Control valve diagnostics
In a diagnosis method of a control valve, position data representing a position of a control valve, and pressure data representing a pressure difference over a valve actuator, and optionally travel direction of the control valve, is measured during online operation of the control valve. The position data and the pressure difference data are processed to contain data around starting points of a plurality of individual travel movements of the control valve during normal online operation of the control valve. Finally, a valve signature graph of the control valve is determined based on the processed position and pressure difference data, collected at a plurality of points along the travel range of the control valve during online operation of the control valve.
1. A valve positioner for operating a control valve, the valve positioner comprising:
a pneumatic supply connection to a pneumatic supply pressure,
a first pneumatic actuator connection and a second pneumatic actuator connection to opposite sides of a pneumatic valve actuator cylinder installed to change a position of a control valve,
a pneumatic output stage connected to the pneumatic supply connection and the first and second pneumatic connections to supply a first pneumatic actuator pressure and a second pneumatic actuator pressure, respectively, to the opposite sides of the pneumatic valve actuator cylinder according to a control signal,
at least one position sensor configured to measure a position of the control valve,
at least one pressure sensor configured to measure a pressure difference of the first and second pneumatic actuator pressures over the pneumatic valve actuator cylinder during online operation of the control valve,
a microprocessor system connected to the at least one position sensor and to the at least one pressure sensor to receive the measured position and the measured pressure difference and configured to generate the control signal to the pneumatic output stage, the microprocessor system detecting a starting point of an individual travel movement and selectively processing the measured position and the measured pressure difference which are immediately around the detected starting point of each individual travel movement of the control valve and excluding the measured position and the measured pressure difference that is not immediately around the detected starting point, thereby producing a reduced amount of processed position data and pressure difference data at the starting points of a plurality of individual travel movements of the control valve during online operation of the control valve,
a memory configured to store the reduced amount of processed position data and pressure difference data at the valve positioner.
2. A valve positioner according to claim 1 , wherein the microcontroller is further configured to determine the microprocessor system is configured to determine a valve signature graph of the control valve based on the processed position and pressure difference data collected at a plurality of points along the travel range of the control valve during online operation of the control valve.
3. A valve positioner for operating a control valve, the valve positioner comprising:
a pneumatic supply connection to a pneumatic supply pressure,
a first pneumatic actuator connection and a second pneumatic actuator connection to opposite sides of a pneumatic valve actuator cylinder installed to change a position of a control valve,
a pneumatic output stage connected to the pneumatic supply connection and the first and second pneumatic connections to supply a first pneumatic actuator pressure and a second pneumatic actuator pressure, respectively, to the opposite sides of the pneumatic valve actuator cylinder according to a control signal,
at least one position sensor configured to measure a position of a control valve,
at least one pressure sensor configured to measure a pressure difference of the first and second pneumatic actuator pressures over the pneumatic valve actuator cylinder during online operation of the control valve,
a microprocessor system connected to the at least one position sensor and to the at least one pressure sensor to receive the measured position and the measured pressure difference and configured to generate the control signal to the pneumatic output stage, the microprocessor system detecting starting point of an individual travel movement and selectively processing the measured position and the measured pressure difference which are immediately around the detected starting point of each individual travel movement of the control valve and excluding the measured position and the measured pressure difference that is not immediately around the detected starting point, thereby producing a reduced amount of processed position data and pressure difference data at starting points of a plurality of individual travel movements of the control valve during online operation of the control valve,
a communication interface configured to transfer the reduced amount of the processed position data and the pressure difference data over a communication bus to a diagnostics system.
4. A valve positioner according to claim 3 , wherein the microcontroller is further configured to determine the microprocessor system is configured to determine a valve signature graph of the control valve based on the processed position and pressure difference data collected at a plurality of points along the travel range of the control valve during online operation of the control valve.