JP6145015B2 - Valve opening inspection support device and method - Google Patents

Description

  The present invention relates to a valve opening inspection support apparatus and method for supporting valve opening inspection.

  Conventionally, many valves are used in oil and chemical plants, and many valves are candidates for maintenance during regular maintenance. The selection of valves to be actually serviced from the large number of valves was conducted by the maintenance orderer and the maintenance contractor as necessary based on reference information such as the period of use. In addition, a device information management system that collects reference information for that purpose and outputs it as a report has also been proposed (see, for example, Patent Document 1).

  In this case, many valves used in the plant include valves that absolutely require open inspection (disassembly) as maintenance work, and conversely valves that require almost no maintenance work. Sorting deals with the trade-off problem between maintenance cost (man-hours, replacement parts cost, etc.) and maintenance effect (safety, operational performance, etc.).

  Recently, with the advancement of information processing systems, the schedule management and performance management of open inspections have been streamlined and advanced. On the other hand, the judgment of open inspection sometimes relies on the intuition of skilled workers. On the other hand, for example, in Patent Document 2, one change tendency is obtained based on a plurality of past diagnosis data for each abnormality diagnosis item of the valve, and the deterioration proceeds according to the obtained change tendency. A technique for creating a maintenance plan in anticipation of when a standard value that requires maintenance is reached is shown.

  If the technique disclosed in Patent Document 2 is applied, a determination index for determining whether or not valve opening inspection is to be performed is determined, and an operator determines a determination criterion (threshold value or threshold value) in which the trend of the determination index is determined in advance. It is conceivable to determine whether or not to perform an open inspection by predicting the time when it will reach a reference standard). As a result, the determination is not subjective, and it is possible to make an appropriate determination without being a skilled worker.

JP 2011-215917 A JP 2002-130531 A (Patent No. 3411980)

  Valves are regularly inspected while being used in oil and chemical plants, but the necessity for open inspection varies depending on the use conditions and operation results. Since the inspection frequency is not frequent, it is necessary to see the trend of the determination index in a relatively long span. However, the operation state in the long span is not constant and varies depending on the nature of the plant.

  For this reason, if the criterion for determining valve opening inspection is fixed to one according to the determination index, it is determined that the opening inspection is necessary at an early stage or that the opening inspection is performed at a later stage. It is determined that it is necessary, and it is not possible to determine the appropriate time for opening inspection. That is, even if the determination index for open inspection is used, the inspection cost will not improve unless the determination criterion for the determination index is improved to the high accuracy side.

  The present invention has been made to solve such a problem, and the object of the present invention is to improve the inspection cost by narrowing down the determination criterion for the determination index to the high accuracy side based on the actual results. It is an object to provide a valve opening inspection support device and method capable of proceeding with the above.

  In order to achieve such an object, the present invention provides an index registration unit for registering a history of a determination index for determining whether or not to perform valve opening inspection, and an opening inspection input from an operator as a result of valve opening inspection. It was validated based on the implementation result registration unit that registers the validity of the implementation, the history of the judgment index registered in the index registration unit, and the validity of the open inspection implementation registered in the implementation result registration unit And a determination criterion determining unit that determines a determination criterion for the determination index from the determination index at the time of performing the open inspection and the determination index at the time of performing the open inspection that has not been validated.

  In this invention, a history of a determination index for determining whether or not to perform valve opening inspection is registered, validity of the opening inspection performed by the operator as a result of performing valve opening inspection is registered, and the registered determination Based on the history of the index and the validity of the open inspection, the judgment criteria (threshold value) for the judgment index are determined from the judgment index at the time of the open inspection that has been validated and the judgment index at the time of the open inspection that has not been validated. Or a reference standard for the operator to determine the threshold). As a result, as the number of examples of open inspection increases, the determination criterion for the determination index is narrowed down to the high accuracy side.

  Even if there is an indicator for open inspection, if the criterion for the indicator is not improved to the high accuracy side, the improvement in inspection cost will not proceed. The inventor has conceived that the judgment criteria can be improved by managing (registering) the implementation status of the open inspection (the result of whether or not it was really necessary). The present invention focuses on this point.

  In the present invention, the determination criterion determination unit, for example, performs a representative value of the determination index at the time of performing the open inspection that has been validated, a representative value of the determination index at the time of the execution of the open inspection that has not been validated, and the open inspection of the valve. A determination criterion is determined from an offset parameter for positively performing the determination. Further, the offset parameter is corrected according to the reliability of the determination criterion. Both the increase in the number of open inspection implementation cases and the judgment of the timing of open inspection on the cautious side (consideration for conscientiousness) regarding the occurrence of failures It will be set to become. In order to make it “a side that actively conducts open inspection”, for example, an intermediate value between a representative value of a judgment index at the time of performing an open inspection and a representative value of a judgment index at the time of an open inspection that has not been validated. Use the offset parameter instead of the value to set the criterion for “actively performing open inspection”. Then, as the number of examples of open inspection increases, that is, as the reliability of the determination criterion increases, the offset parameter is corrected to bring the determination criterion closer to the intermediate value.

  Further, in the present invention, for example, an index registration unit, an implementation result registration unit, and a determination criterion determination unit are provided for each valve having a different use, and priority is given to the carefulness when performing open inspection of a valve having a different use. The order setting unit for setting the order and the criterion setting unit so that the priority set in the order setting unit and the order of the criterion determined by the criterion determination unit match for each valve having a different use. And a determination reference adjustment unit for automatically adjusting the determination reference determined in step (1). Depending on the use of the valve, there is a case where judgment with a high emphasis on prudentity (careful side with respect to failure occurrence) is required, and a case where it is not. Cases of open inspections by application are tabulated, and automatic adjustment is made so that the order of judgments that require careful judgment and the order of judgment criteria match, and customer satisfaction is also improved.

  According to the present invention, the history of a determination index for determining whether or not to perform valve opening inspection is registered, and the validity of the opening inspection performed by the operator as the valve opening inspection execution result is registered and registered. Criteria for judgment indicators based on the judgment criteria at the time of open inspection implementation and the judgment indicators at the time of implementation of open inspection that were not validated based on the history of judgment indicators and the validity of implementation of open inspections Since the determination criteria for the determination index are narrowed down to the high accuracy side based on the actual results, the inspection cost can be improved.

It is a block diagram which shows the principal part of one Embodiment (Embodiment 1) of the opening inspection assistance apparatus of the valve | bulb which concerns on this invention. It is a figure which shows an example of the valve | bulb with which opening inspection is supported by this valve | bulb opening inspection assistance apparatus. It is a diagram showing a valve opening degree PV _AF after servicing the input signals SP development and before the valve opening PV _BF in the case of performing the zero point test. It is a figure which shows the example of calculation of the threshold value B calculated as a criterion with respect to the micro opening degree A. FIG. 3 is a diagram showing a schematic flowchart of processing operations executed by the CPU of the valve opening inspection support device of the first embodiment. FIG. 6 is a block diagram illustrating a main part of a valve opening inspection support device according to a second embodiment. FIG. 10 is a diagram showing a schematic flowchart of processing operations executed by a CPU of the valve opening inspection support device of the second embodiment.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
[Embodiment 1]
FIG. 1 is a block diagram showing a main part of an embodiment (Embodiment 1) of a valve opening inspection support device according to the present invention. The valve opening inspection support device (hereinafter simply referred to as an opening inspection device) 100 (100A) is a software tool on a computer applied to the valve 200 as shown in FIG. To help.

  In FIG. 1, 1 is an index registration unit, 2 is an implementation result registration unit, 3 is a threshold value determination unit, and 4 is an offset correction unit.

  The processing operation of each unit in the open inspection support device 100A is realized by hardware including a processor and a storage device, and a program that realizes various functions in cooperation with these hardware. Specifically, a program is installed in a computer, and is realized as a processing operation of a CPU (Central Processing Unit) according to the installed program.

  The index registration unit 1 registers the history of the minute opening A as a determination index for determining whether or not the valve 200 is to be opened. In this embodiment, the minute opening A is an index indicating a state where the valve 200 is slightly fully closed and cannot be fully closed in response to a fully closing instruction to the valve positioner 201 that drives the valve 200. For example, when the scale adheres to the plug stem guide portion 202, the minute opening A increases.

FIG. 3 shows the input signal SP when the zero point test is performed, the valve opening PV _BF before maintenance, and the valve opening PV _AF after maintenance. When the scale adheres to the plug stem guide portion 202 or the like, when the input signal SP is zero, a difference occurs between the valve opening PV _BF before maintenance and the valve opening PV _AF after maintenance. An index indicating this difference is the minute opening A. The minute opening A is sent to the index registration unit 1 from a minute opening detection unit (not shown).

  When the opening inspection of the valve 200 is performed, the operator registers the validity of the opening inspection in the execution result registration unit 2 as a result of performing the opening inspection of the valve 200. For example, if it can be evaluated that the time is suitable for open inspection, it is registered as “valid”, and if it can be evaluated that it is too early for open inspection, it is registered as “invalid”. The execution result registration unit 2 registers the validity of the opening inspection performed by the operator each time the opening inspection of the valve 200 is performed.

  The threshold value determination unit 3 is registered in the history of the minute opening A registered in the index registration unit 1 and the execution result registration unit 2 when the open inspection implementation case (actual case) reaches a predetermined number of times. Based on the appropriateness of the open inspection from the operator, the representative value (for example, the average value) of the minute opening A of the actual case (usually a plurality of times) that has been validated was assumed to be A1, and was not valid The representative value (for example, average value) of the minute opening A in the actual case (usually a plurality of times) is A2, the offset parameter for positively performing the opening inspection of the valve 200 is α, and the minute opening As a criterion for A, a threshold B is calculated by the following equation (1) (see FIG. 4). Note that the horizontal axis in FIG. 4 is obtained for the sake of visualization because it is obtained from actual cases with different representative values.

B = (A1 + A2) / 2 + α (1)
However, α is α ≦ 0.0.

  The offset correction unit 4 approaches the intermediate value “(A1 + A2) / 2” between the representative values A1 and A2 of the minute opening A as the number of actual cases increases and the reliability of the threshold B increases. The offset parameter α is updated in the direction. That is, every time the threshold value determination unit 3 calculates the threshold value B, α is brought closer to 0.0.

In the case of the present embodiment, since B = A2 in the initial stage is set in consideration of reliability, the initial value of α is preferably set to α0 = (A2−A1) / 2. Further, as a method of bringing α close to 0.0, a correction equation such as the following equation (2) is conceivable.
αi = 0.9 × αi ₋₁ + 0.1 × 0.0 (2)
However, αi: latest value, αi ₋₁ : previous value.

  In this way, according to the present embodiment, the threshold value B for the minute opening A is narrowed down to the high precision side based on the actual results, and the inspection cost can be improved.

  In this embodiment, the threshold value determination unit 3 uses the equation (1) to determine the threshold value B. However, the offset parameter for actively performing the opening inspection of the valve 200 is β, You may make it obtain | require using the following (3) Formula.

B = β · A1 + (1−β) · A2 (3)
However, 0.0 ≦ β ≦ 0.5.

  In this case, as the number of actual cases increases and the reliability of the threshold value B increases, the offset correction unit 4 has an intermediate value (0.5 · A1 + 0) between the representative values A1 and A2 of the minute opening A. The offset parameter β is updated in the direction approaching .5 · A2). That is, every time the threshold value determination unit 3 calculates the threshold value B, β is brought closer to 0.5.

In this case, since B = A2 in the initial stage is set in consideration of reliability, the initial value of β is preferably set to β0 = 0.0. Further, as a method of bringing β close to 0.5, a correction equation such as the following equation (4) is conceivable.
βi = 0.9 × βi ₋₁ + 0.1 × 0.5 (4)
However, βi: latest value, βi ₋₁ : previous value.

  In this embodiment, the threshold value determining unit 3 automatically calculates the threshold value B when the number of actual cases reaches the specified number of times. However, the threshold value determining unit 3 sets the threshold value B according to an instruction from the operator. The calculation may be performed.

  FIG. 5 shows a schematic flowchart of processing operations executed by the CPU of the open inspection support apparatus 100A. The CPU of the opening inspection support device 100A registers the history of the minute opening A as a determination index for determining whether or not to perform the opening inspection of the valve 200 (step S101). Further, the validity of the opening inspection from the operator is registered as a result of the opening inspection of the valve 200 (step S102). Then, when the actual case reaches the specified number of times, the threshold B is determined (step S103). Also, the offset parameter used when calculating the threshold value B is corrected (step S104).

[Embodiment 2]
In an actual large-scale plant, when a plurality of valves are subject to open inspection, it is assumed that the use is different for each valve. When a plurality of valves having different uses are subjected to open inspection, it is preferable to adopt a change method in which the threshold value is always changed to the careful side for changing the threshold value B by automatic adjustment for each valve.

  For example, when priority is set with an emphasis on prudence when performing open inspection, and a threshold value Ba is determined for a valve for a lower priority application, the threshold Bb is set for a valve for a higher priority application. It is preferably set so as to be on the more careful side than the threshold value Ba. If the minute opening A is used as the determination index, the upper limit value when determining the threshold value Bb is preferably set to the threshold value Ba. By adopting such a change method, it is possible to avoid the occurrence of an uncomfortable situation in which a valve on the lower side than the higher priority side of the open inspection is likely to be determined as requiring open inspection. Will be able to.

  FIG. 6 shows a configuration of a main part of the open inspection support apparatus when a plurality of valves having different uses are subjected to open inspection as a second embodiment. The open inspection support device 100 (100B) includes an open inspection support unit 5 that includes the index registration unit 1, the execution result registration unit 2, and the threshold value determination unit 3 for each valve having different applications. In this example, the open inspection support parts 5-1 to 5-n are provided for the valves of the applications (1) to (n).

  Further, for each valve of the usage (1) to the usage (n), the priority setting unit 6 for setting a priority order with an emphasis on prudence when performing the opening inspection of the usage (1) to the usage (n). A threshold adjustment unit 7 that automatically adjusts the threshold B determined by the threshold determination unit 3 so that the priority set in the rank setting unit 6 matches the order of the threshold B determined by the threshold determination unit 3; It has.

  For example, it is assumed that there are four valves having different uses, and the threshold value B to be determined by the threshold value determination unit 3 is Bd, Bc, Bd, Ba in descending order of priority. At this time, for example, when the threshold value B before the adjustment is “Bd = 0.30%, Bc = 0.25%, Bb = 0.20%, Ba = 0.15%” The threshold B is adjusted such that “Bd = 0.15%, Bc = 0.15%, Bb = 0.15%, Ba = 0.15%”, with the threshold B on the lower priority side as the upper limit. To do. For example, when “Bd = 0.25%, Bc = 0.20%, Bb = 0.25%, Ba = 0.30%”, the threshold B on the lower priority side is set as the upper limit value. , The threshold value B is adjusted such that “Bd = 0.20%, Bc = 0.20%, Bb = 0.25%, Ba = 0.30%”.

  FIG. 7 shows a schematic flowchart of processing operations executed by the CPU of the open inspection support apparatus 100B. The CPU of the opening inspection support device 100B sets a priority order that places importance on prudentity when performing the opening inspection of the valves of the usage (1) to the usage (n) (step S201). As a result of registering the history of the minute opening A as a determination index for determining whether or not to perform the opening inspection of each valve of the usage (1) to the usage (n), and performing the opening inspection of the valve. The validity of the open inspection from the operator is registered, and the threshold value B is determined each time the open inspection execution case (actual case) reaches the specified number of times (steps S202-1 to S202-n). Then, the threshold value B for each of the determined usage (1) to usage (n) is adjusted so as to match the priority set in step S201 (step S203).

  In the first and second embodiments described above, the small opening A is used as an indicator for determining whether or not valve opening inspection is performed. However, the opening is not limited to the small opening A. In the first and second embodiments described above, the threshold value determination unit 3 corresponds to the determination criterion determination unit in the present invention.

  In the first embodiment described above, for simplicity of explanation, one valve 200 is a target for open inspection, but a plurality of valves may be a target for open inspection. Also in the second embodiment, a plurality of valve groups having different uses may be subjected to open inspection as one group.

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

  DESCRIPTION OF SYMBOLS 1 ... Index registration part, 2 ... Implementation result registration part, 3 ... Threshold determination part, 4 ... Offset correction part, 5 (5-1 to 5-n) ... Open inspection support part, 6 ... Order setting part, 7 ... Threshold value Adjustment unit, 100 (100A, 100B) ... Valve open inspection support device, 200 ... Valve.

Claims (4)

An index registration unit for registering a history of a determination index whether or not to perform valve opening inspection;
An implementation result registration unit for registering the validity of the implementation of the open inspection input from the operator as the implementation result of the open inspection of the valve;
Based on the history of the determination index registered in the index registration unit and the validity of the open inspection execution registered in the execution result registration unit, the determination index at the time of the open inspection implementation that has been validated, and A valve opening inspection support device, comprising: a determination criterion determination unit that determines a determination criterion for the determination index from a determination index at the time of performing the opening inspection that has not been performed. In the valve opening inspection support device according to claim 1,
The determination criterion determination unit
A representative value of the judgment index at the time of performing the open inspection, a representative value of the judgment index at the time of performing the open inspection that was not valid, and an offset parameter for actively performing the open inspection of the valve To determine a criterion for the determination index,
further,
An opening check support device for a valve, comprising: an offset correction unit that corrects the offset parameter in accordance with reliability of the determination criterion. In the valve opening inspection support device according to claim 1 or 2,
The index registration unit, the execution result registration unit and the determination criterion determination unit are provided for each valve having a different use,
further,
An order setting unit for setting priorities with an emphasis on prudence when performing open inspection of valves of different uses;
The determination determined by the determination criterion determination unit so that the priority set in the rank setting unit matches the determination criterion determined by the determination criterion determination unit for each valve having a different use. A valve opening inspection support device, comprising: a determination reference adjustment unit that automatically adjusts a reference. An index registration step for registering a history of an index for determining whether to perform valve opening inspection;
An execution result registration step of registering the validity of the open inspection execution input from the operator as the implementation result of the valve open inspection;
Based on the history of the determination index registered by the index registration step and the validity of the open inspection execution registered by the implementation result registration step, the determination index at the time of the open inspection execution that has been validated is not valid And a determination criterion determination step for determining a criterion for the determination index from a determination index when the opening inspection is performed.