A valve maintenance support device characterized in that the average value of the fluid pressure supplied to the actuator of the valve within the diagnosis target period is calculated as the actuator pressure. In the valve maintenance support device according to any one of claims 1 to 5.
The diagnostic index presentation unit is
A valve characterized in that, in combination with the diagnostic index of the valve, the diagnostic index is intended for maintenance of the diaphragm of the actuator that receives the supplied fluid pressure and drives the valve shaft of the valve. Maintenance support device. In the valve maintenance support device according to any one of claims 1 to 6.
It is equipped with a valve identification information storage unit that stores the identification information of valves registered as maintenance candidate valves.
The measured value data storage unit is
A plurality of valves including the maintenance candidate valve are targeted for measurement, and the opening measurement value data and the pressure measurement value data are stored in association with the valve identification information for each of the measurement target valves.
The diagnostic index calculation unit is
The valve identification information of the maintenance candidate valve stored in the valve identification information storage unit is read out, and the opening measurement value data and the opening measurement value data stored in the measurement value data storage unit are associated with the read identification information. A valve maintenance support device for calculating the diagnostic index for each of the maintenance candidate valves based on the pressure measurement value data. A valve maintenance support method performed by a valve maintenance support device that supports valve maintenance work that regulates fluid flow.
The measurement value data storage unit of the valve maintenance support device measures the opening measurement value data transmitted from the opening measurement unit that measures the opening of the valve and the fluid pressure supplied to the valve operator. and Luz step to store the pressure measurement value data transmitted from the pressure measuring unit in a memory,
The diagnostic index calculation unit of the valve maintenance support device calculates information on the operation amount of the valve as the valve operation amount based on the opening measurement value data stored in the memory, and stores it in the memory. Information on the fluid pressure supplied to the operator of the valve is calculated as the operator pressure based on the pressure measurement value data, and the product of the calculated valve operating amount and the operator pressure is calculated as a diagnostic index of the valve. and to Luz step,
The diagnostic index presenting unit of valve maintenance support apparatus, valve maintenance support method characterized by comprising the Luz steps to present diagnostic indicator of the valve calculated by the diagnostic indicator calculating step.

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