CN-121830026-B - Fault diagnosis method for intelligent valve positioner

CN121830026BCN 121830026 BCN121830026 BCN 121830026BCN-121830026-B

Abstract

The invention relates to the technical field of data analysis, in particular to a fault diagnosis method of an intelligent valve positioner, which solves the technical problem of low accuracy of fault diagnosis in the prior art. The method comprises the steps of obtaining monitoring data of a valve during the latest multiple adjustment after the valve is adjusted, wherein the monitoring data comprise actual flow and valve setting flow of the valve before and after adjustment and valve dead zone values during adjustment, wherein the valve dead zone values are used for representing response delay intervals of an actuating mechanism of the valve to control instructions, determining fault alarm necessity of the valve according to difference conditions of the actual flow and the valve setting flow of the valve before and after adjustment and change rules of the valve dead zone values, wherein the fault alarm necessity is used for representing emergency degree of the actuating mechanism of the valve for maintenance inspection, and performing fault diagnosis on the valve according to the fault alarm necessity.

Inventors

HUANG ZHIBIN
HUANG ZHIPENG
HUANG HUALONG

Assignees

湖南佳一流体智控技术有限公司

Dates

Publication Date: 20260508
Application Date: 20260311

Claims (8)

1. The fault diagnosis method of the intelligent valve positioner is characterized by comprising the following steps of: After the valve is adjusted, acquiring monitoring data of the valve during the last adjustment for a plurality of times, wherein the monitoring data comprises actual flow of the valve, set flow of the valve before and after adjustment and valve dead zone value during adjustment, and the valve dead zone value is used for representing a response delay interval of an executing mechanism of the valve to a control instruction; determining the fault alarm necessity degree of the valve according to the difference condition of the actual flow of the valve before and after adjustment and the set flow of the valve and the change rule of the dead zone value of the valve, wherein the fault alarm necessity degree is used for representing the emergency degree of the valve which needs to be maintained and checked by an executing mechanism; performing fault diagnosis on the valve according to the fault alarm necessity; The determining the fault alarm necessity of the valve according to the difference condition of the actual flow of the valve and the set flow of the valve before and after adjustment and the change rule of the dead zone value of the valve comprises the following steps: determining the value mismatch degree of the valve at the current adjustment according to the difference of the valve actual flow before and after the current adjustment and the flow change of the valve set flow and the valve actual flow after the current adjustment and the flow change of the valve set flow, wherein the value mismatch degree is used for representing the response hysteresis degree of the valve actual flow to the valve set flow change; Determining the value anomaly degree of the valve in the current adjustment according to the valve dead zone value and the value mismatch degree when the valve is in the current adjustment and the last adjustment, wherein the value anomaly degree is used for representing the degree of deviation of the running state of the valve after the current adjustment from the normal running state; and correcting the numerical value anomaly based on the valve dead zone value of the valve in the last adjustment for multiple times to obtain the fault alarm necessity of the valve.
2. The method of claim 1, wherein after the valve adjustment, acquiring the monitoring data of the valve during the last multiple adjustments, comprises: acquiring the valve set flow before and after the last adjustment through a valve controller; measuring the medium pressure difference of the valves before and after the last adjustment by a differential pressure transmitter, and calculating the actual flow of the valves before and after each adjustment by combining the valve circulation coefficient and the medium specific gravity parameter; And (3) carrying out statistical analysis by sampling a valve position control signal and a valve position feedback signal which are most recently adjusted each time, and calculating a valve dead zone value when each time is adjusted.
3. The method of claim 1, wherein determining the valve value anomaly at the current adjustment based on the valve dead zone value and the value mismatch at the current and last adjustments of the valve comprises: determining the valve dead zone change rate of the valve in the current adjustment according to the valve dead zone value of the valve in the current adjustment and the valve dead zone value in the last adjustment; and determining the value anomaly of the valve in the current adjustment according to the valve dead zone value, the valve dead zone change rate and the value mismatch degree when the valve is in the current adjustment.
4. The fault diagnosis method of an intelligent valve positioner according to claim 1, wherein correcting the numerical anomaly based on a valve dead zone value of the valve at the time of the last multiple adjustments to obtain a fault alarm necessity of the valve, comprises: determining an interference degree parameter according to a valve dead zone value of the valve during the last adjustment for many times, wherein the interference degree parameter is used for representing the interference influence degree of monitoring data; And correcting the numerical value anomaly based on the disturbance degree parameter to obtain the fault alarm necessity degree of the valve.
5. The fault diagnosis method of an intelligent valve positioner according to claim 4, wherein determining the disturbance factor parameter from the valve dead zone value of the valve at the last multiple adjustments comprises: determining a valve dead zone change value when the valve is adjusted for each time according to the valve dead zone value when the valve is adjusted for the last time; Constructing a positive change set according to the valve dead zone change value when each time is adjusted, and determining the valve dead zone change rate when each time is adjusted in the positive change set, wherein the positive change set comprises the valve dead zone change value with a positive value in the last time of adjustment; And carrying out differential analysis on the dead zone change rate of the valve during each adjustment in the positive change set, and determining the interference degree parameter.
6. The fault diagnosis method of an intelligent valve positioner according to claim 5, wherein correcting the numerical anomaly based on the disturbance variable parameter to obtain a fault alarm necessity of the valve comprises: under the condition that the interference degree parameter is smaller than a preset interference degree threshold value, determining a change rate average value of valve dead zone change rates in the positive change set when the valve dead zone change rates are adjusted each time; and correcting the numerical value anomaly based on the disturbance degree parameter and the change rate mean value to obtain the fault alarm necessity degree of the valve.
7. The fault diagnosis method of an intelligent valve positioner according to claim 1, wherein the fault diagnosis of the valve according to the fault alarm necessity comprises: and determining that the actuating mechanism of the valve is in fault under the condition that the fault alarm necessity is larger than an alarm threshold value.
8. The method of fault diagnosis of an intelligent valve positioner according to claim 7, further comprising: And sending fault alarm information, wherein the fault alarm information comprises a valve dead zone value when the valve is currently regulated, the current regulated valve actual flow and the fault alarm necessity.

Description

Fault diagnosis method for intelligent valve positioner Technical Field The invention relates to the technical field of data analysis, in particular to a fault diagnosis method of an intelligent valve positioner. Background In industrial processes, valves are used as a core component for fluid control, the operating state of which directly affects production continuity, safety and economy. The intelligent valve positioner is used as key equipment for valve control, can realize accurate control and state monitoring of a valve actuating mechanism, prevents unplanned shutdown, avoids safety accidents and improves production continuity through fault early warning, and realizes cost reduction, efficiency enhancement and asset fine management according to a data optimization maintenance plan. At present, fault diagnosis of an intelligent valve positioner in the industry is judged by the difference between set flow and actual flow of a valve. However, this conventional monitoring method has certain limitations. In the actual production process, due to external interference factors such as pressure fluctuation, insufficient air quantity and the like of an air supply system, deviation of valve set flow and actual flow can be caused, and even abrupt change of dead zone value can be caused. If judging is carried out only according to the flow difference, the external interference is easily misjudged as the mechanical fault of the actuating mechanism, so that the fault diagnosis accuracy is lower, and the problems of internal abrasion of the valve or external air source cannot be effectively distinguished, thereby influencing the reliability of maintenance decision. Disclosure of Invention In order to solve the technical problem of low accuracy of fault diagnosis in the prior art, the invention aims to provide a fault diagnosis method of an intelligent valve positioner, and the adopted technical scheme is as follows: The application provides a fault diagnosis method of an intelligent valve positioner, which comprises the following steps: After the valve is adjusted, acquiring monitoring data of the valve during the last adjustment for a plurality of times, wherein the monitoring data comprises actual flow of the valve, set flow of the valve before and after adjustment and valve dead zone value during adjustment, and the valve dead zone value is used for representing a response delay interval of an executing mechanism of the valve to a control instruction; determining the fault alarm necessity degree of the valve according to the difference condition of the actual flow of the valve before and after adjustment and the set flow of the valve and the change rule of the dead zone value of the valve, wherein the fault alarm necessity degree is used for representing the emergency degree of the valve which needs to be maintained and checked by an executing mechanism; And carrying out fault diagnosis on the valve according to the fault alarm necessity. In some embodiments, the method comprises: acquiring the valve set flow before and after the last adjustment through a valve controller; measuring the medium pressure difference of the valves before and after the last adjustment by a differential pressure transmitter, and calculating the actual flow of the valves before and after each adjustment by combining the valve circulation coefficient and the medium specific gravity parameter; And (3) carrying out statistical analysis by sampling a valve position control signal and a valve position feedback signal which are most recently adjusted each time, and calculating a valve dead zone value when each time is adjusted. In some embodiments, the method comprises: determining the value anomaly degree of the valve in the current adjustment according to the difference condition of the actual flow of the valve before and after the current adjustment and the set flow of the valve and the valve dead zone value of the valve in the current adjustment and the last adjustment, wherein the value anomaly degree is used for representing the degree of deviation of the running state of the valve after the current adjustment from the normal running state; and correcting the numerical value anomaly based on the valve dead zone value of the valve in the last adjustment for multiple times to obtain the fault alarm necessity of the valve. In some embodiments, the method comprises: determining the value mismatch degree of the valve at the current adjustment according to the difference of the valve actual flow before and after the current adjustment and the flow change of the valve set flow and the valve actual flow after the current adjustment and the flow change of the valve set flow, wherein the value mismatch degree is used for representing the response hysteresis degree of the valve actual flow to the valve set flow change; And determining the value anomaly degree of the valve in the current adjustment according to the valve dead zone value and the value