WO2011104419A1 - Contrôle des performances d'un système pompe-soupape - Google Patents

Contrôle des performances d'un système pompe-soupape Download PDF

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Publication number
WO2011104419A1
WO2011104419A1 PCT/FI2010/050146 FI2010050146W WO2011104419A1 WO 2011104419 A1 WO2011104419 A1 WO 2011104419A1 FI 2010050146 W FI2010050146 W FI 2010050146W WO 2011104419 A1 WO2011104419 A1 WO 2011104419A1
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WO
WIPO (PCT)
Prior art keywords
valve
control valve
flow rate
pressure difference
pump
Prior art date
Application number
PCT/FI2010/050146
Other languages
English (en)
Inventor
Mats Friman
Jouni Pyötsiä
Ismo NIEMELÄ
Original Assignee
Metso Automation Oy
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Filing date
Publication date
Application filed by Metso Automation Oy filed Critical Metso Automation Oy
Priority to PCT/FI2010/050146 priority Critical patent/WO2011104419A1/fr
Publication of WO2011104419A1 publication Critical patent/WO2011104419A1/fr

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Classifications

    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B23/00—Testing or monitoring of control systems or parts thereof
    • G05B23/02—Electric testing or monitoring
    • G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
    • G05B23/0218—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults
    • G05B23/0224—Process history based detection method, e.g. whereby history implies the availability of large amounts of data
    • G05B23/0227—Qualitative history assessment, whereby the type of data acted upon, e.g. waveforms, images or patterns, is not relevant, e.g. rule based assessment; if-then decisions
    • G05B23/0235—Qualitative history assessment, whereby the type of data acted upon, e.g. waveforms, images or patterns, is not relevant, e.g. rule based assessment; if-then decisions based on a comparison with predetermined threshold or range, e.g. "classical methods", carried out during normal operation; threshold adaptation or choice; when or how to compare with the threshold
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/20—Pc systems
    • G05B2219/24—Pc safety
    • G05B2219/24042—Signature analysis, compare recorded with current data, if error then alarm
    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04S—STEREOPHONIC SYSTEMS 
    • H04S2400/00—Details of stereophonic systems covered by H04S but not provided for in its groups
    • H04S2400/05—Generation or adaptation of centre channel in multi-channel audio systems
    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04S—STEREOPHONIC SYSTEMS 
    • H04S2400/00—Details of stereophonic systems covered by H04S but not provided for in its groups
    • H04S2400/11—Positioning of individual sound objects, e.g. moving airplane, within a sound field

Definitions

  • the present invention relates generally to online diagnostics of a pump-valve system. BACKGROUND OF THE INVENTION
  • a control valve is generally used for a continuous control of a liquid or gas flow in various pipelines and processes.
  • a processing industry such as pulp and paper, oil refining, petrochemical and chemical industries, different kinds of control valves installed in a plant's pipe system control material flows in the process.
  • a material flow may contain any fluid material, such as fluids, liquors, liquids, gases and steam.
  • a control valve is part of a process pipeline.
  • a process pipeline often includes a number of pump-valve systems wherein a pump produces a fluid pressure to provide a fluid flow in the pipe- line, and the fluid flow is controlled by a throttling control valve located somewhere in the pipeline after the pump.
  • the pumps are driven by electrical energy.
  • Such throttling flow control means that the "extra" pressure energy produced by the pump is wasted in the throttling control valve. Therefore, it is desired to size the pump-valve system as optimally as possible in order to avoid wasting the pumping energy and to operate the control valve more optimally.
  • a large industrial process may contain hundreds of pump-valve systems, and the amount of wasted pumping energy may be very large.
  • a process analysis during planning enables a plant design engineer to select a pump based on expected flows in a pipeline.
  • actual flows in the process are impossible to predict exactly, and the actual flows typically differ from the estimated designed flows. This may result in a wrongly sized pump.
  • a pump dimension is often exaggerated in order to secure the operation of the plant.
  • Such analysis focuses on the identification of pump and system curves and neglects variations of system curve.
  • the analyzed operation period is typically short, while the period should be significantly long (months or years) in order to be representative because the variations in a system curve are sometimes slow, due to fouling, clogging, etc.
  • the high number of pump-valve systems in a plant also makes it labour- some to analyse and recognise inappropriately operating pump-valve systems.
  • EP0962847 discloses a method and equipment for controlling a pipe network comprising piping, an inverter-controlled pump and at least two control valves.
  • the valve position and the flow through the valve are moni- tored, and the rotational speed of the pump and the position of each valve are adjusted on the basis to the position and flow data received.
  • the rotational speed of the pump is adjusted to be as low as possible but, at the same time, sufficient for maintaining the gain of the valves.
  • the positions of the valves are adjusted to be as open as possible, the valve opening being, however, for the major part of the time, not more than a certain predetermined portion of the opening of the totally open position. As a result, the energy consumption required for the pumping is decreased and the control accuracy of the valves is increased.
  • This prior art approach is only applicable to few pump-systems in a plant but fails to provide an universal way to reduce the waste of pumping energy in the plant containing a high number of pump-valve systems.
  • An object of the present invention is to improve online diagnostics of control valves. This object of the invention is achieved by a method, a valve positioner, systems and a computer program according to the independent claims. Embodiments of the invention are disclosed in the dependent claims.
  • An aspect of the invention is a method for diagnosing a pump-valve system, comprising
  • Another aspect of the invention is a method for diagnosing a pump- valve system, comprising
  • the resized fully open flow rate of the control equals to the actual maximum flow rate plus a predetermined safety marginal.
  • the method comprises reporting the potential reduction of the online pressure difference via an user interface, such as graphical user interface, web-based user interface or voice user interface, or by email, short message service, multimedia message service, or by another messaging or data communication mechanism.
  • an user interface such as graphical user interface, web-based user interface or voice user interface, or by email, short message service, multimedia message service, or by another messaging or data communication mechanism.
  • the method comprises further calculating and reporting, via a graphical user interface, a potential sav- ing in pumping energy and/or pumping cost with the potential reduction in the online pressure difference.
  • the method comprises further calculating and reporting, via a graphical user interface, a recommended resizing of the pump to achieve the potential reduction in the online pressure difference, such as a recommended resizing of a pump propeller.
  • the method comprises determining an installed flow characteristic of the control valve based on the stored inherent Cv-curve, the online-measured valve opening and the online-measured pressure difference or the online-measured flow rate.
  • An aspect of the invention is a valve positioner for operating a control valve, the valve positioner comprising means for implementing steps of any one of the method aspects recited above.
  • An aspect of the invention is an automation system for controlling a process, the automation system comprising means for implementing steps of any one of the method aspects recited above.
  • An aspect of the invention is a valve management system compris- ing means for implementing steps of any one of the method aspects recited above.
  • An aspect of the invention is a system comprising a plurality of pump-valve systems installed in a process, an automation system for controlling the process, and a valve management system, the system further compris- ing means for implementing steps of any one of the method aspects recited above.
  • An aspect of the invention is a computer program comprising program code means adapted to perform steps of any one of the method aspects recited above when the program is run on a computer or a processor.
  • the entire lifecy- cle of pump-valve system (i.e. several years) can be analyzed based on true observed values collected during the entire life-cycle.
  • the analysis and data collection is effective with modest memory requirements. There may be no need to store or retrieve old trend information.
  • Continuous monitoring of pump- ing performance and/or pumping energy can be provided. Analysis of the energy savings potential can be automated. Continuous suggestions of saving potential can be made. Saving potential vs. pumping performance can be shown in one graphical plot.
  • Figure 1 shows a schematic block diagram of an exemplary process automation system and a field device management system
  • Figure 2 illustrates an exemplary pump-valve system wherein em- bodiments of the present invention may be applied
  • Figure 3 illustrates an exemplary control valve having inlet and outlet pressure sensors integrated into the body of valve
  • Figure 4 illustrates examples of pressure curves depicting the measured inlet and outlet pressures of a valve as a function of the actual flow rate
  • Figure 5 illustrates an example of a pressure curve depicting the measured pressure drop over a valve as a function of the actual flow rate
  • Figure 6 illustrates an example of an installed flow characteristics curve
  • Figure 7 illustrates examples of pressure curves depicting the measured inlet and outlet pressures as well as a reduced inlet pressure as a function of the actual flow rate
  • Figure 8 illustrates examples of pressure curves depicting the measured or calculated pressure difference and a reduced pressure difference as a function of a calculated or measured flow rate
  • Figure 9 illustrates an example of a new installed flow characterics curve
  • Figure 10 illustrates an example of a gain of the valve as a function of the flow rate through the valve
  • Figure 1 1 illustrates another exemplary pump-valve system wherein embodiments of the present invention may be applied
  • Figure 12 illustrates an example of providing discrete operating points indexed by the flow rate and the valve opening h
  • Figure 13 illustrates an example of a graph resulting from sorting of calculated pressure reduction values and plotting the sorted values in function of the number n of hits giving each value;
  • Figure 14 illustrates an example of a graph resulting from sorting of calculated pressure reduction values and plotting the sorted values in function of the normalized number n of hits giving each value
  • Figure 15 illustrates another example of a graph resulting from sorting of calculated pressure reduction values and plotting the sorted values in function of a normalized number hits, and calculated monetary savings (in thousand euros per year) as a function of the sorted pressure reduction values.
  • the present invention can be applied in diagnosis of any pump- valve system comprising a combination of a pump and at least one control valve in a process pipeline.
  • FIG. 1 shows a schematic block diagram of an exemplary process automation system and a field device management system wherein the principles of the invention may be applied to a pump-valve system.
  • the control system block 5 generally represents any and all control room com- puter(s)/programs and process control computer(s)/programs as well as databases in the automation system.
  • the control system may be a Direct Digital Control (DDC) system or Distributed Control System (DCS), both well known in the art.
  • DDC Direct Digital Control
  • DCS Distributed Control System
  • the field/process bus 3 generally represents any such interconnection.
  • field devices have been connected to the control system by two-wire twisted pair loops, each device being connected to the control system by a single twisted pair providing a 4 to 20 mA analog input signal.
  • HART Highway Addressable Remote Transducer
  • the HART protocol is described in greater detail for example in the publication HART Field Commu- nication Protocol: An Introduction for Users and Manufacturers, HART Communication Foundation, 1995.
  • the HART protocol has also been developed into an industrial standard. Examples of other fieldbuses include Fieldbus and Profibus.
  • Fieldbus and Profibus.
  • the field/process bus 3 may be based on any one of the alternatives described above, or on any combination of the same, or on any other implementation.
  • the field devices may be managed using a field device management and diagnostics system 4.
  • the management and diagnostics system 4 may further be connected to a local area network LAN of the factory, which allows it to communicate with the control room programs, for example.
  • the field device management and diagnostics system 4 or similar func- tionality may be integrated into the control system 5, e.g. into control room or process control computers.
  • the management and diagnostics system 4 may be connected to the field devices (e.g. valve positioner 2) over the field/process bus 3, as described above.
  • each field device may have a dedicated fieldbus connecting it to a HART multiplexer, which is in turn connected to the management and diagnostics system 4.
  • the management and diagnostics system 4 may comprise a computer workstation provided an appropriate management and diagnostics program.
  • Neles FieldCare software from Metso Automation Inc.
  • Neles FieldCare is an universal FDT/DTM (Field Device Tool / Device Type Manager) -based software.
  • FDT/DTM Field Device Tool / Device Type Manager
  • One of the features of Neles FieldCare is on-line condition monitoring which enables to collect on-line data from field devices and provides tools for predictive maintenance planning.
  • FIG. 2 An exemplary pump-valve system wherein embodiments of the pre- sent invention may be applied is illustrated in Figure 2.
  • Such pump-valve system may be controlled and managed by the automation system illustrated in Figure 1 , or any other type of control system, or it may even be a standalone system.
  • a pump 23 is provided to pump a flow of material to a process pipeline 25, and a control valve 21 is connected to a process pipeline 25 after (downstream from) the pump 23 to control the material flow of a substance in the process pipeline 25.
  • the material flow may contain any fluid material, such as fluids, liquors, liquids, gases and steam.
  • the control valve 21 is usually connected with an actuator, which turns the closing element of the valve to a desired position between fully open and fully closed positions.
  • the actuator may be a pneumatic cylinder-piston device, for example.
  • the actuator for its part, is usually controlled by a valve positioner 22, sometimes referred to as a valve controller, which controls the position of the closing element of the control valve 21 and thus the material flow in the process according to a control signal from a controller in an automation system.
  • a pressure difference ⁇ across the control valve in the pipeline, and an opening h of the control valve is measured and stored online, i.e. while the control valve is normally operating in the pipeline.
  • an inlet pressure p1 provided by the pump 23 in the pipeline 5 upstream from the control valve 21 , is measured by a suitable pressure sensor 24, and the outlet pressure p2 of the control valve 21 to the downstream pipeline 25 is measured by another suitable pressure sensor 26.
  • the pressure sensors 24 and 26 may be separate from the control valve 21 , i.e. they may be attached to the pipeline 5 in a location close to or remote from the control valve.
  • the pressure sensors 24 and 26 may be integrated into the control valve assembly and arranged to provide the pressure information to the valve positioner 22, e.g. over a wired or wireless connection.
  • Figure 3 illustrates an exemplary control valve 21 having the pressure sensors 24 and 26 integrated into the body of valve at the inlet and the outlet, respectively.
  • the pressure sensors 24 and 26 may be provided with wireless communication means, e.g. radio transmitters, for transmitting the pressure data p1 and p2 to a receiver at a valve positioner 22A.
  • a pneumatic actuator 22B operates the control valve under control of the valve positioner 22A.
  • An example of a suitable control valve 21 wherein pressure sensors could be integrated is Neles RotaryGlobe control valve, Series ZX, from Metso Automation Inc.
  • An example of a suitable valve positioner 22A is Intelligent Valve Controller Neles ND9000 from Metso Automation Inc.
  • An example of a suitable actuator 22B is a Pneumatic double-diaghram actuator, Series E, from Metso Automation Inc.
  • the valve positioner 22 e.g. a microprocessor of the valve positioner, is arranged to sample the pressures p1 and p2, and the valve position h at a predetermined sampling frequency during the online operation of the control valve, and to store the sample values in an internal memory of the valve controller, and/or to transfer (ac- tively or on demand) the sample values to the management and diagnostics system 4, or to the automation system, over the field/process bus 3.
  • Valve inherent flow characteristic is defined so that the pressure differential across the valve ( ⁇ ) is kept constant. As the differential pressure ( ⁇ ) is constant, the flow rate (Q) through the valve is proportional to the valve flow coefficient (Cv), as expressed in the simplified equation:
  • ⁇ pressure differential across the valve.
  • valve flow coefficient (Cv) reflects the effective flow cross-section of the valve
  • the valve inherent flow characteristic shows how the effective flow cross-section changes as a function of relative travel or position h of the valve.
  • Such inherent flow characteristic is often presented in form of a Cv characteristic curve which depicts the Cv value as a function of the opening of the valve.
  • an inherent Cv curve may preferably be stored, e.g. in a tabular form, in a memory in the valve posi- tioner, the automation system or the diagnostics system.
  • the inherent flow characteristic is the shape of a flow curve through the valve with a constant pressure drop across the valve.
  • the piping pressure loss which varies as a function of flow rate will cause also the valve pressure drop to vary as a function of flow rate, even if the pressures at the source and receiver were constant.
  • the differential pressure across a valve is seldom constant in the valve travel range because dynamic pressure losses in the flow cause the valve inlet pressure to fall and the outlet pressure to rise as the flow rate increases.
  • the depend- ence of the flow rate q on the position h i.e. the shape of the installed flow characteristic curve, is therefore a function of the process pipeline and of the inherent flow characteristic of the valve.
  • the measured valve opening data and the measured pressure data may be utilized to determine the in- stalled flow characteristic curve of the valve for analysis of the pump-valve system.
  • a characteristic curve depicting the inlet and outlet pressures p1 and p2, or the pressure difference ⁇ , as a function of the flow rate q through the control valve may be defined.
  • respective value for the flow through the control valve may be determined.
  • the required C value for the respective measured opening h can be determined.
  • pressure curves depicting the measured inlet and outlet pressures p1 and p2 as a function of the determined flow rate may be provided as shown in Figure 4.
  • a pressure curve depicting the pressure difference ⁇ as a function of the determined flow rate may be provided as shown in Figure 5.
  • the installed flow characteristic curve and the actual maximum flow rate Cw through the valve may be determined using the inherent Cv curve and the measured opening h of the valve.
  • the accuracy of the installed flow characteristic curve will improve with increasing number of meas- urements.
  • An example of an installed flow characteristics curve is shown in Figure 6. It can be seen that the actual maximum valve opening h max va ive reguired by the actual maximum flow rate is small as compared with the designed maximum opening of the valve. This indicates that the control valve is oversized, which offers a possibility of optimizing the pump-valve system.
  • the flow Q fu n y op en refers to the maximum designed flow rate provided, when the installed valve is fully open.
  • the Qmax refers to the actually observed maximum flow rate in the pipeline required by the process.
  • Figure 7 illustrates pressure curves depicting the measured inlet and outlet pressures p1 and p2, as well as a reduced inlet pressure p1 new as a function of the determined flow rate.
  • the new inlet pressure curve p1 ne w may be determined by first defining a new maximum designed flow rate Qf U n y open new for a fully open valve.
  • the Qf U n y 0P en new is preferably larger than the maximum flow rate Cw required by the process, with a safety margin SM required in each specific application, e.g. 10-15 %.
  • a pressure difference ⁇ over the control valve, when fully open with the new Q fu n y open new may be calculated using the inherent Cv curve and and equation (3), for example
  • new inlet pressure p1 new at any flow rate Q can be obtained such that the new inlet pressure curve p1 new is formed as shown in Figure 7.
  • the potential saving (reduction) in the inlet pressure is the difference ⁇ ⁇ between the original inlet pressure curve p1 and the new inlet pressure curve p1 ne w-
  • the pressure reduc- tion may also be calculated with equation (4)
  • Figure 8 illustrates a pressure curves depicting the measured or calculated pressure difference ⁇ ⁇ 3 ⁇ originaii and a reduced pressure difference ⁇ ⁇ 3 ⁇ new as a function of a calculated or measured flow rate.
  • the new pressure difference curve Ap va i V e new may be determined by first defining a new maximum designed flow rate Qf U n y 0P en new for a fully open valve.
  • the Qf U n y 0P en new is preferably larger than the maximum flow rate Q max required by the process, with a safety margin SM required in each specific application, e.g. 10-15 %.
  • a pressure difference Ap va ive new over the control valve is calculated using the inherent Cv curve and equation (3), for example.
  • the potential pressure reduction ⁇ ⁇ (saving) in the inlet pressure is the difference between the original pressure difference Ap va i V e original and the new pressure difference Ap va i V e new-
  • the pressure reduction ⁇ ⁇ can be calculated at any flow rate Q.
  • the ⁇ ⁇ may be calculated with equation (4), as described above.
  • the inlet pressure saving potential ⁇ ⁇ is proportional to the corresponding saving potential in the pumping height of the preceding pump, and further to the potential saving in the pumping energy. Based on the above measurements, it is possible to calculate an average flow rate through the valve over a period of time. Thus it is possible to estimate the possible saving in the pumping energy, when the pump provides the reduced inlet pressure pl new or the reduced pressure difference Ap va ive new instead of the original inlet pressure p1 or the original pressure difference ⁇ . Finally, when the price of the pumping energy is known, a corresponding monetary saving in comparison with the original pump-valve system can be calculated.
  • the performance and control accuracy of the control valve with the new inlet pressure and settings may be checked, before making corresponding changes in the pump-valve system.
  • a new installed flow characteristic of the valve and the gain of the valve within the control range may be calculated.
  • An example of a new installed flow characteristic curve is shown in Figure 9.
  • the min and max indicate the valve openings h at a minimum flow rate and at the maximum flow rate (C ) required by the process, respectively.
  • An example of a gain of the valve as a function of the flow rate through the valve is shown in Figure 10.
  • the min and max indicate the minimum flow rate and the maximum flow rate (Qmax) required by the process, respectively.
  • the gain of the valve with the new installed flow characteristic may be determined using equation (5), for example
  • G dQ/dh (5)
  • the gain G may be defined in relation to the maximum flow rate C required by the process rather than in relation to the flow rate Qf U n y open new of a fully open valve. Following design constrains may be applied to the gain G within the control range in order to ensure a sufficiently good performance.
  • the ratio of the maximum gain G ma x and the minimum gain G m in shall preferably be less than 2, i.e. (G ma x/G m i n ) ⁇ 2. Further, the gain shall preferably be equal to or higher than 0.5, i.e. G > 0,5.
  • the control error of the valve increases also when the gain G of the valve is high.
  • the gain G within the control range ex- ceeds 3
  • the maximum gain Gmax always is equal to or less than 2 or 3, i.e. Gmax ⁇ 2...3.
  • the new installed flow characteristic of the valve may be checked against the above-described constrains.
  • Typical problem may be that the gain G becomes too small at large openings of valve, and that the ratio of the maximum gain G ma x and the minimum gain G m in exceeds 2. In that case the installed flow characteristic is corrected to remove the problem. If the absolute value of the maximum gain Gmax is exceeds 2...3, the safety marginal may be increased and it may be examined whether it is possible to reduce the gain.
  • the potential savings may be put into practice by, in addition to defining the new installed flow characteristics for the desired ⁇ ⁇ available, replacing the original pump with a new smaller pump, or more preferably, replac- ing or processing the impeller of the original pump to provide the required lower inlet pressure p1 or the pressure difference Ap va ive new- This measure will preferably be made during a maintenance shutdown of the process.
  • Figure 1 1 illustrates another exemplary pump-valve system wherein embodiments of the present invention may be applied.
  • the opening h of the control valve is measured as in the exemplary system of Figure 2.
  • a pressure difference ⁇ across the control valve in the pipeline is not measured, but a flow rate Q is obtained by the flow measurement on the material flow at a suitable point of the pipeline 25.
  • This measured flow Q may be obtained from the flow indicator 30, for instance.
  • the flow indicator 30 is preferably a flow indicator that already exists in the process, or it may be installed in the process for the purpose of the invention.
  • the flow indicator 30 is preferably located after the valve 21 , but it may also be placed at a suitable point of the flow process before the valve 21 , as shown in Figure 1 1 .
  • the pressure drop ⁇ across the valve can then be calculated by using the C v curve of the valve, the measured valve opening h and the measured flow Q.
  • a pressure difference curve as a function of the measured flow rate Q can be provided, e.g. in a similar manner as in Figure 5. Then the analysis may proceed as described in connection with the above exemplary embodiments.
  • the data gathering and analysis is generally represented with a function block 27 in Figures 2 and 1 1 .
  • the data gathering and analysis func- tionality 27 may be located at the valve positioner 22, at the management and diagnostics system 4, or at the automation system, or in a desired manner be distributed among these, the communication being performed over the field/process bus 3.
  • the block 28 generally represents the functionality of stor- ing of the Cv curve, e.g. in a tabular form or in form of a mathematical equation. Also the block 28 may be located at the valve positioner 22, at the management and diagnostics system 4, or at the automation system.
  • the data gathering and/or analysis may generate a huge number of stored measurement results and/or calculation results and/or analysis results which must be stored somewhere. For example, a pair of measured Q and h are stored every second results in 3600 stored pair in an hour.
  • a statistical method may be used for processing the information to be stored. Thereby, the entire life-cycle of the pump-valve system can be stored with limited memory capacity. This is espe- daily significant issue, when the data is primarily stored in the valve positioner.
  • the flow rate range e.g. Q m in-Qfuii y open
  • the valve opening range e.g.
  • 0% - 100% is subdivided into a number subranges of equal size.
  • the crossconnections of the subranges establish op- erating points.
  • a number of discrete operating points indexed by the flow rate Q and the valve opening h This is schematically illustrated in Figure 12.
  • 5 x 5 25 operating points (Q,h)
  • any number of subranges and operating points may be defined depending on the solution.
  • the numbers of Q and h subranges may also be different.
  • Number of hits (n) i.e. number of matching measurements, is included in each operating point.
  • a pair of Q and h measured at a specific moment increments the count n in the matching operating point (Q,h).
  • a pressure data such as a measured or calculated pressure difference ⁇ , a pressure reduction ⁇ ⁇ , etc. may be included in each operating point.
  • the pressure reduction ⁇ ⁇ is calculated and updated at intervals longer than the measuring intervals (e.g. at in- tervals ranging from one hour to days or weeks), and analyzed and reported.
  • the pressure reduction ⁇ ,- is calculated and updated only on demand.
  • Figure 13 is a simplified illustration of an example case wherein the calculated pressure reduction values ⁇ ⁇ are sorted, and then the sorted ⁇ ⁇ plotted as function the number n of hits giving each value of ⁇ ⁇ , and the resulting graph may be displayed to a user,.
  • the same value of ⁇ ⁇ may be obtained in more than one operating point, meaning that the hit number of the value of ⁇ ⁇ may be a sum of hits n in more the one operating point.
  • Figure 13 is a simplified illustration of an example case wherein the calculated pressure reduction values ⁇ ⁇ are sorted, and then the sorted ⁇ ⁇ values are plotted as a function of a normalized number of hits giving each value of ⁇ ⁇ , and the resulting graph may be displayed to a user.
  • the normalized number of hits may be obtained, for example by an equation 1 - (n)/sum(n), wherein n is number of hits for the specific value of ⁇ ⁇ , and sum(n) is the total number of all hits.
  • Embodiments of the invention may further automatically generate reports for impact of impeller replacements on pumping performance, suggestions for magnitudes of pump impeller replacements, calculation of energy and monetary savings of suggested pump impeller replacement.
  • Figure 15 illustrates another example of a graph obtained by sorting the ⁇ ⁇ values and plotting the sorted ⁇ ⁇ values as a function of a normalized number of hits (1 - (n)/sum(n)) calculated after the ⁇ ⁇ sorting.
  • Figure 15 shows also the calculated monetary savings (in thousand euros per year) as a function of the ⁇ ⁇ .
  • the techniques described herein may be implemented by various means. For example, these techniques may be implemented in hardware (one or more devices), firmware (one or more devices), software (one or more modules), or combinations thereof. For a firmware or software, implementation can be through modules (e.g., procedures, functions, and so on) that perform the functions described herein.
  • the software codes may be stored in any suitable, processor/computer-readable data storage medium(s) or memory unit(s) and executed by one or more processors/computers.
  • the data storage medium or the memory unit may be implemented within the processor/computer or external to the processor/computer, in which case it can be communicatively coupled to the processor/computer via various means as is known in the art.
  • components of systems described herein may be rearranged and/or complimented by additional components in order to facilitate achieving the various aspects, goals, advantages, etc., described with regard thereto, and are not limited to the precise configurations set forth in a given figure, as will be appreciated by one skilled in the art.

Abstract

L'invention porte sur un procédé pour diagnostiquer un système pompe-soupape, dans ce procédé, on mesure une ouverture d'une soupape de commande et une différence de pression (Δp) de part et d'autre de la soupape de commande pendant le fonctionnement normal de la soupape de commande. Ensuite, sur la base des données d'ouverture mesurées de la soupape et des données de la pression mesurée, et d'une courbe caractéristique de coefficient d'écoulement inhérent de la soupape (Cv) qui est mémorisé pour la soupape de commande, une différence de pression réelle de part et d'autre de la soupape de commande ainsi qu'une fonction du débit (Qdébit) à travers la soupape de commande, ainsi qu'un débit maximum réel (Qmax) à travers la soupape de commande sont déterminés. Finalement, sur la base de la différence de pression (Δp) et du débit maximum réel (Cmax), il est possible de déterminer une réduction potentielle (Δpr) qui peut être obtenue dans la différence de pression si un débit de pleine ouverture de la soupape de commande est reformé à une valeur (Qentièrement ouverte nouvelle) qui est proche du débit maximum réel et une pompe précédente est remise à jour en conséquence. La réduction potentielle de la différence de pression (Δpr) peut être communiquée à l'utilisateur via une interface utilisateur, telle qu'une interface utilisateur graphique, une interface utilisateur basée sur Internet ou une interface utilisateur vocale, ou au moyen d'un mécanisme quelconque de messagerie ou de communication de données.
PCT/FI2010/050146 2010-02-26 2010-02-26 Contrôle des performances d'un système pompe-soupape WO2011104419A1 (fr)

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US11022985B2 (en) 2011-12-16 2021-06-01 Fluid Handling Llc Discrete valve flow rate converter
US20160186889A1 (en) * 2011-12-16 2016-06-30 Fluid Handling Llc. Discrete Valve Flow Rate Converter
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WO2015166132A1 (fr) * 2014-04-29 2015-11-05 Metso Flow Control Oy Contrôle des performances d'un système de soupape de pompe
CN106462151A (zh) * 2014-04-29 2017-02-22 美卓流体控制有限公司 泵‑阀系统的性能监控
CN106462151B (zh) * 2014-04-29 2019-12-13 美卓流体控制有限公司 泵-阀系统的性能监控
EP3137956A4 (fr) * 2014-04-29 2017-12-13 Metso Flow Control Oy Contrôle des performances d'un système de soupape de pompe
RU2721453C2 (ru) * 2014-12-15 2020-05-19 Флюид Хэндлинг ЭлЭлСи Преобразователь расхода дискретного клапана
CN107250939A (zh) * 2014-12-15 2017-10-13 流体处理有限责任公司 离散阀流率转换器
WO2016100322A1 (fr) * 2014-12-15 2016-06-23 Fluid Handling Llc Convertisseur de débit de vanne discret
CN106091101A (zh) * 2016-06-06 2016-11-09 北京华热科技发展有限公司 一种水力平衡的调试方法及系统
CN114047732A (zh) * 2021-11-15 2022-02-15 中国电子科技集团公司第四十八研究所 一种用于碳化硅外延工艺的蝶阀智能控制方法及系统
CN114047732B (zh) * 2021-11-15 2023-05-30 中国电子科技集团公司第四十八研究所 一种用于碳化硅外延工艺的蝶阀智能控制方法及系统

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