JP6981815B2 - 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. 8 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. 8 uses a reverse operation controller as the actuator 103, a normal actuator may be used. 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. 8, the actuator 103 is operated by air pressure, but there is also a type in which the actuator 103 is operated by hydraulic pressure.

Further, in the valve 100 (100A) shown in FIG. 8, the gap between the valve body 105 and the seat ring 106 is adjusted as the valve opening degree, but as shown in FIG. 9, the diaphragm (diaphragm) is used as the valve body. Valve 100 (100B) that adjusts the gap between the diaphragm 105'and the flow path as the valve opening by using the valve body diaphragm) 105'and dislocating the diaphragm 105'by the vertical movement of the valve shaft 104. ) Also. This type of valve 100 (100B) is called a diaphragm valve.

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 a valve maintenance support device capable of improving the efficiency of valve maintenance work, especially when handling a diaphragm valve. And to provide a method.

In order to achieve such an object, the present invention is a valve maintenance support device (200) that supports maintenance work of a valve (100B) that regulates a fluid flow, in which a diaphragm (105') is used as a valve body. Therefore, the measured value data storage unit (1) that stores the opening measurement value data (D1) transmitted from the opening measurement unit (21) that measures the valve opening (θ), and the measured value data storage. Information on the amount of bite (δ) in the closing direction of the valve body after recognizing that the valve is fully closed based on the opening measurement value data stored in the valve is used as the valve diagnostic index (S). It is characterized by including a diagnostic index calculation unit (3) calculated as, and a diagnostic index presentation unit (4) for presenting a valve diagnostic index calculated by the diagnostic index calculation unit.

In the present invention, the measurement value data storage unit stores the opening measurement value data from the opening measurement unit. Based on the opening measurement value data stored in the measured value data storage unit, the diagnostic index calculation unit recognizes that the valve is fully closed, and then information on the amount of biting into the valve body in the closing direction. Is calculated as a diagnostic index for valves.

For example, the opening measurement value data at the time when the first specified time elapses after recognizing that the valve is fully closed is used as the first opening measurement value data, and as it is after the first specified time elapses. The opening measurement value data at the time when the second specified time has elapsed without opening / closing is used as the second opening measurement value data, and the difference between the first opening measurement value data and the second opening measurement value data is used. The bite amount in the closing direction of the valve body is used, and this bite amount is calculated as a diagnostic index of the valve. This calculated valve diagnostic index is presented to the operator as an index indicating deterioration of the diaphragm of the valve body.

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 closing direction of the valve body after recognizing that the valve is fully closed based on the opening measurement value data stored in the measured value data storage unit. Information on the amount of bite into the valve is calculated as a diagnostic index for the valve, and this calculated diagnostic index is presented to the operator as an index indicating deterioration of the diaphragm of the valve body. Especially when handling a diaphragm valve, the valve is used. It will be possible to improve the efficiency of maintenance work.

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 is accumulated in the measurement value data storage unit of the valve maintenance support device. FIG. 3 is a flowchart for explaining the operation of this valve maintenance support device. FIG. 4 is an image diagram showing an example of valve arrangement of a plant to be maintained. FIG. 5 is a diagram illustrating a change in the biting amount when the diaphragm of the valve body is deteriorated. FIG. 6 is a diagram showing a display example of a diagnostic index of a valve as a maintenance candidate. FIG. 7 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. 8 is a diagram showing an example of a control valve. FIG. 9 is a diagram showing a main part of the diaphragm valve.

[Principle of invention]
Diaphragm valves are mainly used when dealing with highly corrosive chemicals. Therefore, it is necessary to pay attention to the deterioration of the diaphragm (rubber-based material) of the valve body. At this time, since the deterioration of the diaphragm is the hardening of the rubber-based material, we focused on the fact that the hardening can be estimated by the slight change in opening (biting amount) from the closing (seating) of the valve.

In this case, for the bite amount detection, the first point after the first specified time (for example, 30 seconds) has passed since the recognition as fully closed is calculated as the zero point (zero point after the first specified time has elapsed), and further. , The first point after the second specified time (for example, the time until the next day) has passed without opening and closing is calculated as the zero point (zero point after the second specified time has elapsed), and this difference is used as the bite amount. Can be done. Then, by presenting the information on the bite amount to the operator as a diagnostic index, it came to be possible to estimate the deterioration of the diaphragm. This makes it possible to improve the efficiency of valve maintenance work, especially when handling a diaphragm valve.

[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 stores the opening degree measurement value data D1 transmitted from the opening degree measuring unit 21 of the valve 100 used in the plant.

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. 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.

As shown in the flowchart in FIG. 2, 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), the valve maintenance support device 200 receives the received opening degree measurement value data D1. It is stored in the measured value data storage unit 1 (step S102).

In the present embodiment, it is assumed that the opening measurement value data D1 is periodically transmitted from the opening measurement unit 21 of the valve 100 to the measured value data storage unit 1 and 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) from these valves 100 (100-1 _{to 100-N} ) are obtained. It is assumed that the measured value data 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. 3, 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", " 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 the valves A, M, and C are diaphragm valves that handle highly corrosive chemicals and are selected as the highest priority maintenance target in a specific periodic plant maintenance.

FIG. 4 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. 4, 12-A, 12-C, and 12-M are flow rate measuring instruments, 13 is a tank, and 14 is a pressure transmitter. In FIG. 4, 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 Is read (step S203), and the opening measurement value data D1 stored in the measured value data storage unit 1 is read out in association with the read valve IDs “A”, “C”, and “M” (step S204). ..

Then, the diagnostic index calculation unit 3 recognizes that the valves A, C, and M are fully closed based on the opening measurement value data D1 read from the measurement value data storage unit 1, and then the valve body ( valve a information about bite amount δ in the closing direction of the diaphragm), C, M diagnostic index S (S _a of, S _C, is calculated as S _M) (step S205).

In the present embodiment, in step S205, for each of the valves A, C, and M, it is recognized that the valve is fully closed (for example, the valve shaft stops near the minimum opening), and then the first specified time. _{The opening measurement value data D1 (D1 1} ) at the time when T1 (for example, 30 seconds) has elapsed is used as the first opening measurement value data, and after the lapse of the first specified time T1, there is no opening / closing and the second specification. _{The opening measurement value data D1 (D1 2} ) at the time when the time T2 (for example, the time until the next day) has elapsed is used as the second opening measurement value data, and the first opening measurement value data D1 ₁ and the second. The difference from the opening measurement value data D1 _{2 of the above} is taken as the bite amount δ of the valve body (diaphragm) in the closing direction, and this bite amount δ is calculated as the valve diagnostic index S.

FIG. 5 shows the change in the opening degree θ (opening measurement value data D1) when the valve is closed when the valve body (diaphragm) is not deteriorated (healthy) as the characteristic I, and the valve body as the characteristic II. The change of the opening degree θ (opening measurement value data D1) when the valve is closed when the (diaphragm) is deteriorated is shown.

In the case of characteristic I, it is recognized as fully closed at t1 (opening at 0% input), and at t2 (when it is determined to be fully closed) when the first specified time T1 has elapsed since it was recognized as fully closed. , The opening measurement value data D1 at that time is acquired as the _{first opening measurement value data D1 1.} Then, at the time point t3 when the second specified time T2 has elapsed without opening and closing as it is, the opening degree measurement value data D1 at that time is acquired as the _{second opening degree measurement value data D1 2.} Then, the difference between the first opening measurement value data D1 ₁ and the second opening measurement value data D1 ₂ is obtained as the bite amount δ (δ1), and this bite amount δ (δ1) is the diagnostic index S of the valve. It is said that.

In the case of characteristic II, as in the case of characteristic I, it is recognized as fully closed at t1 (opening at 0% input), and at t2 when the first specified time T1 has elapsed since it was recognized as fully closed (total). At the time when it is determined to be closed), the opening measurement value data D1 at that time is acquired as the _{first opening measurement value data D1 1.} Then, at the time point t3 when the second specified time T2 has elapsed without opening and closing as it is, the opening degree measurement value data D1 at that time is acquired as the _{second opening degree measurement value data D1 2.} Then, the difference between the first opening measurement value data D1 ₁ and the second opening measurement value data D1 ₂ is obtained as the bite amount δ (δ2), and this bite amount δ (δ2) is the diagnostic index S of the valve. It is said that.

As can be seen by comparing characteristic I and characteristic II, when the valve body (diaphragm) is not deteriorated (healthy), the bite amount δ is large, but when the valve body (diaphragm) is deteriorated, it bites. The quantity δ becomes smaller. In the present embodiment, the bite amount δ of this valve body (diaphragm) is used as the diagnostic index S.

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 S206). For example, as shown in FIG. 6 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 as # 2 presentation area of the diagnosis target portion in FIG. 6, 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 valve body (diaphragm) of M is targeted, the operator who lacks knowledge about the necessity of maintenance of the diaphragm of the valve body can go to the diaphragm of the valve body. Since the necessity of paying attention to is quantitatively shown, it is possible to reduce the risk of omission of checking of the diaphragm of the valve body.

Diagnosis calculated index calculation unit 3 diagnostic indicator _{S (S A, S C,} S M) is also sent to the determination unit 5. The lower 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 S207), and the diagnostic index from the diagnostic index calculation unit 3. S is compared with the diagnostic index threshold Sth (step S208). 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 less than the diagnostic index threshold value Sth (YES in step S208), the determination unit 5 determines that the valve is a valve requiring maintenance (step). S209). For example, determining the diagnostic indicator S _A, S _C, of the S _M, if diagnostic index S _M is less than or equal diagnostic indicator threshold Sth, 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 S210). 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.

Further, in the present embodiment, the first specified time T1 is set to, for example, 30 seconds, and the second specified time is set to, for example, the time until the next day, but these times differ depending on the rubber-based material of the diaphragm of the valve body. It is necessary as time, and both may be obtained experimentally in advance.

[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. 7 is a diagram showing the configurations of the plant and its equipment management system, and the same configurations as those in FIG. 4 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 that is a candidate for maintenance displayed on the display of the computer 9 and the judgment result of whether or not maintenance is necessary, the operator confirms the valve that should pay particular attention to the inspection of the valve body (diaphragm) of the diaphragm valve. do. 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 ... Diaphragm index calculation unit, 4 ... Diaphragm index presentation unit, 5 ... Judgment unit, 6 ... Threshold storage unit, 7 ... Judgment result presentation unit, 21 ... Open Degree measuring 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, 105'... Diaphragm (diaphragm of valve body), 200 ... Valve maintenance support device.

Claims (6)

A valve maintenance support device that uses a diaphragm as the valve body to support valve maintenance work that regulates the flow of fluid.
A measurement value data storage unit that stores the opening measurement value data transmitted from the opening measurement unit that measures the lift position including the fully closed valve as the opening degree of the valve.
Based on the opening measurement value data stored in the measured value data storage unit, the valve is provided with information on the amount of biting into the valve body in the closing direction after recognizing that the valve is fully closed. Diagnostic index calculation unit that calculates as a diagnostic index of
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,
The diagnostic index calculation unit is
The opening measurement value data at the time when the first specified time elapses after recognizing that the valve is fully closed is used as the first opening measurement value data, and after the first specified time elapses, The opening measurement value data at the time when the second specified time has elapsed without opening and closing is used as the second opening measurement value data, and the first opening measurement value data and the second opening measurement value data are used. A valve maintenance support device characterized in that the difference between the valve body and the valve body is used as the biting amount in the closing direction, and the biting amount is calculated as a diagnostic index of the valve. In the valve maintenance support device according to claim 1 or 2.
A threshold storage unit that stores the lower limit of the normal range for the diagnostic index as a diagnostic index threshold, and
When the diagnostic index of the valve calculated by the diagnostic index calculation unit is equal to or less than the diagnostic index threshold value, a determination unit for determining that the valve is a valve requiring maintenance, and a determination unit.
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 any one of claims 1 to 3.
The diagnostic index presentation unit is
A valve maintenance support device, which, together with the diagnostic index of the valve, indicates that the diagnostic index is intended for maintenance of the valve body of the valve. In the valve maintenance support device according to any one of claims 1 to 4.
It is equipped with a valve identification information storage unit that stores the identification information of valves that are registered as maintenance candidate valves and that use a diaphragm as the valve body.
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 is stored in association with the valve identification information for each valve to be measured.
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 is associated with the read identification information in the opening measurement value data stored in the measurement value data storage unit. Based on this, a valve maintenance support device for calculating the diagnostic index for each of the maintenance candidate valves. It is a valve maintenance support method for automatically operating a valve maintenance support device that supports valve maintenance work that regulates fluid flow, using a diaphragm as the valve body.
The measurement value data storage unit of the valve maintenance support device stores the opening measurement value data transmitted from the opening measurement unit that measures the lift position including the fully closed valve as the opening degree of the valve in the memory. and Luz step,
The closing direction of the valve body after the diagnostic index calculation unit of the valve maintenance support device recognizes that the valve is fully closed based on the opening measurement value data stored in the memory. and Luz step to calculate the information about the amount of biting into a diagnostic indicator of said valve,
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.

Images