WO2021070924A1 - Système de diagnostic, procédé pour faire fonctionner un système de diagnostic et programme de diagnostic - Google Patents

Système de diagnostic, procédé pour faire fonctionner un système de diagnostic et programme de diagnostic Download PDF

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Publication number
WO2021070924A1
WO2021070924A1 PCT/JP2020/038260 JP2020038260W WO2021070924A1 WO 2021070924 A1 WO2021070924 A1 WO 2021070924A1 JP 2020038260 W JP2020038260 W JP 2020038260W WO 2021070924 A1 WO2021070924 A1 WO 2021070924A1
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Prior art keywords
diagnostic
diagnosed
temperature
ultrasonic
calculation process
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PCT/JP2020/038260
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English (en)
Japanese (ja)
Inventor
森田隆寛
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株式会社テイエルブイ
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Priority to JP2021510257A priority Critical patent/JP7036986B2/ja
Publication of WO2021070924A1 publication Critical patent/WO2021070924A1/fr

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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01H—MEASUREMENT OF MECHANICAL VIBRATIONS OR ULTRASONIC, SONIC OR INFRASONIC WAVES
    • G01H17/00—Measuring mechanical vibrations or ultrasonic, sonic or infrasonic waves, not provided for in the preceding groups
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M3/00—Investigating fluid-tightness of structures
    • G01M3/02—Investigating fluid-tightness of structures by using fluid or vacuum
    • G01M3/04—Investigating fluid-tightness of structures by using fluid or vacuum by detecting the presence of fluid at the leakage point
    • G01M3/24—Investigating fluid-tightness of structures by using fluid or vacuum by detecting the presence of fluid at the leakage point using infrasonic, sonic, or ultrasonic vibrations
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M99/00—Subject matter not provided for in other groups of this subclass
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/02—Analysing fluids
    • 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
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05D—SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
    • G05D16/00—Control of fluid pressure
    • G05D16/20—Control of fluid pressure characterised by the use of electric means

Definitions

  • the present invention relates to a diagnostic system capable of diagnosing process equipment that controls the flow of process fluids flowing through a chemical plant, a method of operating the diagnostic system, and a diagnostic program.
  • process equipment such as on-off valves and control valves are used to control the flow of process fluids such as raw materials, intermediates, and products.
  • process equipment such as a safety valve and a rupture disc that does not circulate the process fluid in normal times but circulates the process fluid only in an emergency is also used. Since all of these process equipment are required to prevent leakage of process fluids, process equipment is generally subject to regular or non-regular inspections.
  • Patent Document 1 discloses a technique for diagnosing the pressure regulator based on the pressure on the secondary side of the pressure regulator. .. Further, Japanese Patent Application Laid-Open No. 2013-242909 (Patent Document 2) detects a failure or deterioration of a spring that urges the valve body toward the valve seat based on the pressure of the process fluid and the mobility of the valve. The technology is disclosed. In addition, Japanese Patent Application Laid-Open No. 2013-54483 (Patent Document 3) discloses a technique for diagnosing an abnormality of a control valve based on a valve opening degree that is periodically sampled.
  • Japanese Patent Application Laid-Open No. 2016-524233 (or US Patent Application Publication No. 2014/0352408) Japanese Patent Application Laid-Open No. 2013-242909 (or US Patent Application Publication No. 2009/0222220) Japanese Patent Application Laid-Open No. 2013-54483 (or US Patent Application Publication No. 2013/0060523)
  • Patent Documents 1 to 3 it is necessary to provide a detection device for detecting a physical quantity in advance in or around the process device main body to be inspected.
  • process equipments that are operated (or operated) only under special circumstances such as open maintenance or when an abnormality occurs, and are not operated (or not operated) in normal times.
  • Such process equipment may not be provided with a detection device because it is generally less necessary to monitor the pressure and temperature of the flowing process fluid, the operating state of the process device, and the like. Therefore, with the techniques such as Patent Documents 1 to 3, it is not possible to diagnose a process device in which a detection device is not provided.
  • a diagnostic system capable of diagnosing process equipment that is not provided with a detection device for detecting a physical quantity, an operation method of the diagnostic system, and a diagnostic program.
  • the diagnostic system is a diagnostic system capable of diagnosing process equipment that controls the flow of a process fluid containing at least one of raw materials, intermediates, products, and wastes that flow through a chemical plant, and is ultrasonic. It is provided with an ultrasonic measuring unit capable of measuring the temperature, a temperature measuring unit capable of measuring the temperature, and a calculation unit, and the calculation unit is the diagnosis target based on the ultrasonic waves measured by the ultrasonic measuring unit. Presence or absence of leakage of the process fluid in the device to be diagnosed based on the first diagnostic calculation process for determining the presence or absence of leakage of the process fluid in the device to be diagnosed, which is a process device, and the temperature measured by the temperature measuring unit. It is possible to execute the second diagnostic calculation process for determining the above, and the first diagnostic calculation process is configured to be executed before the second diagnostic calculation process.
  • the operation method of the diagnostic system is a diagnostic system capable of diagnosing a process device that controls the flow of a process fluid containing at least one of raw materials, intermediates, products, and wastes flowing in a chemical plant.
  • the operation method includes an ultrasonic measurement step of acquiring an ultrasonic measurement result, a temperature measurement step of acquiring a temperature measurement result, and a calculation step, and the calculation step is performed in the ultrasonic measurement step.
  • the first diagnostic calculation process for determining the presence or absence of leakage of the process fluid in the device to be diagnosed which is the process device to be diagnosed, and the temperature measured in the temperature measurement step
  • the second diagnostic calculation process for determining the presence or absence of leakage of the process fluid in the device to be diagnosed is executed by a computer, and the first diagnostic calculation process is performed by the computer before the second diagnostic calculation process. It is characterized by executing by.
  • the diagnostic program according to the present invention is a diagnostic program capable of diagnosing a process device that controls the flow of a process fluid containing at least one of raw materials, intermediates, products, and wastes distributed in a chemical plant.
  • the first diagnostic calculation process for determining the presence or absence of leakage of the process fluid in the device to be diagnosed, which is the process device to be diagnosed, and the diagnosis target based on the measured temperature.
  • the computer executes the second diagnostic calculation process for determining the presence or absence of leakage of the process fluid in the device, and the computer executes the first diagnostic calculation process before the second diagnostic calculation process. It is characterized in that it is configured to allow.
  • the diagnostic system according to the present invention is selected from the substance name of the process fluid flowing through the diagnostic target device in the operating state, and the gas and liquid on the primary side of the diagnostic target device in the operating state.
  • An input unit capable of inputting the state of the process fluid and a storage unit for storing the boiling point of each substance that is a candidate for the process fluid are further provided, and the second diagnostic calculation process is input to the input unit.
  • the boiling point reading process of reading the boiling point of the process fluid flowing through the device to be diagnosed from the storage unit, the boiling point, and the state input to the input unit are used. It is preferable to include a heat vaporization prediction process for predicting whether or not the temperature of the device to be diagnosed is lowered due to the heat of vaporization of the process fluid when a leak occurs in the device to be diagnosed.
  • the accuracy of diagnosis of the process equipment can be improved based on the state of the process fluid in the process equipment to be diagnosed and the boiling point of the process fluid.
  • the calculation unit when the calculation unit determines that the device to be diagnosed has not leaked in the first diagnosis calculation process, the calculation unit does not execute the second diagnosis calculation process. Is preferable.
  • the process equipment can be diagnosed with the minimum necessary arithmetic processing, so that the time required for the diagnosis can be shortened and the power consumption of the arithmetic processing can be reduced.
  • the first diagnostic calculation process includes a first ultrasonic wave measured for the device to be diagnosed and a second ultrasonic wave measured for a pipe connected to the device to be diagnosed. It is preferable to include an ultrasonic comparison process for comparing the above.
  • the ultrasonic waves (first ultrasonic waves) detected in the device to be diagnosed are caused by an abnormality in the device to be diagnosed or due to the installation environment of the device to be diagnosed.
  • the calculation unit in the ultrasonic comparison process, has the intensity of the first ultrasonic wave larger than the intensity of the second ultrasonic wave and the first ultrasonic wave.
  • the difference in intensity between the second ultrasonic wave and the second ultrasonic wave is equal to or greater than a predetermined threshold value, it is preferable to determine that the device to be diagnosed has a leak.
  • the ultrasonic waves (first ultrasonic waves) detected for the device to be diagnosed are not caused by the installation environment of the device to be diagnosed, the device to be diagnosed is leaked. Since it can be judged, the accuracy of diagnosis can be improved.
  • the second diagnostic calculation process is connected to the primary side temperature measured for the pipe connected to the primary side of the diagnostic target device and the secondary side of the diagnostic target device. It is preferable to include a temperature comparison process for comparing the secondary temperature measured for the pipe and the two temperatures selected from the air temperature.
  • the accuracy of diagnosis can be improved based on the mode of temperature change that can occur when a process fluid leak occurs.
  • the ultrasonic measurement step is a closing measurement step of acquiring ultrasonic measurement results for the diagnostic target device in a state where the downstream side of the diagnostic target device is closed.
  • an open measurement step of acquiring ultrasonic measurement results for the diagnosis target device in a state where the downstream side of the diagnosis target device is open, the first diagnostic calculation process was measured in the closure measurement step. It is preferable to include an opening / closing comparison process for comparing the ultrasonic waves with the ultrasonic waves measured in the open measurement step.
  • the accuracy of diagnosis can be improved based on the combination of ultrasonic measurement and the operation of opening and closing the flow path.
  • the diagnostic system according to the present invention the operation method of the diagnostic system, and the embodiment of the diagnostic program will be described with reference to the drawings.
  • the diagnostic system according to the present invention is used in the diagnostic system 1 capable of diagnosing the process equipment that controls the flow of the process fluid in the chemical plant.
  • a process fluid is defined as a fluid containing at least one of raw materials, intermediates, products, and wastes distributed in a chemical plant. That is, the process fluid means a fluid related to a substance directly supplied to a reactant in the reaction step, a mixture to be separated in the separation step, or a substance directly discharged from these steps. Therefore, even fluids used in chemical plants, fluids used as auxiliary in production activities in chemical plants (instrumented air, steam, refrigerant, hydraulic oil, etc.) are not included in the category of process fluids.
  • process fluids are hydrogen, hydrogen sulfide, saturated hydrocarbons (methane, ethane, propane, n-butane, isobutane, n-pentane, isopentane, cyclopentane, etc.), unsaturated hydrocarbons (ethylene, propylene, 1-butene, etc.). , Sis-2-butene, trans-2-butene, 1-pentene, cis-2-pentene, trans-2-pentene, 2-methyl-1-butene, etc.), aromatic hydrocarbons (benzene, toluene, etc.), etc. Can be mentioned. However, the process fluid is not limited to the above example. Also, the process fluid may be a mixture.
  • the process equipment is defined as the equipment that controls the flow of the process fluid.
  • an on-off valve, a control valve, a safety valve, a rupture disc, and the like are applicable.
  • the on-off valve and the control valve are implemented as valves of a known type such as a globe valve, a gate valve, and a ball valve.
  • the diagnostic system 1 includes a diagnostic device 10, a management terminal 20, and a server device 30 (FIG. 1).
  • the diagnostic device 10 includes an ultrasonic measurement unit 11 capable of measuring ultrasonic waves, a temperature measurement unit 12 capable of measuring temperature, a calculation unit 13 capable of arithmetic processing, and a storage unit 14 capable of storing various information.
  • a communication unit 15 capable of communicating with the management terminal 20, and an RFID tag reader 16.
  • the management terminal 20 is implemented as a tablet computer, and has a touch panel 21 (example of an input unit) capable of receiving input from a user and displaying information to the user, and a storage unit capable of storing various types of information.
  • the server device 30 is implemented as a server-type computer, and has a storage unit 31 that can store various types of information and a communication unit 32 that can be connected to the network N.
  • the ultrasonic measuring unit 11 and the temperature measuring unit 12 are provided at the tip of the rod-shaped probe 10a (FIG. 2).
  • the ultrasonic measuring unit 11 is provided with a known ultrasonic detecting element (for example, a piezoelectric element)
  • the temperature measuring unit 12 is provided with a known temperature measuring element (for example, a thermocouple).
  • the ultrasonic wave measured by the ultrasonic wave measuring unit 11 and the temperature measured by the temperature measuring unit 12 are stored in the storage unit 14 as electronic data, respectively.
  • the storage unit 14 is implemented as a semiconductor memory (flash memory or the like).
  • the calculation unit 13 is implemented as a calculation device having a CPU as a core member, and can perform comparative calculation of ultrasonic wave and temperature data related to a plurality of measurements stored in the storage unit 14.
  • the RFID tag reader 16 can read the control number of the process device from the RFID tag attached to each process device.
  • the read control number identifies the process equipment to be inspected.
  • the communication unit 15 reads the ultrasonic waves measured by the ultrasonic measurement unit 11, the raw temperature data measured by the temperature measurement unit 12, and the arithmetic processing data arithmetically processed by the arithmetic unit 13 by the RFID tag reader 16. It can be sent to the management terminal 20 (communication unit 24) in association with the control number of the processed process device to be inspected.
  • the diagnostic device 10 also has an input button 17 capable of receiving input from the user and a liquid crystal display 18 capable of displaying information to the user (FIG. 2).
  • the liquid crystal display 18 contains ultrasonic data measured by the ultrasonic measuring unit 11, temperature data measured by the temperature measuring unit 12, results of arithmetic processing by the arithmetic unit 13, and various information necessary for diagnostic work. Is displayed.
  • the input button 17 receives an input such as an operation for switching the information displayed on the liquid crystal display 18.
  • the management terminal 20 is implemented as a tablet computer, and the touch panel 21 functions as an input / output interface for the user. Details of various information input / output via the touch panel 21 will be described later.
  • the communication unit 24 can receive various data sent from the diagnostic device 10 (communication unit 15). The received data is stored in the storage unit 22. Further, the communication unit 24 can communicate with the server device 30 (communication unit 32) via the network N and exchange various information with the server device 30. In addition, the communication unit 24 can also communicate with other computers (not shown) on the network N, and various information can be acquired from such other computers.
  • the storage unit 22 is implemented as a semiconductor memory (flash memory or the like).
  • the calculation unit 23 generates a diagnosis result report screen 40 to be displayed on the touch panel 21 based on various data and various information stored in the storage unit 22. The data and information stored in the storage unit 22 and the contents of the diagnosis result report screen 40 will be described later.
  • the server device 30 exchanges various information with the management terminal 20 (communication unit 24) via the communication unit 32, and stores various information in the storage unit 31.
  • the storage unit 31 is mounted as a large-capacity storage device such as a hard disk.
  • the server device 30 can be accessed from other terminals (not shown) of the management terminal 20, and various information stored in the storage unit 31 can be viewed from such other terminals. For example, when an inspector diagnoses a process device using the diagnostic device 10 and the management terminal 20 and stores the diagnosis result in the server device 30, the administrator of the process device can view the diagnosis result from another terminal. ..
  • the information stored in the storage unit 31 of the server device 30 has a position as master data.
  • the storage unit 22 of the management terminal 20 stores information that has not yet been stored in the storage unit 31 after being acquired, input, or the like, and information selected for use in processing on the management terminal 20. Therefore, for example, information that is infrequently displayed on the touch panel 21 is stored in the storage unit 31 and then deleted from the storage unit 22.
  • the diagnosis result report screen 40 is created for each process device to be diagnosed.
  • the diagnosis result report screen 40 serves as an input interface when the inspector inputs the diagnosis result for each process device, and the inspector, the manager, and other related persons view the diagnosis result for each process device. It functions as an output interface.
  • the diagnosis result report screen 40 includes location information 41, fluid information 42, equipment information 43, operation information 44, diagnosis result 45, repair status 46, plan view 47, piping equipment diagram 48 (P & ID 48), and location photograph 49. Is done.
  • the location information 41 includes information for identifying the location where the process equipment to be diagnosed is installed. Specifically, the control number of the process equipment, the name of the area where the process equipment is installed, the name of the process where the process equipment is installed, the name of the piping where the process equipment is installed, and the process. The name that identifies the location where the equipment is installed, the hierarchy where the process equipment is installed, and the method for accessing the location where the process equipment is installed (accessible on foot or using a stepper, etc.) It is necessary to do it, etc.). With this information, each of the process equipment to be diagnosed is surely identified, and it assists the worker to reach the process equipment for repair work and the second and subsequent inspections.
  • the fluid information 42 includes information on the fluid distributed to the process equipment to be diagnosed. Specifically, the type of fluid flowing through the process equipment, the state of the fluid flowing through the process equipment (type of gas, liquid, etc.), the line pressure of the fluid flowing through the process equipment, and the process equipment. The back pressure of the circulating fluid is included. All of these pieces of information are information on the state of the process equipment during normal operation. From this information, it is possible to know under what conditions the process equipment is used.
  • the device information 43 includes information about the process device itself to be diagnosed. Specifically, the type of the process equipment (on-off valve, control valve, safety valve, rupture disc, etc.), the open / closed state of the process equipment during normal operation, the manufacturer and model name of the process equipment, and the setting of the process equipment. Includes pressure, as well as inlet and outlet dimensions and connection specifications for the process equipment. This information reveals the specifications of the process equipment and makes it easier to prepare for repair and replacement.
  • the operation information 44 includes information on the operation frequency of the process equipment to be diagnosed. In the example shown in FIG. 3, it is shown that the line on which the process equipment is installed is in operation and its operating time is 24 hours / day and 365 days / year. From this information, the load status of the process equipment can be estimated.
  • the diagnosis result 45 includes information on the diagnosis result of the process device to be diagnosed. Specifically, the date of diagnosis, the inspector who made the diagnosis, the judgment result by the diagnosis, the surface temperature of the inlet and outlet of the process equipment at the time of diagnosis, and the temperature difference thereof are included. The judgment result is expressed in three stages of "normal”, “confirmation required", and "leakage”.
  • the determination result of "normal” means that it can be determined by the diagnosis using the diagnostic machine 10 that the process equipment is in a normal state without any leakage.
  • the determination result of "leakage” also means that it can be determined that a leak has occurred from the process equipment by the diagnosis using the diagnostic machine 10.
  • the determination result of "confirmation required” means that the presence or absence of leakage cannot be determined from the diagnosis using the diagnostic device 10, and a more detailed inspection is required to determine the presence or absence of leakage.
  • the repair status 46 displays the repair status of the process equipment to be diagnosed.
  • the date when the process equipment was confirmed to have been repaired can be input and displayed.
  • plan view 47 a plan view of the periphery of the place where the process equipment to be diagnosed is installed is displayed.
  • the plan view displayed here is a reproduction of the layout plan of the plant owned by the business operator or the like operating the plant in which the process equipment is installed, around the place where the process equipment is installed. ..
  • a display 47a indicating the installation location of the process equipment is displayed.
  • the scale of the plan view 47 can be freely changed. The plan view 47 assists the worker to reach the process equipment for repair work, the second and subsequent inspections, and the like.
  • Piping equipment diagram 48 displays a piping equipment diagram (P & ID) around the place where the process equipment to be diagnosed is installed.
  • the piping equipment diagram displayed here is a copy of the piping equipment diagram for the plant owned by the business operator, etc. that operates the plant where the process equipment is installed, around the location where the process equipment is installed. Is. Further, in the piping equipment diagram 48, an indicator 48a indicating the process equipment on the piping equipment diagram is displayed. The scale of the piping equipment FIG. 48 can be freely changed. Plumbing equipment Figure 48 helps inspectors, managers, and other stakeholders understand the role of the process equipment in the process.
  • Location photograph 49 includes photographs of the process equipment to be diagnosed and its surroundings.
  • a zoom photograph 49a zoomed in on a bulb (an example of a process device) and an out photograph 49b showing the surroundings of the bulb together are displayed side by side. Further, in the zoom photograph 49a and the out photograph 49b, indicators 49c and 49d for identifying the bulb in the respective photographs are displayed.
  • Location Photo 49 assists the worker in reaching the valve for repair work, the second and subsequent inspections, and the like.
  • a thermal image can be used in place of or in addition to a normal digital image.
  • the thermal image 49f of the bulb to be diagnosed is displayed by superimposing it on a normal digital image.
  • the temperature difference is expressed on the thermal image by displaying the light color to the dark color from the high temperature part to the low temperature part, and the temperature of the valve is high due to the presence of the high temperature process fluid.
  • the primary side (left side in FIG. 4) is shown in light color and the secondary side (right side in FIG. 4) where such process fluid is absent and the temperature is low is shown in dark color.
  • the operation method of the diagnostic system 1 will be described.
  • the inspector possesses the diagnostic machine 10 and the management terminal 20 and inspects each process equipment installed in the plant one by one.
  • the case where the secondary side of the process equipment to be inspected is connected to the flare stack and therefore the secondary side of each process equipment is at atmospheric pressure will be described as an example.
  • the RFID tag reader 16 of the diagnostic device 10 first reads the RFID tag attached to the device to be diagnosed. As a result, the calculation unit 13 acquires the management number of the device to be diagnosed.
  • the acquired management number is sent to the management terminal 20.
  • the calculation unit 23 of the management terminal 20 uses the management number received from the diagnostic device 10 as a key to search whether or not the data related to the device to be diagnosed exists in the storage unit 22 of the management terminal 20.
  • the diagnosis result report screen 40 relating to the device to be diagnosed is displayed on the touch panel 21.
  • the inspector compares the items displayed on the diagnosis result report screen 40 with the installation status and usage status of the equipment to be diagnosed confirmed at the site, and inputs the correction points if there are items to be corrected.
  • the inspector determines the location information 41, the fluid information 42, the device information 43, and the information based on the location where the device to be diagnosed is installed, the piping connected to the device to be diagnosed, the information written on the name plate of the device to be diagnosed, and the like.
  • Each item of the operation information 44 is input. Further, the inspector performs an input operation for designating the position of the device to be diagnosed on the plan view 47, and arranges the indicator 47a at the designated position. Similarly, the indicator 48a is arranged on the piping device FIG. 48.
  • a zoom photograph and an out photograph of the device to be diagnosed are taken and registered as a zoom photograph 49a and an out photograph 49b, respectively.
  • This photographing may be performed using either a photographing device (not shown) provided integrally with the management terminal 20 or a photographing device (not shown) provided separately from the management terminal 20.
  • a photographing device not shown
  • a photographing device not shown
  • a photographing device not shown
  • a photographing device not shown
  • the liquid crystal display 18 displays an instruction to measure the main body of the device to be diagnosed.
  • the inspector presses the probe 10a of the diagnostic machine 10 against the main body of the device to be diagnosed to perform the inspection.
  • the ultrasonic measurement by the ultrasonic measuring unit 11 and the temperature measurement by the temperature measuring unit 12 are performed, and the calculation unit 13 acquires the measurement results of both measurements. Further, these measurement results are stored in the storage unit 14, and further stored in the storage unit 22 of the management terminal 20 and the storage unit 31 of the server device 30.
  • the calculation unit 13 performs a primary determination calculation (an example of the first diagnostic calculation process) based on the intensity of the detected ultrasonic waves (FIG. 5).
  • the calculation unit 13 compares the intensity of the ultrasonic wave (S11) measured by the ultrasonic wave measurement unit 11 with a predetermined threshold value (S12). If the intensity of the ultrasonic waves is less than the threshold value, the device to be diagnosed is determined to be in a "normal" state with no leakage. On the other hand, when the intensity of the ultrasonic wave is equal to or higher than the threshold value, the liquid crystal display 18 displays an instruction to measure the pipes (hereinafter referred to as peripheral parts) on the upstream side and the downstream side of the device to be diagnosed. To.
  • the inspector sequentially presses the probe 10a against the pipes on the upstream side and the downstream side of the device to be diagnosed, and measures the vibration and temperature of these pipes (S13).
  • the calculation unit 13 acquires the measurement result of the peripheral portion in the same manner as the measurement of the main body portion. Further, the measurement result of the peripheral portion is stored in the storage unit 14.
  • the calculation unit 13 compares the intensity of ultrasonic waves between the main body unit and the peripheral portion (S14a, S14b, an example of ultrasonic wave comparison processing).
  • the intensity of the ultrasonic wave in the peripheral portion (example of the second ultrasonic wave) is sufficiently larger than the intensity of the ultrasonic wave in the main body portion (example of the first ultrasonic wave) (that is, the intensity of the ultrasonic wave in the peripheral portion is high). If the intensity of the ultrasonic waves in the main body is greater than that of the ultrasonic waves and the difference is greater than or equal to a predetermined reference value), the calculation unit 13 determines that the device to be diagnosed is in a "normal" state.
  • the calculation unit 13 determines that the device to be diagnosed is in a “leakage” state. In this case, it is not considered that the cause of the ultrasonic wave detected in the main body is the disturbance, and it can be determined that the ultrasonic wave is caused by the leakage of the process fluid.
  • the state is "normal” or "leakage” based on the intensity of ultrasonic waves as in these cases, the secondary to quaternary determination described later is not executed.
  • the calculation unit 13 determines that the state of the device to be diagnosed cannot be determined by the primary determination calculation in the “confirmation required” state.
  • the measured ultrasonic wave and temperature data and the determination result are sent to the management terminal 20.
  • the management terminal 20 receives these information, and these information are stored in the storage unit 22. Further, the calculation unit 23 acquires the information, and the diagnosis result report screen 40 displays the items of the diagnosis result 45, the inlet surface temperature, the outlet surface temperature, and the temperature difference based on the received data. ..
  • the diagnostic date is entered based on the date and time the data was received.
  • the diagnostician may be input by the inspector himself, or may be automatically input by a method such as linking to the login ID of the management terminal 20.
  • the management terminal 20 appropriately sends various data stored in the storage unit 22 to the server device 30. Various data are also stored in the storage unit 31 of the server device 30.
  • the calculation unit 23 performs a secondary determination operation (example of the second diagnostic operation process) based on the detected temperature (FIG. 6).
  • the calculation unit 23 acquires the boiling point value of the process fluid from the storage unit 22 based on the input type of the process fluid (S21, example of boiling point reading process). If the type of process fluid has not been input, a guide prompting the input is displayed on the touch panel 21. If the storage unit 22 does not store the boiling point value of the process fluid, the boiling point value is acquired from the server device 30 or another computer via the network N.
  • the calculation unit 23 determines whether or not the process fluid is a liquid on the primary side of the device to be diagnosed in normal times based on the input state of the process fluid (type of gas, liquid, etc.). (S22).
  • the process fluid is a liquid
  • the boiling point of the process fluid obtained in S21
  • the ambient air temperature may be acquired by the temperature measuring unit 12 or may be acquired by another known method.
  • the diagnosis target is determined by the secondary determination calculation. It is determined that the device is in a "confirmation required" state in which the state of the device cannot be determined. In this case, a tertiary determination, which will be described later, is required for further determination.
  • the process fluid is liquid on the primary side of the device to be diagnosed and its boiling point is lower than the temperature, and a leak occurs in the device to be diagnosed, the process fluid leaked from the device to be diagnosed is released to atmospheric pressure. causes rapid vaporization of the process fluid. At this time, the heat of vaporization takes away the heat around the flow path on the secondary side, so that the temperature drops on the downstream side of the device to be diagnosed. That is, based on the state of the process fluid on the primary side of the device to be diagnosed and the boiling point of the process fluid, it is possible to predict whether or not the temperature will drop due to the heat of vaporization when a leak occurs in the device to be diagnosed (vaporization). Example of heat prediction processing).
  • the calculation unit 23 compares the temperature on the downstream side of the device to be diagnosed with the temperature and air temperature on the upstream side (S24, example of temperature comparison processing).
  • the calculation unit 23 determines that the device to be diagnosed is in a “leakage” state. In this case, it can be said that a clear temperature drop is observed on the downstream side (there is a temperature difference that exceeds the temperature difference range due to errors, variations, etc.), so the process fluid leaks and the temperature drop due to the heat of vaporization occurs. This is because it can be determined that it has occurred.
  • the calculation unit 23 further compares the temperature on the downstream side with the air temperature ( S25, example of temperature comparison processing).
  • the calculation unit 23 determines that the device to be diagnosed is in the "normal" state. This is because if there is a leak, the temperature should drop due to the heat of vaporization as described above, so the phenomenon that the temperature on the downstream side is equal to or higher than the outside air temperature cannot be observed. is there.
  • the calculation unit 23 performs a tertiary determination calculation (an example of the second diagnostic calculation process) based on the detected temperature (FIG. 7). The calculation unit 23 compares the temperature on the upstream side of the device to be diagnosed with the ambient temperature of the device to be diagnosed at the time of diagnosis (S31).
  • the calculation unit 23 determines that the state of the device to be diagnosed cannot be determined by the tertiary determination calculation in the "confirmation required" state. In this case, a quaternary determination described later is required for further determination.
  • the calculation unit 23 compares the temperature on the downstream side with the air temperature (S32).
  • the calculation unit 23 causes the touch panel 21 to display a guide to confirm the state of the steam trace on the downstream side of the device to be diagnosed (S33).
  • the inspector confirms the state of the steam trace by visual inspection, palpation, etc. according to the guidance, and determines whether or not the installation state of the steam trace changes the temperature state on the downstream side of the device to be diagnosed. ,
  • the result is input to the touch panel 21 (S34).
  • the calculation unit 23 determines that the device to be diagnosed is in a “leakage” state.
  • the temperature on the upstream side is higher than the air temperature, that is, the process fluid having a temperature higher than the air temperature is circulating on the primary side of the device to be diagnosed. Therefore, if the process fluid leaks to the secondary side of the equipment to be diagnosed, the temperature of the piping on the secondary side rises. It is determined that the temperature rise is not caused by the poor installation condition of the steam trace. For the above reasons, in the above case, it is determined that the state is "leakage”.
  • the calculation unit 23 determines the state of the device to be diagnosed by the tertiary determination calculation. It is determined that the status is "confirmation required". In this case, a quaternary determination described later is required for further determination.
  • the calculation unit 23 informs the touch panel 21 that the state of the steam trace around the device to be diagnosed is confirmed.
  • Display The inspector confirms the state of the steam trace by visual inspection, palpation, etc. according to the guidance, determines whether the installation state of the steam trace changes the temperature state of the device to be diagnosed, and the result. Is input to the touch panel 21 (S36).
  • the calculation unit 23 determines that the device to be diagnosed is in the "normal" state.
  • the calculation unit 23 determines the device to be diagnosed by the tertiary judgment calculation. It is determined that the state is a "confirmation required" state in which the state of is cannot be determined. In this case, a quaternary determination described later is required for further determination.
  • a quaternary determination is performed (FIG. 8). First, it is confirmed whether or not there is a valve that can be opened and closed on the downstream side of the device to be diagnosed (S41). If such a valve does not exist, or if such a valve exists but the valve cannot be operated due to circumstances such as operating conditions, it is determined that the state of the device to be diagnosed cannot be determined, and the calculation unit 23 diagnoses it. Confirm the judgment that the status of the target device is "confirmation required".
  • the calculation unit 23 causes the touch panel 21 to display a guide to the effect that ultrasonic measurement of the device to be diagnosed should be performed (S42).
  • the inspector brings the probe 10a of the diagnostic device 10 into contact with the device to be diagnosed according to the guidance, and starts the ultrasonic measurement by the ultrasonic measuring unit 11.
  • the calculation unit 23 causes the touch panel 21 to display a guide to open / close the valve while continuing the ultrasonic measurement (S43, S45).
  • the inspector confirms the result of the ultrasonic measurement when the valve is closed (S44, an example of the closing measurement process) and the ultrasonic measurement when the valve is opened (S46, an example of the opening measurement process).
  • the ultrasonic wave is also detected in the ultrasonic wave measurement (S42) before the valve operation is performed.
  • the calculation unit 23 determines that the device to be diagnosed is in a "leakage" state (comparison process when opening and closing). Example). If the valve on the downstream side is closed when a leak has occurred, the pressures on the primary side and the secondary side of the device to be diagnosed will eventually become the same, and the leak will not occur and ultrasonic waves will not be detected. However, when the valve is opened, a pressure difference is generated again, so that a leak occurs and the ultrasonic wave is detected again. For the above reasons, in the above case, it is determined that the state is "leakage".
  • the calculation unit 23 determines that the device to be diagnosed is ". It is determined that the state is "normal". In this case, it is determined that the ultrasonic waves (S12, S42) previously detected from the main body are due to disturbance.
  • the diagnostic results for each process device are accumulated.
  • Inspectors, plant managers, and other related parties (hereinafter referred to as viewers) have diagnosed the results of each process device on the management terminal 20, the administrator terminal for the administrator, or any other terminal.
  • the report screen 40 can be displayed to view the diagnosis results and related information of each process device. Further, the viewer can see a list of process devices in the "leakage” state, a list of process devices in the "confirmation required” state, based on the diagnosis results of the plurality of process devices stored in the storage unit 31 of the server device 30. You can browse secondary information such as counting the number of process equipment in "leakage" status for each plant area.
  • each diagnostic target device is superimposed on the plan view of the plant, and the color of each icon corresponds to the state of each diagnostic target device (“normal” is green, “confirmation required” is yellow. , “Leakage” is red) It is also possible to output the equipment distribution map.
  • repair measures such as repair and replacement are required.
  • the process equipment should be dismantled and inspected at the opportunity of shutting down the plant, and if any leakage is found, repair measures are required.
  • any viewer can input the implementation status of the repair measures to the repair status 46 of the diagnosis result report screen 40.
  • the repair measures have been completed for the process equipment diagnosed as "leakage”
  • the state of the process equipment is changed to "leakage (repaired)”.
  • the process equipment to be repaired can be identified locally by referring to the location information 41, the fluid information 42, the equipment information 43, the plan view 47, the piping equipment diagram 48, and the location photograph 49. It's easy to do.
  • the diagnostic system 1 can update the parts other than the repair status 46 of the diagnosis result report screen 40 only from the management terminal 20 for the parts other than the repair status 46, such as an administrator terminal. It is configured so that it cannot be updated from other terminals.
  • the location information 41, the fluid information 42, the equipment information 43, the operation information 44, the plan view 47, the piping equipment diagram 48, and the location photograph 49 are information that do not need to be updated in principle, and the diagnosis result 45 is the diagnostic machine. This is because the information should be updated only when it is based on the actual measurement using 10. The above configuration can prevent information that should not be updated from being accidentally updated.
  • the configuration in which the diagnostic system 1 includes the diagnostic device 10, the management terminal 20, and the server device 30 has been described as an example.
  • the ultrasonic measuring unit, the temperature measuring unit, and the arithmetic unit, and any other components may be one, two, or. It can exist as four or more constituent devices.
  • the diagnostic system according to the present invention may be configured, for example, to perform arithmetic processing by an arithmetic unit of a server device.
  • a configuration in which the arithmetic processing related to the primary determination is executed by the arithmetic unit 13 of the diagnostic machine 10 and the arithmetic processing related to the secondary to quaternary determination is executed by the arithmetic unit 23 of the management terminal 20 will be described as an example. did.
  • the allocation of which arithmetic unit performs each arithmetic processing is arbitrary.
  • the vibration of the pipes on the upstream side and the downstream side of the device to be diagnosed will be measured as an example. did.
  • the measurement of the second ultrasonic wave according to the present invention is not limited to the above mode as long as the ultrasonic wave is measured for the pipe connected to the device to be diagnosed. For example, the vibration of only one of the pipes on the upstream side and the downstream side of the device to be diagnosed may be measured.
  • the method of determining the presence or absence of leakage of the process fluid based on ultrasonic waves is not particularly limited.
  • the waveform, feature amount, average value, etc. of the ultrasonic wave can be used as the determination material.
  • the method of determining the presence or absence of leakage of the process fluid based on the temperature is not particularly limited.
  • the time-varying rate of temperature, the moving average, the maximum value or the minimum value in a predetermined period, and the like can be used as judgment materials.
  • the method for determining the presence or absence of leakage of the process fluid based on the temperature is not particularly limited. For example, when the temperature on the upstream side of the device to be diagnosed is lower than the air temperature, the phenomenon that the temperature drops on the secondary side due to the leakage of the process fluid may be utilized.
  • the diagnosis result report screen 40 shows the location information 41, the fluid information 42, the equipment information 43, the operation information 44, the diagnosis result 45, the repair status 46, the plan view 47, the piping equipment diagram 48, and the location photograph 49.
  • the configuration including is described as an example. However, without being limited to such a configuration, the diagnosis result report screen according to the present invention does not necessarily have to include all the above information.
  • information other than those illustrated above may be included, and may include, for example, the color of the flare stack flame at the time of diagnosis, an image of the flame, and the like.
  • the diagnostic system can diagnose the process equipment installed in any manner as long as it is a process equipment that controls the flow of the process fluid.
  • the criteria for each of the primary to quaternary determinations can be arbitrarily changed based on the conditions under which the process equipment is installed. For example, if the secondary side of the process equipment has a pressure lower than the primary side and higher than the atmospheric pressure, the range of temperature drop caused by the heat of vaporization of the leaked process fluid can be small, so the judgment conditions are set in consideration of this. ..
  • the method of specifying the device identification information for identifying the device to be diagnosed is not particularly limited. For example, an inspector visually reads the device identification information written on the name plate of the device to be diagnosed. This may be a method of inputting this into the diagnostic system.
  • the present invention can be used, for example, in a diagnostic system capable of diagnosing process equipment that controls the flow of process fluids in a chemical plant.
  • Diagnostic system 10 Diagnostic machine 10a: Probe 11: Ultrasonic measurement unit 12: Temperature measurement unit 13: Calculation unit (diagnosis machine) 14: Memory unit (diagnostic machine) 15: Communication unit (diagnostic machine) 16: RFID tag reader 17: Input button 18: Liquid crystal display 20: Management terminal 21: Touch panel 22: Storage unit (management terminal) 23: Calculation unit (management terminal) 24: Communication unit (management terminal) 30: Server device 31: Storage unit (server device) 32: Communication unit (server device) N: Network 40: Diagnosis result report screen 41: Location information 42: Fluid information 43: Equipment information 44: Operation information 45: Diagnosis result 46: Repair status 47: Plan view 47a: Indicator (plan view) 48: Piping equipment diagram 48a: Indicator (Piping equipment diagram) 49: Location photo 49a: Zoom photo 49b: Out photo 49c: Displayer (zoom photo) 49d: Displayer (out photo) 49e: Alternative example of zoom photo 49f: Thermal image

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Automation & Control Theory (AREA)
  • Fluid Mechanics (AREA)
  • Acoustics & Sound (AREA)
  • Health & Medical Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Analytical Chemistry (AREA)
  • Biochemistry (AREA)
  • General Health & Medical Sciences (AREA)
  • Immunology (AREA)
  • Pathology (AREA)
  • Testing And Monitoring For Control Systems (AREA)
  • Examining Or Testing Airtightness (AREA)
  • Investigating Or Analyzing Materials By The Use Of Ultrasonic Waves (AREA)

Abstract

La présente invention concerne un système de diagnostic 1 capable de diagnostiquer un équipement de traitement pour réguler l'écoulement d'un fluide de traitement qui s'écoule à travers une installation chimique, et est pourvu d'une unité de mesure ultrasonore 11, d'une unité de mesure de température 12, et d'une unité de calcul 13, 23, caractérisé en ce que l'unité de calcul 13, 23 est capable d'exécuter un premier traitement de calcul de diagnostic pour déterminer, sur la base d'ondes ultrasonores mesurées par l'unité de mesure ultrasonore 11, la présence ou l'absence d'une fuite de fluide de traitement dans un équipement en cours de diagnostic, qui est l'équipement de traitement qui est diagnostiqué, et un second traitement de calcul de diagnostic pour déterminer, sur la base de la température mesurée par l'unité de mesure de température 12, la présence ou l'absence d'une fuite de fluide de traitement dans l'équipement en cours de diagnostic, et en ce que la configuration est telle que le premier traitement de calcul de diagnostic est exécuté avant le second traitement de calcul de diagnostic.
PCT/JP2020/038260 2019-10-11 2020-10-09 Système de diagnostic, procédé pour faire fonctionner un système de diagnostic et programme de diagnostic WO2021070924A1 (fr)

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CN113339688B (zh) * 2021-06-02 2024-03-12 江苏高特阀业有限公司 一种疏水阀泄漏监控系统及其方法

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