William
David, Duff
Winslow
Kevin, Mcdonald
Francis
Xavier
| 1. | A nonintrusive method for timing the full operational motion of a valve plug in an electrically actuated, pneumatically operated valve comprising: sending an actuation signal to the valve; nonintrusively sensing arrival of the actuation signal at the valve; sending a start timing signal to a time measurer when the actuation signal is sensed, nonintrusively sensing when the valve plug reaches a limit of motion; sending an end timing signal to the time measurer when the valve plug reaching a limit of motion is sensed; measuring the time elapsed from the start timing signal to the end timing signal with the time measurer; and recording the time elapsed. |
| 2. | In a process plant having a valve, the combination comprising; a valve actuation signal generator; an electrical conductor of the valve actuation signal; an electrically actuated, pneumatically operated valve; a means for signaling arrival of the valve actuation signal at the valve, without involving an electrically conductive connection to the electrical conductor of the activation signal; a means for generating a limit signal indicative of the limit of the valve operation without applying a force to the valve; a means for measuring the time difference from the arrival signal to the limit signal; a means for recording the time difference. |
| 3. | The combination of claim 2, wherein the electrically actuated, pneumatically operated valve contains a solenoid; and the means for signalling the arrival of the valve actuation signal at the valve is a coil of wire around the solenoid. |
| 4. | The combination of claim 2, wherein the electrically actuated, pneumatically operated valve contains a solenoid; and the means for signalling the arrival of the valve actuation signal at the valve is an accelerometer on the solenoid. |
| 5. | The combination of claim 2, wherein the electrically actuated, pneumatically operated valve contains a permanent pressure sensor; and the means for signalling the arrival of the valve actuation signal at the valve is a signal from the pressure sensor. |
| 6. | The combination of claim 2, including a plurality of means for signalling the arrival of the valve actuation signal at the valve. |
| 7. | The combination of claim 2 wherein the means for generating a limit signal indicative of the limit of the valve operation comprises a laser measurement means. |
Background of the Invention
The present invention is directed to non-intrusively measuring the
time for the full stroke operation of a pneumatically controlled valve, and
more particularly, to measuring the time interval for an electrically actuated,
pneumatically controlled valve to fully open or close in a nuclear facility.
Pneumatically controlled valves are used extensively in nuclear power
generating plants. The time interval for individual valves to open or close
is very important for many safety aspects of nuclear plant operation. Valves
need to fully operate within set parameters to ensure that safety regulations
are being met. To date the timing of valves has been accomplished by hand
held stop watches and technicians in different locations communicating by
phone. One technician will start the valve closing or opening sequence
from the control room while another technician observes the valve operation
and performs the timing by hand. Other methods include observing
indicator lights which may or may not be properly set up or functioning.
There are many disadvantages to the present methods of timing
valves. In both cases, observation of the valve per se or observation of the
indicator lights, there is the human variable of when the timing begins and ends. Not only can the timing be inaccurate, but because of variations in the human hand and eye between individuals and even between the same
individual from day to day, the degree of inaccuracy will be inconsistent.
Thus, it can be difficult to accurately identify valve degradation over a period
of months or years by comparing valve timings. Also in cases where the
timing is performed by actually observing the valve start and stop, there is
no accurate compensation for the time elapsed for the operation of the
pneumatic control mechanism.
At present there are methods available for testing valve operation in
the plant. Use of such methods, however, would require disconnecting the
valve control mechanism from the control room. A signal would be
generated from the test equipment to cause valve actuation. Timing could
then be performed from various test sights on the valve. This method of
valve testing is unacceptable for safety testing the operation of valves in
many nuclear power plants. The valve needs to perform in the same
environment and situation it would need to perform in if an actual emergency were to occur. The disconnection and then reconnection of
safety related signal and/or control lines presents licensing problems.
Summary of the Invention
The present invention non-intrusively measures the timing operation
of a pneumatically controlled valve. The valve is allowed to function with
the normal controls of the valve. The invention passively measures
indications of the arrival of the electrical activation signal from the control
room and begins timing. The invention then non-intrusively measures the
physical movement of the valve and ends timing when the valve has fully
closed or opened. The invention can very accurately measure the timing of the closing or opening of the valve from the arrival of the signal at the
valve control mechanism from the control room, to the full closing or
opening of the valve. The accurate timing can be saved and compared to
later test data to observe if degradation of the valve has occurred over time.
The indications of the arrival of the activation signal from the control
room can be measured in several ways. In a valve control mechanism an
electrical signal is converted to an air pressure. The electrical signal from
the control room operates a solenoid which in turn admits air to the valve
operator. A coil can be placed around the solenoid housing to measure the
change in the electrical field that occurs in the solenoid when the electrical
actuation signal arrives. This is particularly useful when the solenoid is
operated by a large alternating current. Alternatively, an accelerometer can be placed on the solenoid to measure the vibrations due to movement of the
solenoid mechanism. In some control mechanisms, the actuation signal from
the control room is a direct current signal. The induced voltage from the
increase or decrease of the direct current can be measured. Some valve
control mechanisms have a permanent pressure sensor attached between the
valve control mechanism and the pneumatically controlled valve. A
measurement of the increase or decrease in air pressure can indicate arrival
of the activation signal, and therefore can be used to begin the timing of the valve operation. For timing of the valve, only a single method mentioned
need be used to indicate arrival of the actuation signal at the actuator.
The movement of the valve can be directly measured. To be non-
intrusive, a method of measuring valve motion must not significantly increase the forces on the valve stem. Significant increases in forces on the valve
stem would effect valve timing. One method of measuring the position of
the valve is to place a sensor on the valve stem, then mechanically measure
the position of the valve stem and therefore the valve plug. Another method
can be the use of a laser valve position indicator. The laser measuring
device includes a laser head and a reflective surface. The laser head or
reflective surface is attached to the valve yoke or body and the other
component is attached to the valve stem. The laser and associated signal
processing equipment can then very accurately measure the position of the
valve and indicate when the valve plug has reached a limit of motion. The
valve plug includes any means for blocking the flow of a fluid through a
passage, such as a gate, a cock, etc. The laser measuring device has low
mass and so does not add significant forces when attached to the valve stem,
therefor not effecting valve timing.
The timing device measures digitally or by analog means, the time
between two signals generated by the test equipment and records the
information for the technician operating the equipment.
In the best mode a coil of wire is wrapped around the alternating
current controlled solenoid in the valve control mechanism, and in combination with the laser valve position measuring device. The laser
measuring device is disclosed in United States Patent Application No.
924,371 , filed on July 31 , 1992, the disclosure which is incorporated by
reference. Loops of wire are wrapped around the solenoid housing to
indicate the arrival of the signal and the laser head and reflector are clipped to the valve body and the valve stem. In a direct current controlled valve
control mechanism, the induced voltage would be measured, but in a digital
recording system a condenser may be required to hold the voltage spike long
enough for the system to record the signal. This would also be combined
with the laser valve position sensor. The advantage of this system is that it
measures the longest possible time, from the arrival of the actual signal from
the control room to the final opening or closing of the valve. It is also the
least intrusive method because of the very limited physical attachment of the
test equipment to the valve and valve control mechanism. Another
advantage is the speed of being able to quickly attach and detach the test
equipment from the valve, facilitating the testing of many valves in a short
period of time.
An accelerometer can measure as an indication of the arrival of the
signal from the control room by the movement of the solenoid slug.
However, there can be a delay between the arrival of the signal and the start
of actual movement of the solenoid slug, leading to errors in time measurement. One advantage of such a method of measurement is that the accelerometer can be very easily temporarily attached to the solenoid by a
magnet on the accelerometer. The accelerometer senses the vibration of the
solenoid slug moving in the solenoid. Such timing errors are further
increased if the measurement of the signal arriving from the control room is
indicated from a permanent pressure sensor between the valve control
mechanism and the pneumatic valve.
The timing system can also be used as a diagnostic tool for the valve. Time measurements can be taken from the coil on the solenoid, the
accelerometer, the pressure sensor between the control valve mechanism and
the pneumatic valve and the valve position sensor. By comparing the times
between each sensor reading, a technician can determine not only whether
the valve timing is increasing, but what component may be causing the
increase. If the cause of an increase in valve operation time can be
narrowed to one or two components of the valve system, less time and costs
need be incurred in repair of the valve.
In the preferred embodiment, a technician would have the invention
on a rolling cart. The technician would wrap wire around the solenoid of the actuator and attach the wire to the timing equipment. Next the technician
would attach the laser measuring equipment to the valve by securing the
laser head to the valve body and clipping the reflective surface to the valve
stem. Then the technician would "zero" the laser measuring equipment. A plant operator in the control room would then send an activation signal to
the valve actuator. The current in the solenoid would induce a current in
the coil indicating arrival of the activation signal. The timing equipment
would process the signal from the coil and begin timing. When the laser
measuring device indicated that the valve had reached the limit of motion,
the timing equipment would process the information from the laser
measuring device and stop timing. The timing information would then be
recorded by the timing equipment. Finally the technician would remove the
coil and laser measuring device from the valve.
Brief Description of the Drawings
These and other objects and advantages of the invention will be
described below in connection with the preferred embodiment of the
invention and with reference to the accompanying drawings, in which:
Figure 1 is a side view partially in section of the timing device
attached to a two position valve in accordance with the invention;
Figure 2 is a side view partially in section of the timing device
attached to a variable position valve.
Description of the Preferred Embodiment
Figure 1 shows a two position valve 10 with the timing mechanism
12. The valve has a main body 14 with two flanges 16 and 18 for
attachment into a fluid piping system not shown. The main body 14 has
passages 20 and 22 for fluid to flow through the valve. Inside the main
body 14 is sleeve 24 in which the plug 26 slides. When the plug 26 is at
the down limit position as shown, the plug rests against seat 28 forming a
fluid tight seal. Were the plug in the up limit position, not shown, fluid
would flow through passage 30. The main body 14 also contains a drain
plug 32. The plug 26 is moved by stem 34 which passes through the upper
housing 36 of the valve 10.
The upper housing 36 contains packing 38 and sleeve 40 for guiding
the stem 34. The stem 34 continues into the top of the valve 10 called the
operator 42. The operator has an operator housing 44. The stem 34 passes
through the operator housing 44 to a plate 46. The plate 46 is attached to the operator housing 44 by a diaphragm 48. The diaphragm 48 is flexible
to allow the plate 46 to move up and down along with the stem 34 and plug
26. The diaphragm 48 is air-tight. The spring 50 keeps the plate 46, stem
34, plug 26 assembly in the up limit position when no air pressure is applied
to the valve. When air of sufficient pressure is applied through line 52 to
the operator 42, a force is applied to the top of plate 46 overcoming the
opposing force of the spring 50 and driving the plate 46, stem 34, plug 26
assembly down until it is in the down limit position. Valves can also be
constructed such that the valve is normally closed, and air pressure opens
the valve.
The rest of the permanent valve equipment may be considered an
actuator in the form of a solenoid operated valve (SOV)60. The invention
consists of the timing equipment 12 with multiple possible inputs. The first
inputs indicate arrival of the signal over line 62 to the actuator and start the
timing procedure. Only a single method of indicating arrival of the signal
need be employed. However, all suggested methods are shown at once. A
coil of wire 68 can be wrapped around the outside of the solenoid 56. The
changing electro-magnetic field from the arrival of the activation signal at the
solenoid will induce a current in the coil 68, connected to the timing
equipment 12 by lines 69. The induced current in the coil 68 indicates to
the timing equipment 12 that timing should begin. An accelerometer 70 can
be attached to solenoid 56 by magnet 64 and connected to the timing equipment 12 by line 71 . The accelerometer senses the vibration of the
motion of the solenoid slug. When the slug begins motion, the timing
equipment 12 can process the input from the accelerometer 70 to indicate
that timing should begin. The timing equipment 12 can also be attached by
line 73 to pressure sensor 72. When the SOV 60 opens, air pressure in line
52 will increase. A signal from pressure sensor 72 can be processed by timing device 12 to indicate that timing should begin. The timing device 12
ends timing by reception of information on line 75 from laser motion sensor
74. Laser motion sensor 74 consists of a laser head 76 mounted to the
operator housing 44 by attachment means 78. Attachment means 78 could be an adhesive, a plastic tie going around the operator housing 44 or any
other convenient means of attachment. The laser head 76 aims a laser beam
80 at a reflecting surface 82. The reflecting surface 82 is attached to the
valve stem 34 by support 84. Support 84 can be a test tube clamp or other attachment sufficiently rigid to support the reflecting surface 82. Timing
equipment 12 contains processing equipment to support the laser motion
sensor 74. When the laser motion sensor 74 indicates that the plug 26 is in
the up limit position or the down limit position, the timing equipment 12
stops timing and records the time in memory by display, by printing, or other
recording means.
Figure 2 shows a partial section drawing of the timing equipment 12
attached to a variable position valve 86. Variable position valve 86 is similar
to valve 10 with several additions. The position of plug 26 in sleeve 24 can
be controlled so that the plug 26 is in positions other than the up limit
position or the down limit position. A positioner 88 is connected by air line
90 to l/P transducer 102. An activation signal on line 104 to the l/P
transducer changes the pressure in line 90 to positioner 88. The positioner
88 is attached to stem 34 by arm 92. The positioner 88 determines the
position of the plug 26 by sensing the position of stem 34 through arm 92.
The positioner 88 compares the air pressure in line 90 from the l/P
transducer 102, the full air pressure in line 94 and sends an air pressure
signal on line 96 to valve 98. Valve 98 controls the full air pressure in line
100 to the operator 42. By a mechanical feed back loop sensing the position
of the arm 92, the full air pressure in line 94 and the air pressure from the
l/P transducer 102, the positioner 88 can control the position of the plug in
26 in the valve by adjusting the air pressure in line 96 to valve 98. The
timing equipment 12 is connected in the same manner to the variable
position valve 86 as to the valve 10. Line 69 connects to a coil 68 on the
solenoid 56. Line 71 connects to the accelerometer 70, attached to actuator
54 by magnet 64. Line 75 connects to the laser motion sensor 74. The
reflective surface 82 is attached to arm 92. The reflective surface could also
be attached to the stem 34 by the method shown in Figure 1 . The actuation signal to the actuator arrives on line 106. The actuator
54 is set up, when signalled, to override the pressure signal from positioner
88. While a signal on line 104 can fully open or close the valve through the
positioner 88, line 106 is a more secure emergency line and acts directly on
the actuator 54 for a more direct response.