Source: https://patents.google.com/patent/CN1271410A/en
Timestamp: 2020-07-03 15:17:35
Document Index: 218982780

Matched Legal Cases: ['art 34', 'art 49', 'art 50', 'art 53', 'art 50', 'art 53', 'art 53', 'art 53', 'art 50', 'art 53', 'art 49', 'art 49', 'art 49', 'art 51']

CN1271410A - Diagnostic device and method for pressure regulator - Google Patents
Diagnostic device and method for pressure regulator Download PDF
CN1271410A
CN1271410A CN98809373A CN98809373A CN1271410A CN 1271410 A CN1271410 A CN 1271410A CN 98809373 A CN98809373 A CN 98809373A CN 98809373 A CN98809373 A CN 98809373A CN 1271410 A CN1271410 A CN 1271410A
CN98809373A
CN1143971C (en
P·R·亚当斯
K·J·加贝尔
D·G·罗珀
费希尔控制产品国际公司
1997-09-22 Priority to US08/935,176 priority Critical patent/US6035878A/en
1997-09-22 Priority to US08/935,176 priority
1998-09-10 Application filed by 费希尔控制产品国际公司 filed Critical 费希尔控制产品国际公司
2000-10-25 Publication of CN1271410A publication Critical patent/CN1271410A/en
2004-03-31 Publication of CN1143971C publication Critical patent/CN1143971C/en
238000003745 diagnosis Methods 0.000 claims description 17
230000035945 sensitivity Effects 0.000 claims description 11
230000004075 alteration Effects 0.000 claims 2
230000000694 effects Effects 0.000 description 26
238000006073 displacement Methods 0.000 description 10
A diagnostic device and method for an intelligent pressure regulator which maintains a fluid in a process at a predetermined pressure. The regulator includes an electronic controller which enhances regulator performance and provides self-diagnostics and communications capabilities. The electronic controller includes a pressure sensor which provides a signal indicating the pressure of the fluid being controlled, an adjusting pressure for adjusting the position of a throttling element; and a PID controller which receives the signal indicating the pressure of the fluid being controlled and applies the adjusting pressure to the actuator in response to the signal.
The diagnosis apparatus and the method that are used for pressure regulator
The application be by same inventor the application number of submitting on the same day that is entitled as " intelligent pressure regulator " for _ _ _ _ _ the co-applications of U.S. Patent application, here cite entire description for your guidance.
The present invention relates to fluid pressure regulator, relate in particular to and a kind ofly have in order to the intelligent electric subset that improves performance and the modified model fluid pressure regulator of software.
Generally speaking, four of the process control loop fundamentals comprise measurement, controller and the control piece of process variables, process sensor or the process variables state that will control.This sensor provides the characterization value of process variables state to controller, and this controller also contains characterization value or " set point " of required process variables state.Controller calculate after process variables state and set point are made comparisons a corrected signal, transmit the signal to control piece, so that process is exerted one's influence and made it reach the set point state.This control piece is the decline in loop, and the most frequently used final stage control piece is a valve, although it also can comprise for example speed-changing driving device or pump.
Pressure regulator is a kind of independence (self-contained) control system that simply has of one's own, and it is combined in process sensor, controller and valve in the unit.Pressure regulator is widely used for the pressure control in fluid distribution application and the production and processing industry, and the delivery pressure that reduces, the while that for example are used to keep required provide desired fluid flow rate to satisfy different downstream requirements again.Pressure regulator is divided into two kinds of main types usually: directly effect type regulator and lead control effect type (pilot-operated) regulator.
A kind of typical directly effect type regulator 11 in the prior art has been shown among Fig. 1.The typical use of this direct effect type regulator comprises: industry, commerce and air feed service; Instrument (instrument) is supplied with gas or gas; Be conducted to the combustion gas of burner; Hydraulic pressure control; The steam supply service; And container is sealed (tank blanketing).This direct effect type regulator 11 has a regulator body 12, and this main body has an inlet 13 and one outlet 14.Fluid flow channel district 15 with a restricted zone 16 will enter the mouth and 13 link to each other with outlet 14.This restricted zone 16 have such as stopper, diaphragm, blade, sleeve pipe (sleeve) but or when it moves the throttling element 17 the similar current-limiting apparatus of limit fluid (gas or liquid) flow rate.An actuator that includes the sensor with two sides reacts to the variation in the controlled fluid pressure.The example of sensor comprises diaphragm, barrier film or piston.The barrier film 18 that embodiment shown in Figure 1 adopts sensor to use.Pilot pressure puts on first side or the control side 19 of sensor via the passage 20 of control wiring or regulator body 12 inside.If control wiring is used for this purpose, then it can be integral or be arranged in adjacent tubes with regulator body 12.Second side or the reference side 21 of sensor generally are referred to as atmospheric side.Additional force such as spring 22 can be applied to actuator, and this additional force is biased to throttling element on the precalculated position of representing set point.
Because sensor (barrier film 18) is linked by the pressure (in the fluid output side) 14 of an inner passage 20 with the regulator downstream, therefore direct effect type regulator 11 shown in Figure 1 is a kind of " decompression " regulators.Increment in the downstream pressure is applied to control side 19 by inner passage 20, and pressure is applied to barrier film 18 and forces this barrier film upwards to overcome the power of spring 22.Then, throttling element is moved upward to restricted zone 16, thereby has reduced the hydrodynamic pressure of regulator outlet 14.
Pressure reducing regulator is regulated flow rate by the pressure in induction regulator downstream.Pressure reducing regulator typically is applied to steam boiler, and in this used, pressure reducing regulator provided initial pressure to regulate.If barrier film 18 links with upstream pressure and throttling element 17 moves to the opposite side of restricted zone 16, then directly effect type regulator 11 should be called a kind of " back pressure " regulator.This back pressure regulator is applied to for example compressor, in order to guarantee vacuum state can not occur in the compressor.
The structure of leading control effect type regulator is to directly effect type regulator is similar.Fig. 2 A is shown schematically in the prior art a kind of typical decompression and leads control effect type regulator 23, then shows in the prior art a kind of back pressure among Fig. 2 B and leads control effect type regulator.This is led control effect type regulator and has all structural elements of direct effect type regulator, and has increased and lead control 24 (also being referred to as relay, amplifier or multiplier).This leads control is an auxiliary device, and it has amplified the load pressure on the regulator actuator, in order to regulate pressure.This structure of leading control is similar to self-applying type regulator, and has and the essentially identical element of self-applying type regulator.
In the control effect of the leading type regulator 23 shown in Fig. 2 A and Fig. 2 B, inlet pressure applies via the pressure nozzle (tap) 27 of the upstream that is arranged in regulator 23.Lead in the control effect type regulator 23 in the back pressure shown in Fig. 2 B, in pressure nozzle 27, also can comprise a restricted zone 26.Be applied to the inlet pressure of leading control and also can be applied to regulator body by the pressure nozzle of one.Outlet pressure feeds back by the pipeline 20 that the downstream with regulator 23 links to each other.Downstream pressure with lead control 24 and master selector 10 links.Lead the pressure difference that control 24 amplifies across master selector barrier film 18, so that control upstream (back pressure) or downstream (decompression) hydrodynamic pressure.
Pressure regulator has the many advantages that are better than other control gear.The cost of regulator is lower.They generally do not need external power supply to carry out pressure control function; On the contrary, regulator will be used as power from the pressure in the controlled process.In addition, process sensor, controller and control valve are combined in less having of one's own in the individual packages.Other advantage comprises good frequency response, good adjustable extent, less size and seldom or not exists bar to sew (stem 1eakage) usually.
Certainly, existing regulator also exists some shortcomings.The prominent question relevant with existing pressure regulator comprises " sagging (droop) " and " rise (build-up) ", also is referred to as deviation or proportional region.Reducing of the sagging controlled pressure that is defined as pressure reducing regulator when moving to flowing state at full capacity from low-load, rising then is defined as the increase of the controlled pressure of back pressure regulator when moving to the full load flowing state from low-load.They are generally represented with percentage.Sagging and rising especially is prevalent in the direct effect type regulator, but its also less degree ground is present in existing leading in the control effect type regulator.
Regulator usually needs to enter the not flowing state of a kind of being referred to as " locking " or " resetting ".In pressure reducing regulator 11 such as self-applying type regulator shown in Figure 1 or the control effect of the leading type regulator 23 shown in Fig. 2 A, that downstream pressure can reach is 11 desired for regulator, stop the point that fluid flows fully.When being in this downstream pressure, the pilot pressure that feeds back to barrier film 18 is moved into throttling element 17 among the restricted zone 16 fully, blocks thus and flows.This state is referred to as " locking ".In back pressure regulator shown in Fig. 2 B, such as leading control effect type regulator 23, the upstream pressure of regulator can be reduced to needs regulator to cut off on the force value that flows.In this case, the upstream pilot pressure drops on such value, i.e. bearing spring and/or lead governor pressure throttling element 17 is shifted on the position that the total blockage fluid flows.Inner member goes wrong, pollution or the bonding (binding) of inner member in moving all can make locking function weaken.
Because regulator is a kind of autonomous control system that has of one's own, therefore existing regulator does not generally comprise the ability of communicating by letter with the other parts of process control system.This will cause following shortcoming.Owing to the device that provides set point or tuning regulator to use at a distance is not provided, therefore must manually adjusts.Thereby this adjustment is to apply required power by the adjustment knob on the rotation regulator on actuator to carry out.This is particularly undesirable in the process of the pressure of remote application or control dangerous substance.Owing to do not have the control room that shows regulator performance, thereby the operator can only come inference to determine the fault of regulator by the reading that other process shows.
The communication and the shortage of Processing capacity also can cause the problem of maintaining.Owing to be difficult to or can't in the whole time period, watch like a hawk the performance of regulator, thereby can send hardly and repair or the more alarm in advance of switching regulator.Also lack the alarm in advance of emergency, this particularly bothers for existing pressure regulator: because they are process energy supplies, so they generally do not comprise the fault mode running.If the running barrier film of spring load pressure reducing regulator breaks down, then this regulator will be opened fully.Like this, if this moment, the downstream pipeline can't be resisted the upstream pressure state,, will cause problem if perhaps can deal with the non-existent words of reduction valve of the maximum flow rate of regulator.When barrier film breaks down, back pressure regulator will cut out fully, and this will cause similar problem in the upstream portion of process.
As everyone knows, available control valve replaces pressure regulator in can adopting numerous occasions of pressure regulator.This control valve have with mobile throttling element control that flow rate uses in execute the motor-driven actuator that signal reacts.What estimated is, suitably utilizes regulator to replace control valve in 25% the application of adopting control valve.Slowly the reason that dare not replace control valve with regulator is because due to the relevant defective of existing pressure regulator to a great extent.Main cause comprises droop characteristic and lacks remote-controlled operation.Yet the user of process device waits in expectation and have more competitiveness on cost.Except the treatment effeciency and the improvement in the uptime of seeking existing process device, the user of process device is also seeking a kind of process control cheaply.If eliminated the above-mentioned defective of regulator, the application that then can be numerous control valves provides a kind of selection scheme cheaply.
US enterprise will spend about 200,000,000,000 dollars and come factory installation is maintained every year.This shows that the maintenance cost accounts for the 15-40% of annual COGS (cost of goods sold).In addition, spending in 1/3rd of U.S. dollar in the maintenance is wasted in the unnecessary or invalid maintenance.For example, because existing regulator does not have diagnosis or the communication capacity of using with the external system exchange message, therefore be difficult to find fault.Usually in the trial of revising unrecognized procedure fault, changed regulator, but found that regulator performance is normal.More switching regulator may need suspend whole process, and this will waste the production time widely.The performance of the process instrument of raising such as pressure regulator and improve maintenance characteristics and all will reduce manufacture cost significantly by improving process capability and communication capacity.
Therefore, need a kind of improved pressure regulator that compensates droop characteristic and have improved performance.In addition, preferably have communication and diagnosis capability for this modified model regulator, so that carry out remote-controlled operation, and the energy swap data is to improve maintenance characteristics.In addition, these newly-increased characteristics also need to have both pressure controlled economic benefits simultaneously.
The present invention improves regulator performance by providing a kind of, comprises that the intelligent pressure regulator of processing and communication capacity solves existing the problems referred to above in the prior art.This is to keep at the same time under the situation of the existing simple in structure and advantages of being cheap of pressure regulator to realize.
One main aspect in, the present invention one demonstration provides a kind of fluid that is used for process to remain on intelligent regulator on the predetermined pressure with embodiment, it comprises: fluid input, fluid output, the fluid flowing passage that connects this entrance and exit, and the throttling element that can in this flow channel, move, be used for selectively to limit the fluid flow rate that flows through flow channel.Actuator and this throttling element link, and are used for selectively mobile throttling element.This actuator has control side and reference side, and wherein reference load and this reference side link, and is used for throttling element is biased to the preset reference position of representing predetermined pressure.Feedback line will be applied to control side from the pressure of controlled fluid, move so that actuator overcomes reference load, thereby throttling element is moved to adjust fluid flow rate in flow channel, come the hydrodynamic pressure in the control procedure thus.The present invention also has: the pressure transducer of the signal of expression controlled fluid pressure is provided, adjusts the adjustment pressure that the throttling element position is used, and receive the pressure of expression controlled fluid and apply the controller of adjusting pressure to actuator according to this signal.Other embodiment provides the ability that is used for ratio, integration and differential (PID) control, diagnostic process and communicates by letter with external means.
According to another embodiment of the present invention, the invention provides a kind of electronic controller that is used for pressure regulator, this pressure regulator is located throttling element by the pressure that utilizes controlled fluid, the fluid flow rate that flows through self-applying type pressure regulator in order to restriction remains on hydrodynamic pressure on the predetermined value roughly, this electronic controller comprises: the pressure transducer that the signal of expression controlled fluid pressure is provided, receive the signal of this expression controlled fluid pressure, and to the Signal Processing device of this adjustment of throttling element output expression, and except that controlled fluid pressure, the signal of exporting according to processor is applied to the adjustment pressure of throttling element.
In aspect another is main, the invention provides a kind of sagging method that is used for the compensatory pressure regulator, this pressure regulator by the pressure that utilizes controlled fluid locate throttling element, the fluid flow rate that flows through self-applying type pressure regulator in order to restriction remains on hydrodynamic pressure on the predetermined value roughly.This method comprises following action: the pressure of determining controlled fluid, by the pressure and the predetermined value of this controlled fluid are made comparisons the error of calculations value, convert this error amount to adjustment pressure, and reorientate throttling element by this adjustment pressure that applies to throttling element except that controlled fluid pressure.
Fig. 1 is a schematic representation, and it shows a kind of typical directly effect type pressure regulator in the prior art.
Fig. 2 A is a schematic representation, and it shows a kind of control effect type pressure reducing regulator of typically leading in the prior art.
Fig. 2 B is a schematic representation, and it shows a kind of control effect type back pressure regulator of typically leading in the prior art.
Fig. 3 is a schematic representation, and it shows the demonstration embodiment that a kind of back pressure of the present invention is controlled intelligent regulator.
Fig. 4 is a schematic representation, and it shows a demonstration embodiment of a kind of intelligent regulator that reduces pressure of the present invention.
Fig. 5 A has figured out the sagging compensate function of the electronic controller that is used for one embodiment of the invention.
Fig. 5 B has figured out the rising compensate function of the electronic controller that is used for one embodiment of the invention.
Fig. 6 is the block diagram of intelligent regulator, and it has highlighted the functional zone of self-applying type regulator and electronic controller.
Fig. 7 is shown schematically in the electronic controller of one embodiment of the invention.
Fig. 8 A is the deviation chart of a regulator, and it has drawn the setup pressure value that is used for pressure reducing regulator and the relation of pilot pressure flow rate.
Fig. 8 B is the deviation chart of a regulator, and it has drawn the setup pressure value that is used for back pressure regulator and the relation of pilot pressure flow rate.
Fig. 9 A is a regulator inlet sensitivity chart, and it shows the pilot pressure curve of the various inlet pressures that are used for pressure reducing regulator.
Fig. 9 B is a regulator inlet sensitivity chart, and it shows the pilot pressure curve of the various inlet pressures that are used for back pressure regulator.
Figure 10 is a chart, and it shows the measurement to the hysteresis error of pressure regulator.
Figure 11 A is a chart, and it shows " locking " in the pressure reducing regulator.
Figure 11 B is a chart, and it shows " resetting " in the back pressure regulator.
Figure 12 shows to adopt and has a simple lay zygonema of Field bus (Fieldbus) to the communication line between intelligent regulator of the present invention and external control chamber.
Figure 13 shows to adopt and has a simple lay zygonema of Hart (HART) to the communication line between intelligent regulator of the present invention and external control chamber.
Figure 14 show adopt four lines, multiple twin zygonema right be configured in communication line between intelligent regulator of the present invention and the external control chamber.
Figure 15 shows and adopts the communication line of radio contact between intelligent regulator of the present invention and external control chamber.
Figure 16 shows the communication line of other communicator between intelligent regulator of the present invention and external control chamber employing such as modulator-demodulator or the optical fiber.
See also accompanying drawing now, especially referring to Fig. 3 and Fig. 4, be shown schematically in two embodiments of intelligent pressure regulator of the present invention among the figure.Each embodiment represents by label 10, and respectively include a self-applying type regulator and an electronic controller (being surrounded by dotted line) in Fig. 3 and Fig. 4.Generally, Fig. 3 shows the present invention a kind of intelligent regulator of use in back pressure control is used, and Fig. 4 then shows the present invention a kind of intelligent regulator of use in decompression is used.In Fig. 3, fluid is to flow to a left side from the right side.In Fig. 4, fluid then is to flow to the right side from a left side.Specific embodiment shown in Fig. 3 and Fig. 4 includes a self-applying type regulator, but the skilled artisan in the art also can advantageously make the present invention adopt a kind of control effect type regulator of leading.
See also accompanying drawing, self-applying type regulator 11 has a main body 12, and this main body then has 13, the one fluid outlet 14 of fluid inlet and a joint access 13 and a mobile passage 15 that exports 14.Among this flow channel 15, be provided with a restricted zone 16, and have a throttling element 17 to play the effect that the fluid flow rate of this restricted zone 16 is flow through in restriction.This throttling element 17 can have a stopper, diaphragm, blade, sleeve pipe or other can control the suitable element that fluid flows when it is mobile in restricted zone 16.Regulator 10 also includes the actuator with a sensor, and in Fig. 3 and specific embodiment shown in Figure 4, this sensor has a barrier film 18 that links with regulator body 12.This sensor also can adopt the form of diaphragm or piston.One sliding bar 29 links to each other throttling element 17 with barrier film 18.This barrier film 18 has a control side 19 that is applied with pilot pressure 30 on it.This pilot pressure 30 by means of in a control wiring (not shown) or the valve body 12 or its outside passage (not shown) be connected to barrier film 18.
Because pilot pressure 30 is applied on the barrier film 18 that is in regulator 10 party upstream, therefore regulator 10 embodiment illustrated in fig. 3 is a kind of back pressure regulators.Shown in Fig. 4 is a kind of pressure reducing regulator, and wherein the barrier film 18 that links to each other with pilot pressure 30 is in the downstream side of regulator 10.Barrier film 18 also has a reference side 21 relative with control side 19 and that reference atmosphere is pressed.In existing regulator, reference side generally has a spring 22 or other applies a proper device additional force, such as weight to this reference side 21.In addition, a location screw 31 also is set, in order to the initial position of setting spring 22.
In back pressure regulator shown in Figure 3 10, process-liquid flows by a pipeline 32 as shown in the figure.Spring 22 is setovered, so that throttling element 17 remains on the position of closing substantially.Fluid flows into inlet 13, and flow out from exporting 14 the restricted zone of flowing through 16 backs.Thereby pilot pressure 30 be in such a way, be system pressure from a upstream position be applied to control side 19, the power that forces barrier film 18 to overcome spring 22 move necessarily movement rod and throttling element 17 with change flow through the flow rate of restricted zone 16, the mode of regulated fluid pressure is connected to the control side 19 of barrier film 18 thus.
Pressure reducing regulator 10 shown in Figure 4 is to operate in the mode that is similar in conjunction with the described back pressure regulator of Fig. 3, and just pilot pressure 30 is to experience in the downstream side of regulator 10, and throttling element 17 is positioned on the opposite side of restricted zone 16.In this pressure reducing regulator 10, spring 22 is so that throttling element 17 is biased on the basic position of opening or the mode of disengaging restricted zone 16 applies power to the reference side 21 of barrier film 18.Pilot pressure 30 is applied to the control side of barrier film 18 from position, a downstream, throttling element 17 is further moved into or shift out restricted zone 16, thereby control downstream pressure by the flow rate that restricted zone 16 is flow through in adjusting.
Under the situation of the spring load system of typical self-applying type regulator, along with flow rate is changed to maximum value from minimum value, the pressure of being controlled tends to reduce.This is called the rising (also being referred to as proportional region or deviation) in the sagging and back pressure regulator in the pressure reducing regulator.The present invention can compensate sagging and rise, and improves the precision of regulator by setting up an electronic controller 28 that receives the characterization value of set point and pilot pressure simultaneously.This controller is made comparisons set point and pilot pressure, and the reference side to barrier film applies an adjustment pressure then, in order to the restriction of compensated regulator spring body system.
Fig. 5 A has figured out the sagging regulatory function of electronic controller, and wherein the y axle is represented pilot pressure, and the x axle is then represented flow rate.In Fig. 5 A, with " a " sign curve representation be a kind of sagging or deviation of typical self-applying type pressure reducing regulator, wherein pilot pressure reduces along with the increase of flow rate.With the curve representation of " b " sign is to be used for the output quantity of electronic controller of the sagging usefulness that curve a among the compensation image 5A presented.Ignore rubbing action, the mutual basically minute surface symmetry of these curves.Curve " c " expression be result after curve " a " and " b " synthesize, equate with set point.
Similarly, Fig. 5 B has figured out the rising regulatory function.The same with Fig. 5 A, the curve representation of usefulness " a " sign is a kind of rising or deviation of back pressure regulator among Fig. 5 B, and wherein pilot pressure increases along with the increase of flow rate.With the curve representation of " b " sign is to be used for the output quantity of electronic controller of the rising usefulness that curve a among the compensation image 5B presented.Ignore rubbing action, these curves are with the mutual basically minute surface symmetry of the mode that is similar to the sagging curve shown in Fig. 5 A.Curve " c " expression be result after curve " a " and " b " synthesize, equate with set point.
Please return on Fig. 3 and Fig. 4, electronic controller 28 includes processor and one electric current-pressure (I/P) transducer 35 that one pressure-electric current (P/I) transducer 33, is used as proportion integration differentiation (PID) controller 34.This PID controller 34 can be included in the microprocessor.Electronic controller 28 is by an external power supply 36 power supplies, and shown in Fig. 3 and Fig. 4 is one 24 volts of power supplys.This electric energy can be by comprising such as providing from the transformer or the external power supply the loop power of distributed control system, the some suitable power supply of generator, solar energy source or battery power that will be used as the self-applying type regulator inside of the energy from the pressure in the controlled process.Pressure 37 is supplied in I/P transducer 35, and it provides Pneumatic pressure to the reference side 21 of barrier film 18, so that provide sagging necessarily or the rising compensation according to flow condition.Under the situation that does not include I/P transducer 35, utilizing pressure feed 37 that the another kind of method of Pneumatic pressure is provided is to drive the actuator that has a motor.(rather) or rather, this motor should receive direct signal from PID controller 34.
Fig. 6 shows the functional zone of the demonstration of intelligent regulator 10 with embodiment.Required pressure or the set point of thick set point piece 38 expressions, this is the form that adopts the regulator bearing spring of the power that applies on the reference side of barrier film in an embodiment of the present invention, shown in summing junction 39.Because sagging by the pressure adjusting meeting that self-applying type regulator 11 is carried out, so set point 38 is one " slightly " set points.The positioning screwn of using by load that adjust to set spring for governor and should input to self-applying type regulator by thick set point 38.Overcome the power of (+) just that the barrier film applied force is summing junction 39 places as shown in the figure by the regulator bearing spring.
Set the position of regulator throttling element restricted zone from the power that summing junction 39 is come out together with the spring constant (rate) of regulator.Amplification factor 40 is applied to position information to set the output flow rate W of regulator.This output flow rate W makes comparisons with required flow rate or load flow rate WL in summing junction 41.If output flow rate W equates that with load flow rate WL then system is in steady state, and pilot pressure P cKeep constant.If system is not in steady state, then P cFeed back to barrier film, as shown in the figure, the power that is in one negative (-) of summing junction 39 will can not offset at summing junction 39 places.Throttling element is moved up to summing junction 39 relative to restricted zone to be output as till zero.In other words, P cOn barrier film, applied opposite force, thereby changed the position of throttling element, so just adjusted flow rate, regulated pressure thus by the bearing spring applied force.
For compensate and improve the performance of self-applying type regulator, the characterization value of pilot pressure also transfers to electronic controller 28.Can be with the adjacent tubes regulator one or that be installed on external regulator on the P/I transducer 33 of pressure converter with P cConvert the signal that the 4-20mA that is provided as typical simulated pressure transducer is provided to.This P cSignal then is sent in the PID controller 34 of electronic controller.This P cMultiply by derivative constant 42, and then and P cSignal is sent in the summing junction 43 together.The output of this summing junction 43 summing junction 45 places with make comparisons from the smart set point signal 44 of the outside source such as main frame or distributed control system, produce an error signal thus.This error signal is multiplied by proportionality constant 46 and integration constant 47, and is sent in the summing junction 48, produces an output signal thus.This output signal is input in the I/P transducer 35, provides Pneumatic pressure to barrier film thus, as one just shown in the power of (+) of summing junction 39 places.
The above-mentioned adding that is used to compensate sagging and the Processing capacity that tightens control has also improved the performance of pressure regulator others; Comprise: remote-controlled operation with communicate by letter, maintenance ability of the processing operation of enhancing, diagnosis capability, enhancing, trend (trending) ability, alert capability etc.Along with further describing of electronic controller, it is very clear that these enhancings will become.
Fig. 7 is shown schematically in an embodiment of intelligent regulator 10.Self-applying type regulator 11 illustrates in schematic form.Except that above-mentioned PID controller part 34, electronic controller 28 also includes diagnosis part 49, transducing part 50, communications portion 51, power supply unit 52 and conversion (alternate) input part 53.These funtion parts of electronic controller can be included in the microprocessor simultaneously.
Transducing part 50 provides error signal according to all signals of expression inlet pressure P1, downstream pressure P2 and actuator load pressure P L to PID controller 34, and these are handled according to the PID constant.These signals can be provided or be come from external sensor by the sensor with the regulator body one.Receive other process variables by conversion input part 53.These inputs can comprise from the temperature signal 65 of the temperature transducer regulator one or that be installed on external regulator.For example, audio frequency or vibration transducer 66 provide and can represent sewing and/or the input of the cavity or the phenomenon of releasing in the restricted zone.The information of displacement of valve rod 67 and actuator displacement 68 is sent in the conversion input part 53 to monitor the state of these elements via movement transducers.Information such as above-mentioned input all is the examples that can be sent to the process element in the conversion input part 53 of electronic controller 28.Other suitable process data such as pH or flow rate also can be via providing with the sensor regulator one or that be positioned at external regulator.Arbitrary signal in the sensor signal or all signals can be for being converted to the analogue signal of digital numerical value by electronic controller.
The baseline diagnostic data can be used for deriving " feature indication (signature) " of particular adjustments device, and it can be stored in the storage of the storage of controller or external system.Then can handle from transducing part 50 and conversion input part 53 and offer the performance information of diagnosing part 49, and itself and base-line data or feature indication made comparisons, if the characteristic of regulator and performance break away from desired characteristic performance and surpass certain prearranging quatity, diagnose then that part 49 can give the alarm to system operator, physical fault and expection fault and other diagnostic message.Alarm state can spontaneously be reported via the uncalled communication from the regulator to the main frame or via the polling from main frame.Polling can carry out by preset time at interval.Perhaps, provide the warning device of sound for example or visual alarm can send and the inconsistent signal of feature indication.Then, this information can be used for keeping in repair the improvement of forecast, systematic function, the accumulative total of Life cycle etc.Hereinafter will narrate can be by the example of the diagnosis part 49 handled specific informations of one embodiment of the invention.
Deviation: as mentioned above, existing regulator presents the deviation such as sagging or rising.Fig. 8 A and Fig. 8 B have drawn the setup pressure value of self-applying type regulator and the pilot pressure chart to the flow rate on the x axle.This setting value is constant in whole flow rate range.Shown in the curve that identifies with " regulator " among Fig. 8 A, the pilot pressure that is used for pressure reducing regulator reduces along with the increase of flow rate, and shown in Fig. 8 B, the pilot pressure that is used for back pressure regulator increases (the sagging or compensation of rising of the electronic controller of ignoring) along with the increase of flow rate.Lead control effect type regulator and should present similar curve, but deviation is smaller.Distance between the setpoint profile on sagging curve (Fig. 8 A) or an ascend curve (Fig. 8 B) and the given flow rate promptly is the deviation of regulator.The deviation of each point can be determined at its each point place by following formula:
Deviation=Δ P*K L
Wherein: Δ P is the difference between pilot pressure and inlet pressure, and K LIt then is the flow coefficient at this some place.The processor of intelligent regulator can monitor this deviation, and itself and a baseline value are made comparisons.Variation in the deviation can be represented for example load force of this regulator (spring) problem.So, can be with this state notifying operator.
Inlet pressure sensitivity: Fig. 9 A and Fig. 9 B show three kinds of curves of pilot pressure flow rate on the multiple inlet pressure that identifies with a, b and c respectively.This shows the sensitivity for the regulator of different inlet pressures.For a given flow rate, the difference between the pilot pressure of different inlet pressures has constituted inlet sensitivity.All curve among Fig. 9 A shows the inlet sensitivity of pressure reducing regulator, and Fig. 9 B then shows the inlet sensitivity curve of back pressure regulator.Owing to there is deviation.Inlet sensitivity can be made comparisons with baseline information, so that provide diagnosis and fault expected information from electronic controller to the user.
Lag behind and the dead band: lagging behind is defined as depending on that the input system that is produced is still reduced by last value increase and causes that instrument provides the trend of different outputs for a given input.Figure 10 shows the measurement of the hysteresis error that comprises hysteresis and dead band.Curve with " a " sign shows the curve that is used for the pilot pressure flow rate that the requirement flow rate reduces.Curve with " b " sign shows the similar curve that is used for the increase of requirement flow rate.In other words, curve " a " has been drawn the pilot pressure that is used for given flow rate when throttling element when first direction moves, and curve " b " has then been drawn the pilot pressure that is used for corresponding flow rate when throttling element is mobile in opposite direction.Difference between two curves is called " dead band ".The slope that monitors hysteresis curve can provide for example information of relevant spring constant.Variation in variation in the dead band or the hysteresis curve slope can indicate or be used to forecast that spring, actuator, throttling element or other regulator member have problem.
Locking and resetting: Figure 11 A and Figure 11 B have figured out locking and reset mode.In pressure reducing regulator (Figure 11 A), when downstream pressure reached a predetermined point that is positioned on the setting value, pilot pressure should make throttling element shift on the position of closing fully, thereby stoped fluid to flow.This locking point identifies with " a " in Figure 11 A.Figure 11 B shows back pressure regulator and locking is corresponding resets.Reset in the time of under upstream pressure drops to set point,, identify by " b " among Figure 11 B so that throttling element is shifted to closed position.Locking/pilot pressure the value that resets and between setting value and locking or reduction point the slope of regulator pressure section can be determined and be stored in an intelligent regulator diagnosis part or the outer computer.Perhaps, can adopt the transducer of sewing such as audio frequency or earthquake transducer that locking or reset mode are associated with known flowing state.Locking/reseting performance and these baseline values of regulator are made comparisons with the running of diagnosis regulator.Variation in locking/reseting performance for example can indicate inner body has problem or inner body bonding to be arranged in moving.
The PID control of expectation: by checking pilot pressure, deviation, flow rate and/or hysteresis error, and the performance that the PID of these variablees and expectation controls made comparisons to obtain total regulator performance.Can adopt that regulator body is used, relevant flow coefficient parameter in electronic controller internal calculation flow rate with liquid stream, air-flow and vapor stream.Then, the displacement of this inside flow rate and actuator and the correction factor of regulator body are made comparisons to calculate regulator main flow rate.These calculating can be carried out in the processor of electronic controller, and perhaps this information can be calculated via communications portion and and use main-machine communication.
Autotune: above-mentioned factor also can be used for deriving P, I and the tuning constant of D.Stepping (step) variation is input in the set point via electronic controller, then measures the output response and diagnose to carry out system dynamics.
Displacement: actuator displacement is an important diagnostic factor.In other respects, actuator displacement also is used to calculate the load and the position of throttling element.Is to calculate and the power on the barrier film opposite side relatively displacement as an example of diagnostic purpose.The diagnosis of processor part can be calculated bearing spring by regulator and be applied to power on the barrier film reference side:
(T l+I s) *K l
Wherein: T lThe displacement of=actuator, I s=initial spring the adjusted value that sets by positioning screwn, and K l=spring constant.This compares with the masterpiece that is applied on the barrier film control side:
P c*A
Wherein: P c=pilot pressure, and A=diaphragm area.In leading control effect type regulator, the displacement of leading the control actuator also can be used for diagnosis in a similar manner.In addition, adopting motor to adjust in the regulator of throttling element, the voltage and current of motor also can be counted as corresponding with the displacement that is used for diagnostic purpose.These relatively, and the expression of inlet and pilot pressure, inlet sensitivity, hysteresis error and flow rate is used to provide normal condition and performance-relevant diagnostic message with regulator.
Release and the cavity phenomenon: these all are the phenomenons that take place in liquid stream, and they can bring noise and vibration to regulator, may shorten the working life of regulator.It is all relevant with formation bubble in fluid with the cavity phenomenon to release.When fluid flow through restricted zone, flow velocity increased, and pressure reduces, and had so just formed bubble.In case fluid flows through restricted zone, flow velocity slows down, and the pressure recovery, and bubble is sharply broken.No matter be that acoustic frequency sensor or vibration transducer all can be used for making comparisons by the noise/vibration characteristic relatively sensed and with them and baseline characteristics and directly respond to cavity or the existence of the phenomenon of releasing, perhaps another process variables Δ P ACan calculate by following formula
ΔP A＝K C(P l-r C?P v)
Wherein: K C=the cavity or the index of releasing, P l=inlet pressure, r C=critical pressure specific ray constant, and P v=vapor pressure.The input constant of this value and liquid stream vapor pressure is made comparisons directly determining to release or the existing of cavity phenomenon, and transmits an alarm.
Under the situation that possesses the diagnosis capability that joins the novelty in the regulator, can in above-mentioned all kinds of zones and other zone, carry out inline diagnosis.A kind of electronics " impact "---the step type step change is to setting value---may be introduced in the system.This can make the process control loop not normal, and intelligent thus regulator can be attempted to revise.When regulator reacted to electron bombardment, the performance of the regulator that relates to above-mentioned various factor (and other factor) was partly measured in the diagnosis of electronic controller, and the feature indication of itself and regulator is made comparisons.One benchmark so just is provided,, and has not made process severe disorder or multilated so that formerly diagnose.
Can exchange by various communicators and external system and device with set point, configuration, diagnosis and other information of intelligent regulator from demonstration.The ability of distant control regulator so just is provided, and this is a key character of difference existing mechanical pressure regulator.The operator can be sent to instruction regulator, change operating parameters and Report Parameters.In addition, also diagnostic message can be sent to the external system that deals with usefulness, rather than in regulator, handle.Demonstration is particularly useful for keeping in repair and operating the remote and dangerous environment of difficulty with the communication capacity of intelligent regulator.
Multiple communication medium can be used with intelligent regulator of the present invention, a simple lay zygonema that is applied the communication that (overlaid) modulate such as having on power power-supply or with power power-supply to, the simple lay zygonema that only is used for data communication to, wireless, modulator-demodulator, optical fiber, concentric cable and some other communication technologys.The present invention demonstrate with embodiment's communication capacity also can with other the process instrument or with external control system or main frame exchange configuration and control information.
Shown in Figure 12 is the sketch that can adopt two kinds of electric wires communications that digital Field bus communication protocol implements with an embodiment of the intelligent regulator of the present invention, wherein digital data the simple lay zygonema on combine with the power supply of the electronic controller that is used for intelligent regulator.54 signals that send are by way of a low-pass filter 55, so that system power power supply and data are separated from the control room.Then, this power supply is conducted to the intelligent regulator of the present invention and other device behind power conditioning circuitry 56.The Field bus signals that is received is by way of high-pass filter 57, so that communication data and system power power supply be separated, and reaches the channel part 51 of electronic controller.The information that sends back main system is by way of a modulator-demodulator 58, so that data combine with the system power power supply signal.
Shown in Figure 13 is to adopt the sketch of Hart agreement with the another kind communication of one embodiment of the invention enforcement, and wherein digital communications data is superimposed upon on the analogue signal of 4-20mA.From the signal in control room 54 by way of impedance Control and eliminator 59.Then, the signal of this 4-20mA is conditioned, so that provide suitable power to intelligent regulator and other device.The signal that is received is filtered at 57 places, so that communication data is taken out from the Hart signal of 4-20mA, and is reached the communications portion 51 of electronic controller.The data that transmitted are by way of a modulator-demodulator 58, so that these data combine with the 4-20mA signal.
Figure 14 shows an example that adopts the right communications system of multiple twin zygonema.Power power-supply is conditioned at 56 places, and is conducted to intelligent regulator and other device on right wherein a pair of of two-wire.Data from the control room 54 cross another line to, through transmitting and receiving circuit 60 reaches the communications portion 51 of electronic controller.
Figure 15 illustrates an example of the communications setting of adopting radio traffic.The data that contain radio signal are delivered to a wireless 61 that is associated with intelligent regulator from the control room.This signal is by way of a power power-supply control gear 62 (if the wireless of regulator is not equipped with the words of data transmission preparations control) and suitable data communication hardware 63, and then this information is reached the communications portion 51 of regulator.Similarly, Figure 16 shows and be used to a kind of configuration of utilizing modulator-demodulator or optical fiber to communicate between control room 54 and the intelligent regulator of the present invention.Configuration shown in Figure 16 also can be used with other communication medium.Data 54 are delivered to a suitable transceiver 64 from the control room, and this transceiver is handled this data, and make it through reaching the communications portion 51 of electronic controller behind communication hardware 63.
Several above-mentioned demonstrations can not become limitation of the present invention with the usefulness that embodiment only makes example.Under the prerequisite that does not break away from the scope of the invention and spirit, all embodiments and method described herein all can have multiple version.The present invention only is subjected to the restriction of the scope and the spirit of following claim.
1. a fluid that is used for process remains on the pressure regulator on the predetermined pressure, and it comprises:
Limit fluid input, fluid output and with the main body of the fluid flowing passage of described entrance and exit fluid communication;
Can in described fluid passage, move, be used for selectively to limit the throttling element of the fluid flow rate that flows through flow channel;
Link, be used for the selectively actuator of mobile this throttling element with described throttling element, described actuator has control side and reference side;
Link, be used for throttling element is biased to the reference load of preset reference position with the described reference side of actuator;
Thereby be used for being applied to from the pressure of the fluid of process actuator described control side so that actuator overcome that described reference load moves will be at the feedback line of the location of the throttling element in the described flow channel;
First pressure transducer of the signal of the pressure of fluid on first of process in the expression process is provided; And
Receive described signal, and the controller of output and the corresponding error signal of difference between pressure of being sensed and scheduled pressure value of expression hydrodynamic pressure, described controller includes: be used for during the running of described pressure regulator, store the number storage of the error signal that engraves when different, and the error signal that engraves when being used to carry out with difference is made comparisons to obtain the processor with the program (routine) of the corresponding diagnostic data of running of pressure regulator.
2. pressure regulator as claimed in claim 1 is characterized in that, the number storage of described controller includes the corresponding base-line data of baseline running characteristic with described pressure regulator.
3. pressure regulator as claimed in claim 2, it is characterized in that, also comprise the emergency alarm that links with described controller, wherein this controller is suitable for described diagnostic data and described base-line data is made comparisons and just activate described emergency alarm when comparative result shows that diagnostic data has broken away from the certain prearranging quatity of base-line data.
4. pressure regulator as claimed in claim 1, it is characterized in that, also comprise second pressure transducer that is used to respond to the pressure of fluid on second of process, wherein said controller be suitable for calculate on the different time points and between the pressure measured by described first sensor and by described second sensor corresponding regulator deviate of difference between the measured pressure, and the digitizing characterization value that described controller is suitable for the regulator deviate that will calculate is stored in the described controller storage.
5. pressure regulator as claimed in claim 4, it is characterized in that, described first pressure transducer is suitable for detecting the hydrodynamic pressure of ingress, and described second pressure transducer is suitable for detecting the hydrodynamic pressure in outlet port, and described processor is suitable for carrying out and is used for determining being stored in program in the described controller storage at the regulator deviate of a plurality of different inlet pressures and with it.
6. pressure transducer as claimed in claim 1, it is characterized in that, the sensor that also comprises the movement direction that is used to measure described throttling element, wherein said processor be suitable for by: (i) will reflect when throttling element and be stored in the described controller storage by first digital signal of the measured pressure of described first pressure transducer when first direction moves; (ii) will reflect when throttling element and be stored in the controller storage by second digital signal of the measured pressure of first pressure transducer when second direction moves; And (iii) described first and second digital signals are made comparisons and produce the diagnostic data relevant with the hysteresis error of pressure regulator with the difference signal that produces the hysteresis error that reflects described pressure regulator.
7. pressure regulator as claimed in claim 1, it is characterized in that, described controller storage includes the base-line data that reflects predetermined fluid pressure, wherein said throttling element will be shifted to the position of closing fully on described predetermined fluid pressure, and described processor is suitable for: (i) will be stored in the controller storage by the measured corresponding digital signal of hydrodynamic pressure of described first pressure transducer, wherein throttling element is shifted to the position of closing fully on described hydrodynamic pressure; And (ii) with described base-line data and with make comparisons by the corresponding described digital signal of the measured hydrodynamic pressure of first pressure transducer, wherein throttling element is shifted to the position of closing fully on this hydrodynamic pressure, thereby produces and the corresponding diagnostic signal of the difference between the signal that is compared.
8. device that is used for the cavity in the induction pressure regulator and the phenomenon of releasing, thus described pressure regulator utilizes the hydrodynamic pressure in the process that the fluid flow rate of this pressure regulator is flow through in the restriction of throttling element location, and described device comprises:
Inlet pressure transducer;
Processor, described processor have the storage of the input constant that includes the cavity/index of releasing, critical pressure specific ray constant and the fluid steam pressure that are stored in wherein;
Described processor includes and is used for according to Δ P A=K C(P l-r CP v) calculate absolute pressure drop (Δ P A) program, wherein: K C=the cavity or the index of releasing, P l=the inlet pressure sensed, r C=critical pressure specific ray constant, and P v=vapor pressure; And
Described processor also includes and is used for Δ P AMake comparisons with the input constant of fluid steam pressure and to release and the program of cavity phenomenon with detection.
9. device that is used for the cavity phenomenon in the induction pressure regulator, thus described pressure regulator utilizes the hydrodynamic pressure in the process that the fluid flow rate of this pressure regulator is flow through in the restriction of the location of the throttling element in the flow channel, and described device comprises:
Be suitable for detecting at least one physical parameter that is associated with described pressure regulator and sensor with the measured corresponding electrical signal of physical parameter is provided, wherein said physical parameter will be along with the appearance of cavity phenomenon and existence and is changed;
Have the storage that wherein stores first group of baseline physical parameter electrical signal, described first group of baseline physical parameter signal with and the physical parameter characteristic that is associated of at least one stage of phenomenon of releasing corresponding; And
Be suitable for receiving from described sensor, with the measured corresponding electrical signal of physical parameter, be suitable for receiving the baseline physical parameter signal of described storage and processor with the identification signal electrical signal that phenomenon exists of making comparisons, just provide when signal approximate match (match) reflection to release be provided.
10. device as claimed in claim 9, it is characterized in that, described sensor is the sonic transducer that links, is used to respond to the noise characteristic in this flow channel with described flow channel, and described first group of baseline physical parameter signal with and the noise characteristic that is associated of each stage of phenomenon of releasing corresponding.
11. device as claimed in claim 9, it is characterized in that, described sensor is the seismic sensor that links, is used to respond to the vibration characteristics in this flow channel with described flow channel, and described first group of baseline physical parameter signal with and the vibration characteristics that is associated of each stage of phenomenon of releasing corresponding.
12. device as claimed in claim 9, it is characterized in that, described storage has the second group of baseline physical parameter electrical signal that is stored in wherein, described second group of baseline physical parameter signal with and the physical parameter characteristic that is associated of at least one stage of phenomenon of releasing corresponding; And described processor be suitable for receiving from described sensor, with the measured corresponding electrical signal of physical parameter, be suitable for receiving second group of baseline physical parameter signal of described storage and make comparisons, just provide when the signal approximate match reflection cavity electrical signal that phenomenon exists described identification signal.
13. one kind is used for coming the regulate fluid flow rate throttling element by apply pressure process to actuator, remaining on the method for carrying out inline diagnosis on the pressure regulator on the setting value with this pressure with process, described method comprises following action:
Collection is used for baseline performance data described regulator, that reflect the running characteristic of this pressure regulator under one group of given operation condition, and described baseline performance data is stored in the storage arrangement;
With the described set point of the temporary transient introducing of step change, so that this set point is become a controlled setting value;
When regulator during to described controlled setting value, is gathered the performance data of the running characteristic of reflection regulator with the pressure process band;
More described performance data and the running relevant diagnostic message of base-line data with acquisition and pressure regulator.
14. method as claimed in claim 13 is characterized in that: (i) action of described collection baseline performance data comprises the action of induction process pressure and definite and the corresponding baseline deviate of difference between pressure of being sensed and required predetermined pressure; (ii) the action of described collecting performance data comprises the action of induction process pressure and definite and the corresponding aberrations in property value of difference between pressure of being sensed and required predetermined pressure; And the action of (iii) described relatively performance data and base-line data comprises the action that described baseline deviate and described aberrations in property value are made comparisons.
15. method as claimed in claim 13 is characterized in that, the action of described collection baseline performance data comprises determines that described throttling element shifts to the action of the pressure process when stoping the position that fluid flows fully.
16. method as claimed in claim 15 is characterized in that, the action of described collecting performance data comprises determines that described throttling element shifts to the action of the pressure process when stoping the position that fluid flows fully.
17. method as claimed in claim 13, it is characterized in that, described actuator has reference side and control side, and the action of described collection baseline performance data and the action of described definite performance data respectively comprise: determine to be applied to first power on the described reference side; Determine to be applied to second power on the described control side; And more described first and second power are with identification actuator fault.
18. inlet pressure sensitivity of method that is used for determining pressure regulator, described pressure regulator comes the regulate fluid flow rate throttling element, with this pressure in process is remained on the setting value by apply pressure process to actuator, this pressure regulator has an inlet, and described method comprises following action:
On very first time point, detect regulator inlet pressure, and will be described given fluid flow rate and the characterization value of putting measured pressure in the very first time are stored in the number storage at given fluid flow rate;
The regulator inlet pressure that monitors the whole time period is to discern second time point, and the pressure on described second time point is different from the pressure on the very first time point;
With given fluid flow rate and on second time point characterization value of measured pressure be stored in the number storage;
With given fluid rate and on very first time point measured pressure characterization value with given fluid flow rate and on second time point characterization value of measured pressure make comparisons, thereby the difference signal of representing inlet pressure sensitivity is provided.
19. method that is used for the hysteresis error of definite pressure regulator, described pressure regulator comes the regulate fluid flow rate throttling element, with this pressure in process is remained on the setting value by apply pressure process to actuator, this pressure regulator has an inlet, and described method comprises following action:
The flow through flow rate of fluid of described regulator of detection;
Identification very first time point, the flow rate that flow through regulator this moment is first flow rate;
Discern second time point after described very first time point, the flow rate that flow through regulator this moment is second flow rate, and wherein said second flow rate is less than described first flow rate, and the characterization value of the pressure process at the second time point place is stored in the number storage;
Discern the 3rd time point, the flow rate that flow through regulator this moment is the 3rd flow rate;
Discern the 4th time point after described the 3rd time point, the flow rate that flow through regulator this moment is the 3rd flow rate, and wherein said the 3rd flow rate is greater than described the 3rd flow rate, and the characterization value of the pressure process at the 4th time point place is stored in the number storage; And
The characterization value of the second time point place pressure and the characterization value of the 4th time point place pressure are made comparisons, thereby calculate the dead band value that the diagnosis regulator is used.
20. method as claimed in claim 19 is characterized in that, described the 3rd time point is after described second time point.
CNB988093731A 1997-09-22 1998-09-10 Diagnostic device and method for pressure regulator CN1143971C (en)
US08/935,176 US6035878A (en) 1997-09-22 1997-09-22 Diagnostic device and method for pressure regulator
US08/935,176 1997-09-22
CN1271410A true CN1271410A (en) 2000-10-25
CN1143971C CN1143971C (en) 2004-03-31
ID=25466659
CNB988093731A CN1143971C (en) 1997-09-22 1998-09-10 Diagnostic device and method for pressure regulator
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EP1466221A1 (en) 2004-10-13 Flow measurement module and method
2000-10-25 PB01 Publication
2018-10-09 CX01 Expiry of patent term
Granted publication date: 20040331