method for developing a designed life profile for a component of a process control device

专利摘要:
VALVE PROGNOSTICS FOR POLYMERIC COMPONENTS BASED ON ACCELERATED AGING TECHNIQUES The claimed method and system develops accelerated aging test protocols for a component of a process control device, such as a polymeric component of a valve assembly, in which the Accelerated aging test protocol was specifically developed in response to the operating conditions that must be used when operating the process control device in a process plant installation. The test data from the accelerated aging tests developed is analyzed to determine a projected component life profile that generates the component profile through failure under these expected operating conditions. Particular profiling for polymeric characteristics includes profiling of oxidation failure and other fatigue conditions
公开号:BR112015022150B1
申请号:R112015022150-5
申请日:2014-03-14
公开日:2020-11-03
发明作者:Ted Dennis Grabau；Meredith Bell
申请人:Fisher Controls International Llc；
IPC主号:

专利说明:

Technology field
[0001] The present disclosure relates to processing control devices in processing plants and, more specifically, to techniques for making useful life predictions in processing control devices. Foundations
[0002] Existing processing control systems can perform periodic diagnostics on processing control devices, such as valves, in order to determine the operability and performance of these devices. The determination of the operability of a processing control device can enable a better organization of the maintenance of the processing control device, thus reducing the occurrences of failures and shortening the time. This can result in increased efficiency, safety and performance. Processing control systems can use sensors and other measuring devices to observe characteristics of a processing control device. For example, some existing control systems may use a digital valve controller to measure and collect data from various sensors on a control valve.
[0003] Among the uses of data collected from control valves, customers expect the data to plan preventive maintenance for their processing plants, hoping to avoid unforeseen maintenance and loss of production caused by unexpected failures. Customers, for example, will want to know the designed life of a valve before requesting maintenance, as well as what repair procedures and replacement options are available and recommended. For the manufacturer, providing a life expectancy forecast is somewhat challenging, since the actual processing conditions will vary dramatically from customer to customer, or from installation to installation, even in a processing plant. Specification sheets can be provided to customers, providing some projection data and sometimes in response to the design conditions provided by the customer. However, factors such as temperature and pressure often vary dramatically from those provided under the customer's design conditions and, in any case, other variable conditions, such as fluid state (liquid or vapor) and impurities (solid, liquid or vapor) are not usually provided in the design conditions, or, as with other factors, may vary considerably during actual use.
[0004] Conventionally, customer service and repair history data would be collected in order to generate Average Time to Failure (MTTF) and Average Time between Failure (MTBF). This MTTF and MTBF data could then be used to predict the life of a valve. However, the use of this historical data can be limiting due to the fact that maintenance records may be incomplete or nonexistent. In addition, customers may not wish to share such information because they are concerned that their operating conditions would be exposed to competition. The result is that MTTF and MTBF data, based on historical data, is often incomplete and insufficiently informative.
[0005] Another technique for predicting MTTF and MTBF is through the use of laboratory data produced in conditions as close as possible to real life. Pressure and temperature conditions are generally easy to obtain in a well-equipped laboratory. Fluid properties and contamination, however, are much more difficult to simulate; although the essential fluid properties can typically be obtained, which are: oxidizing, non-oxidizing, wet, dry, lubricating and non-lubricating. Occasionally, even a known contamination can be obtained, as with particles in the fluid flow. Laboratory cycles testing, in particular, for example, the same temperature, pressure and fluid properties that represent specific valve service applications can be an effective substitute for real field data. This is especially the case for valve components that are subject to normal mechanical wear or fatigue.
[0006] Although laboratory testing is used, for the foregoing reasons and other reasons, conventional testing methods for determining MTTF and MTBF are absent. The methods are unable to explain the varied conditions and the different factors that affect the useful life of the device, especially those related to the sliding-stem valves, where the various components capable of damaging or wearing, resulting in the failure of the valve, are numerous and each with potentially different responses to operating conditions, such as temperature, pressure, fluid, etc.
[0007] Summary of the invention
[0008] According to an example, a method is provided for the development of a life profile designed for a component of a processing control device. The method may include receiving an identification of a component capable of experiencing mechanical wear or damage, over time, during the operation of the processing control device, and receiving an operating parameter corresponding to the component. Such component performance degrades over time as a result of changes in operating parameter values. The method may include receiving previously recorded performance data from a reference component collected during the operation of the reference component under conditions compatible with the conditions under which the processing control device must operate. The method may also include the development of the projected life profile for the component based on previously recorded performance data, where the projected life profile indicates a projected life of the component as a function of the values of the operational parameter.
[0009] According to another example, a method for determining a projected remaining life for a component of a processing control device is provided. The method may include receiving a projected life profile, where the projected life profile is developed based on previously recorded performance data collected during the operation of a reference component under conditions compatible with the conditions under which the processing control device must operate, and where the designed life profile indicates a designed life of the component as a function of an operational parameter. The method may include receiving current data in the operational parameter for the component during the operation of the processing control device. The method also includes the analysis of these current data and the projected life profile in order to determine a projected remaining life for the component. The method may also include determining a component operator notification status based on the remaining projected life. In some examples, notification status data is communicated to employees remotely, such as a processing control device operator or employees. maintenance in order to schedule component maintenance.
[0010] Brief description of the figures
[0011] FIG. 1 is a diagram of a processing plant for receiving and coordinating data transfer between many functional areas of the plant;
[0012] FIG. 2 is a block diagram of a processing control device used in a processing control system, where the exemplary processing control device is a set of valves that have an integrated diagnostics module attached;
[0013] FIG. 3 is a block diagram of another example of a processing control device used in a processing control system, where the exemplary processing control device is a set of valves and a remote computer contains an integrated diagnostics module;
[0014] FIG. 4 illustrates an example of the valve set in Figs. 2 and 3, which show various valve components whose profiles can be generated;
[0015] FIG. 5 is a block diagram of an integrated diagnostic module used to generate service life profiles of the valve components of FIG. 4; and
[0016] FIGS. 6A-6D are graphs of projected life profiles developed by the integrated diagnostics module for each of the valve components identified in FIG. 3.
[0017] FIG. 7 is a block diagram of an example profiler to develop accelerated aging test protocols and life profiles.
[0018] FIG. 8 illustrates an accelerated example against the test protocol frame developed by the profiler in FIG. 7. description
[0019] Although the following text presents a detailed description of numerous different modalities, it should be understood that the legal scope of the description is defined by the words of the claims presented at the end of this patent. The detailed description should be constructed only as an example and does not describe every possible modality since describing every possible modality would be impractical, if not impossible. Numerous alternative modalities could be implemented, using the current technology or the technology developed after the filing date of this patent, which would still be within the scope of the claims.
[0020] Referring now to FIG. 1, a processing plant 10 includes a number of businesses and other computer systems interconnected with a number of control and maintenance systems by one or more communication networks. Processing plant 10 includes one or more processing control systems 12 and 14. Processing control system 12 and 14 can be, for example, DeltaVTM controllers sold by Fisher-Rosemount Systems, Inc. of Austin, Texas, or any other desired type of controller or DCS, which may include an operator interface 12A coupled to a controller 12B and to input / output (I / O) cards 12C, which, in turn, are coupled to various control devices field, such as analog field devices and Fast Addressable Remote Transmitter (HART) 15. The processing control system 14 may include one or more operator interfaces 14A coupled to one or more controllers 14B distributed over a bus, such as an Ethernet bus. Controllers 14B are connected via input / output devices to one or more devices 16, such as Fieldbus or HART field devices or other smart or non-smart devices, including, for example, those using any one among the PROFIBUS®, WORLDFIP®, Device-Net®, AS-interface and CAN protocols. As is known, field devices 16 can provide analog or digital information to controllers 14B, related to processing variables, as well as other device information. Operator interfaces 14A can store and execute the tools available to the processing control operator to control the operation of the process, including, for example, controlling optimizers, diagnostic specialists, neural networks, tuners, etc.
[0021] In addition, maintenance systems such as computers that run a resource maintenance application or any other device monitoring and communication applications can be connected to processing control systems 12 and 14 or their individual devices to perform activities maintenance and monitoring. For example, a maintenance computer 18 can be connected to controller 12B and / or devices 15 via any desired lines or networks (including wireless networks or portable devices) to communicate with and, in some cases, reconfigure or perform other maintenance activities on devices 15. Likewise, resource management applications can be installed and run by one or more of the user interfaces 14A associated with the distributed processing control system 14 to perform maintenance and monitoring functions, including data collection related to the operating status of devices 16.
[0022] The processing plant 10 also includes various rotating equipment 20, such as turbines, motors, etc., which are connected to a maintenance computer 22 via a permanent or temporary communication link (such as a bus, a communication system) wireless devices or handheld devices that are connected to equipment 20 to take readings and then be removed). Maintenance computer 22 can store and run known monitoring and diagnostic applications 23 provided by, for example, CSI 2140 Machinery Health Analyzer from CSI-Computational Systems, lnc.de Knoxville, TN or any other known application used to diagnose, monitor and optimize the operational status of rotating equipment 20. Maintenance personnel generally use applications 23 to maintain and monitor the performance of rotating equipment 20 at plant 10 to determine problems with rotating equipment 20 and to determine when and whether rotating equipment 20 should repaired or replaced.
[0023] In order to facilitate communications related to the maintenance of the various equipment (that is, processing control devices), in the illustrated example, a computer system 30 is provided, which is communicatively connected to the computers or interfaces associated with the several functional systems in plant 10, including processing control functions 12 and 14, maintenance functions, such as those implemented in computers 18, 14A, 22 and 26 and business functions. In particular, the computer system 30 is communicatively connected to the processing control system 12 and the maintenance interface 18 associated with the control system, it is connected to the processing control and / or to the maintenance interfaces 14A of the control system processing 14 and is connected to the rotating equipment maintenance computer 22, all via a bus 32. Bus 32 can use any desired or suitable local area network (LAN) or wide area network (WAN) protocol to provide communication .
[0024] As illustrated in FIG. 1, computer 30 is also connected via the same network bus or a different bus 32 to business system computers and maintenance planning computers 35 and 36, which can run, for example, enterprise resource planning systems (ERP), material resource planning (MRP), accounts, production and customer ordering, maintenance planning or any other desired business application, such as raw materials and supplies ordering applications, organization applications production, etc. The computer 30 can also be connected via, for example: bus 32, to a LAN 37, a corporate WAN 38, as well as a computer system 40 that allows remote monitoring or communication with the plant 10 from remote locations.
[0025] Generally speaking, computer 30 stores and runs a resource management system 50 that collects data and other information generated by processing control systems 12 and 14, maintenance systems 18, 22 and 26 and information systems. businesses 35 and 36, as well as information generated by the data analysis tools executed in each of these systems.
[0026] In addition, in general, one or more user interface routines 58 can be stored on and executed by one or more of the computers in plant 10. For example, computer 30, user interface 14A, the system business computer 35 or any other computer can run a user interface routine 58. Each user interface routine 58 can receive or subscribe to information from the resource management system 50 and both the same resources and different data resources can be sent to each of the 58 user interface routines. Any of the 58 user interface routines can provide different types of information using different screens for different users. For example, one of the user interface routines 58 may provide a screen or set of screens to a control operator or a business person to allow the person to set limits or choose optimization variables for use in a control routine. standard or in a control optimizer routine. User interface routine 58 can provide a control guidance tool that allows the user to view the indexes created by the index generation software 51 in some coordinated manner. This operator guidance tool can also allow the operator or anyone else to obtain information on the condition of the devices, the control steps, the units, etc., and easily view information related to problems with these entities, since this information was detected by other software in the processing plant 10. User interface routine 58 can also provide performance monitoring screens that use the performance monitoring data provided or generated by tools 23 and 27, maintenance programs, such as a resource management application or any other maintenance program, or as generated by the models in conjunction with the resource management system 50. Obviously, the user interface routine 58 can provide access for any user or allow the user change preferences or other variables used in one or all functional areas of the plant 10.
[0027] Plan 10 illustrates several processing control devices (for example, devices 14, 15,16, 20 and 25), which can degrade performance over time and require maintenance. Certain processing control devices, such as control valves, are used to modulate or control the flow of fluid in process control systems under the control of process control systems 12 and 14. (Fluids in this case may include fluids gases, such as compressed nitrogen gas, etc.). These are provided by way of example, since it should be understood by someone minimally versed in the technique that, although the exemplary modalities described here are based on pneumatic control valves, other processing control devices, such as pumps, electronically activated valves and buffers will also affect the operation of the processing plant and can be included in the techniques described here.
[0028] In general, processing control devices, such as control valve assemblies, can be positioned in ducts or pipes to control fluid flow by changing the position of a moving element, such as a valve connector inside the control valve, using an actuator or a coupled positioner. Adjustments in the control element can be used to influence some processing conditions to maintain the selected flow rate, fluid level or temperature.
[0029] A set of control valves is normally operated from a regulated source of pneumatic fluid pressure, such as air from a plant compressor. This fluid pressure is introduced into the actuator (such as a spring or diaphragm actuator for sliding-stem valves or a piston actuator for rotary valves) through a positioner or a valve control instrument that controls the fluid pressure in response to a signal received from the processing control system. The magnitude of fluid pressure in the actuator determines the movement and position of the spring and diaphragm or piston within the actuator, thereby controlling the position of a valve stem coupled to the moving element of the control valve. For example, in the spring and diaphragm actuator, the diaphragm must work against a bias spring to position the movable element (ie, the valve connector) within a valve passage between the valve inlet and outlet control to modify the flow within the processing control system. The actuator can be designed in such a way that the increase in the fluid pressure in the pressure chamber either increases the extension of the opening of the moving element or decreases it (for example, with direct action or reverse action), the first situation being implied in this document . Although these descriptions may apply to a sliding-stem valve, corresponding components and operations would apply to rotary valves.
[0030] Fig. 2 illustrates a set of general control valves 100 that can be used in processing control system 12 or 14. A control valve 102 can have a movable element, such as a valve stem and a connector for valve (not shown), which is selectively positioned by an actuator 104 being controlled by a positioner to modify the flow of processing. It is understood by someone minimally skilled in the art that an indication of the position of the moving element of the valve connector is provided by means of a position sensor 106, which can be integrated into the valve position controller 108 or can be an independent positioning transmitter. . Control valve 102 generates a variable orifice within the flow passage of the processing control system to control the flow of processing materials in the processing control system. The processing control system can generally use transmitter 110 to detect a processing variable in order to characterize processing. The processing variable can be transmitted back to a processing device controller 112 directing the operation of the processing plant to control processing.
[0031] A valve controller 114 includes valve position controller 108, position sensor 106 and may also include a driver control signal generator 116, which may include, for example, an electropneumatic step (not shown) which is controlled by a microcomputer provided in this, which generates an output signal from the valve position controller 108 to drive the actuator 104. It must be appreciated by someone minimally skilled in the technique that the actuator can be an electric actuator (not shown) and the driver control signal generator can provide an electrical control signal to control or modify the position of the electric driver. The driver control signal generator 116 converts the output signal from the valve position controller 108 to the corresponding control value to be set on driver 104. Position sensor 106 can monitor driver 104 for input information from position (through the positioning of the actuator stem) or to the control valve 102 (through the valve stem), displayed as a dotted line.
[0032] In operation, a user interacts with control valve 102 and processing 118 on a user processing control interface 120 that provides commands to processing controller 112 responsible for controlling all processing, where the processing controller 112 is in communication with other control devices (not shown) used at the plant for processing control. The processing controller 112 can translate the input commands provided by the user at interface 120 into nominal value signal commands. The setpoint signal commands can then be sent to valve controller 114 and, specifically, to valve position controller 108. Valve position controller 108 may have the microcomputer described above in it. The microcomputer can be programmed to follow an algorithm to control the control valve 102 in response to received setpoint signal commands and direct the control signal generator from driver 116 to generate a corresponding control signal at driver 104 to position the control valve 102.
[0033] In the system of Fig. 2, increases in the magnitudes of the setpoint controls can cause corresponding increases in the pneumatic pressure provided by the driver control signal generator 116 in the valve controller 114, thus effecting it through the driver 104 , corresponding increases in the opening controlled by the moving element of the control valve 102. The resulting position of the moving element can have an effect on the processing and therefore on the processing variable monitored and detected by the processing variable transmitter 110. The transmitter processing variable 110 transmits a signal representative of the processing variable back to processing controller 112. One of ordinary skill in the art will understand that processing controller 112 uses the representative signal as an indication of processing status as feedback to control the system.
[0034] As discussed above, the processing controller 112 may be in communication with other control devices used in the plant for processing control. The processing controller 112 may further include or may be connected to a computer that has general computing elements, such as a processor or processing apparatus, a memory, an input device and a display device (for example, a monitor) . The processor can be connected to memory, the display device and the input device, as is known to those skilled in the art. In addition, the computer can include a network interface to connect a network and the computer to provide communication between them. In one embodiment, the computer can form a part of the processing controller, as in a digital processing controller. In another embodiment, the user processing control interface can represent the computer. Alternatively, the computer can be connected on a network to the processing controller, but be physically remote from the processing controller.
[0035] Valve controller 114 also includes or, alternatively, receives information from an operating condition sensor 122 that monitors one or more operating conditions for valve 102 and / or one or more environmental conditions under which valve 102 is operating. The operating condition sensor 122 can be any sensor or transmitter that detects or otherwise monitors an operating condition on or near valve 102 or valve driver 104. For example, the operating conditions sensor can monitor a fluid temperature flowing through valve 102, a fluid temperature that operates valve valve 104, a fluid temperature that moves through position controller 108, a temperature ambient air from valve 102, valve actuator 104 or valve position controller 108, a pH level of any of the fluids mentioned above, a pressure (downstream or upstream) of any of the above fluids, a salinity or viscosity of any of the above fluids, etc. Operational condition sensor 122 is coupled to provide detected operational condition data 102 to valve position controller 108 to affect valve control 102 and to an integrated diagnostics module 124. In some embodiments, the condition sensor Operational 122 transmits data to a data historian or other centralized data collection element, and the diagnostics module 124 retrieves data from its operational condition.
[0036] Multiple operating condition sensors 122 and / or multiple position sensors 106 can be arranged throughout the system shown in Fig. 2 in order to detect and / or measure characteristics of the control device and the system and can provide this information of characteristics or data to the computer or to the processing device controller 112 for display in the display device element. In one embodiment, sensor data from sensors 106 and 122 is collected by the integrated diagnostic module 124, which can include a computer processor and memory. In some examples, a diagnostic monitor 126 coupled to module 124 represents a computer display device that displays sensor data or data output through module 124. The computer input device element can be, for example, a keyboard, a tactile keyboard, a mouse, an optical mouse, an optical pen, a microphone (for example, for voice command inputs), etc. Note also that several modalities of the claimed method and the system described below can be implemented as a set of instructions in the computer processor for execution, as known to those skilled in the art.
[0037] The integrated diagnostic module 124 develops and implements prognostic algorithms for the processing control devices to predict the end of life usable for these devices and / or various components thereof. The exemplary processing control devices in this document are valve assemblies. However, more broadly, an integrated diagnostic module can be used with any processing control device that experiences mechanical damage or wear over time, including devices that modulate fluid flow in a process, such as valves, pumps and dampers, and can be implemented to predict the end of life usable for the components of any and all of these devices.
[0038] The integrated diagnostic module 124 gathers prognostic algorithms for components that form the processing control device and from which data of the remaining life time (for example, remaining life cycle, projected maintenance data ) can be determined. As discussed later, the integrated diagnostic module 124 can derive these algorithms from the documented average or minimum service life of multiple processing control devices of the same type and construction materials, as used in a given application, from laboratory collected in a manner that comes closest to field service conditions (eg operating environment) and / or historical data from identical or similar devices, or parts of devices, on the plant or in the environment in which the device or part are installed. Such algorithms can, therefore, take into account the components that normally fail due to mechanical damage or wear and that can be characterized as having a fixed or average useful life when new. For example, when designing the cycle life, the integrated diagnostic module 124 can shorten a fixed or average life cycle for each cycle experienced during operation. Such a decrease would occur automatically, for example, in response to an automatic sensor in the processing control device or from an operator input. As another example, the integrated diagnostic module 124 can shorten a medium or fixed movement life (for example, of a seal around a valve stem) by the cumulative movement of a part (for example, the valve stem) as detected by position sensor 104 on valve driver 104 or valve 102, as controlled by driver control signal generator 116, as controlled by valve position controller 108 or even as controlled by processing controller 112.
[0039] In some examples, the remaining life span is determined based, at least in part, on sensor data (for example, sensors 106 and 122) that measure normal operating conditions, where data is collected at intervals certain periodicals, either on a continuous basis, or in response to some triggering event. In some instances, the remaining life is determined based, at least in part, on information from processing controller 112, valve position controller 108 and / or valve driver 104. For example, the remaining life may be determined, in some embodiments, according to one or more operating conditions as detected by sensor 122 and according to the number of open / close cycles, as instructed by processing controller 112 (as opposed to receiving the number of opening / closing actuator 104 or position sensor 106).
[0040] The integrated diagnostic module 124 is capable of determining the remaining service life for each of the replaceable components of the processing control device (for example, connectors, seals, bushings, bearings, etc.), as well as for the device processing control as a whole. In both cases, the remaining service life may be based only on the characteristics of the specific processing control device or components in question or based on measured characteristics of other devices in the processing or data plant. The latter may include other devices that operate in coordination with the device in question, as well as general operating conditions of the processing plant. Specific data of remaining life can be stored in a computer-readable memory device, for example, by a smart positioning device in a valve configuration, such as inside valve controller 114 of Fig. 2.
[0041] The integrated diagnostic module 124 is capable of communicating with a remote computer, such as a system controller 12 or 14, through a communication interface 128 which can be a wired or wireless communication interface, whose computer remote control can, in some cases, take some processing control action (for example, adjusting the use of a valve - for example, the speed or frequency of actuation to prolong the life of a valve component by switching to a redundant device / a flow passage, etc.) based on data received from an integrated diagnostic module 124.
[0042] As illustrated in Fig. 2, and as described above, the diagnostics of the integrated module 124 can receive a variety of inputs in various implementations. Among the inputs are inputs from one or more operating condition sensors 122, one or more position sensors 106, one or more variable processing transmitters 110, processing controller 112 and communication interface 128. Each of the sensors operating conditions 122 can detect a different parameter (for example, temperature, pressure, viscosity, flow rate, etc.), or can detect the same parameter as another sensor, but in a different location (for example, upstream pressure and downstream, the temperature of the fluid flowing through valve 102 and the temperature of the driver control fluid 104, etc.). Each of the one or more position sensors 106 can detect a position of a different element (for example, the position of a valve stem and the position of a driver stem). The integrated diagnostic module 124 can also include (for example, as stored in a memory device) or retrieve / receive (for example, through communication interface 128) data and / or algorithms to use in determining the remaining life span device or device components.
[0043] In the example in Fig. 2, the integrated diagnostic module 124 is incorporated into the valve assembly 100. For example, module 124 can be implemented by an on-board processor (from controller 114), or by instructions to be executed by that processor, into a smart processing control device. Fig. 3 illustrates another example of configuration, with a set of valves 100 ', having characteristics similar to those of the set of valves 100, except that an integrated diagnostic module 150 is contained within a remote computer system 152, such as a computer multiplexed host, a DCS system, a plant resource management system (such as the resource management system 50) or any combination thereof. Communication interface 128 'packages operating condition data from sensor (s) 122' and sensor (s) 106 'and transmits it to remote computer system 152 for profiling by part of the integrated diagnostic module 150.
[0044] Fig. 4 is an exemplary processing control device in the form of a set of valves 200 made of various components, which have potentially different life profiles that will be determined by an integrated diagnostic module (for example, the integrated diagnostic module 124). In the illustrated examples, these life profiles are cyclical life profiles, as they depend on the number of operating cycles that the valve experiences (for example, the number of fully experienced open / closed operations and the number of partially open / closed operations experienced). In the illustrated example, valve set 200 is made up of a series of components whose profiles can be generated using laboratory test data or historical data previously collected from the valve sets in use. In this way, life profiles can be developed from real data that reflect specific conditions experienced in a processing plant installation. The specific components illustrated include a diaphragm header component 202 and a shaft receptacle 204 connected to a sealing component 206 and wrapped with a valve body 208 through the packing joint component (bushings or bearings) 210.
[0045] A valve controller 212 corresponding to valve controller 114, in whole or in part, controls the position and activation of the valve. A diagnostic module integrated within valve controller 212 collects various operational data and profile data to determine a cyclical life profile for each of these various components, using a prognostic algorithm. In some examples, such as FIG. 2, the prognosis algorithm is applied by an on-board processor inside a dedicated positioning instrument, inside a valve controller. In some examples, such as FIG. 3, the prognostic algorithm is applied by a multiplexed host computer in communication with valve controller 212, such as computer systems 30, 35 or 36. In other examples, a distributed processing control system (DCS) or a plant resource management system, such as resource management system 50, in communication with controller 212, can be used. In yet other examples, a combination of these analysis configurations can be used, which can provide a benefit when the component's cyclical life from several different sources is used.
[0046] Fig. 5 illustrates an example of integrated diagnostic module 400 (corresponding, for example, to integrated diagnostic module 124 or 150), as it may be contained in valve controller 312 or in remote computer system 152. The module 400 is configured to have access to a device descriptor 402 that identifies the specific processing control device under analysis (for example, valve assembly, pump assembly, damper, etc.). The device descriptor 402 can be incorporated into the processing control device by the manufacturer or the customer and can be a file, stored in a memory device, which is fixed or rewritable, in various modalities. In some instances, device descriptor 402 is a rewritable or otherwise configurable part of user processing control interface 120, in order to facilitate manual identification or selection of the specific processing control device whose profile will be generated. In any case, the device descriptor 402 can be stored locally in the processing control device or in a remote computer system, such as systems 12, 14, 30, 35 or 36.
[0047] The device descriptor 402 accesses a 404 listing file that identifies the components that make up the processing control device and that have a usable useful life, and can identify, for each component, any data necessary to create a profile of component life as described below. In the example of Fig. 4, the listing file 404 identifies the diaphragm header component 302, the shaft receptacle 304, the sealing component 306 and the sealing gasket component 310 as usable components of the valve assembly 300.
[0048] In some embodiments, the components listed in the 404 listing file depend on the type of processing control device. For a set of sliding stem valves, for example, a 404 listing file can identify one or more of the following components that experience damage or mechanical wear during operation: actuator piston or diaphragm and bar seals, bushings or bearing bearings actuator, valve stem, connector or stem guide bearings or bushings, valve connector balance seals, valve connector, valve cage, bellows seals and / or actuator springs. For a set of rotary valves, listing file 404 can identify the driver's piston or diaphragm or the bar and piston seals, valve shafts, valve bearings or bushings, seals, discs, balls, segmented balls or connectors and / or driver springs.
[0049] In other modalities, the 404 listing file can include all components for a specific line of devices of a specific type, or all components for a complete product line from manufacturers. In these modalities, the integrated diagnostic module 400 can retrieve from the list file 404 only the data related to the devices identified by the device descriptor 402. For example, the device descriptor 402 can identify (for example, by being programmed / configured by an operator or technician) a certain type of valve actuated by a specific type of actuator. The module 400 can then retrieve data from the device descriptor 402 related to the components that are associated with the specific driver and valve types. In some embodiments, the 404 listing file can be stored remotely, such as on a server accessible via a communication network, such as a LAN (for example, where the 404 listing file is stored on a plant server) or the Internet (for example, where the 404 listing file is stored on a server from the device manufacturer).
[0050] The 404 listing file can also identify stressful accessories mounted to a valve set or a valve positioner, such as volume amplifiers, solenoids, travel valves, limit alternators, position transmitters, supply pressure regulators pneumatic instrument and tubes.
[0051] Although a single 404 listing file is shown in Fig. 5, multiple listing files can be used, for example, to allow valve components to be listed in one listing file or fatigue accessories listed in another listing file.
[0052] Where several components are stored in device descriptor 402, different listing files 404 for each part can be accessed under instruction of the integrated diagnostic module 400.
[0053] The 404 listing files can be started and updated by the device manufacturer or by the customer, from the operator's input. For example, a GUI interface can be provided (via interface 120) to an operator to allow the selection of pre-existing stored component entries, as well as for adding and / or deleting component entries. The formation of the listing file 404, thus, can be carried out before the operation of the processing control device. The 404 listing file can be updated to include additional components added during the assembly operation. Such an update can occur through manual entry by an operator or automatically, for example, for systems where, while accessories are added to a part assembly, those accessories are automatically detected by the part controller.
[0054] In addition to identifying the components, the list file 404 can identify, for each of the components listed, an operational parameter that affects the fatigue or mechanical wear of that component during the operation of the device. Since the useful life of each component can be affected by different operating conditions, in some examples, the list file 404 identifies the different operational parameters that are to be accessed by the integrated diagnostic module 400 in the development of a service life profile. component. For example, a valve positioner can fatigue in response to various parameters, such as the current-to-pressure (l / P) ratio experienced by the valve / flap nozzle, the piezo crystal, or the moving solenoid component. Additional parameters include the pressure on a pressure relay, the position of the connections on a valve, the position of various feedback devices, whether such feedback is from a potentiometer, encoder or resolver device. Generally, these operational parameters identify the metrics that are to be detected and evaluated using a prognostic algorithm to determine a component's life profile and the process control device in general.
[0055] As discussed later, the integrated diagnostic module 400 can also access the stored historical data 406 with the operational data, maintenance data, average time of failure, or other data on the device and its components obtained previously.
[0056] In the illustrated example, the integrated diagnostic module 400 also accesses laboratory test data 407 for the process control device and corresponding components listed in list file 404. In other examples, only one of the test data laboratory 407 or historical data 406 is accessed by module 400.
[0057] In the configuration of FIG. 2, historical data 406 and laboratory test data 407 can be stored locally or accessed remotely via communication interface 128. In the configuration of FIG. 3, historical data 406 and laboratory test data 407 can be stored on remote computer system 152, for example, accessible by computer system 12, 14, 30, 35, and / or 36.
[0058] In order to diagnose the operations of a process control device and to develop the service life profiles, the integrated diagnostic module 400 includes a 408 profiler that collects and stores 406 historical data and laboratory test data 407 at least for some of the components listed in the list file 404. From this data, the profiler 408 determines a life profile for each of the identified components and based on the corresponding operational parameter (s) ( s) identified (s) associated with that component. The 408 profiler can store the previously developed life profiles or you can build them.
[0059] The determined service life profiles are stored in a plurality of different profiles 410, as illustrated. The example profiles are illustrated in Figs. 6A-6D.
[0060] Fig. 6A is a service life profile developed by profiler 408, for diaphragm component 302, which indicates the service life (in hours) of a diaphragm oxidation level as a function of temperature and showing a downward inclined linear profile. Fig. 6B illustrates a life cycle profile for the gasket component 310, indicating the amount of leakage (measured in parts per million) as a function of operating cycles for the component. The life cycle profile includes profile data for at least four different gasket components, collected from historical data 406 and / or laboratory test data 407.
[0061] When profiler 408 is supplied with multiple data sets, profile 408 can average the data to determine an average time to failure, that is, in which the data sets correspond to the same operational parameters. In some examples, the stored data may include historical or laboratory test data taken at different operating parameters (for example, one data set showing actual life as a function of pressure, another taken showing real life depending on temperature). In such cases, profiler 408 can develop profiles for a component in each of the different operating parameters.
[0062] Fig. 6C is a life cycle profile developed for the sealing component 306, indicating the amount of leakage (in ppm) as a function of the number of operating cycles. Fig. 6D is a life cycle profile for axis component 304, which indicates the percentage of failure as a function of the number of operating cycles. Although four life cycle profiles are shown, for example, it will be appreciated that any number of life cycle profiles can be stored in profiler 408 and used by the integrated diagnostic module 400.
[0063] In some examples, profiler 408 is pre-filled with service life profiles for the components identified in the list file 404, for example, in which the components have already been profiled, under similar operating conditions. In any case, the 408 profiler is capable of updating the service life profiles based on the elapsed time, the number of cycles, or other parameters. For example, for a valve assembly, profiler 408 can receive a cycle count from a valve positioner or valve status counter 414. Profiler 408 can receive a temperature value from a temperature sensor (not shown) ). Profiler 408 can receive position data for the valve from a position sensor. The 408 profiler is able to adjust the service life profiles for the components and for the valve assembly in general, based on these parameters.
[0064] The integrated diagnostics module 400 collects sensor data (for example, from sensors 106 and 122) and stores the operating conditions for the process control device in an operational data module 410. Operating conditions can be the detected data in real time corresponding to the operational parameters identified in the list file 404. As discussed above, for a valve assembly, the detected data can include any parameter that will affect the fatigue or mechanical wear of the listed components or the valve assembly as a whole, including the pressure current (L / P) suffered by the valve / flap nozzle, the piezo crystal, or the moving solenoid component, the pressure, the component temperature, the ambient temperature, the fluid rate , the leak, the level of oxidation, the position of connections of a valve, and the position of various feedback devices.
[0065] The operational data from module 410 are provided, together with the life profiles of the profiler 408, to a remaining life analyzer 412 that analyzes the current operational data against the corresponding profiles, for the components, in order to determine the projected remaining life for each component and / or the entire process control device. For the latter, the analyzer 412 applies a multifactorial analysis algorithm to the data received, in order to determine the projected useful life, based on the projected useful lives of each of the components. The projected values for remaining life can be life cycle values, when indicated depending on the remaining operating cycles of a valve assembly, for example. Although in other examples, the projected values of remaining life can be measured or indicated on a time counter or projected failure date. For example, the life analyzer 412 can receive the cycle count value from counter 414 which it then compares with the profiles of the profiler 408 to determine a projected remaining cycle life.
[0066] The analyzer 412 may include a confidence determination that assesses whether sufficient operational data and profiles have been provided for it to make a sufficiently accurate determination of the projected cycle life for the process control device. A warning indication can be provided if insufficient sensor data is collected and a remaining design life cannot be determined for a given valve component.
[0067] The analyzer 412 provides the determination of the projected cycle life for a decision module 418 that determines a notification status for the determination. In one example, the notification status has one of three conditions: (i) NORMAL, indicating that there is no maintenance required; (ii) MAINTENANCE, indicating that maintenance or replacement will be necessary in the next scheduled service; or (iii) ALERT, indicating that maintenance or replacement is necessary before the next scheduled service. An alert mechanism can be provided on the process control device to indicate the notification status, for example, with color-coded lights or a display. The decision module 418 is coupled to a communication interface 420 (which can be communication interfaces 128 or 128 ') to communicate the notification status and the projected life determination for a remote computer or an operator, such as remote computer systems 12, 14, 30, 35, and / or 36, shown in Fig. 1. In addition to providing a local indication of the notification status, the communication interface 420 can be a wired or wireless communication interface providing indication of the notification status to a host computer, DCS, remote computer, or the like, which, at least in some modalities, causes a controller to modify the operation of the processing plant according to the notification status, for example , by decreasing the frequency or speed of operation, or by moving to a redundant flow path.
[0068] In this way, the present techniques can provide a warning message to a control room operator, maintenance department or reliability engineering department, in which the warning message quantifies the remaining time predicted for the component failure. In some examples, warnings can be set in advance enough that they appear during a scheduled maintenance interruption that occurs before the projected failure time. This would provide personnel with an opportunity to prepare for service or component replacement before the expected failure. Warning messages may include repair data, such as recommended spare parts or recommended service actions. Warning messages can be delivered to a remote computer system to facilitate manual repair ordering or to enable automatic ordering of spare parts from a component manufacturer. The warning message can be provided for business system computers and maintenance planning computers 35 and 36, which can not only facilitate ordering or replacement parts as described, but also schedule such replacement, for example, during an already scheduled maintenance interruption or during a future maintenance interruption.
[0069] In some examples, the timing of the warning message may be set by the operator of the process control device to be longer or shorter than previously defined, depending on the evaluated condition of the process control device and the imminent service projection. For example, the integrated diagnostics module 400 can be configured to provide more frequent warning messages as the projected point of failure approaches. The timing of the warning messages can also be controlled after the warning message was initially sent.
[0070] While the performance of a process control device deteriorates, and more specifically, while the performance of the various components deteriorates, the projected cycle life data, as well as any life cycle data actual cycles are stored in historical data 406. From here, data, such as MTTF and MTBF for components, can be stored for later reference by the integrated diagnostic module 400 or a module for another device, thus increasing accuracy future projections of cycle life. In some instances, such historical data may be shared with manufacturers, through determined wired and wireless communications, with the consent of the component owner. For example, such data may be provided by granting access to a shared database, website, or wireless network, by storing a copy of historical data 406. Providing such data eventually allows for replacement of laboratory data with data developed using more reliable algorithms by the manufacturer.
[0071] The prognostic capabilities of the system here can be customized, based on field experience for a specific application. As with profiler 408, the criteria of the life analyzer 412 and decision module 418 can be defined based on various parameters, such as elapsed time, valve displacement, cycles, temperature, etc. In this way, diagnostic capabilities can be based on field experience in previous installations and data collected by the device controller.
[0072] FIG. 7 illustrates an example profiler 500 to develop and monitor the performance of accelerated laboratory tests and to determine the life profiles designed for process control devices and / or their components. The profiler 500 can be implemented in an integrated system, as well as the integrated diagnostic module of FIG. 5 which provides life projections and assessments based on current operating conditions. In other examples, the profiler 500 can be implemented as a stand-alone system. Profiler 500 can be implemented within a control of a process control device or from a dedicated process controller, including, for example, any of the process control systems 12, 14, 30, 35, and 36 , or a combination thereof. In any case, the profiler 500 can be implemented as a special purpose processor coded to perform the functions of the profiler 500 or as a general purpose processor, specially configured to execute the computer instructions to perform the functions of the profiler 500.
[0073] In the example of FIG. 7, the profiler 500 is described with reference to determining a service life profile for a valve component that is susceptible to the operational parameters that result in oxidation aging. The profiler 500 develops laboratory testing protocols for use in accelerated aging tests that determine when the component has failed due to oxidation. While profiling for oxidation failure is assessed and described, it will be appreciated that none of the present techniques here are limited to the particular examples described. Instead, these techniques can be used to individually generate the component life profile of any number of components (such as those described above), for any number of different types of process control devices (such as those described above) ), for multiple types of component failure (such as those described above and below), and for operating conditions other than those discussed for example here (such as those described above). Furthermore, profilers can be called upon to profile a single component, or multiple components simultaneously, for example, in the development of multi-variable life profiles, such as when generating the component life profile for various parameters simultaneous operations, as well as when profiling a process control device with different components, each with different profiles of useful life.
[0074] The profiler 500 is coupled to a device descriptor 502 and an associated component descriptor 504, which, respectively, identify the process control device to be profiled and all its components. For example, device descriptor 502 can identify valve assembly 200, while component descriptor 504 can identify diaphragm component 202 or drive stem sealing component 206 (typically a retainer), by type, material, configuration, etc. These are examples of components that experience mechanical wear or fatigue in response to different operating conditions and will eventually result in valve oxidation failure. The component descriptor module 504 will identify any number of these and other components for the accelerated laboratory test possible. Other valve-specific components include elastomeric bellows that protect the actuation stem, which may be contained in packaging component 210. However, other components that respond to (or are indicative of) oxidation aging include the piston driver, specifically, piston and stem seals, be they seals, quad-ring rings, spring-loaded edge seals or plastic wear rings with elastomeric backup rings. The oxidation aging components in a valve positioner include pressure seal seals and diaphragms in the relay assembly, seals that seal the pressure and / or current sensors to the pressure transducers, and seals that seal different modules and / or compartments together or seal the positioner from the surrounding environment.
[0075] The component descriptor module 504 can further identify the normal oxidation aging components contained in the accessories of a valve assembly, including elastomeric retainers, diaphragms, plugs and / or seats in volume amplifiers, soft seats or retainers in solenoids, soft seats or seals on release valves, elastomeric dust seals on limit switches, elastomeric dust seals on position transmitters, diaphragms, seals and soft plugs or seats on instrument supply pressure regulators, and polymeric pneumatic tubing .
[0076] To develop a particular projected life profile, the profiler 500 creates accelerated laboratory test protocols that are specific to the condition, that is, that model the predicted operational conditions suffered by the device and / or the components of the device, when working. The profiler 500, therefore, can be coupled to a module of process operational parameters 506, which provides data on the expected operating conditions. The 506 process operating parameter module can reside within a control system and contains the operating condition data generated automatically and / or manually supplied, such as the composition of the fluid pumped, the pressure, the current to pressure (L / P ) suffered, component temperature, ambient temperature, fluid rate, leakage, oxidation level, valve position, component position, maximum and minimum valve stroke positions, diaphragm compression , the material hardness, as well as the position of various feedback devices.
[0077] An accelerated test referee 508 receives the device descriptor, component data, and operational parameter data. In some instances, referee 508 performs initial analyzes to identify the components for profiling, such as identifying the components that have been profiled previously, identifying the components marked for profiling, identifying the components that are more accurate predictors of lifetime useful statistically designed, the identification of components that can be profiled more accurately by means of accelerated laboratory tests. In some instances, referee 508 may classify components based on these or other factors. In some examples, referee 508 can identify all components that meet the threshold suitability condition for profiling.
[0078] Referee 508 can determine whether sufficient operational parameter data has been collected from module 506 to formulate accelerated laboratory tests. For example, referee 508 can compare the data received from module 508 against the operating parameter data received from module 504. Referee 508 can assess whether a minimum amount of operational condition data has been provided, from the which accelerated laboratory test protocols can be developed.
[0079] Referee 508 then formulates the accelerated laboratory test conditions, based on the operational condition data received, producing, for example, a series of instruction data tables, such as the one shown in FIG. 8. An accelerated laboratory test protocol 600 includes a process control device identification field 602, a component field 604, and a plurality of operating condition fields 606A-606D, corresponding to different operating conditions. The 606A-606D fields can be expressed in various formats, for example, including maximum and minimum parameter values, rate of change of values for these parameters, duration of tests, etc. For each component identified in fields 604, those other than the operating condition fields 606A-606D can be completed with accelerated test instructions. A field 608 stores the guarantee factor data that can be used to determine whether a sufficient amount of accelerated aging test data is obtained. For example, field 608 can store the number of accelerated aging tests requested to be performed from component renderings, to ensure data accuracy.
[0080] For elastomeric components, accelerated test protocols are developed that model the aging of operating life. The desire is to replicate the operational parameters, such as the amount of oxygen available to react with the elastomeric materials in the diaphragm, as well as the temperature of these reactions, together with the internal pressure of the device.
[0081] In some examples, test protocols may include entries for each of the operational parameters that affect performance. Test protocols can include not only the values of the operating parameters, but instructions on how these parameters are to be cycled, up or down, during testing. In addition, the total amount of time to perform the test (indicated in a field 606i) can be taken into account, in the definition of parameters, so as not to delay the completion of the failure test or to hamper profiling by activating other mechanisms. For example, a test protocol that uses too low a temperature can take a long time to establish a component failure, while using too high a temperature can cause other chemical reactions to occur in an elastomeric material, such as activation of the healing system. High temperatures can also affect the test facility, especially if the facility is painted, made of a thermoplastic, zinc or aluminum, due to deformation and / or thermal expansion.
[0082] In some examples, the accelerated tests must correspond to and model the dominant failure mechanisms operating in the real service, which can be switched to different process control devices in different processing plant applications and / or under different conditions operational. For example, tissue-reinforced diaphragms ultimately fail due to oxidation, embrittlement, so that they fracture during flexion. Any other failure mode, such as loss of flange retention, ozone cracks, or deletion results from premature failure that must be eliminated through product design and / or material properties. The static seals ultimately fail due to the established compression, causing the leak. The same elastomer formulation will exhibit different activation energy when tested as a retainer that fails due to established compression or as a diaphragm that fails due to oxidation weakening. In other words, when performing accelerated tests, care must be taken to properly measure among the many potential operating conditions that may appear to predict life failure. Therefore, the accelerated test must replicate the actual operating conditions of the running application as accurately as possible.
[0083] In addition, a statistically significant number of samples must be tested to avoid data dispersion error. More data points will restrict the statistical confidence interval of the resulting profile life and provide more reliable models.
[0084] Test protocols 600 can be stored in local memory 510 and communicated to an optional test instruction module 512 which can be used to convert protocols to executable instructions to automatically operate a laboratory's accelerated test equipment. system 514. In other examples, module 512 can produce an instruction file for an operator to manually perform the accelerated test using system 514. Profiler 500 can communicate with system 514 via a wired or wireless communication link .
[0085] The 514 accelerated test system performs the accelerated aging test on a process control device and its components, measuring the operational conditions until the component fails. The collected data is supplied to a 516 data analysis profile module, which develops the projected life profile for the tested components and / or for the process control device itself, in which the life profile is stored in a 518 memory.
[0086] Before storage, module 516 can perform data analysis on the received accelerated test data. Module 516 can determine whether sufficient operational condition data was collected during the accelerated test. Module 516 can determine if the fault condition is sufficiently correlated with any of the collected operational conditions, for example, through a linear regression analysis. Module 516 can determine which of the operational condition data is most accurate in the failure prediction, for example, which has collected the operational parameter data of an elastomeric material (pressure, temperature, diaphragm compression, hardness, etc.) best predicts a oxidation failure. In this way, module 516 can store profiles selected from service life profiles developed for use by an integrated diagnostic module.
[0087] In other words, module 516 may be able to discriminate between different tests of accelerated aging to determine which or which are more predictive of useful life and to identify such tests for use. For example, for some process plant operating conditions, a simple hardness test may be the preferred measure to assess the extent to which an elastomeric component has progressed to failure. The harder the elastomeric material, the closer it will be to the failure. Accelerated test data shows that a given elastomer in a given application can fail repeatedly, as it approaches a given hardness value. Such indicators may be specific to the elastomeric material, for example. In some instances, all elastomers under certain operating conditions may experience this failure when approaching the same level of hardness.
[0088] In any case, module 516 is capable of developing a projected life profile based on accelerated laboratory tests carried out under different operating conditions, and in such a way that the profile can be adjusted while several of these operating conditions are changed. That is, at least, some of the operating conditions can be variable to allow the refinement of the service life profile during service. For example, depending on the measured hardness of a diaphragm component, for example, performed when the valve assembly is in operation, the projected life profile can be extended over time if the measured hardness is below an expected value or shortened in the time if the measured hardness is higher than expected. These changes in the service life profile can be made automatically, in response to the operational condition data collected during the actual installation in the process plant. For example, the service life profile may include an adjustable parameter that can be refined by the user of the component based on the characteristics of elastomers taken out of service, which have not yet failed. Depending on the measured hardness of these components taken out of service, for example, the adjustable parameter can be adjusted to increase or decrease the predictable failure time if the measured hardness is lower or higher than expected, respectively.
[0089] A similar scenario for measuring the progressive oxidation of an elastomeric component is the relative size of the characteristic peak wave number using Fourier transform infrared spectrometry (FTIR). Carbon-supported oxidation elastomers form C = O bonds, which can be detected with FTIR at about wave number 1702. This wave number varies, however, depending on nearby neighboring bonds. As more connections are formed progressively, the relative height of the peak is greater. Although feasible, this form of measurement may be less desirable than a simple measurement of predictive hardness, because of the cost of instrumentation and expertise required to complete the test, as well as because of the difficulty in quantifying the relative peak heights.
[0090] Note that the elastomeric components can fail by other mechanisms besides oxidation. For example, dynamic seals and seals can fail from simple mechanical wear. Fatigue is another failure mode that is possible due to cyclic cutting or tensile stress and is accelerated by oxidation aging. This phenomenon can be accelerated with high temperature techniques.
[0091] The profiler 500 can not only request accelerated tests based on increasing temperature, but also accelerated tests designed to design low operational temperature profiles for an elastomeric material. Cracks and failure can occur prematurely at low operating temperatures. In at least one embodiment, low operating temperatures mean that temperatures approach -60 ° C (for example, temperatures below -30 ° C, temperatures below -40 ° C, temperatures below -50 ° C, etc. ). When heated to room temperature, the properties of the elastomer become new, and may not show oxidation aging. However, the increased stiffness of the elastomeric diaphragm (flexural modulus), transmitted by the low temperature, can cause the diaphragm to flex in a more localized area, thus increasing the applied stress and starting the fatigue cracks that eventually spread to failure . The profiler 500 can therefore develop an accelerated test protocol for the end of life cycle as a function of temperature, producing the life profile curves for more than one elastomer compound and multiple data points each temperature. In doing so, the profiler 500 can predict the service life profiles for components based on exposure to only low temperatures or in combination with oxidation aging.
[0092] Numerous variations from the above will be appreciated. For example, instead of developing the actual accelerated aging test instruction, a profiler can compare and determine test protocols against a database of accelerated aging tests previously performed to determine whether adequate test data already exists, from of which profiling can take place at the same time.
[0093] In several modalities, a hardware module can be implemented mechanically or electronically. For example, a hardware module may comprise dedicated circuits or logic that is permanently configured (for example, as a special-purpose processor, such as a field programmable port arrangement (FPGA) or an application-specific integrated circuit ( ASIC)) to perform certain operations. A hardware module may also comprise programmable logic or circuitry (for example, as covered within a general purpose processor or other programmable processor) that are temporarily configured by software to perform certain operations. It will be appreciated that the decision to implement a hardware module mechanically, on dedicated and permanently configured circuits or on temporarily configured circuits (for example, configured by software) can be driven by cost and time considerations.
[0094] Therefore, the term "hardware module" should be understood to cover a tangible entity, whether it is an entity that is physically constructed, permanently configured (for example, with rigid wire) or temporarily configured (for example, programmed) to operate in a certain way or to perform certain operations described here. As used herein, "hardware implemented module" refers to a hardware module. Considering modalities in which hardware modules are temporarily configured (for example, programmed), each of the hardware modules does not need to be configured or instantiated in any instance over time. For example, when hardware modules comprise a general purpose processor configured using software, the general purpose processor can be configured as respective different hardware modules at different times. Software can therefore configure a processor, for example, to constitute a particular hardware module in one instance of time and to constitute a different hardware module in a different instance of time.
[0095] Hardware modules can provide information for, and receive information from, other hardware modules. Therefore, the described hardware modules can be considered to be communicatively coupled. When multiples of such hardware modules exist at the same time, communications can be achieved through signal transmission (for example, through appropriate circuits and buses) that connect the hardware modules. In modalities in which multiple hardware or software modules are configured instantiated at different times, communications between these hardware modules can be achieved, for example, through the storage and retrieval of information in memory structures for which the multiple memory modules. hardware have access. For example, a hardware module can perform an operation and store the output of that operation on a device to which it is connected communicatively. An additional hardware module can then later access the memory device to retrieve and process the stored output. Hardware modules can also initiate communications with input or output devices, and can operate on a resource (for example, a collection of information).
[0096] The various operations of the example methods described here can be performed, at least partially, by one or more processors that are temporarily configured (for example, by software) or permanently configured to perform the relevant operations. If configured temporarily or permanently, these processors can constitute modules implemented in processors that operate to perform one or more operations or functions. The modules mentioned here may, in some example modalities, comprise modules implemented in a processor.
[0097] Likewise, the methods or routines described here can be at least partially implemented in a processor. For example, at least some of the operations of a method can be performed by one or more processors or hardware modules implemented in the processor. The performance of some of the operations can be distributed among the one or more processors, not only residing within a single machine, but also deployed in a series of machines. In some example modalities, the processor or processors may be located in a single location (for example, within a home environment, an office environment, or a server farm), although in other modalities the processors may be distributed through of a number of locations.
[0098] Furthermore, the figures represent preferred modalities of a map editing system for illustration purposes only. A person skilled in the art will readily recognize from the following discussion that the alternative modalities of the structures and methods illustrated here can be employed without departing from the principles described here.
[0099] When reading this disclosure, those versed in the technique will appreciate even more alternative structural and functional projects for a system and a process for the identification of road terminal segments through the principles disclosed here. Thus, while particular applications and modalities have been illustrated and described, it is to be understood that the disclosed modalities are not limited to the precise construction and components disclosed in this document. Various modifications, alterations and variations, which will be evident to those skilled in the art, can be made in the arrangement, operation and details of the method and apparatus disclosed in this document without departing from the spirit and scope defined in the attached claim.

权利要求:
Claims (17)
[0001]
1. Method for the development of a life profile designed for a component of a process control device, the method comprising: the receipt, in a profiler, of an indication of at least one operational parameter of the component that affects the aging of the component, over time, during the operation of the process control device in a process installation; the receipt, in the profiler, of operational operating conditions in which the component is expected to suffer during the operation of the process control device in the process installation; the development, in the profiler, of at least one accelerated aging test protocol, based on the operational operating conditions in which the component is expected to suffer, in which at least one accelerated aging test protocol was designed to simulate the component operation to failure under operating operating conditions; the receipt, from an accelerated test system, of accelerated aging test data developed by performing at least one accelerated aging test protocol on a component instance; the development, in the profiler, of a service life profile designed for the component based on the accelerated aging test data, characterized by the fact that the receipt, in an operational data module, during operation of the component in the process installation, detected data including at least: data that reflects the operability of the component when in use in the process installation; or data that reflects conditions experienced by the component during operations of the process control device when in use in the process installation; and determine, in a life analyzer, the remaining life projected for the component and the detected data.
[0002]
2. Method according to claim 1, characterized by the fact that the process control device is a valve assembly and in which the component is formed by a polymeric component.
[0003]
3. Method, according to claim 1 or 2, characterized by the fact that it still comprises: the receipt of the indication of at least one operational parameter, the component of a component descriptor in communication with the profiler, and in which at least an operating parameter is selected from the group consisting of fluid composition that passes through the valve assembly, pressure, current to pressure (L / P), component temperature, room temperature, fluid flow rate, valve leak , oxidation level, valve position, maximum and minimum valve stroke positions, polymer component compression, and material hardness of the polymer component.
[0004]
4. Method according to claim 2, characterized by the fact that the polymeric component is an elastomeric component.
[0005]
5. Method, according to claim 2 or 4, characterized by the fact that it still comprises: the development of a plurality of proposed accelerated aging test protocols; the identification, among the plurality of proposed accelerated aging test protocols, of at least one test protocol in correlation with an oxidation failure of the polymeric component; and the establishment of the identified of at least one test protocol in correlation to the oxidation failure as at least one accelerated aging test protocol.
[0006]
6. Method according to any one of claims 1 to 5, characterized by the fact that it further comprises: the identification of a plurality of test protocols in connection with the oxidation failure of the polymeric component; and identifying from the plurality of test protocols in correlation to the oxidation failure of a subset having a higher correlation than the oxidation failure a remaining subset of the plurality of text protocols in correlation to the oxidation failure; and the establishment of the subset identified as at least one accelerated aging test protocol.
[0007]
Method according to any of claims 2, 4, 5 and 6, characterized by the fact that it further comprises: the development of a plurality of accelerated aging test protocols; the receipt, from the accelerated test system, of accelerated aging test data developed by carrying out each of the plurality of accelerated aging test protocols; the determination, in the profiler and from the accelerated aging test data, of the accelerated aging test protocol more correlative to a failure of oxidation of the polymeric component; and the development of the projected life profile based on the accelerated aging test data from the accelerated aging test protocol most correlated with oxidation failure.
[0008]
Method according to any one of claims 1 to 7, characterized in that the projected life profile is an oxidation fatigue profile, a fluid leak profile, a low temperature fatigue profile.
[0009]
9. Method according to any one of claims 1 to 8, characterized by the fact that it still comprises the determination of whether a statistically significant amount of accelerated aging test data has been received by the profiler, and the development of the useful life profile projected, if a statistically significant amount was received, otherwise, the non-development of the projected useful life profile.
[0010]
10. Method according to any one of claims 1 to 9, characterized by the fact that the projected life profile is configured to be upgradeable in response to changes in actual operating conditions.
[0011]
11. Method according to any one of claims 1 to 10, characterized in that the projected life profile includes an adjustable parameter to adjust the life profile according to a measured component characteristic, which corresponds to the component , which were previously in operation.
[0012]
12. Method, according to claim 11, characterized by the fact that the measured characteristic is hardness and further comprises: the adjustment of the adjustable parameter to extend a projected service life for the component if the measured hardness of the components that were previously in operation is less than expected according to the projected life profile; and the adjustment of the adjustable parameter to shorten the projected life of the component, if the measured hardness of the components that were previously in operation is greater than expected according to the projected life profile.
[0013]
13. Method according to any one of claims 1 to 12, characterized by the fact that receiving accelerated aging test data comprises: the operation of the process control device, while exposing the component to a low temperature during a first period operation of the process control device; operating the process control device, while exposing the component to normal operating temperatures for a second period of operation, after the first period of operation; the receipt, from the accelerated test system, of the accelerated aging test data developed after the first and second period of operation, and the reflection of at least one first non-oxidative failure.
[0014]
14. Method according to claim 15, characterized in that the operation of the process control device, while exposing the component to a low temperature, comprises exposing the component to a temperature below -30 ° C.
[0015]
Method according to either claim 13 or claim 14, characterized in that the operation of the process control device, while exposing the component to a low temperature comprises exposing the component to a temperature below -50 ° C.
[0016]
16. Method according to any one of claims 13 to 15, characterized by the fact that the projected life profile is predictive, for the exposure of the component at low temperature, of the useful life of the exclusive component of oxidative effects.
[0017]
17. Method according to any one of claims 13 to 16, characterized by the fact that the projected life profile is predictive, for the exposure of the component to low temperature, of the component's life taking into account oxidative failures and non-oxidative.

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Knall2014|Heating, Ventilation, and Air Conditioning Fault Detection Using the Fuzzy Jess Toolkit

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Esposito2005|Gaining digital capabilities with an intelligent valve interface: overall process control is only as good as the effectiveness of the final control element. Many problems that plague conventional control valve positioners--namely susceptibility to wear and poor calibration--can be overcome with the use of a digital positioner and an intelligent valve interface

同族专利:

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公开号 | 公开日

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MX354791B|2018-03-21|

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WO2014152117A1|2014-09-25|

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EP2972217B1|2017-07-19|

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RU2665829C2|2018-09-04|

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AR095323A1|2015-10-07|

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JP2016517521A|2016-06-16|

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US20150088434A1|2015-03-26|

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BR112015022150A2|2017-07-18|

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CA2904081A1|2014-09-25|

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CN104049627B|2018-06-08|

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JP6517780B2|2019-05-22|

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EP2972217A1|2016-01-20|

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RU2015140961A|2017-04-17|

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CN104049627A|2014-09-17|

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MX2015012954A|2016-07-20|

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US10718727B2|2020-07-21|

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CA2904081C|2021-05-25|

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法律状态:
2018-11-13| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2019-12-31| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2020-05-26| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2020-11-03| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 14/03/2014, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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US201361785014P| true| 2013-03-14|2013-03-14|

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US61/785,014|2013-03-14|

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PCT/US2014/026970|WO2014152117A1|2013-03-14|2014-03-14|Valve prognostics for polymeric components based on accelerated aging techniques|

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