JP6802025B2 - Valve operation monitoring method and valve operation abnormality sign detection method - Google Patents

Description

The present invention relates to a valve operation monitoring method and a valve operation abnormality sign detection method. In particular, the valve operation abnormality sign detection method according to the present invention relates to a valve abnormality sign detection method using the valve operation monitoring method of the present invention.

Water treatment plant equipment installed in water purification plants and the like realizes a water treatment function by operating a large number of devices in conjunction with each other. Of course, even if an abnormality occurs in one of these many devices that are interlocked with each other, there is a risk that the entire plant equipment will not function normally. Therefore, in addition to diagnosing whether or not an abnormality has actually occurred in the function of the plant equipment, a technique for determining the presence or absence of an abnormality sign that may lead to the occurrence of an abnormality has been developed.

For example, conventionally, as data for diagnosing an abnormality sign of a device provided in a plant facility, it is described that the time from the start of the valve opening operation to the fully open state of the valve is used. (See, for example, Patent Document 1).

Japanese Unexamined Patent Publication No. 2003-131729

Here, regarding the valves included in the plant equipment of a general water purification plant currently in operation, the opening / closing operation is not monitored on the existing control system for operating the plant equipment. As a concrete method for monitoring, it is assumed that the worker actually watches the opening and closing operation of each valve at the site. However, it naturally takes a huge amount of time and effort to realize such a monitoring method.
Further, Patent Document 1 does not clarify a specific method for monitoring the valve opening operation.

Therefore, an object of the present invention is to provide a monitoring method capable of monitoring the operation of a valve included in a plant facility easily and with high accuracy.
Another object of the present invention is to provide a valve operation abnormality sign detection method capable of easily and highly accurately detecting an abnormality sign of valve operation provided in a plant facility.

The present inventor has conducted diligent studies for the purpose of solving the above problems. Then, the present inventor attaches a monitoring device including a magnetic sensor to the valves included in the plant equipment and acquires data on the operation of each valve, so that the operation of the plant equipment is not stopped. We have found that it is possible to monitor the operation of the valve with high accuracy, and completed the present invention.

That is, the present invention aims to solve the above problems advantageously, and the valve operation monitoring method of the present invention is a valve operation monitoring method in a plant facility including a valve, and uses a magnetic sensor. , Time data from the closed state to the open state of the valve based on the sensing process that outputs different values depending on whether the valve is in the closed state and the open state and the output value of the magnetic sensor. And / Or, it is characterized by including a data accumulation step of acquiring and accumulating time data from an open state to a closed state, respectively. In such a valve operation monitoring method according to the present invention, time data related to valve operation is acquired and accumulated based on an output value of a magnetic sensor that senses the open / closed state of the valve included in the plant. Therefore, according to the valve operation monitoring method of the present invention, the operation of the valve included in the plant equipment can be easily and highly accurately monitored.

The present invention also aims to advantageously solve the above problems, and the valve operation abnormality sign detection method of the present invention uses the time data accumulated in the data storage step of the monitoring method. It is characterized by including a plotting process of plotting on a two-dimensional coordinate space with the vertical axis representing time data and the horizontal axis representing data numbers. As described above, in the valve operation abnormality sign detection method of the present invention, by plotting the time data related to the valve operation on a predetermined two-dimensional coordinate space, it is possible to detect the valve operation abnormality sign easily and with high accuracy. it can.

Further, the valve operation abnormality sign detection method of the present invention preferably includes a straight line approximation step of linearly approximating a plurality of data points with one or a plurality of straight lines on the plot obtained in the plotting step. By using one or a plurality of straight lines obtained by the straight line approximation step, the fluctuation pattern of the valve operation can be easily detected, so that the abnormality sign of the valve operation can be detected more easily.

Further, in the valve operation abnormality sign detection method of the present invention, at least one of the one or a plurality of straight lines obtained in the linear approximation step, in which the absolute value of the vertical intercept value is the maximum or minimum. For a straight line, an abnormality sign is detected based on the positional relationship between the buffer setting step for setting the buffer area, the buffer area set in the buffer setting step, and one or more newly acquired data points, and then It is preferable to include an abnormality sign notification step for notifying. By such a valve operation abnormality sign detection method, it is possible to more easily detect an abnormality sign of valve operation.

Further, in the valve operation abnormality sign detection method of the present invention, the maximum buffer area is set for the straight line having the maximum absolute value of the vertical intercept in the buffer setting step, and the maximum is set in the abnormality sign notification step. When there is a data point whose vertical coordinate value is larger than the buffer area, it is preferable to detect and notify it as an abnormality sign. By such a valve operation abnormality sign detection method, it is possible to easily detect a sign of failure in which the valve opening / closing time becomes long.

Further, in the valve operation abnormality sign detection method of the present invention, the minimum buffer area is set for the straight line in which the absolute value of the vertical intercept value is the minimum in the buffer setting step, and the minimum buffer area is set in the abnormality sign notification step. When there is a data point whose vertical coordinate value is smaller than the buffer area, it is preferable to detect and notify it as an abnormality sign. By such a valve operation abnormality sign detection method, it is possible to easily detect a sign of failure in which the valve opening / closing time is shortened.

Further, in the valve operation abnormality sign detection method of the present invention, one or a plurality of newly acquired data points are also plotted in the plotting step, and the linear approximation step is performed by the minimum square method. A straight line approximation is performed by one or a plurality of straight lines for all data points on the two-dimensional coordinate space, and a determination coefficient value is calculated for each straight line obtained by the straight line approximation, which is obtained in the straight line approximation step. It is preferable to include an abnormality sign notification step of notifying as an abnormality sign when the minimum value of the one or a plurality of the determination coefficient values becomes equal to or less than a predetermined threshold value. By such a valve operation abnormality sign detection method, the accuracy of valve operation abnormality sign detection can be further improved.

According to the valve operation monitoring method of the present invention, the operation of the valve included in the plant equipment can be monitored easily and with high accuracy.
According to the valve operation abnormality sign detection method of the present invention, it is possible to easily and highly accurately detect a valve operation abnormality sign of a valve provided in a plant facility.

It is a top view which shows the schematic structure of the monitoring device for carrying out the monitoring method of a valve operation according to this invention. It is a plot which shows an example (closed state to open state) of the time data of a valve operation which can be acquired by the valve operation monitoring method according to this invention. It is a plot which shows an example (open state-closed state) of the time data of a valve operation which can be acquired by the valve operation monitoring method according to this invention.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. The valve operation monitoring method and the valve operation abnormality sign detection method of the present invention are not particularly limited, and are applied to, for example, various plant facilities installed in water purification plants, chemical plants, sewage treatment plants, and the like. be able to. In particular, the valve operation monitoring method and the valve operation abnormality sign detection method of the present invention make a plurality of valves included in the water treatment plant equipment installed in a water purification plant or the like suitable monitoring targets and operation abnormality sign detection targets. be able to.

Here, the control device provided in the various plant equipments in operation accumulates various data related to the target processing of the plant equipment, but in the case of such processing, the commands and the like sent to each component of the plant equipment are related. Generally, it does not have a function to accumulate data related to maintenance of the plant equipment itself including data. Therefore, for example, how many times each valve included in the plant equipment was opened and closed, how much data was required for each opening and closing, etc., for general plant equipment currently in operation The current situation is that it has not been accumulated. However, in order to stop the operating plant equipment and replace the software of the control device included in the plant equipment, it is necessary to replace the processing performed by the plant by another means, which is extremely troublesome. It takes. Therefore, the present inventors have not stopped the operation of the plant equipment in operation, and further, without modifying the control device already included in the plant equipment in operation, the valves included in the plant equipment. The present invention has been completed for the purpose of acquiring time data regarding opening and closing.

(Valve operation monitoring device)
FIG. 1 is a plan view showing a schematic configuration of an example of a monitoring device for carrying out a valve operation monitoring method according to the present invention. The monitoring device 10 may be composed of a magnetic sensor 1, an open position magnet 2A and a closed position magnet 2B, and a control device 3. Further, the monitoring device 1 optionally has a recorder 4. Then, the monitoring device 10 detects the magnetic field generated by the open position magnet 2A and the closed position magnet 2B provided in the valve 5 by the magnetic sensor 1, and detects the magnetic field generated by each of the open position magnet 2A and the closed position magnet 2B. A sensing step that outputs different values when detected is performed. In this way, the monitoring device 10 can measure the time required for the valve 5 to shift from the open state to the closed state and the time required for the valve 5 to shift from the closed state to the open state. ..

The magnetic sensor 1 can be attached to the pipe 6 to which the valve 5 is attached via an arbitrary attachment member such as an adapter, or via an adhesive member or the like. The magnetic sensor 1 outputs different values depending on whether the valve 5 is in the closed state or the valve 5 is in the open state. The magnetic sensor 1 can be mounted, for example, by a Hall sensor. The magnetic sensor 1 is located at a position where the strength of the magnetic field emitted from the open position magnet 2A provided in the valve 5 becomes equal to or higher than a predetermined value when the valve 5 is completely opened. It can be arranged at a position where the strength of the magnetic field emitted from the closed position magnet 2B provided in the valve 5 becomes a predetermined value or more when the valve 5 is in the closed state.

The valve 5 can be any existing valve without particular limitation, as long as it has a movable part capable of opening and closing the flow path of the fluid. On FIG. 1, a handle wheel as a movable portion is illustrated as a valve 5. The handle wheel rotates around the stem 7. The valve 5 is not particularly limited as long as the direction of the handle wheel changes between the open state and the closed state, and may be any existing valve such as a ball valve, a gate valve, a butterfly valve, and a diaphragm valve. .. Further, the drive mechanism for opening and closing the valve is not particularly limited, and may be a pneumatic drive mechanism. When the drive mechanism is a pneumatic type, an abnormality may occur in the opening and closing of the valve due to deterioration of the packing used for the piston provided in the drive mechanism. In such a case, it is possible to normalize valve opening and closing by, for example, replacing the deteriorated packing or applying grease to the packing.

The open position magnet 2A and the closed position magnet 2B generate a magnetic field, respectively. As shown in FIG. 1, the open position magnet 2A and the closed position magnet 2B can be arranged 90 ° apart from each other with respect to the stem 7. Preferably, the open position magnet 2A and the closed position magnet 2B generate different magnetic fields. More preferably, the open position magnet 2A and the closed position magnet 2B have different directions of magnetic fields. For example, an open position magnet 2A and a closed position magnet 2B are formed by magnets having S pole and N pole, respectively, and one magnet has the S pole on the outside and the other magnet has the N pole on the outside, centering on the stem 7. It can be oriented so as to be attached to the valve 5. According to such an arrangement, the directions of the magnetic fields generated by the open position magnet 2A and the closed position magnet 2B are different. Therefore, the magnetic sensor 1 detects magnetic fields in different directions depending on whether the valve 5 is in the open state or the closed state. Therefore, the magnetic sensor 1 can detect whether the valve 5 is in the open state or the closed state. The open-position magnet 2A and the closed-position magnet 2B are not particularly limited, and may be composed of various existing magnets such as neodymium magnets, samarium-cobalt magnets, ferrite magnets, and alnico magnets. Since the magnetic force is strong and the cost is low, neodymium magnets can be preferably used.

The control device 3 may be connected to the magnetic sensor 1 by wire or wirelessly. When the control device 3 and the magnetic sensor 1 are wirelessly connected, the magnetic sensor 1 and the control device 3 may have a communication unit. Then, the control device 3 can be implemented by, for example, a microcomputer that can have a storage unit, a calculation unit, and peripheral circuits. Specifically, the storage unit may be composed of a memory. Further, the arithmetic unit may be configured by a CPU (Central Processing Unit). The control device 3 can read the program stored in the storage unit by the calculation unit and execute the calculation according to the program contents. Such a program may be, for example, a program for calculating the time from the time when the magnetic sensor 1 detects the magnetic field emitted from the open position magnet 2A to the time when the magnetic field generated by the closed position magnet 2B is detected.

The recorder 4 can be connected to the magnetic sensor 1 by wire or wirelessly. When the recorder 4 and the magnetic sensor 1 are wirelessly connected, the magnetic sensor 1 and the control device 3 may have a communication unit. Then, the recorder 4 can be, for example, a data logger that records the time data measured by the magnetic sensor 1. Such a data logger may be composed of a volatile memory or a non-volatile memory without particular limitation. Preferably, the recorder 4 may be configured with a non-volatile memory. Since the non-volatile memory can retain the acquired data even after the energization is stopped, it is possible to perform monitoring using the accumulated data when the energization is re-energized and the monitoring is restarted. In FIG. 1, the recorder 4 is shown as a device separate from the control device 3. However, if necessary, the control device 3 may be configured to include a circuit capable of realizing a data logging function.

Here, due to the characteristics of plant equipment such as a water treatment plant, it is difficult to stop the operation even for the purpose of remodeling for attaching monitoring equipment. For this reason, it is important to easily monitor the valve operation of operating plant equipment without stopping the operation. In this respect, the monitoring device provided with each component as described above can be easily applied to the existing plant equipment. For example, both the magnetic sensor 1 and the control device 3 can be mounted by an inexpensive and small device, and can be installed externally to the plant equipment. Further, the open-position magnet 2A and the closed-position magnet 2B are inexpensive and lightweight in themselves, and when the piping of the target plant equipment is made of metal, no mounting member or adhesive member is used. , It can be directly attached to the pipe 6 by magnetic force. Therefore, all of these components constituting the monitoring device 10 can be easily externally attached to the existing operating plant equipment.

Up to this point, an example of a schematic structure of the monitoring device 10 capable of carrying out the valve operation monitoring method of the present invention has been described with reference to FIG. However, the configuration of the monitoring device capable of implementing the valve operation monitoring method of the present invention is not limited to the configuration specifically shown in FIG. For example, in FIG. 1, the monitoring device 10 has one magnetic sensor 1 and one open-position magnet 2A and one closed-position magnet 2B 90 ° apart from the stem 7 and time for "opening and closing" the valve. It is illustrated as a device for recording data. However, a monitoring device capable of implementing the valve operation monitoring method of the present invention includes two or more magnetic sensors and three or more magnets, and these magnets and sensors switch the branching of the fluid flow path by the valve. Of course, it can be configured to be detectable. At this time, the magnets may be arranged apart from each other at an angle of less than 90 ° about the stem 7. At this time, the magnetic sensors can also be arranged at arbitrary intervals.

Further, the monitoring device may have a large number (M) of magnets. In this case, a large number of magnets can be attached to the bulb so that the S-pole and the N-pole are randomly arranged on the outer surface of the stem 7 as the center. Then, the monitoring device may have a large number (N) of magnetic sensors for detecting each magnetic field generated by such a large number of magnets. At this time, M is a natural number of 3 or more, N is a natural number of 2 or more, and M> N can be satisfied. According to the monitoring device provided with such a large number of magnets and magnetic sensors, it is possible to detect not only "opening and closing" of the valve but also "opening" and "branching". For example, a monitoring device including a large number of magnets arranged at intervals of 10 ° over the entire circumference of the valve and nine magnetic sensors will be described with specific examples. S (0 °) S (10 °) N (20 °) N in the clockwise direction, with the 12 o'clock position as 0 ° when the magnet looks up at the flow direction of the fluid flowing in the pipe provided with the valve. (30 °) N (40 °) S (50 °) N (60 °) S (70 °) S (80 °) N (90 °) N (100 °) N (110 °) N (120 °) S (130 °) N (140 °) S (150 °) S (160 °, abbreviated below) SNNNNNN ... The nine magnetic sensors are the fifth centered at the 12 o'clock position. It is assumed that four sensors are arranged on each side. In this case, if the arrangement of the magnets "SSNNNNSNS" is detected by the nine magnetic sensors, it can be seen that the magnets arranged at the 110 ° position are at the 12 o'clock position.

Further, in FIG. 1, it is illustrated as a device provided with one control device for one magnetic sensor and two magnets. However, one control device having high computing performance may be connected to a plurality of magnetic sensors by wire or wirelessly. In this case, one such high-performance control device can process the data acquired by the plurality of magnetic sensors.

(Valve operation monitoring method)
The valve operation monitoring method of the present invention is a valve operation monitoring method in a plant facility including a plurality of valves. The valve operation monitoring method of the present invention can be carried out using the monitoring device as described above. The valve operation monitoring method of the present invention is based on a sensing process in which a magnetic sensor outputs different values depending on whether the valve is in the closed state or the open state, and a valve based on the output value of the magnetic sensor. Includes a data storage step of acquiring and accumulating time data from the closed state to the open state and / or time data from the open state to the closed state, respectively. Hereinafter, the monitoring device of the present invention will be specifically described as being applied to a water treatment plant by using the monitoring device shown in FIG.

<Installation process>
The valve operation monitoring method of the present invention may optionally include an attachment step of attaching the monitoring device 10 including the magnetic sensor 1 to the valve 5 included in the plant equipment, in addition to the sensing step and the data storage step. Of course, such an installation process may be performed when modifying existing plant equipment or when replacing a monitoring device. Then, once the mounting step is performed, the above-mentioned sensing step and data storage step, and various steps described later can be repeatedly carried out over an arbitrary period thereafter.

A monitoring device having a simple configuration such as the monitoring device 10 can be easily installed in the plant equipment, and it is not necessary to stop the operation of the plant equipment at the time of installation. Moreover, the valve operation monitoring method of the present invention does not involve overly complex data processing. Therefore, in the monitoring method of the present invention, it is possible to use a general arithmetic unit that is easily available as an arithmetic unit. Therefore, the valve operation monitoring method of the present invention is excellent in applicability to existing plant equipment.

<Sensing process>
In the sensing step, the magnetic sensor 1 outputs different values depending on whether the valve 5 is in the closed state or the open state.

<Data storage process>
Here, the data storage step can be realized by the control unit 3 or the recorder 4 as described above with reference to FIG. More specifically, the control unit 3 or the recorder 4 receives the output value from the magnetic sensor 1 via a wired or wireless connection and stores it in the non-volatile memory.

In the data storage process, the operation of the valve can be monitored with high accuracy by acquiring the data of the time required for opening and closing each valve based on the output value of the magnetic sensor 1 provided in each valve. More specifically, when the open position magnet 2A has an S pole and the closed position magnet 2B has an N pole, the control unit 3 or the recorder 4 determines the strength of the magnetic field emitted from the S pole by the magnetic sensor 1. The time required to detect that the strength of the magnetic field emitted from the N pole is equal to or greater than a predetermined threshold value is accumulated as the time required for the valve to open. When the change in the magnetic field by the magnetic sensor 1 is the opposite, the control unit 3 or the recorder 4 accumulates the time required for the valve to close.

For example, data acquisition by the monitoring device 10 can be continuously performed over a predetermined data acquisition period. For example, when one data acquisition period is 30 seconds, the monitoring device 10 determines how many times the valve opening and / or closing operations occur within the 30 seconds, and each opening operation and / or the occurrence. The time of each closing operation is recorded in the recorder 4. The recorder 4 has a volatile memory and a non-volatile memory, records each open operation and each closed operation in the volatile memory, and records within that period when the 30-second data acquisition period ends. The maximum time of all open operations and the maximum time of all closed operations recorded within that period may be stored in the non-volatile memory. Then, in the simple abnormality sign detection method using such a monitoring method, when the maximum time required is updated, it can be detected and notified as an abnormality sign.

Such a data storage step can be carried out for a certain period of time after the mounting step as described above. The time to carry out the data accumulation step can be arbitrarily determined according to the operating mode of the plant to which the monitoring method according to the present invention is applied. Then, by carrying out such a data storage process, accumulating time data related to opening and closing of the valve by a predetermined amount or more, and then utilizing it in the valve operation abnormality sign detection method described later, the abnormality sign accuracy can be remarkably improved. it can.

(Valve operation abnormality sign detection method)
The valve operation abnormality sign detection method of the present invention includes a plotting step of plotting the time data accumulated in the above-mentioned data storage step on a two-dimensional coordinate space with the vertical axis as the time data and the horizontal axis as the data number. .. Further, the valve operation abnormality sign detection method of the present invention may include a linear approximation step and a buffer setting step as various analysis steps for analyzing the plotted time data. Then, the valve operation abnormality sign detection method of the present invention may include an abnormality sign notification step of notifying the abnormality sign by receiving the results of these various analysis steps. Hereinafter, each step will be described.

<Plot process>
In the plotting step, the time data related to valve opening and closing accumulated in the data accumulating step is plotted to obtain plots as shown in FIGS. 2A and 2B. More specifically, the time required for opening and closing the valve is set on the vertical axis, and the data number of the acquired data point is set on the horizontal axis for plotting. Here, the "data point data number" is a data number when the time data related to valve opening / closing acquired by the monitoring device 10 is arranged in the acquired time series. Here, in the plot shown in FIG. 2A, the vertical axis is shown as a negative value, and in the plot shown in FIG. 2B, the vertical axis is shown as a positive value. This is just such a notation in this example in order to make it possible to clearly distinguish between the time required for the opening operation and the time required for the closing operation, and the actual time required is shown in FIG. 2A. Is the time corresponding to the absolute value on the vertical axis.

Here, referring to FIG. 2A, it can be seen that the opening operation of the valve, that is, the time required from the closed state to the open state of the valve can be roughly stratified into three groups. Further, referring to FIG. 2B, it can be seen that the valve closing operation, that is, the time required for the valve to change from the open state to the closed state can be roughly stratified into two groups. The cause of the tendency of the time required for opening and closing the valve to take such a tendency is not clear, but a possible cause is fluctuation of the water pressure pattern in the pipe in which the valve is installed. Therefore, the number of groups in which the obtained data can be stratified can vary depending on the valve installation environment.

When there is a high possibility that an abnormality will occur in a valve, it is considered that data that is out of the category of fluctuation of the water pressure pattern according to the installation environment of such a valve will be acquired. An explanation of this situation by applying it to the pattern illustrated in FIG. 2A is as follows. For example, when a data point having a larger absolute value than the data group having the largest absolute value on the vertical axis among the three groups illustrated in FIG. 2A is newly acquired, the valve opens or closes. It means that the time required for is longer. On the contrary, when a new data point having a smaller absolute value than the data group having the smallest absolute value on the vertical axis among the three groups illustrated in FIG. 2A is newly acquired, the time required for the valve opening / closing operation is obtained. Means that has become shorter. If the cause of the change in the time required for opening and closing the valve is not the change in water pressure in the pipe in which the valve is installed but the valve itself, there is a risk that an abnormality will occur in the valve's movable mechanism. Means that. Therefore, from these data trends, the present inventors have found that various analysis steps as described in detail below can be useful for detecting signs of abnormality. Hereinafter, the flow of the analysis process of the two patterns will be specifically described.

<Analysis pattern 1>
[Linear approximation process]
In the straight line approximation step, a plurality of data points are linearly approximated by one or a plurality of straight lines on the plot obtained in the plotting step. The specific method of linear approximation is not particularly limited, and a least squares method or a principal component analysis method can be used. In the valve operation abnormality sign detection method according to the present invention, the operation pattern of the valve targeted for abnormality sign detection is obtained by performing a linear approximation step on the time data plotted on the specific two-dimensional coordinate space. Since it can be accurately grasped, it is possible to more easily detect an abnormality sign of valve operation.

[Buffer setting process]
In the buffer setting step, the buffer area is set for at least one straight line having the maximum or minimum absolute value of the vertical intercept value among the one or a plurality of straight lines obtained in the straight line approximation step. The width of the buffer area can be arbitrarily determined according to the distance between the plurality of straight lines obtained in the straight line approximation step and the variation in time data. In the buffer setting step, for example, the maximum buffer area can be set for the straight line having the maximum absolute value of the value of the vertical intercept. Alternatively, in the buffer setting step, for example, the minimum buffer area can be set for the straight line having the minimum absolute value of the value of the vertical intercept. By carrying out such a buffer setting process, it becomes possible to easily determine whether or not the newly obtained data points correspond to an abnormality sign, and as a result, it is easy to detect the abnormality sign. It becomes.

In the buffer setting step, not only the maximum buffer area and the minimum buffer area as described above, but also, for example, when a plot as shown in FIG. 2A is obtained in the plotting step, the value of the vertical intercept is The third buffer area can also be set for a straight line whose absolute value falls between the maximum value and the minimum value. Then, for example, when the third buffer area is set in addition to the maximum buffer area and the minimum buffer area, one or a plurality of data points newly acquired in the abnormality sign detection step described later are any of them. If it does not belong to the buffer area, it can be determined that a valve operation abnormality sign has occurred, and it can be detected and notified as an abnormality sign.

[Abnormal sign notification process]
Then, in the abnormality sign notification step, the abnormality sign is detected and notified based on the positional relationship between the buffer area set in the buffer setting step and one or a plurality of newly acquired data points. More specifically, when there is a data point whose vertical coordinate value has an absolute value larger than that of the maximum buffer area, it can be detected and notified as an abnormality sign. As a result, it is possible to improve the accuracy of detecting a sign of failure in a mode in which the movement of the valve movable mechanism becomes poor and the movement related to valve opening / closing becomes slow. Alternatively, when there is a data point whose vertical coordinate value has an absolute value smaller than that of the minimum buffer area, it can be detected and notified as an abnormality sign. As a result, the movable mechanism of the valve is loosened, and the accuracy of detecting a sign of failure in such a manner that the valve is switched at an excessively high speed can be improved.

Furthermore, when detecting an abnormality sign based on the positional relationship between the buffer area and the newly acquired data point, for example, by measuring the shortest distance between the contour of the buffer area and the data point, the degree of abnormality Can be determined. In this way, by acquiring information on the degree of abnormal signs that have occurred in addition to the presence or absence of abnormal signs, the magnitude of possible abnormalities can be predicted and what kind of measures are required. It can be used for judgment.

The method of notifying the abnormality sign is not particularly limited, and the ID of the bulb in which the abnormality sign is detected is turned on by turning on the lamp installed near the bulb or on an electric bulletin board or the like provided in a place different from the bulb. There is an explicit notification method such as displaying.

In addition, the workers who referred to the notified abnormality sign information can take arbitrary measures based on the abnormality sign information. For example, workers can prevent or delay the occurrence of an abnormality by maintaining or replacing parts such as packing provided in the drive mechanism for driving the movable mechanism of the valve.

<Analysis pattern 2>
In the analysis pattern 2, first, in the plotting step, in addition to the time data accumulated in the data accumulating step, one or more newly acquired data points are also plotted on the same coordinate space. Then, in the straight line approximation step, the least squares method is particularly adopted as the straight line approximation method. By the straight line approximation by the minimum square method, the straight line approximation by one or a plurality of straight lines is performed for all the data points in the two-dimensional coordinate space, and the determination coefficient value is calculated for each straight line obtained by the straight line approximation. To do. Then, in the abnormality sign notification step, when the minimum value of one or a plurality of determination coefficient values obtained in the linear approximation step becomes equal to or less than a predetermined threshold value, the abnormality sign is notified. According to such an abnormality sign detection method, when a data point deviating from the valve opening / closing pattern obtained by a plurality of already acquired data points is acquired, it can be detected as an abnormality sign, so that the accuracy is higher. It is possible to detect abnormal signs of valve operation.

Further, such an analysis related to the analysis pattern 2 can be executed in parallel with the analysis pattern 1 as needed. When the analysis patterns 1 and 2 are executed in parallel, in the abnormality sign notification step, when the abnormality sign is detected in the analysis pattern 1 or 2, the abnormality sign is notified as an abnormality sign. In this case, the frequency of notification of abnormal signs increases, but the risk of overlooking the abnormal signs can be reduced accordingly.

Up to this point, each of the above-mentioned steps may be carried out by a control device provided in each of a plurality of valves included in the plant equipment, or may be acquired by a magnetic sensor provided in each valve. It may be performed by an arithmetic unit having an arithmetic function capable of processing data collectively. Such an arithmetic unit is not particularly limited, and may be, for example, a PC (Personal Computer) capable of acquiring various data through a server.

Further, in the valve operation abnormality sign detection method of the present invention, without particular limitation, when the data of the number of times the abnormality sign is detected in the abnormality sign notification step is accumulated and the abnormality sign is notified, the latest Information on how many times the abnormality sign that has occurred is the abnormality sign of the valve may also be notified. This makes it possible to grasp, for example, the degree of deterioration of the valve in which a sign of abnormality is detected. Further, in the abnormality sign notification step, the elapsed time from the previous detection of the abnormality sign may also be notified. Such information can be utilized, for example, in determining the urgency and degree of necessary measures for a valve in which a sign of abnormality is detected.

According to the valve operation monitoring method of the present invention, the operation of the valve included in the plant equipment can be monitored easily and with high accuracy.
According to the valve operation abnormality sign detection method of the present invention, the valve operation abnormality sign detection method provided in the plant equipment can be detected easily and with high accuracy.

1 Magnetic sensor 2A Open position magnet 2B Closed position magnet 3 Control device 4 Recorder 5 Valve 6 Piping 7 Stem 10 Monitoring device

Claims (4)

A method for monitoring valve operation in plant equipment including valves.
A sensing process in which a magnetic sensor outputs different values depending on whether the valve is in the closed state or the open state.
Data accumulation that acquires and accumulates time data from the closed state to the open state and / or time data from the open state to the closed state based on the output value of the magnetic sensor. Process and
A plotting process in which the time data accumulated in the data storage process is plotted on a two-dimensional coordinate space with the vertical axis representing the time data and the horizontal axis representing the data number.
A linear approximation step of linearly approximating a plurality of data points with one or a plurality of straight lines on the plot obtained in the plotting step is included, and further.
In the plotting step, one or more newly acquired data points are also plotted.
In the straight line approximation step, a straight line approximation is performed by one or a plurality of straight lines for all data points in the two-dimensional coordinate space by the least squares method, and each straight line obtained by the straight line approximation is determined. Calculate the coefficient value and
Includes an abnormality sign notification step of notifying as an abnormality sign when the minimum value of one or a plurality of the determination coefficient values obtained in the linear approximation step becomes equal to or less than a predetermined threshold value.
How to monitor valve operation. A buffer setting step of setting a buffer area for at least one straight line having the maximum or minimum absolute value of the vertical intercept value among the one or a plurality of straight lines obtained in the straight line approximation step.
The claim includes an abnormality sign notification step of detecting and notifying an abnormality sign based on the positional relationship between the buffer area set in the buffer setting step and one or a plurality of newly acquired data points. valve operation abnormality warning detection method according to 1. In the buffer setting step, the maximum buffer area is set for the straight line having the maximum absolute value of the vertical intercept value.
In the abnormality sign notification step, when there is a data point whose vertical coordinate value has an absolute value larger than that of the maximum buffer area, it is detected and notified as an abnormality sign.
The valve operation abnormality sign detection method according to claim 2 , which includes the above. In the buffer setting step, the minimum buffer area is set for the straight line having the minimum absolute value of the vertical intercept value.
In the abnormality sign notification step, when there is a data point whose vertical coordinate value has an absolute value smaller than that of the minimum buffer area, it is detected and notified as an abnormality sign.
The valve operation abnormality sign detection method according to claim 2 or 3 , which includes the above.

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