CA3044175A1 - Non-invasive wireless remote monitoring method(s) for measuring, predicting and quantifying valve position, travel, cavitation, flashing, erosion, leakage and mechanical failure - Google Patents
Non-invasive wireless remote monitoring method(s) for measuring, predicting and quantifying valve position, travel, cavitation, flashing, erosion, leakage and mechanical failure Download PDFInfo
- Publication number
- CA3044175A1 CA3044175A1 CA3044175A CA3044175A CA3044175A1 CA 3044175 A1 CA3044175 A1 CA 3044175A1 CA 3044175 A CA3044175 A CA 3044175A CA 3044175 A CA3044175 A CA 3044175A CA 3044175 A1 CA3044175 A1 CA 3044175A1
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- CA
- Canada
- Prior art keywords
- valve
- monitoring device
- wireless remote
- mechanical
- sensor node
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16K—VALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
- F16K37/00—Special means in or on valves or other cut-off apparatus for indicating or recording operation thereof, or for enabling an alarm to be given
- F16K37/0025—Electrical or magnetic means
- F16K37/0041—Electrical or magnetic means for measuring valve parameters
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16K—VALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
- F16K31/00—Actuating devices; Operating means; Releasing devices
- F16K31/44—Mechanical actuating means
- F16K31/60—Handles
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M13/00—Testing of machine parts
- G01M13/003—Machine valves
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- Engineering & Computer Science (AREA)
- General Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Indication Of The Valve Opening Or Closing Status (AREA)
Abstract
Described are the method(s) and devices that integrate sensors, algorithms, software applications, wireless technologies, data protocols, communication networks, data storage, energy harvesting, computing and processing at the device, and machine learning techniques to measure valve opening, closing and intermediate travel statuses based on the position and/or orientation measurements obtained wirelessly using said devices and peripherals attached to a handwheel or lever or handle or any other mechanical linkage that is attached to a valve stem or shaft or plug or disc or any throttling mechanism inside a valve for the purpose of valve monitoring remotely. The wireless valve monitoring device can be fitted as a plug-and-play attachment to any type of valve including, but not limited to, ball, gate, plug, on/off, butterfly, globe, pinch, disc, angle, multi-way and any customized valve design with a stem or shaft or plug or disc which are actuated by a handwheel or lever or handle or any mechanical linkage. The wireless valve monitoring device can be used to measure percentage of valve movement in sliding stem, rotary, quarter turn or multi-turn valves which are actuated by handwheel or lever or handle driven by manual human intervention or using a pneumatic or electric or mechanical or electro-hydraulic mechanism. In addition to the valve travel, the device uses a combination of sensor data and machine learning algorithms to non-invasively measure, predict and quantify mechanical failures that are detrimental to valves such as valve cavitation, erosion, flashing, clearance leakages, hydraulic shocks, hydrodynamic/aerodynamic noise, stiction, hysteresis, hammering, slamming, leakage through packing-valve body/bonnet, pipeline induced vibration, and actuator air leakages. Valve travel, communication status, and valve mechanical health are transmitted wirelessly from the valve monitoring device over network or relay devices and gateways to a centralized data processing hub at a remote location and alerts can be sent to the end-users electronic communication or visualization for further decision-making, historizing, and automation purposes.
Description
FIELD OF INVENTION:
This invention relates to remote wireless monitoring, controlling and maintenance operations related to any type of valve including, but not limited to, ball, gate, plug, on/off, butterfly, globe, pinch, disc, angle, control valve, multi-way and any customized valve design. In particular, this invention relates to remote monitoring of domestic, commercial and industrial operations, which use multiple types and sizes of valves. Some of the remote monitoring applications include, but not limited to, oil and gas, mining, pipeline, energy, chemical, construction, oilsands, refinery, power, offshore petroleum, petrochemical, pharmaceutical, food, water and waste, textiles, commercial facilities, utilities, paper and pulp, building automation, tankage, and transportation.
This invention relates to remote wireless monitoring, controlling and maintenance operations related to any type of valve including, but not limited to, ball, gate, plug, on/off, butterfly, globe, pinch, disc, angle, control valve, multi-way and any customized valve design. In particular, this invention relates to remote monitoring of domestic, commercial and industrial operations, which use multiple types and sizes of valves. Some of the remote monitoring applications include, but not limited to, oil and gas, mining, pipeline, energy, chemical, construction, oilsands, refinery, power, offshore petroleum, petrochemical, pharmaceutical, food, water and waste, textiles, commercial facilities, utilities, paper and pulp, building automation, tankage, and transportation.
2 BRIEF DESCRIPTION OF THE DRAWINGS:
Figure.] illustrates how the wireless remote valve monitoring device can be installed or placed or used as a plug and play attachment on a handwheel or lever or handle or any mechanical linkage connected to a valve stem or disc or plug or throttling mechanism inside a valve.
Figure.2 illustrates the various electronic and computational blocks inside the wireless remote valve monitoring device and additional modules that compute valve position, travel, and mechanical health information of the valve.
Figure.3 is an illustrating of how the information from the wireless remote valve monitoring device is delivered to control systems, enterprise, end-user, and mobile operator using wireless networks, on premise, cloud, application software and mobile applications.
Figure.4 is an embodiment of a graphical user interface used by the end-user to monitor valve position, travel and health metrics SUMMARY:
Valve travel and/or position of a manual valve or automated control valve is a significant measurement variable for process control, automation, and alarming in various industrial operations including, but not limited to, oil and gas, mining, pipeline, energy, chemical, textiles, commercial facilities, construction sites, power, offshore petroleum, petrochemical, pharmaceutical, food, water and waste, utilities, paper and pulp, building automation, tankage, and transportation. Prior art methods used to measure valve travel and/or position involved installing commercially available valve position transmitters that require special mounting brackets and physical mechanical linkages to the valve throttling components such as stem/shaft/plug/disc making it an expensive solution for installation on several manual valves seen in industries. As these prior art methods require mechanical linkages to the throttling components of the valves in order to detect valve travel, any new installation required taking the valve offline resulting in process outage and disruption to the business.
Some of the practical issues with these prior art methods include, but not limited to, inefficiency with different mounting brackets and mechanical linkages for various types of valves and sizes, existing valve body/bonnet modifications, and external power requirements making it less economical and impractical for an end-user using prior art methods.
In this invention, we are proposing a wireless remote valve monitoring device 100 that can measure valve travel or position using a novel, non-invasive method without any modifications to the existing valve and actuator assembly. Using a plug-and-play concept, the wireless remote valve monitoring device 100 can be attached seamlessly to a handwheel or lever or handle or any other mechanical linkage that is attached to a valve stem or shaft or plug or disc or any throttling mechanism inside a valve. Referring to Figure.1, the wireless remote valve monitoring device 100 can be installed in different orientations depending upon the mechanical properties of the handwheel such as size, radius, and flexibility. 101, and 102 shows the placement of the wireless remote valve monitoring device 100 on the rim and the centre of the handwheel. Placement 103 shows how the wireless remote valve monitoring device 100 can be installed and attached to the circumference providing the installation flexibility the end-user. Similarly, placement 104 and 105 illustrates how the wireless remote valve monitoring device 100 can be seamlessly attached to a handle or a centre locknut of a valve stem associated with various types of valve configurations.
Referring to Figure.2, the wireless remote valve monitoring device 100 moves along with the handwheel as the user turns the handwheel to open or close a valve. Device 100 runs an on-board proprietary machine learning algorithm along with error detection and drift compensation to estimate valve position and /or travel. Embodiment 111 illustrates components that implement estimation algorithms to predict valve movement statuses such as close, open, travelling, and percentage travel. Embodiment 111 also illustrates how the wireless remote valve monitoring device 100 is powered by a hybrid power source that uses a combination of energy harvesting and battery onboard. Embodiment 111 also shows components such as radio, self-calibration and reset routines, variables such as temperature, pressure, humidity, acoustic, acceleration, gyro, and magnetometer that are required to estimate valve statuses and the mechanism to transmit the information over wireless networks to an end-user. An on-demand light indicator and is present in the device 100 that flashes if the end-user wants to identify the valve under low-light conditions. A
proximity sensor is also present in the wireless remote valve monitoring device 100 that can be enabled to detect any disturbance to the valve or handwheel by un-authorized personnel.
Additional sensor nodes 107, 108 are placed on the pipeline either upstream or downstream of the valve body. These additional sensor nodes run proprietary digital processing algorithms to identify valve mechanical problems including, but not limited to, valve cavitation, erosion, flashing, clearance leakages, hydraulic .. shocks, hydrodynamic/aerodynamic noise, stiction, hysteresis, hammering, slamming, leakage through packing-valve body/bonnet, pipeline induced vibration, and actuator air leakages.
The sensor node(s) 107, 108 periodically runs machine learning algorithms at the node(s) and communicate the valve mechanical health status to wireless remote valve monitoring device 100 which further transmits the valve travel, communication status, and valve mechanical health to a remote end-user. Embodiment 112 shows various components that constitute the add-on module(s) for additional intelligence about the valve mechanical integrity and health.
Referring to Figure.3, the embodiment shows how the valve travel, communication status, and valve mechanical health are transmitted from the proposed wireless remote valve monitoring device 100 over a wireless network(s) 113, 114 to a centralized data processing hub at a remote location 117 and alerts can be sent to the end-users for further decision-making, historizing, and automation. The embodiment also shows how a mobile operator can walk next to the valve to receive valve travel, communication status, and valve mechanical health wirelessly on their smart phone or tablet application 115. The mobile operator 115 can also securely update the software of the device 100 standing in the vicinity of the valve.
Device 100 has an onboard non-volatile storage that stores 24 hours of data related to valve travel, communication status, and valve mechanical health which the mobile operator 115 can download wirelessly to his phone, tablet or a wireless laptop. The mobile operator can ping the device 100 from their smart phone or tablet to identify a valve using the on-demand light indication present in device 100. Any personnel 118 driving by the valve and wireless remote valve monitoring device 100 can also download valve travel, communication status, and valve mechanical health wirelessly on their smart phone or tablet applications. Remote end-user(s) 117 can view the valve travel, communication status, and valve mechanical health on their console. 116 illustrates a typical dashboard that shows valve travel, communication status, and valve mechanical health. The end user(s) can further expand data of various variables to further analyse the valve travel, communication status, and valve mechanical health as shown in 118. In addition to the live display, all the valve travel, communication status, and valve mechanical health are stored onsite and cloud for future retrieval and decision making.
Figure.] illustrates how the wireless remote valve monitoring device can be installed or placed or used as a plug and play attachment on a handwheel or lever or handle or any mechanical linkage connected to a valve stem or disc or plug or throttling mechanism inside a valve.
Figure.2 illustrates the various electronic and computational blocks inside the wireless remote valve monitoring device and additional modules that compute valve position, travel, and mechanical health information of the valve.
Figure.3 is an illustrating of how the information from the wireless remote valve monitoring device is delivered to control systems, enterprise, end-user, and mobile operator using wireless networks, on premise, cloud, application software and mobile applications.
Figure.4 is an embodiment of a graphical user interface used by the end-user to monitor valve position, travel and health metrics SUMMARY:
Valve travel and/or position of a manual valve or automated control valve is a significant measurement variable for process control, automation, and alarming in various industrial operations including, but not limited to, oil and gas, mining, pipeline, energy, chemical, textiles, commercial facilities, construction sites, power, offshore petroleum, petrochemical, pharmaceutical, food, water and waste, utilities, paper and pulp, building automation, tankage, and transportation. Prior art methods used to measure valve travel and/or position involved installing commercially available valve position transmitters that require special mounting brackets and physical mechanical linkages to the valve throttling components such as stem/shaft/plug/disc making it an expensive solution for installation on several manual valves seen in industries. As these prior art methods require mechanical linkages to the throttling components of the valves in order to detect valve travel, any new installation required taking the valve offline resulting in process outage and disruption to the business.
Some of the practical issues with these prior art methods include, but not limited to, inefficiency with different mounting brackets and mechanical linkages for various types of valves and sizes, existing valve body/bonnet modifications, and external power requirements making it less economical and impractical for an end-user using prior art methods.
In this invention, we are proposing a wireless remote valve monitoring device 100 that can measure valve travel or position using a novel, non-invasive method without any modifications to the existing valve and actuator assembly. Using a plug-and-play concept, the wireless remote valve monitoring device 100 can be attached seamlessly to a handwheel or lever or handle or any other mechanical linkage that is attached to a valve stem or shaft or plug or disc or any throttling mechanism inside a valve. Referring to Figure.1, the wireless remote valve monitoring device 100 can be installed in different orientations depending upon the mechanical properties of the handwheel such as size, radius, and flexibility. 101, and 102 shows the placement of the wireless remote valve monitoring device 100 on the rim and the centre of the handwheel. Placement 103 shows how the wireless remote valve monitoring device 100 can be installed and attached to the circumference providing the installation flexibility the end-user. Similarly, placement 104 and 105 illustrates how the wireless remote valve monitoring device 100 can be seamlessly attached to a handle or a centre locknut of a valve stem associated with various types of valve configurations.
Referring to Figure.2, the wireless remote valve monitoring device 100 moves along with the handwheel as the user turns the handwheel to open or close a valve. Device 100 runs an on-board proprietary machine learning algorithm along with error detection and drift compensation to estimate valve position and /or travel. Embodiment 111 illustrates components that implement estimation algorithms to predict valve movement statuses such as close, open, travelling, and percentage travel. Embodiment 111 also illustrates how the wireless remote valve monitoring device 100 is powered by a hybrid power source that uses a combination of energy harvesting and battery onboard. Embodiment 111 also shows components such as radio, self-calibration and reset routines, variables such as temperature, pressure, humidity, acoustic, acceleration, gyro, and magnetometer that are required to estimate valve statuses and the mechanism to transmit the information over wireless networks to an end-user. An on-demand light indicator and is present in the device 100 that flashes if the end-user wants to identify the valve under low-light conditions. A
proximity sensor is also present in the wireless remote valve monitoring device 100 that can be enabled to detect any disturbance to the valve or handwheel by un-authorized personnel.
Additional sensor nodes 107, 108 are placed on the pipeline either upstream or downstream of the valve body. These additional sensor nodes run proprietary digital processing algorithms to identify valve mechanical problems including, but not limited to, valve cavitation, erosion, flashing, clearance leakages, hydraulic .. shocks, hydrodynamic/aerodynamic noise, stiction, hysteresis, hammering, slamming, leakage through packing-valve body/bonnet, pipeline induced vibration, and actuator air leakages.
The sensor node(s) 107, 108 periodically runs machine learning algorithms at the node(s) and communicate the valve mechanical health status to wireless remote valve monitoring device 100 which further transmits the valve travel, communication status, and valve mechanical health to a remote end-user. Embodiment 112 shows various components that constitute the add-on module(s) for additional intelligence about the valve mechanical integrity and health.
Referring to Figure.3, the embodiment shows how the valve travel, communication status, and valve mechanical health are transmitted from the proposed wireless remote valve monitoring device 100 over a wireless network(s) 113, 114 to a centralized data processing hub at a remote location 117 and alerts can be sent to the end-users for further decision-making, historizing, and automation. The embodiment also shows how a mobile operator can walk next to the valve to receive valve travel, communication status, and valve mechanical health wirelessly on their smart phone or tablet application 115. The mobile operator 115 can also securely update the software of the device 100 standing in the vicinity of the valve.
Device 100 has an onboard non-volatile storage that stores 24 hours of data related to valve travel, communication status, and valve mechanical health which the mobile operator 115 can download wirelessly to his phone, tablet or a wireless laptop. The mobile operator can ping the device 100 from their smart phone or tablet to identify a valve using the on-demand light indication present in device 100. Any personnel 118 driving by the valve and wireless remote valve monitoring device 100 can also download valve travel, communication status, and valve mechanical health wirelessly on their smart phone or tablet applications. Remote end-user(s) 117 can view the valve travel, communication status, and valve mechanical health on their console. 116 illustrates a typical dashboard that shows valve travel, communication status, and valve mechanical health. The end user(s) can further expand data of various variables to further analyse the valve travel, communication status, and valve mechanical health as shown in 118. In addition to the live display, all the valve travel, communication status, and valve mechanical health are stored onsite and cloud for future retrieval and decision making.
Claims (16)
1. A wireless remote valve monitoring device comprising: nine-degree of freedom inertial measurement sensor system containing accelerometer, gyroscope and magnetometer; computing and processing algorithms and machine learning techniques at the device; software applications, wireless technologies, data protocols, relays and communication network(s), data storage and energy harvesting.
2. The wireless remote valve monitoring device of claim 1 is attached to a handwheel or lever or handle or any other mechanical linkage that is connected to a valve stem or shaft or plug or disc or any throttling mechanism inside a valve to obtain valve opening, closing and intermediate travel statuses.
3. The wireless remote valve monitoring device attachment described in claim 2 can be installed in any orientation and an in-built auto calibration algorithm(s) will be able to scale sensor measurements accordingly.
4. The valve statuses of claim 2 are estimated from the position and/or orientation measurements provided by the nine-degree of freedom inertial measurement sensor system containing accelerometer, gyroscope and magnetometer described in claim 1.
5. Additional sensor nodes are placed on the pipeline either upstream or downstream of the valve body to identify valve mechanical problems including, but not limited to, valve cavitation, erosion, flashing, clearance leakages, hydraulic shocks, hydrodynamic/aerodynamic noise, stiction, hysteresis, hammering, slamming, leakage through packing-valve body/bonnet, pipeline induced vibration, and actuator air leakages.
6. The additional sensor node(s) in claim 5 run machine learning algorithms at the node(s) and communicate the valve mechanical health status to wireless remote valve monitoring device described in claim 1.
7. The additional sensor node(s) in claim 5 complement the wireless remote valve monitoring device described in preceding claims and provide additional intelligence about the valve mechanical integrity and health.
8. The wireless remote valve monitoring device and sensor node(s) described in preceding claims are non-intrusive and do not interfere with the mechanical integrity of the valve or the pipe line.
9. The wireless remote valve monitoring device and sensor node(s) described in preceding claims fit valves and pipelines of any size, shape or form factor.
10. The wireless remote valve monitoring device and sensor node(s) described in preceding claims have the capability to lock the information inside the device(s) and node(s) when they are tampered or forcibly moved from their geo fence.
11. The wireless remote valve monitoring device and sensor node(s) described in preceding claims have remote alarming capability(s) and send last measured value, time stamp, geological coordinates, and alarm code for tampering to the remote server before shutting down.
12. The wireless remote valve monitoring device and sensor node(s) described in preceding claims have the capability(s) to disconnect automatically from all and any data networks and displayed in a color coded virtual representation to the end user.
13. The wireless remote valve monitoring device and sensor node(s) described in preceding claims store the time stamped measurement and diagnostic data from the last 24 hours in an on-board non-volatile memory.
14. The wireless remote valve monitoring device and sensor node(s) described in preceding claims can be embedded into the valve and pipe mechanical parts during manufacturing and draw renewable energy from the heat or friction or vibration of the valve and pipeline.
15. The data from the wireless remote valve monitoring device and sensor node(s) described in preceding claims can be used to build inferential models and calculations for estimating the flow rate through the pipeline.
16. The data from the wireless remote valve monitoring device and sensor node(s) described in preceding claims can be used for detecting pipe flow conditions such as stratification, laminar vs turbulence flow and presence of air in the pipelines.
DEFINITIONS(S):
Geo-fence: a virtual geographic boundary, defined by GPS or RFID technology, which enables software to trigger a response when a mobile device enters or leaves a particular area.
DEFINITIONS(S):
Geo-fence: a virtual geographic boundary, defined by GPS or RFID technology, which enables software to trigger a response when a mobile device enters or leaves a particular area.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA3044175A CA3044175A1 (en) | 2019-05-24 | 2019-05-24 | Non-invasive wireless remote monitoring method(s) for measuring, predicting and quantifying valve position, travel, cavitation, flashing, erosion, leakage and mechanical failure |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA3044175A CA3044175A1 (en) | 2019-05-24 | 2019-05-24 | Non-invasive wireless remote monitoring method(s) for measuring, predicting and quantifying valve position, travel, cavitation, flashing, erosion, leakage and mechanical failure |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA3044175A1 true CA3044175A1 (en) | 2020-11-24 |
Family
ID=73549191
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA3044175A Abandoned CA3044175A1 (en) | 2019-05-24 | 2019-05-24 | Non-invasive wireless remote monitoring method(s) for measuring, predicting and quantifying valve position, travel, cavitation, flashing, erosion, leakage and mechanical failure |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA3044175A1 (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113567108A (en) * | 2021-07-09 | 2021-10-29 | 同济大学 | A method for measuring erosion and wear of spool valve port |
| CN114152430A (en) * | 2021-12-24 | 2022-03-08 | 东方电气集团东方汽轮机有限公司 | A comprehensive performance evaluation method for the surfacing layer of valve seat sealing surface |
-
2019
- 2019-05-24 CA CA3044175A patent/CA3044175A1/en not_active Abandoned
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113567108A (en) * | 2021-07-09 | 2021-10-29 | 同济大学 | A method for measuring erosion and wear of spool valve port |
| CN114152430A (en) * | 2021-12-24 | 2022-03-08 | 东方电气集团东方汽轮机有限公司 | A comprehensive performance evaluation method for the surfacing layer of valve seat sealing surface |
| CN114152430B (en) * | 2021-12-24 | 2024-05-03 | 东方电气集团东方汽轮机有限公司 | Comprehensive performance evaluation method of surfacing layer of sealing surface of valve seat |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Discontinued |
Effective date: 20220325 |
|
| FZDE | Discontinued |
Effective date: 20220325 |