CN101278180B - 过程阀门的泄漏检测器 - Google Patents

过程阀门的泄漏检测器 Download PDF

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CN101278180B
CN101278180B CN2006800360373A CN200680036037A CN101278180B CN 101278180 B CN101278180 B CN 101278180B CN 2006800360373 A CN2006800360373 A CN 2006800360373A CN 200680036037 A CN200680036037 A CN 200680036037A CN 101278180 B CN101278180 B CN 101278180B
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leakage
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CN101278180A (zh
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格雷戈里·C·布朗
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Rosemount Inc
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16KVALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
    • F16K37/00Special means in or on valves or other cut-off apparatus for indicating or recording operation thereof, or for enabling an alarm to be given
    • F16K37/0075For recording or indicating the functioning of a valve in combination with test equipment
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01MTESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M3/00Investigating fluid-tightness of structures
    • G01M3/02Investigating fluid-tightness of structures by using fluid or vacuum
    • G01M3/04Investigating fluid-tightness of structures by using fluid or vacuum by detecting the presence of fluid at the leakage point
    • G01M3/24Investigating 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
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01MTESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M3/00Investigating fluid-tightness of structures
    • G01M3/02Investigating fluid-tightness of structures by using fluid or vacuum
    • G01M3/26Investigating fluid-tightness of structures by using fluid or vacuum by measuring rate of loss or gain of fluid, e.g. by pressure-responsive devices, by flow detectors
    • G01M3/28Investigating fluid-tightness of structures by using fluid or vacuum by measuring rate of loss or gain of fluid, e.g. by pressure-responsive devices, by flow detectors for pipes, cables or tubes; for pipe joints or seals; for valves ; for welds
    • G01M3/2876Investigating fluid-tightness of structures by using fluid or vacuum by measuring rate of loss or gain of fluid, e.g. by pressure-responsive devices, by flow detectors for pipes, cables or tubes; for pipe joints or seals; for valves ; for welds for valves

Abstract

描述了一种泄漏检测系统,用于检测通过设置在工业过程的上游管道和下游管道之间的关闭阀门的泄漏。可插入板(302)与和所述流体流共线的管道中的所述阀门相连。传感器(316)连接所述流体并且提供标记图输出。泄漏检测器(324)与所述传感器(16)相连,并且适用于基于所述标记图输出检测通过所述阀门的泄漏。

Description

过程阀门的泄漏检测器
技术领域
本发明涉及一种工业过程中的阀门,更具体地,涉及一种对通过闭合阀门的流体泄漏的检测和诊断。
背景技术
在过程控制工业中,自动控制阀门被广泛地用于控制工业过程的过程流体质量流量和/或速度。在一些情况下,尤其在批量过程中,需要阀门在阀门闭合时实现紧密关闭的条件。术语“紧密关闭”指的是零或近似零的流体流过所述阀门的阀门位置。具体地,紧密关闭条件存在于如下情况下:没有流体流过阀门;或者将流体流量减小为一种水平,这种水平使得流体对于过程几乎没有影响。
在要求紧密阀门关闭条件的工业过程中,如果阀门没有紧密地关闭,所产生的泄漏到批量(batch)接收处的材料可以毁灭该批。如果紧密关闭的阀门泄漏了有害或有毒的化学药品,则所述泄漏会对种植人员产生危害,并且可以导致需要涉及环境保护组织(EPA)的事件。这两个结果可能是非常昂贵的。
控制阀门的紧密关闭通常使用诸如弹性密封或Teflon
Figure 2006800360373_0
密封之类的密封。对于腐蚀性的过程流体,优选地将Teflon
Figure 2006800360373_1
和其他抗腐蚀材料用作密封材料。不幸地是,由于多种原因密封会失效,这些原因包括腐蚀、污垢、气蚀、物理磨损等。腐蚀典型地侵蚀密封,产生表面不完整性,所述不完整性使得难以实现紧密的密封。污垢指的是在阀座或密封件上聚集的材料,所述材料阻碍阀门实现紧密的关闭。气蚀指的是在空气流体内的局部形成物或由于流体内压力降低(例如当将阀门从闭合调节到打开位置时)而在阀门内急剧膨胀的气穴(vapor pocket)。流体内气穴的膨胀可能引起金属侵蚀和最终的阀门故障。“物理磨损”指的是在使阀门塞和阀座或密封件之间的材料收缩的阀门闭合过程期间损坏密封,从而损坏座或密封体的情况。最后,碎片通常也会妨碍密封或阀门行进,从而妨碍阀门紧密关闭。
在过程控制工业中需要用于检测阀门密封件或阀门定位器何时出现故障或者紧密关闭的阀门是否出现泄漏的装置。本发明的实施例提出了对于这些和其他问题的解决方案,并且提供了相对于现有技术的其他优点。
发明内容
提供了一种泄漏检测系统,用于检测通过用于工业过程的闭合阀门的泄漏。可插入板与流体流成共线地与阀门相连。传感器与所述流体流相连。泄漏检测器与传感器分接管相连,并且适用于检测通过所述阀门的泄漏。
提供了一种泄漏检测系统,用于检测通过设置在工业过程的上游管道和下游管道之间的关闭阀门的泄漏,所述系统包括:所述关闭阀门和下游管道之间的与所述关闭阀门相连的可插入板,所述可插入板和流体流共线;传感器分接管,所述传感器分接管延伸穿过所述可插入板至所述管道的管腔;以及泄漏检测器,与所述传感器分接管相连,并且适用于基于所测量的声标记图来检测通过所述关闭阀门的泄漏,其中,所述可插入板提供可变面积的通道。
还提供了一种声泄漏检测系统,用于检测通过工业过程的阀门的流体泄漏,所述阀门使上游通道与下游通道和阀门关闭元件相连,所述阀门关闭元件适用于选择性地关闭通过所述阀门的流体流,所述阀门具有与所述下游通道相邻的、延伸到所述阀门中的一个或更多个传感器分接管,所述系统包括:泄漏检测器,与所述一个或更多个传感器分接管相连,并且适用于基于所测量的声信号来检测通过所述阀门的泄漏;其中,所述泄漏检测器还包括:可变面积流量区域,设置在所述下游通道中,与所述阀门关闭元件相邻,以从所述阀门关闭元件漏出积聚的流体,所述可变面积流量区域适用于使得所述泄漏检测器对于与泄漏相关联的产生低流体流量的频率敏感。
还提供了一种泄漏检测系统,用于检测通过设置在工业过程的上游 管道和下游管道之间的阀门组件的关闭阀门元件的泄漏,所述系统包括:第一传感器,设置在所述关闭阀门元件下游的所述阀门组件的上部中,并且适用于测量下游部分中的压力;流量限制元件,所述流量限制元件设置在所述关闭阀门下游的所述阀门组件的底部中;横孔,暴露于流体流,并且从所述关闭阀门的方向延伸到所述流量限制元件中不超过所述流量限制元件的总宽;第二传感器,设置在所述阀门组件的下部中并且与所述横孔相连,所述第二传感器适用于测量所述下游部分中的静态压力;以及泄漏检测器,与所述第一和第二传感器相连,并且适用于基于差分标记图来检测通过所述关闭阀门的泄漏;其中,所述流量限制元件包括:可变面积流量通道,用于将低流体流量从所述关闭阀门元件引导至所述下游管道。
附图说明
图1是根据本发明实施例的具有与阀门机械连接的致动器和声泄漏检测器的阀门定位器的简化方框图。
图2是根据本发明实施例的具有连接在阀门法兰和下游管道之间的泄漏检测器的阀门的简化方框图。
图3是根据本发明实施例的配置用于声泄漏检测的图2的泄漏检测器的截面图。
图4A是根据本发明实施例的配置用于使用差压测量进行泄漏检测的图2的泄漏检测器的截面图。
图4B是图4A的泄漏检测器的实施例的侧视截面图。
图5是根据本发明实施例的、与具有差压端口的阀门相关联的基于差压的泄漏检测器的简化方框图。
图6A和6B是根据本发明实施例的泄漏检测系统的简化方框图。
图7是根据本发明实施例的诊断泄漏检测器是否正确运行的方法的简化流程图。
图8是基于声标记图和阀门位置信息来识别阀门故障类型的方法的简化流程图。
图9是基于所测量的声信号和阀门控制信息来估计阀门泄漏和故障程度的方法的简化流程图。
尽管以上表示的说明是用于阐述优选实施例,还要考虑本发明的其他实施例,一些其他实施例在所述讨论中没有提到。在所有情况下,该公开介绍了本发明的所示实施例,作为示例而不是限制。本领域普通技术人员可以得出落在本发明原理的范围和精神内的各种其他小的修改和实施例。
具体实施方式
本发明描述了用于在阀门处于完全闭合位置时针对紧密关闭的阀门来监测泄漏的技术。典型地,将这种紧密关闭的阀门用在工业过程中的蒸汽或其他高能气体或流体递送系统中。
图1是具有适用于打开和闭合阀门的定位器/发送器102的紧密关闭阀门组件100的简化方框图。通常,控制室104通过双线电流回路106向阀门定位器/发送器102发送希望的阀门位置信号。也可以使用其他通信回路,包括三线和四线电流回路和无线通信链路。
定位器102接收气动空气的供应,并且提供控制压力110,作为来自控制中心114的希望阀门位置设定点和以下两个变量的函数:控制压力信号112和所感测的位置信号114的导数。控制压力110向致动器116提供加压空气,所述致动器116与直行程阀杆控制阀门118机械相连,尽管旋转或其他类型的关闭阀门也可用于本发明。
致动器116包括隔膜120,当来自加压空气的控制压力110压向所述隔膜120时,所述隔膜120偏移,从而向下推进阀杆122。所述阀杆122与阀门闭合元件或塞124相连,调节所述塞的大小以与阀座126配对以闭合所述阀门118,从而当塞124完全落座时停止第一通道128和第二通道130之间的流体流。阀门118经由法兰132与管道部分134相连并且由扣件133固定,所述管道部分运送流体流。
在定位器102内,收发器140从控制中心104接受4-20mA的信号,但是例如也可以从手控通信器(handhold communicator)、无线通信链 路或任意其他通信路径接收信号。所述回路上电流的量表示所希望的阀门位置,但是可以根据诸如HART
Figure 2006800360373_2
、Foundation现场总线、CAN之类的协议或诸如DE、BRAIN
Figure 2006800360373_3
、Infinity或Modbus
Figure 2006800360373_4
之类的其他数字协议,在电流上叠加包括传感器选择命令和数据的数字信息。对于严格的控制,位置信号114可以是微处理器内补偿的温度。
控制电路142提供命令输出144,作为来自收发器140的希望设定点、位置信号114和压力信号112的函数。电路内部的时间导数电路146和气动装置(pneumatics)148提供相对于用于电路146内的控制算法的时间的速度反馈信号(压力信号112的导数)。优选地,取决于特定的实现,将压力信号用作速度反馈信号、扭矩信号或力信号。
优选地,换能器电路和气动装置148使用自适应控制算法,所述自适应控制算法使用诸如压力、位置、力、密封和底座磨损之类的可用感测信号来精细地调谐与成比例-积分-微分控制特征。通常,换能器电路和气动装置148接收每平方英寸(PSI)0-200磅的空气供应108,并且提供控制压力110,作为来自控制电路142的控制信号144函数。感测装置150感测来自控制压力110的压力传感器152和机械位置传感器154的信号,并且向控制电路142提供条件压力112和位置114。
传感器160和与第二通道130相邻的阀门118相连,并且适用于感测在所述第二通路130内由流过阀门118的流体引起的声信号。然后泄漏检测器156处理所感测的声信号162,所述泄漏检测器156将所感测的声信号162与所存储的声标记图159或从存储器158检索的模板相比较,以确定所述阀门118是否泄漏。在一个实施例中,泄漏检测器156与阀门位置(阀杆122和塞124的位置)无关地监测阀门118的声标记图。在可选实施例中,泄漏检测器156基于所感测的声信号161与从存储器158检索的所存储标记图159的比较和位置控制信号166两者,来产生泄漏输出164。在另一个实施例中,泄漏检测器156基于所感测的声信号162与从存储器158检索的所存储标记图159的比较和所测量的机械位置154两者,产生泄漏输出信号165。在另一个实施例中,在从控制中心104或控制电路142接收到触发168时,泄漏检测器156只将声信号162与从存储器158检索的所存储标记图159进行比较。所得到 的输出164将是“盲测”,意味着在没有考虑所希望的或实际的阀门位置的情况下产生输出。然后,依赖于特定的实现,由控制电路142或控制中心104处理输出164。
最后,尽管各种函数块被当作分离的元件,但是可以组合一些函数块。例如,泄漏检测器156可以包括传感器160。具体地,泄漏检测器可以包括传感器、微处理器、存储器和发送电路,所述发送电路适用于从控制中心接收/向控制中心发送信号。
图2是根据本发明实施例的过程控制阀门组件200的简化方框图。阀门202经由通信链路208,通过阀门监测和控制电子装置206与控制中心204通信相连。为了简单起见,将省略关于阀门而配置的更多细节。
如上所述,供应210向阀门监测和控制电子装置206提供加压流体,所述阀门监测和控制电子装置206控制阀杆212和塞214的位置。阀体216包括第一通道218,所述第一通道218通过阀座222与第二通道220相连。随着阀杆212向下前进,塞214与阀座222紧密配合以停止第一和第二通道218、220之间的流体流。
法兰224将阀门216与相邻管道部分228的法兰226相连。将泄漏检测板230定位于阀门216和阀门216下游并且与流体流共线的管道部分228之间。紧固件227将管道部分228固定到阀门216,并且在下游一侧紧固件227将管道部分228固定到板230和阀门216。优选地,法兰224与阀座222紧邻,并且最优地,法兰224中的一个与阀体216一体形成。
板230配置有一个或更多传感器分接管(如图3至5所示),用于容纳与泄漏检测器232相连的传感器。所述传感器可以是声传感器或压力传感器,具有足够的带宽以俘获目标音频信号。泄漏检测器232配置有传感器233、存储器234和微处理器236,用于将所测量的下游信号与在存储器234中存储的参考信号进行比较,并且用于向控制中心204产生输出诊断信号238。优选地,传感器233是声传感器,但是也可以是压力传感器或差压传感器,适用于测量所希望声频率范围内的过程产生信号,所述声频率范围可以落在或者不落在可听见频率范围内。
对于高能过程流体,因为阀门闭合(意味着塞214朝着阀座222前 进并且进入所述阀座222),通过阀门216的流体通道变窄,并且产生了声噪声。该效应有时相对于标准家用龙头是能被察觉的,所述家用龙头产生可听见的变化噪声。典型地,声噪声是由流过阀门216的流体产生的,并且声噪声的频率一直增加,直到当阀门216完全闭合(意味着塞214完全落在阀座222中)时所述声噪声突然停止(或变化)。应该理解的是在一些示例中,所述声噪声落在可听见的频率范围内。在其他实施例中,声噪声处于可听见的频率范围之外的频率,但是仍然通过声传感器或压力传感器能够检测到,所述传感器能够测量声噪声的频率范围。
通过估计由声传感器检测的、流过阀门的过程的噪声信号,可以检测何时阀门还没有实现紧密关闭。如果阀门216没有实现紧密关闭条件,则声噪声保持处于频率和幅度的中间值。
通过检测过程控制阀门202上的声频率行进(从打开的阀门位置到闭合的阀门位置),可以确定阀门202是否完全关闭或阀门202是否允许过程流体泄漏到下游管道段228中。在泄漏检测器232中设置的微处理器236用于处理声传感器信息,并提供诊断输出238和可选输出240(如虚线所示),所述可选输出240响应于由传感器拾取的声信号,例如可以表示阀门位置。在这种情况下,可以基于相对于参考噪声标记图的声频率来推断阀门位置。
首先,存储参考图案,所述参考图案表示当阀门从打开位置调节为完全闭合(紧密关闭)条件时产生的声信号。这种所存储的参考图案包含频率和幅度序列信息,可用作跟踪阀门闭合过程的参考模板。如果随着时间的过去,频率和幅度图案匹配所述模板,但是没有在紧密关闭条件下结束,则电子装置可以输出表示泄漏阀门的警报或警告。通过观察与模板相关的测量信号并且注意表示没有实现紧密关闭的终点出现的地方,可以估计泄漏量(或者故障程度)。
检测泄漏阀门可如下实现。当阀门216处于80%闭合和完全打开之间时,通过阀门216的流体噪声基本上是恒定的。然而,当阀门216开始关闭时(即,当阀门塞214落于阀座216内,以便将流过阀门216流体关闭约81%和99%时),流过阀门216的过程所产生的噪声开始在幅度和频率两方面都增加。最后,当阀门216实现了紧密关闭条件时(即, 塞214完全落于阀座222中,使得所述通道100%闭合),噪声信号迅速从其最大频率和幅度降低至基本上为0。
本领域普通技术人员应该理解的是,几乎总是存在过程噪声。然而,当阀门闭合时,传感器所测量的过程噪声改变。微处理器236适用于将所测量的声频率与所存储的模板或来自存储器234的声标记图进行比较,并且可以检测当阀门完全关闭时的声变化。泄漏检测器232适用于从感测信号中分离过程(背景)噪声以便隔离与泄漏相关的噪声。
与在存储器234中存储的基线标记图相比,也可以基于声噪声标记图中的变化来检测在过程中形成的问题。具体地,背景噪声中的变化可以表示在工业过程中的固定装置中形成的问题,例如轴承损坏、泵损坏等。例如,当可旋转装置中的轴承开始损坏时,它们通常产生尖锐噪声,这是潜在的轴承损坏的早期征兆。如果这种装置开始产生额外的过程噪声,所述噪声聚集了已有的过程噪声。过程噪声幅度的显著变化或正常范围外(并且在所存储的声标记图中不存在)的频率信号的卷积可以表示固定过程装置中形成的问题。
在一个实施例中,除了产生与阀门216有关的诊断信号之外,微处理器236适用于提供表示过程装置的整体机能的预测诊断信号。该可选择的过程装置诊断信号是基于所测量的背景噪声和所存储的参考记号图的背景噪声之间的差。具体地,如果所测量的背景噪声相对于所存储的参考记号图变化大于预定限度,所述泄漏检测器232适用于向控制中心204产生警报信号。
通常,电子装置可以共同位于单独的封装中(如图1所示)。可选地,如图2所示,泄漏检测器232可以与阀门监测和控制电子装置206分离。
在优选实施例中,泄漏检测器232提供经由外部装置或经由本地操作界面(LOI)242设定初始值的能力,可以将LOI集成到包含泄漏检测器232的发送器244中。在优选实施例中,电子装置经由如HART、Foundation现场总线、CAN之类的数字总线或任意其他的双向通信标准的双向通信。这种通信能力用于设定初始值以及输出各种级别的警报。针对这种类型的仪表,所述电子装置典型地是供有4-20mA的回路。
图3是包括板302的声泄漏检测器300的简化截面图,声泄漏检测器300适用于容纳发送器304。所述发送器304适用于检测由流过阀门的流体(如图2所示)引起的声信号,并且向控制中心306发送测量和诊断信号。
通常,板302具有环形本体308,限定了管腔(lumen)310的大小以与下游管道段(例如图2中的元件228)配合。板302配置有延伸件312和定位元件,所述延伸件312适用于在安装期间向现场的操作者提供视觉参考,所述定位元件用于将板302定位于阀门法兰和下游管道段之间。之后,将分接管(tap)314设置在本体308中,用于容纳感测元件316。通常,分接管314几乎在板302的整个壁厚度上延伸。在可选实施例中,分接管314延伸通过本体308的整个壁并且进入管腔310中,并且感测元件316适用于密封所述分接管开口,并且在操作期间与流体流直接接触。
发送器304包括声传感器318,适用于检测由所述感测元件316所测量的声信号。发送器304包括微处理器320,用于调节所测量的声信号。收发器322适用于向控制中心306发送测量和诊断信号,并且从所述控制中心306接收控制信号。最后,泄漏检测器324配置用于基于所测量的声信号与在存储器326中存储的基线信号的比较的变化,检测通过阀门的泄漏。
通常,以虚线、按照部分示出了发送器304的全部元件,这是因为依赖于具体的实现,可以将各种功能和功能性组合到单独的电路元件或多个电路和/或软件元件中。具体地,每一个元件(318-326)只是示出用以说明声发送器304的操纵能力。
图4A示出了泄漏检测器400的替换实施例。泄漏检测器400包括板402,用于连接在阀门和下游管道段之间,并且与流体流共线。所述板402与差压发送器404相连,所述差压发送器404又与控制中心406相连。板402包括延伸元件408,延伸元件408可以在安装期间用以定位和确定板402的方向。如图3所示,板402限定了管腔410,调节管腔410的大小以与阀门和下游管道段之间的阀门腔室(chamber)相连。此外,板402的管腔410用包括可变面积流体区域414的流量限制元件 412制成,所述可变面积流体区域414逐渐减小为点415。优选地,可以将板402插入到紧密关闭的阀门和下游管道段之间。
调节可变面积流量区域414的大小,使得在阀门出口和可插入板402之间的流体高差随着泄漏(流体)速率的增加而增加。在图4A中,为清楚起见对该可变面积特征414的尺寸进行了放大。通常,V形可变面积414使得差压发送器对于低流量更敏感。将两个压力端口416和418设置在板402的壁中,并且横孔从板402的阀门侧向压力端口418延伸。
差压发送器404与设置在压力端口416和418内的传感器417和419相连,以测量板402的管腔410内的差压,并且延伸通过相关联的阀门和下游管道段。差压发送器404配置有泄漏检测器422,用于基于与在存储器中存储的基线差压相比的差压变化,识别通过阀门的泄漏。泄漏检测器422以虚线示出并且与所述差动发送器404重叠,以表示泄漏检测器422可以包含在所述差动发送器404内,或者可以是分离的。此外,控制中心404可以基于从所述差压发送器406接收到的测量数据,执行泄漏检测器422的特定功能。
通常,将压力端口416定位于管腔410的顶部附近,以在过程流体流过流量限制板402时监测所述过程流体的高差。将压力端口418定位于管腔410的底部附近,以测量管道静态压力,使得压力测量是实际的差压。压力端口416和压力端口418沿与流体流过板402(当所述板402与阀门相连时)的方向大致横向的方向延伸进入所述板402。为了测量所述差压,优选地,将端口416和418沿与流体方向横向的轴大致对齐(如图4B所示)。所述横孔402延伸穿过板402并且进入端口418。当流体积聚在可变区域414中时,静态压力在所述横孔402中增加,并且由在压力端口418中的压力传感器测量到。尽管已经关于差压传感器描述了本实施例,两计示压力传感器或绝对压力传感器也可以用于进行这种测量。
如下来实现检测泄漏阀门。当阀门打开时,下游管道基本上充满过程流体。当阀门关闭时,管道中的流体开始流干。对于管道充满的条件,压力端口416和418均由流体覆盖。只要是这样的情况,所测量的差压就保持基本不变。一旦管道中的流体下降到顶部端口416以下,发送器 404测量管道中的流体高差(head)。如果阀门紧密地关闭,流体高差继续减少,直到流体的高度与流量限制器412的可变区域(通道)414的底部高度相同为止。此时,没有额外的流体出现,差压测量达到稳定状态并且保持基本不变。发送器404测量在紧密关闭条件期间的流体高差,并且将所述高差测量存储在存储器424中作为参考值。
如果阀门在关闭之后泄漏,一些过程流体泄漏到板402和阀门之间的区域。该流体流出到流量限制器412和板402中的可变区域414上。可变区域414适用于容易地检测在流体接近零流量(或无流量)条件时少量流体增量的高差变化。因为流体泄漏通过阀门密封,所述差压测量略微改变。如果差压测量变化超过预定量,则泄漏检测器422产生警报或警告,并且在发送器404的输出上提供。在该实施例中,将安装设计配置为使得当阀门关闭时阀门下游流干。
在图4B中,示出了处于原位的板402和部分截面图。优选地,板402包括基本上与轴432对齐的上部孔(压力分接管)416和下部孔(压力分接管)418,所述轴432与流体方向横向地延伸。将所述板402设置在阀门426和下游管道段428之间,并且由夹紧装置430将其固定就位。
如图所示,横孔420(以虚线示出)从板420的上游表面421延伸至下部孔418。将所述横孔420设置在流量限制器412内,并且暴露于所述流体。通过闭合阀门从阀门部分426所接收的流体泄漏积聚在流量限制器412后面,并且沿V形区域的底部(由虚线415表示)流过流量限制器412的可变面积V形部分(图4A中的元件414)。当流体积聚在流量限制器412后面时,一些泄漏流体流到横孔420中,并且设置在下部孔(压力分接管)418内的传感器可以适用于测量所述横孔内的静态压力。可以将来自下部孔418中的传感器的静态压力测量与上部孔416中的传感器进行的压力测量之间的差压用于检测通过阀门的非常小的泄漏。
可变面积流量限制器的底部部分145从阀门426朝着下游管道段428倾斜,以促进流出。如果所述阀门紧密地关闭,流体从板402中流出,并且在短暂的时间段之后,全部流体从流量限制器通过底部部分415流出,并且进入下游管道段428中。如果泄漏继续,流体继续流到阀门 部分426中,积聚在流量限制器412后面,并且流到横孔420中,从而产生差压。图4A的泄漏检测器422可以用于识别表示泄漏条件的差压。如果检测到泄漏,例如,可以向气动致动器产生控制信号以使阀门更紧密地进入阀座。可选地,可以向控制中心(例如控制中心406)产生警报信号。在任一情况下,差压分接管416和418提供用于检测泄漏阀门的装置。
图5示出了具有根据本发明可选实施例的泄漏检测系统500的紧密关闭阀门的简化方框图。在该实施例中,将图4A和4B的锥形流量限制器和压力端口(或分接管)并入到阀体中,消除了对于单独的板的需要。
所述泄漏检测系统500包括与气动阀门504相连并且适用于打开和关闭所述阀门的发送器502。此外,发送器502经由通信链路508与控制中心506通信。在一个实施例中,通信链路508是双线回路。然而,也可以使用其他通信链路,包括无线链路或者三线或四线链路。通常,控制中心506在双线电流回路508上向阀门定位器/发送器502发送所希望的阀门位置信号。也可以使用其他通信链路,包括三线和四线电流回路以及无线通信链路。
定位器/发送器502接收气动空气512的供应,并且提供控制压力514,作为来自控制中心506的所希望阀门位置设定点和以下两个变量的函数:控制压力信号516和所感测的位置信号518的导数。控制压力514向致动器514提供加压空气,所述致动器504与直行程阀杆控制阀门520机械相连,但是旋转或其他类型的关闭阀门也适用于本发明。
致动器522包括隔膜524,当来自加压空气的控制压力514压向所述隔膜524时,所述隔膜524偏移,从而向下推进所述阀杆526。所述阀杆526与阀门塞528相连,调节阀门塞528的尺寸来匹配阀座530以关闭阀门520,从而当塞528完全落座时停止第一通路532和第二通路534之间的流体流动。阀门520与承载流体流的过程管道部分540相连。所述阀门520经由阀门法兰536和管道法兰538与管道部分540相连,阀门法兰536和管道法兰538由扣件542固定。
在定位器/发送器502中,收发器510从控制中心516接收4-20mA的信号,但是也可以例如从手持通信器、无线通信链路、或任意其他通 信路径接收信号。回路上电流的幅度表示所希望的阀门位置,但是也可以根据诸如HART
Figure 2006800360373_5
、Foundation现场总线之类的协议或诸如DE、BRAIN
Figure 2006800360373_6
、Infinity或Modbus
Figure 2006800360373_7
之类的其他数字协议在电流上叠加包括传感器选择命令和数据的数字信息。对于严格的控制,位置信号518可以是在微处理器内补偿的温度。
控制电路544提供命令输出546,作为来自收发器510的所希望设定点、位置信号518和压力信号516的函数。换能器电路和气动装置548基于控制信号546来控制压力514。在一个实施例中,时间导数函数(未示出)提供相对于控制电路544内的控制算法的时间的速度反馈信号(压力信号516的导数)。优选地,依赖于具体的实现,将所述压力信号516用作速度反馈信号、扭矩信号或力信号。
优选地,换能器电路和气动装置548使用自适应控制算法,所述自适应控制算法使用诸如压力、位置、力、封装和底座磨损之类的可用感测信号来精细地调谐比例-积分-微分控制特征。通常,换能器电路和气动装置548接收每平方英寸(PSI)0-200磅的气体512的供应,并且提供作为来自控制电路544的控制信号546的函数的控制压力514。感测装置550感测来自控制压力514的压力传感器552和机械位置传感器554的信号,并且向所述控制电路544提供调节的压力516和位置518的测量。
差压传感器556和与第二通路534相邻的阀门520相连,并且适合于感测由流过阀门520的流体引起的第二通路534内的声信号。具体地,将上部压力分接管558(或压力端口)和下部压力分接管560设置在阀门520的外壳中。可以将横孔561设置在从面对沿阀座530的方向、从流量限制元件562的表面延伸的可变面积流量限制元件562中。通过阀门泄漏的流体积聚在所述流量限制元件562后面,填充横孔561,从而在横孔561内提供可由分接管560内的传感器测量的静态压力,所述分接管560与所述横孔561交叉。
通常,可以将感测装置(未示出)定位于分接管558、560内,并且与用于测量所述第二通路534内的差压的差压传感器556相连。在所述第二通路534内制造具有可变面积564的流量限制元件562,用于测 量流过所述阀门520的低流体流量。
如前所述,上部分接管558测量在所述第二通路534内流动的过程流体的高差。下部分接管560基于横孔561内的流体,测量所述阀门562的静态压力。当阀门520关闭时(意味着塞528落于阀座530中),通路534内的流体流开始流出。当压力分接管558、560均由流体覆盖时,所测量的差压不会改变(并且在每一个端口558和560处测量的压力基本上相同)。然而,当流体泄漏到上部分接管558的水平面以下时,发送器502测量阀门520内的流体高差。如果阀门520紧密地闭合,流体高差继续降低,直到流体的高度为零并且没有额外的流体出现为止。此时,与差压测量相关联的图案达到平稳状态。可以将所述高差测量存储在存储器566中,并且可以由泄漏检测器568用于在高差测量的低点与所存储的高差测量相比的变化超过预定限度时标识阀门泄漏。
可以通过使用阀门控制信号546(由箭头570表示)来额外地增强所述泄漏检测器568。具体地,所述泄漏检测器568可以监测阀门控制信号570,以检验当控制中心506要求闭合阀门时的紧密关闭。如果流体噪声的幅度和频率并不表示已经实现了紧密的关闭条件,泄漏检测器568通过收发器510可以发送表示阀门520可能泄漏的诊断警告或报警。此外,通过跟踪阀门控制信号546、570,泄漏检测器568可以基于所感测的流过阀门520的流体的声频率与在存储器566中存储的声频率分布,来提供阀门位置的辅助标记。
图6A和6B是示出了本发明的泄漏检测器的两种可能实现的简化方框图。在图6A中,泄漏检测系统600包括与传感器604和存储器606相连的泄漏检测器602。泄漏检测器602从传感器604接收测量信号并且从阀门位置传感器608接收阀门位置信号。泄漏检测器602考虑阀门位置传感器608的阀门位置测量,将来自传感器604的测量信号与来自存储器606的所存储测量信号进行比较,并且确定阀门是否泄漏。如果来自传感器604的测量表示流体流动,但是阀门位置传感器608表示阀门是打开的,则不存在泄漏。另一方面,如果阀门位置传感器608表示完全关闭的阀门,但是传感器604表示流体流动,则泄漏检测器602产生表示在其输出端上泄漏的警报610。
通常,所述传感器604可以是声传感器、差压传感器或任意其他类型的传感器,适用于检测下游管道段或阀门的辅助通道中的低流体流量。
图6B示出了根据本发明实施例的泄漏检测系统620的可选实施例。所述泄漏检测系统620包括与传感器624和存储器626相连的泄漏检测器622。所述传感器624与工业过程相连,所述工业过程与阀门的辅助通道相邻或集成。传感器624检测管道部分或阀门的管腔内的流体流,并且泄漏检测器将所测量的流体流与来自存储器622的所存储标记图进行比较。在优选实施例中,根据通过阀门的流体产生的声标记图来测量流体流。所述声标记图可以落在或不落在可听见的频率范围内,但是仍然可由具有足够带宽的声传感器或压力传感器检测到,以捕获目标声信号。
泄漏检测器622利用阀门位置控制信号或检测器触发信号628。泄漏检测器628使用阀门位置控制信号(表示所希望阀门位置)来提供表示是否实现所希望阀门位置的辅助标记。具体地,所述阀门只是部分地关闭,阀门塞的定位应该引起声标记图变化,并且所述变化应该与所存储的参考声频率相对应。如果所述阀门塞引起与针对所希望插头位置的所存储参考频率不同的声频率,泄漏检测器622产生表示所述阀门处于与所希望关闭不同的关闭的输出。与所存储的参考频率的背离程度可以提供阀门定位器超过或未达到所希望阀门位置的程度表示。
可选地,如果所述信号628是检测器触发信号,控制器可以通过泄漏检测器622发起测试。泄漏检测器622在接收所述触发信号628时,轮询传感器624,并且将所检索的测量信号与来自存储器626的所存储测量信号进行比较。如果这两个信号之间的差超过了预定限度,可以在泄漏检测器输出630上发出警报信号。
尽管已经主要关于具有用于物理地定位阀门的气动致动器的阀门而描述了本发明,本发明也可以使用诸如电动、水压等之类的其他致动器。通常,本发明用于紧密关闭的应用,例如在食品加工业,其中必须紧密地控制对于一批产品的热传送(经由蒸汽)或成分传送。
如这里所使用的,术语紧密关闭指的是如下条件:通过阀门的流体流减小为零流体流量,或减小为较慢速率的流体流,使其对于批量过程 没有影响。
在可选实施例中,具体地在应用于蒸汽应用时,可以将压力或是声检测器用温差发送器来代替。具体地,当阀门关闭时,管道内的蒸汽将冷凝并且流出到下游管道段中。如果所述蒸汽通过阀门较慢地泄漏,上部分接管和下部分接管应该具有较大的温差。在一个实施例中,所述蒸汽将迅速冷凝,并且上部温度传感器测量到比下部温度传感器低得多的温度。可选地,所述蒸汽通过“关闭阀门”迅速地漏出,引起上部温度传感器继续测量到高温,而下部温度传感器(定位于阀门底部)(在全部液体已经从阀门流出之后)冷却。
通常,本发明提出了一种在线检测方法,检测当阀门应该关闭时阀门是否泄漏。此外,相对于频率/幅度模板的变化可以提供泄漏的严重程度或程度的表示。本发明还部分地对于用户而言是简单可实现的,因为安装不需要焊接或热铸(hot tapping)。可以容易地将所述阀门紧固在阀体上。可选地,具有相关传感器的孔板(orifice plate)可以容易地插入在阀门和下游管道段之间。
此外,本发明提出了一种简单装置,用于简单地通过检测当阀门打开时在操作期间是否存在正常的流噪声,来测试泄漏检测器(声传感器)。如果差压发送器的频率响应足够高,则可以将差压发送器用作声传感器。与附加阀门、管道、通风以及用于处理需要紧密关闭的严格阀门的硬件的安装相关联的成本相比,本发明提供了低成本的泄漏检测方案。
通常,所述电子装置包括适用于接收压力信号并且调节所述压力信号的电路和/或软件。此外,电子装置包括适用于识别泄漏流的不可接受值的泄漏检测器(或者泄漏检测功能)。此外,所述电子装置包括用于存储设定值的存储器,并且至少提供数字处理容量。在优选实施例中,所述存储器是非易失性存储器。
作为诊断,任意堵塞的流量限制几何结构都可以表现为关闭时的泄漏条件。作为估计任意警报或警告的一部分,可以在确定阀门密封是否需要维修之前容易地去除所述板并且检查堵塞。在可选实施例中,可以将锥形流量限制和压力端口直接并入到阀体中,从而消除了对于单独的板的需要。
图7示出了根据本发明实施例的诊断泄漏检测器是否运行的方法。首先,打开阀门(步骤700)。传感器检测流过打开阀门的流体的打开阀门标记图(步骤702)。泄漏检测器检索所存储的打开阀门参考标记图(步骤704)并且将所测量的打开阀门标记图与所存储的打开阀门标记图进行比较(706)。如果所测量的打开阀门标记图和所存储的打开阀门(参考)标记图之间的差超过预定限度,则产生表示泄漏检测器问题的警报(步骤708)。
图8是根据本发明实施例的诊断阀门故障方法的简化流程图。泄漏检测器测量阀门的声标记图(步骤800)。泄漏检测器从适用于监测阀门位置的例如阀门杆位置传感器、控制电路或其他元件检索阀门位置信息(步骤802)。泄漏检测器测试阀门位置信息,以察看阀门是否关闭(步骤804)。如果阀门是关闭的,泄漏检测器将所测量的阀门标记图与所存储的“关闭”位置处的参考标记图进行比较(步骤806)。如果所测量的阀门标记图表示阀门是关闭的(步骤808),则阀门是关闭的,并且泄漏检测器继续监测所述阀门(块810)。如果所测量的标记图与关闭位置处的参考标记图不匹配(步骤808),则阀门没有关闭,并且产生表示泄漏阀门的警报(步骤812)。
如果阀门没有关闭(步骤804),将测量的阀门的声标记图与所检索阀门位置处的所存储参考标记图进行比较(步骤814)。如果所测量的标记图与阀门位置处的所存储参考标记图匹配(步骤816),泄漏检测器继续监测所述阀门(步骤810)。如果所测量的标记图与阀门位置处的所存储参考标记图不匹配(步骤816),泄漏检测器产生表示阀门定位器存在问题的警报(步骤818)。
在该示例中,由定位器或控制器电路监测阀门位置,因此声泄漏检测器适用于提供泄漏阀门诊断和阀门位置的辅助确认。如果所述定位器没有正确地运行,则泄漏检测器不能够将所测量的信号与所希望阀门位置处的参考信号相匹配,会产生阀门故障(定位器故障)警报。
图9是基于所测量的声信号来估计泄漏的泄漏阀门诊断方法的简化流程图。通常,当阀门从完全打开调节到完全关闭位置时,监测正确运行的阀门,并且将与阀门的调节相关联的声图案存储在存储器中,作为 参考图案。如这里所使用的,短语“正确运行”指的是当阀门完全关闭时实现了紧密关闭。在操作期间,泄漏检测器监测阀门控制信号(步骤900)。在接收到阀门调节控制信号时,当将所述阀门从第一位置调节到第二位置时,泄漏检测器监测所述阀门的变化的声图案(步骤902)。所述泄漏检测器将所测量的声图案与所存储的参考图案进行比较(步骤904)。如果所述图案匹配(步骤906),则所述阀门正确运行,并且所述泄漏检测器继续监测所述阀门(步骤908)。
如果所述图案不匹配(步骤906),泄漏检测器识别所测量的声图案中与第二阀门位置相对应的终点(步骤910)。所述泄漏检测器计算所识别的终点和所存储的参考图案中与第二阀门位置相对应的点之间的距离(步骤912)。距离计算是在所测量的声图案中已识别的终点与所存储的声图案中的点相比较时其间的差别的测量。在一个实施例中,所述距离是作为一组变量的平方差之和的平方欧几里德距离。然后,所述泄漏检测器基于所述终点来估计泄漏量或阀门的故障程度(步骤914)。更具体地,泄漏检测器适用于基于所计算的距离来估计泄漏量和阀门的故障程度。最后,泄漏检测器914产生表示阀门故障并且表示泄漏量或阀门故障程度的警报(步骤916)。
通常,在终点和参考图案中的所希望点之间的计算距离可以提供故障程度或泄漏程度的表示。在一个实施例中,所述距离(D)根据以下线性等式提供对于泄漏程度的表示:
E=kD
其中E是泄漏或故障的程度,D是计算的距离,k是标量(scalar)。在该实施例中,标量(k)可以包括与通过所述系统的流体流速相关联的因子。
在批量过程中,泄漏量或故障程度可以提供是否可以补救所述批次或是否必须丢弃所述批次的表示。此外,泄漏或故障程度表示与参考样式的背离,可以将其用于预测对于阀座的污垢、侵蚀或损坏程度,以便警告操作者在开始新的批次之前检查阀门,以便防止不希望的阀门故障。
尽管已经参考优选地实施例描述了本发明,但本领域普通技术人员应当理解,在不脱离本发明的精神和范围的情况下,可以对这些实施例 进行形式和细节上的多种改变。

Claims (21)

1.一种泄漏检测系统,用于检测通过设置在工业过程的上游管道和下游管道之间的关闭阀门的泄漏,所述系统包括:
所述关闭阀门和下游管道之间的与所述关闭阀门相连的可插入板,所述可插入板和流体流共线;
传感器分接管,所述传感器分接管延伸穿过所述可插入板至所述下游管道的管腔;以及
泄漏检测器,与所述传感器分接管相连,并且适用于基于所测量的声标记图来检测通过所述关闭阀门的泄漏,
其中,所述可插入板提供可变面积的通道。
2.根据权利要求1所述的系统,其中,所述泄漏检测器适用于基于所测量的声标记图和所存储的参考标记图之间的差,来识别泄漏。
3.根据权利要求1所述的系统,其中,所述泄漏检测器适用于如果所测量的声标记图与所存储的声标记图的差超过预定限度,向控制中心产生警报信号。
4.根据权利要求1所述的系统,其中,所述泄漏检测器适用于基于超过预定噪声限度的背景过程噪声的幅度和/或频率的变化,来检测工业过程的固定装置中的问题。
5.根据权利要求1所述的系统,其中,所述泄漏检测器适用于基于所测量的声标记图相对于所存储的声标记图之间的差的幅度,来预测已经泄漏通过所述关闭阀门的流体量。
6.根据权利要求1所述的系统,其中,所测量的声标记图包括频率和幅度图案,并且其中所述泄漏检测器适用于基于所述频率和幅度图案与所存储的参考图案之间的差,来估计已经泄漏通过所述关闭阀门的流体量。
7.根据权利要求6所述的系统,其中,基于相对于所存储的参考图案上的对应点的所述频率和幅度图案的终点,来估计已经泄漏通过所述关闭阀门的流体量。
8.一种声泄漏检测系统,用于检测通过工业过程的阀门的流体泄漏,所述阀门使上游通道与下游通道和阀门关闭元件相连,所述阀门关闭元件适用于选择性地关闭通过所述阀门的流体流,所述阀门具有与所述下游通道相邻的、延伸到所述阀门中的一个或更多个传感器分接管,所述系统包括:
泄漏检测器,与所述一个或更多个传感器分接管相连,并且适用于基于所测量的声信号来检测通过所述阀门的泄漏;
其中,所述泄漏检测器还包括:
可变面积流量区域,设置在所述下游通道中,与所述阀门关闭元件相邻,以从所述阀门关闭元件漏出积聚的流体,所述可变面积流量区域适用于使得所述泄漏检测器对于与泄漏相关联的产生低流体流量的频率敏感。
9.根据权利要求8所述的系统,其中所述一个或更多个传感器分接管之一延伸进入所述阀门中,与所述可变面积流量区域相邻。
10.根据权利要求8所述的系统,其中所述泄漏检测器包括:
声发送器,适用于检测来自流过所述阀门的流体的声信号;以及
电路,适用于基于所述声信号和所存储的参考信号之间的差来检测通过所述阀门的泄漏。
11.根据权利要求8所述的系统,其中在存在至少两个传感器分接管的情况下所述泄漏检测器包括:
差压发送器,与所述传感器分接管相连,所述传感器分接管具有足够的带宽以捕获与流过所述阀门的流体相关联的差分声信号。
12.根据权利要求8所述的系统,其中所述泄漏检测器还包括:
存储器,适用于存储正确运行的阀门的参考声图案。
13.根据权利要求8所述的系统,其中所述泄漏检测器包括:
电路,适用于如果所测量的声信号和所存储的参考信号之间的差超过预定限度,向控制中心产生诊断信号。
14.根据权利要求8所述的系统,其中所述泄漏检测器适用于基于所测量的声信号和所存储的参考信号之间的差,来估计通过所述阀门的泄漏量。
15.一种泄漏检测系统,用于检测通过设置在工业过程的上游管道和下游管道之间的阀门组件的关闭阀门元件的泄漏,所述系统包括:
第一传感器,设置在所述关闭阀门元件下游的所述阀门组件的上部中,并且适用于测量下游部分中的压力;
流量限制元件,所述流量限制元件设置在所述关闭阀门下游的所述阀门组件的底部中;
横孔,暴露于流体流,并且从所述关闭阀门的方向延伸到所述流量限制元件中不超过所述流量限制元件的总宽;
第二传感器,设置在所述阀门组件的下部中并且与所述横孔相连,所述第二传感器适用于测量所述下游部分中的静态压力;以及
泄漏检测器,与所述第一和第二传感器相连,并且适用于基于差分标记图来检测通过所述关闭阀门的泄漏;
其中,所述流量限制元件包括:可变面积流量通道,用于将低流体流量从所述关闭阀门元件引导至所述下游管道。
16.根据权利要求15所述的泄漏检测系统,其中所述流量限制元件和所述第一和第二传感器沿一轴线大致在轴向上对齐,该轴线与流体流方向成大致横向。
17.根据权利要求15所述的泄漏检测系统,其中所述第一传感器和所述第二传感器包括压力传感器,所述差分标记图包括差分压力标记图。
18.根据权利要求15所述的泄漏检测系统,其中所述第一传感器和所述第二传感器包括压力传感器,所述压力传感器适用于测量在所述下游部分中的频率范围中的压力信号,并且其中所述差分标记图包括差分声标记图。
19.根据权利要求15所述的泄漏检测系统,其中所述阀门组件包括:
阀门元件,包括外壳,所述外壳连接在上游和下游管道部分之间,并且限定了所述上游和下游管道部分之间的流体通道,所述阀门元件包括适用于密封地关闭所述流体通道的阀门关闭元件;以及
板,与流体通道相连,和所述流体流共线,并且位于所述阀门元件和所述下游管道部分之间,所述板在所述板的下部上具有所述流量限制元件,所述可变面积流量通道适用于引导在所述关闭阀门和所述下游管道之间的低流体流量;
其中所述第一和第二传感器、所述可变面积流量通道和横孔设置在所述板中。
20.根据权利要求19所述的泄漏检测器,其中所述板包括:
上部和下部压力分接管,设置在所述板中,并且适用于分别容纳所述第一传感器和所述第二传感器,所述下部压力分接管延伸到所述板中至所述横孔。
21.根据权利要求19所述的泄漏检测器,所述板的所述可变面积流量通道包括:
与所述板的内壁的下表面一体形成的平坦区域。
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EP1931962B1 (en) 2015-04-08
US20070068225A1 (en) 2007-03-29
US20090303057A1 (en) 2009-12-10
CA2623096C (en) 2014-07-08
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US7940189B2 (en) 2011-05-10
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JP2009510443A (ja) 2009-03-12
CN101278180A (zh) 2008-10-01

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