CN1898535A - 工业过程中的冲击管道诊断 - Google Patents
工业过程中的冲击管道诊断 Download PDFInfo
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- G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
- G01L19/00—Details of, or accessories for, apparatus for measuring steady or quasi-steady pressure of a fluent medium insofar as such details or accessories are not special to particular types of pressure gauges
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- G—PHYSICS
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- G01F—MEASURING VOLUME, VOLUME FLOW, MASS FLOW OR LIQUID LEVEL; METERING BY VOLUME
- G01F25/00—Testing or calibration of apparatus for measuring volume, volume flow or liquid level or for metering by volume
- G01F25/10—Testing or calibration of apparatus for measuring volume, volume flow or liquid level or for metering by volume of flowmeters
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- G—PHYSICS
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
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- G—PHYSICS
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
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Abstract
提供了一种在工业过程中的冲击管道线路(112)的诊断操作。振动源(144)将振动信号通过管道进行发送,振动信号接收器(146)接收振动信号。冲击管道线路(112)的操作基于所接收到的振动信号被诊断,例如故障或者即将发生的故障。
Description
技术领域
本发明涉及过程装置。具体而言,本发明涉及通过过程通道(processpiping)连接到过程流体的过程装置。
背景技术
各种类型的过程装置被用于测量过程变量并通过过程管道连接到过程流体。例如,流体流量计在工业过程控制环境中用于测量流体流,并提供与流指示器和过程控制器相关的输出。推导式流量计通过测量管之内的不连续附近的压降而测量管内的流体流。不连续(主元件)可以是孔、喷嘴、文氏管、皮托管、涡旋脱落杆、物体或者甚至管内的简单弯曲。围绕不连续区域的流导致压降并增加湍流。压降通过放置在管之外并通过冲击管线(impulse lines)或者冲击(impulse)通道连接到管内的流体的压力传感器(辅助元件)检测。这些连接也称为冲击管道(impulse piping)。可靠性依赖于保证正确的校准。冲击线路随着时间可能变得堵塞,这负面地影响校准。
冲击管线的卸装和检测是用于识别和校正线路的堵塞(plugging)的方法。用于检测堵塞的另外的方法是从压力传感器周期地将“检测脉冲”增加到测量信号。该检测脉冲导致连接到传感器(transmitter)的控制系统干扰流体。如果压力传感器不能准确地检测流体扰动,将产生指示管线堵塞的警报信号。另外的用于检测管线堵塞的公知的方法是传感静压力和压差,然后产生指示线路堵塞的警报信号。另外的用于检测线路堵塞的公知方法是检测静压力并将它们通过高通和低通滤波器。从滤波器获得的噪音信号与阈值进行比较,如果噪音中的变化小于阈值,可以触发指示管道堵塞的警报信号。
这些公知的方法依赖于提供静压力传感器,流量计的卸装或者用于诊断的外部控制系统的使用。所述方法增加了复杂性并减小了可靠性。这样需要一种改进的诊断技术,所述诊断技术可以提供预测、反应维护更少,从而减小成本或者改进可靠性。
发明内容
提供了一种用于诊断工业过程中的冲击管道线路的诊断操作的装置和方法。振动源将振动信号通过管道传送到被配置以接收振动信号的接收器。管道的操作基于所接收的振动信号而被诊断。
附图说明
图1是显示了包括本发明的过程冲击管道诊断的过程装置的简化方框图。
图2是传感器和过程耦合(process coupling)的分解透视图。
图3A是俯视平面图,图3B是侧视剖面图,图3C是如图2中所示的过程耦合的部分剖视图。
具体实施方式
图1是包括连接到过程管104的过程传感器102的过程控制或者监测系统100的部分视图。过程管104可以是任何类型的容器,所述容器承载过程流体,包括例如储存容器。过程管104承载过程流体,传感器102被配置为测量过程流体的过程变量,例如压力,并提供输出。输出的一个实例是双线过程控制环106,所述双线过程控制环106根据例如HART协议、Fieldbus,Profibus等标准通信协议来进行操作。
传感器102通过过程连接110连接到过程流体。过程连接提供冲击管道112,所述过程管道112在过程流体和例如压力传感器114的传感器之间延伸。冲击管道112可以是承载过程流体的直接流体连接,在一些实施例中,如果需要可以包括隔离隔膜,以将耦合到传感器114的填充流体与过程流体隔离。
在操作期间,冲击管道112可能变得堵塞。堵塞可能是部分的或者是完全的。如背景技术部分所讨论,各种技术被用来诊断和识别冲击管道112的这样的堵塞。部分堵塞可能特别难于识别,因为冲击管道没有完全堵住,传感器114继续报告可能不准确的数据。
本发明提供了一种用于识别冲击管道112的阻塞或者堵塞的技术。在如图1所示的实施例中,过程传感器102包括连接到传感器114的测量电路120。输入/输出电路122连接到过程控制环106并提供用于测量电路120的输出,所述输出与传感器114的输出相关。例如,该输出可能涉及过程流体的压力,过程流体的流速、过程流体的水平或者其他过程变量。
根据本发明的一个实施例,传感器100包括诊断电路140,所述诊断电路140具有存储器141。诊断电路140连接到传感器142。传感器142物理地连接到过程冲击管道112,例如通过连接到过程连接110或者通过其他连接。传感器142可以是单个传感器或者可以是通过信号源144和信号接收器146所形成的两个单独的传感器。在一些实施例中,传感器146是提供发送和接收功能的单个元件。发送和接收功能可以连续地操作或者可以多路传输(multiplexed)。
根据本发明的一个实施例,信号源144是将振动信号发送到冲击管道线路112中的振动信号源。振动的谱成分(spectral content)可以根据需要选择。例如,谱成分可以包括大体上在相对恒定的振幅的随机噪音,所述噪音具有低于选择的上限的频率。为了基于反射信号的诊断,更高频率的声频范围是有利的。更高的频率更具有取向性(directional),并更容易沿着部分堵塞的线路从聚集的位置处往回反射。因为堵塞位置产生了低通滤波器,低频信号不能从堵塞位置反射,但是可以被传送,这依赖于低通滤波器的特性。同样,短脉冲串(short burst)声学信号使用更高的频率更容易产生,这允许确定提供反射的界面的位置。这对于湿/干支路(leg)物位高度诊断(level height diagnostics)中特别重要。直至40KHz的频率对于该类型的突发模式信号是有用的。突发模式信号也允许侦听在脉冲串(burst)之间的异常噪音模式的过程噪音谱。突发噪音频率没有被过程噪音屏蔽(mask)是很重要的。在优选的实施例中,与测量的背景噪音谱相比,对于最大的信噪比,被发送的询问信号的准确频率将被改变。
本发明的诊断没有依靠环境噪音,而是利用了源144来产生振动噪音。接收器146被配置以从冲击线路112接收振动噪音并将信号提供给诊断电路140。因为噪音源144提供了具有恒定的轮廓(profile)或者根据需要调节的轮廓的随机噪音,诊断电路140可以区别所接收的信号中的变化并识别变化源是由于冲击线路112的堵塞的改变还是通过源144所施加的振动信号中的改变所引起的。传感器146可以连接到作为单独的部件的过程集管或者可以容纳在传感器102的主体之内。任何合适的传感器和接收器结构可以被使用。一种类型的变送元件是优选地适于高温安装的压电元件。但是,可以使用包括电动机械等的任何技术。为了改进效率,压电元件可以有效地沿着声能传输的所需方向耦合到集管,并在其他方向上去耦(decouple)。该结构增加了沿着所需的方向上所施加的噪音信号和敏感性。
根据一个实施例,图2是与过程连接件110相邻的过程传感器102的分解透视图。但是,连接件110可以是任何类型的连接或者凸缘结构。在图2中,过程连接件110被显示为用于将压差传感器连接到过程管104的三通阀集管凸缘。凸缘110包括闭塞阀110A、110B以及平衡阀110C。压差测量可以例如用于测量流速或者产品物位(product level)。过程传感器102包括连接到测量模块160的传感器模块162。传感器模块162包括压差传感器,所述压差传感器通过一系列过程冲击管道线路连接到过程流体。典型地,隔离隔膜(isolation diaphragms;未示出)包含在传感器102的表面内,所述传感器102安装到过程连接件110的表面170。延伸通过过程连接件110的一部分冲击管道112可以在图2中看到。
按照一个实施例,传感器142连接到过程连接件110的侧面并通过布线172、插头174和插座(receptacle)176连接到传感器102的诊断电路140(如图1中所示)。优选地,插头174和插座176被配置以达到真正安全的要求,并对环境提供密封。在图2中,显示了两个传感器142并通过过程连接件110用于诊断两个冲击连接112的阻塞。可以理解,对于例如测量绝对或者表压(gauge pressure)的其他应用,对于一个冲击线路只需要仅一个传感器。
图3A是传感器142安装到其侧面上的过程连接件110的俯视平面图。过程连接件110包括被配置以阻塞所述冲击管道112的闭塞阀110A、110B。传感器142延伸通过孔182并进入冲击管道112。
图3B是显示在图3A中的过程连接件110的侧面剖视图,图3C是显示在图3B中的剖视图的放大部分透视图。如图3C中所示,冲击管道112包括多个部件。冲击管道112包括如图1所示连接到过程管104的过程连接管道190。管道190通过固定件192连接到过程连接件110。主体110内的主腔194被配置以容纳管道190、传感器142的尖部194和阀110B。阀1110B被配置以根据需要将腔部192与传感器连接196密封。
如图3C中所示,振动信号200通过传感器142经由过程冲击管道112传送和接收。在如图3C所示的实施例中,传感器142的尖部194被倾斜并被配置为沿着从传感器102离开的方向指引振动信号200。当传感器142被显示为连接到传感器102时,可以使用其他结构,包括单独连接到传感器142,这不需要来自传感器102的电源。
在操作期间,如图1所示的诊断电路140控制传感器146的操作。如图1所示的诊断电路140控制传感器146的操作。在一些实施例中,振动信号200的谱成分(spectral content)通过诊断电路140控制。例如,诊断电路140可以包括模数转换器,所述转换器将通过接收器146接收的信号数字化。模拟电路也可以被用于一些实施例中。高级数字处理技术可以被使用,包括对所接收的信号执行快速傅立叶变换(FFT)。
堵塞或者部分堵塞的线路条件可以基于所接收的振动信号检测。例如,声学噪音的、包括噪声宽谱脉冲串的信号,或者扫频信号(sweptsignal)通过噪音源144施加到冲击管道112。噪音脉冲串可以直接地连接到过程连接110中,这样其沿着过程流体在冲击管道112内行进。如果整个或者部分界面由于堵塞、部分填充的湿或者干支路(leg)或者其他条件而在线路112中存在,一部分声学能量被反射回传感器142的接收器146。传感器将该接收的声学能量转换为电信号,所述电信号被提供给诊断电路140。另一方面,如果不存在由于阻塞所导致的故障状态,只被反射的信号将只是由于固定件、弯曲部和线路112中的正常阻塞。这些反射是由于固定源所导致。这样,在名义条件中的过程冲击线路112的声学轮廓可以被存储在诊断电路140的存储器141中。在操作期间,实际的被反射的信号可以与存储的轮廓(profile)进行比较。被存储的轮廓和所接收的反射信号之间的变化被诊断电路140用来识别过程线路112中的故障或者将来临的故障。因为施加的声学信号是已知的,为了识别线路堵塞,与现有技术相比,本发明在环境噪音中不太容易受到变化。
在一些实施例中,本发明被用于检测过程连接的湿或者干支路中的故障状态。湿支路典型地用于基于压力差的物位测量(level measurement)应用中,其中至箱或者其他容器的顶部连接用冲击线路被连接到传感器的低压输入部,所述冲击线路特意保持填充过程流体。但是,可能需要维护,当湿支路只是部分填充流体时性能可能降低。最坏的情况是其中湿支路填充水平随着时间变化。这可能导致测量不准确。干支路(dry leg)安装是相似的,除了冲击线路特意保持没有过程流体,即线路是干的。任何填塞在干的支路中的流体导致传感器测量中的明显漂移。通过检测湿或者干冲击线路中的流体水平,本发明可以检测所述水平不合适的时间并响应地提供诊断输出。
当冲击线路变得堵塞,所述堵塞趋于用作低通滤波器。更高频率的传感器信号被衰减并部分反射回到传感器142。诊断电路140可以识别被反射的信号的谱成分中的改变,这可能是线路堵塞的指示。在预定水平的衰减上,例如,早期的警告报警可以通过输入/输出电路122在过程控制环106上通信至远处的位置。
除了检测来自源144的反射信号之外,接收器146也可以用于检测环境过程噪音。这可以用于诊断例如泵故障、气穴现象等的诊断过程条件。这可以与其他诊断技术连接并用于在所述过程中诊断其他条件。
本发明的基于振动的诊断也可以被用于识别过程传感器102中的隔离流体的损耗。如上所述,典型的隔离隔膜被使用,其将过程流体从传感器114隔离。隔离流体将隔离隔膜连接到传感器114,这样过程压力中的变化通过隔离隔膜和隔离流体油至过程传感器。但是如果隔离流体泄漏,在传感器测量中引起错误,传感器将最终发生故障。油/隔离器/传感器形成用于声音信号的低通滤波器。当填充流体油在传感器中丢失,该低通滤波器的特性改变。低通滤波器的拐角(即,信号减小3dB处的频率)频率随着隔离填充流体丢失移动下降。本发明的传感器可以用于识别该低通滤波器中的变化并诊断填充流体损耗条件。诊断电路140将被反射的信号与已知轮廓进行比较以确定填充流体损耗。
诊断电路140也提供自诊断。例如,过程冲击管道112中的特定的堵塞和结构提供了被反射的脉冲的固定或者已经建立的时间延迟和振幅。测量随着时间的时间延迟和振幅,诊断电路140可以识别传感器142的性能降低或者故障。
本发明的诊断可以使用单个传感器或者通过多个传感器来实施。诊断电路和传感器可以并入传感器电子设备或者可以作为单独的装置的一部分。传感器可以连接到包括其他集管结构的任何类型的过程冲击管道。不同类型的传感器可以包括压力、温度、pH、流体、物位(level)和其他类型。诊断电路140可以与装置中的其他电路共享部件,例如微处理器、存储器、放大器、模数转换器、数模转换器等。诊断电路可以用硬件、软件或者它们的组合来实施。
尽管本发明已经参照了优选的实施例进行了描述,普通技术人员将理解,在不背离本发明的精神和范围的情况下可以对细节和形式进行修改。例如,振动信号可以是任何合适频率或者谱成分。信号可以脉冲串或者脉冲连续地施加,或者是例如斜波信号(ramped signal)等的其他的波形。诊断电路可以将所接收的振动信号与参考值进行比较并识别信号中的趋势或者突然改变。此外,诊断电路可以监测背景噪音,例如当振动源关闭时,并将被监测的环境噪音与所存储的噪音谱或者标记进行比较。所述比较可以提供过程设备的异常或者将来临的故障的指示。在一些实施例中,振动信号的频率或者谱成分根据需要调节。例如,谱成分可以被调节以实现所需的信噪比。本发明的诊断电路也可以被配置以诊断形成物位测量装置的被填充毛细支路的类型的冲击管道中的变化,例如故障模式。在这样的结构中,传感器提供了物位测量输出。实例故障包括油的损耗、破裂的或者丢失过程隔离器,或者弯曲或者断裂的毛细支路管。
Claims (32)
1.一种用于诊断工业过程中的冲击管道线路的诊断操作的装置,包括:
振动信号源,所述振动信号源被配置以通过冲击管道线路传送振动信号;
振动信号接收器,所述振动信号接收器被配置以从冲击管道线路接收振动信号;和
诊断电路,所述诊断电路被配置以基于所接收的诊断信号诊断冲击管道的操作。
2.根据权利要求1所述的设备,其中诊断电路被进一步配置用于监测背景噪音。
3.根据权利要求1所述的设备,其中所述诊断电路包括用被存储的参考噪音标记(signature)监测的背景噪音以识别过程设备的故障或者将来临的故障。
4.根据权利要求1所述的设备,其中振动信号的频率被调节以改变信噪比。
5.根据权利要求1所述的设备,其中诊断电路被配置以诊断形成物位测量装置的填充毛细支路的冲击管道中的变化。
6.根据权利要求1所述的设备,其中诊断电路包括存储器,所述存储器包含被接收的振动信号的谱轮廓。
7.根据权利要求1所述的设备,其中诊断电路包括将所接收的振动信号与参考值进行比较。
8.根据权利要求1所述的设备,其中振动信号源和信号接收器通过传感器形成。
9.根据权利要求1所述的设备,其中振动信号包括噪音信号。
10.根据权利要求1所述的设备,其中振动信号具有小于约20Hz的频率。
11.根据权利要求1所述的设备,其中振动信号源和振动信号接收器连接到过程连接件。
12.根据权利要求1所述的设备,其中冲击管道线路将压力检测元件连接到过程流体。
13.根据权利要求1所述的设备,其中振动信号源被配置沿着冲击管道线路的长度指引被传送的振动信号。
14.根据权利要求11所述的设备,其中振动信号源和振动信号接收器被插入通过和设置在凸缘内的开口中。
15.一种传感器,包括如权利要求1所述的装置。
16.根据权利要求15所述的设备,其中所述传感器包括流体压力或者物位传感器。
17.根据权利要求15所述的设备,其中所述传感器包括传感器壳体,振动信号源和振动信号接收器通过传感器壳体中的开口连接到传感器内的诊断电路。
18.根据权利要求15所述的设备,其中所述传感器被配置为连接到双线过程控制环并被配置以用从过程控制环接收的电源完全提供动力。
19.根据权利要求1所述的设备,其中所述诊断电路被配置为诊断冲击管道线路的堵塞或者填充流体的损耗。
20.根据权利要求1所述的设备,其中诊断电路被配置以诊断形成物位测量装置的湿支路的冲击管道线路中的变化。
21.根据权利要求1所述的设备,其中诊断电路基于所接收的振动信号执行自诊断。
22.一种用于诊断工业过程中的冲击管道的操作的方法,包括:
沿着冲击管道发送振动信号;
从冲击管道线路接收振动信号;和
基于所接收的振动信号诊断冲击管道的操作。
23.根据权利要求22所述的方法,其中所述诊断包括重新得到所接收的振动信号的谱轮廓。
24.根据权利要求22所述的方法,其中所述诊断包括将所接收的振动信号与参考值进行比较。
25.根据权利要求22所述的方法,其中振动信号包括噪音信号。
26.根据权利要求22所述的方法,其中振动信号具有小于大约20Hz的频率。
27.根据权利要求22所述的方法,其中包括将振动信号耦合至过程连接件。
28.根据权利要求22所述的方法,其中所述冲击管道将压力传感器耦合到过程流体。
29.一种传感器,所述传感器执行权利要求22所述的方法。
30.根据权利要求22所述的方法,其中包括诊断冲击管道中的填充流体的损耗。
31.根据权利要求22所述的方法,其中包括诊断形成物位测量装置的湿或者干支路的冲击管道中的变化。
32.根据权利要求22所述的方法,包括基于所接收的振动信号执行自诊断。
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Also Published As
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JP2007516445A (ja) | 2007-06-21 |
WO2005066590A2 (en) | 2005-07-21 |
CN100504310C (zh) | 2009-06-24 |
EP1697698B8 (en) | 2013-08-28 |
EP1697698A2 (en) | 2006-09-06 |
US20050132808A1 (en) | 2005-06-23 |
RU2006126655A (ru) | 2008-01-27 |
US7523667B2 (en) | 2009-04-28 |
RU2366898C2 (ru) | 2009-09-10 |
WO2005066590A3 (en) | 2005-10-06 |
EP1697698B1 (en) | 2013-07-24 |
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