SYSTEM AND METHOD FOR MONITORING AND DIAGNOSTICS OF AN ACTUATOR DEVICE FOR ACTUATION OF A VALVE FOR FLUID PIPELINES, AND ACTUATOR DEVICE FORMING PART OF THIS SYSTEM

Abstract

A monitoring system (500) of an on/off type actuator device (1) for activating a valve for fluid pipelines is described, the actuator device (1) being configured to move a valve member of said valve between a first position and a second position. The actuator device (1) comprises at least one fluid cylinder (6) configured to control a linear movement of an actuator rod (8). The monitoring system (500) comprises a plurality of sensors mounted on the actuator device (1) and configured to detect a plurality of operating parameters of the actuator device, and an electronic processing and control unit (50). The electronic processing and control unit (50) is configured to impart a micro-movement to the valve member, to detect signals indicative of the values of said operating parameters during said micro-movement of the valve member, and as a function of said values of said detected operating parameters to estimate if said actuator device (1) is capable of applying a torque or force value sufficient to make said valve member perform the entire movement from the first position to the second position. The micro-movement is such as to constitute only the start of movement of the movable member of the valve, corresponding only to the overcoming of mechanical clearances and dissipative and deformation effects internal to the actuator (1), and furthermore is such as not to substantially involve any alteration in the flow of fluid controlled by the valve. In this way, it is possible to estimate the state of health of the actuator device (1) without causing variations in the flow of fluid through the aforesaid valve.

Claims

1. A monitoring system (500) for an on/off actuator device (1) for activating a valve for fluid pipelines, said actuator device (1) being configured for moving a valve member of said valve between a first position corresponding to a normal operating condition of the valve and a second position corresponding to an emergency operating condition of the valve, said actuator device (1) comprising at least one fluid cylinder (6) configured to drive a linear movement of an actuator rod (8), wherein said monitoring system (500) comprises a plurality of sensors mounted on the actuator device (1) and configured to detect a plurality of operating parameters of the actuator device (1), characterized in that said plurality of sensors comprises: at least one pressure sensor (60) for detecting the pressure in the fluid cylinder (6), a temperature sensor (61) for detecting the temperature in the fluid cylinder (6), a linear position sensor (62) for detecting the linear position of the actuator rod (8), and one or more deformation sensors of one or more components of the actuator, and in that said monitoring system comprises an electronic processing and control unit (50) configured for: activating said actuator device (1) to impart a micro-movement of the valve member, detecting, via said plurality of sensors, signals indicative of the values of said operating parameters during said micro-movement of the valve member, and as a function of the values of said operating parameters detected during said micro-movement of the valve member, estimating whether said actuator device (1) is capable of applying a torque or force value sufficient to make said valve member perform the entire movement from the first position to the second position, said micro-movement being such as to constitute only the start of movement of the movable member of the valve, corresponding only to the overcoming of mechanical clearances and dissipative and deformation effects internal to the actuator (1), and furthermore being such as not to substantially involve any alteration in the flow of fluid controlled by the valve, and said steps of detecting the sensor signals and estimating the torque or force value applicable by the actuator device (1) being automatically activated immediately following the execution of said micro-movement.

2. A monitoring system (500) according to claim 1, wherein said electronic processing and control unit (50) is further configured to estimate, according to the values of said operating parameters detected during said micro-movement of the valve member, the time necessary for said valve member to complete the entire movement from the first position to the second position.

3. A monitoring system (500) according to claim 1, wherein: said actuator device (1) is configured for rotating said valve member of said valve between said first position and said second position, said actuator device (1) comprises an actuator shaft (5) for driving the rotation of said valve member between said first position and said second position, and a transmission (10) for transforming a linear movement of said actuator rod (8) into a rotation of said actuator shaft (5), and said plurality of sensors comprises an angular position sensor (63) to detect the angular position of the actuator shaft (5).

4. A monitoring system (500) according to claim 1, wherein said electronic processing and control unit (50) is configured for: calculating an applicable torque or force value, which the actuator device (1) is able to apply to the valve member in case the actuator device is controlled to make the valve member perform the entire movement from the first position to second position, calculating a resisting torque or force value, which is required for the actual movement of the valve member from the first position to the second position, comparing said applicable torque or force value to a minimum reference value, and/or comparing said resisting torque or force value to a maximum reference value, generating a signal indicative of anomaly of the actuator device (1) if said applicable torque or force value is lower than said minimum reference value, and generating a signal indicative of anomaly of the valve if said resisting torque or force value is higher than said maximum reference value.

5. A monitoring system (500) according to claim 4, wherein said electronic processing and control unit (50) is configured for identifying, as a result of said applicable torque or force value being lower than said minimum reference value, at least one component or sub-unit of said actuator device (1) due to which said applicable torque or force value is lower than said minimum reference value.

6. A monitoring system (500) according to claim 4, wherein: an electro-pneumatic control unit (54) is associated with said actuator device (1), and said electronic processing and control unit (50) is configured for identifying, as a result of said applicable torque or force value being lower than said minimum reference value, at least one component or sub-unit of said electro-pneumatic control unit (54) due to which said applicable torque or force value is lower than said minimum reference value.

7. A monitoring system (500) according to claim 1, wherein: said normal operating condition of the valve corresponds to an opened condition of the valve and said emergency operating condition of the valve corresponds to a closed condition of the valve, said at least one fluid cylinder (6) is a single-acting fluid cylinder, which is normally active for holding the valve member in its first position, the actuator device (1) further comprises at least one spring (18) coupled to the actuator rod (8′) and tending to rotate the valve member towards its second position, so that closing of the valve in an emergency condition is obtained by de-activating said fluid cylinder (6), and said plurality of sensors comprises at least one of a temperature sensor (65) for detecting the temperature at said spring (18), and a load cell sensor (66) for detecting a force exerted by said spring (18) on the actuator rod (8′).

8. A monitoring system (500) according to claim 1, wherein said at least one fluid cylinder (6) is a double-acting cylinder activatable in a direction to move the valve member towards the first position and in an opposite direction to move the valve member towards the second position.

9. A monitoring system (500) according to claim 1, wherein said at least one fluid cylinder (6) comprises a first single-acting cylinder activatable to move the valve member towards the first position, and a second single-acting cylinder activatable to move the valve member towards the second position.

10. A monitoring system (500) according to claim 1, comprising an interface panel (52) mounted on the actuator device (1) and configured for: communicating the values of said detected operating parameters, providing a command for activating said actuator device (1) for causing a micro-movement to the valve member, and communicating an alert message in case the actuator device (1) is not able to apply to the valve member said value of torque or force sufficient to make the valve member perform the entire movement from the first position to the second position.

11. A monitoring system (500) according to claim 1, comprising a remote interface panel (52), connected to the actuator device (1) by means of a wired or wireless communication line, and configured for: communicating the values of said detected operating parameters, providing a command for activating said actuator device (1) for causing a micro-movement to the valve member, and communicating an alert message in case the actuator device (1) is not able to apply to the valve member said value of torque or force sufficient to make the valve member perform the entire movement from the first position to the second position.

12. A monitoring system (500) according to claim 1, wherein said electronic processing and control unit (50) is mounted on board the actuator device (1).

13. A monitoring system (500) according to claim 1, wherein: said electronic processing and control unit (50) is located in a remote control station (56) and connected to the actuator device (1) by means of a wired or wireless communication line, the sensors in said plurality of sensors mounted on the actuator device (1) transmit signals indicative of the values of said operating parameters of the actuator device (1) to said electronic processing and control unit (50), and said electronic processing and control unit (50) transmits command signals to said actuator device (1) for its activation.

14. A monitoring system (500) according to claim 13, wherein said electronic processing and control unit (50) is connected to a plurality of actuator devices of the on/off type for activating respective valves for fluid pipelines and is configured for: activating said actuator devices to impart micro-movements to the respective valve members, detecting, by the respective plurality of sensors, respective signals indicative of the values of said operating parameters during the micro movements of the respective valve members, and as a function of the values of the respective operating parameters detected during the micro-movements of the respective valve members, estimating whether said actuator devices are capable of applying respective torque or force values sufficient to make the respective valve members complete the entire movement from the first position to the second position.

15. An actuator device (1) of the on/off type for activating a valve for fluid pipelines configured to cooperate with a monitoring system (500) according to claim 1, said actuator device (1) being configured for moving a valve member of said valve between a first position corresponding to a normal operating condition of the valve and a second position corresponding to an emergency operating condition of the valve, said actuator device (1) comprising at least one fluid cylinder (6) configured for controlling a linear movement of an actuator rod (8) and a plurality of sensors configured for detecting a plurality of operating parameters of the actuator device (1), characterized in that said plurality of sensors comprises: at least one pressure sensor (60) for detecting the pressure in the fluid cylinder (6), a temperature sensor (61) for detecting the temperature in the fluid cylinder (6), a linear position sensor (62) for detecting the linear position of the actuator rod (8), one or more deformation sensors of one or more actuator components, and in that said actuator device (1) comprises an electronic processing and control unit (50) configured for: activating said actuator device (1) to cause a micro-movement of the valve member, detecting, via said plurality of sensors, signals indicative of the values of said operating parameters during said micro-movement of the valve member, and as a function of the values of said operating parameters detected during said micro-movement of the valve member, estimating whether said actuator device (1) is capable of applying a torque or force value sufficient to make the valve member perform the entire movement from the first position to the second position, said micro-movement being such as to constitute only the start of movement of the movable member of the valve, corresponding only to the overcoming of mechanical clearances and dissipative and deformation effects internal to the actuator (1), and furthermore being such as not to substantially involve any alteration in the flow of fluid controlled by the valve, and said steps of detecting the sensor signals and estimating the torque or force value applicable by the actuator device (1) being automatically activated immediately following the execution of said micro-movement.

16. A method for monitoring, during operation, the state of health of an on/off type actuator device (1) for activating a valve for fluid pipelines by means of a monitoring system according to claim 1, said method comprising: activating (801) said actuator device (1) to cause a micro movement of the valve member, detecting (801), via said plurality of sensors, signals indicative of the values of said operating parameters during said micro-movement of the valve member, and as a function of the values of said operating parameters detected during said micro-movement of the valve member, estimating whether said actuator device (1) is capable of applying a torque or force value sufficient to make the valve member perform the entire movement from the first position to the second position, wherein said micro-movement is such as to constitute only the start of movement of the movable member of the valve, corresponding only to the overcoming of mechanical clearances and dissipative and deformation effects internal to the actuator (1), and furthermore is such as not to substantially involve any alteration in the flow of fluid controlled by the valve, and wherein said steps of detecting the sensor signals and estimating the torque or force value applicable by the actuator device (1) are automatically activated immediately following the execution of said micro movement.

Description

DESCRIPTION OF A PREFERRED EMBODIMENT

[0064] Further characteristics and advantages of the invention will become apparent from the description that follows with reference to the attached drawings, provided purely by way of non-limiting example, wherein:

[0065] FIG. 1, already described above, is a cross-sectional perspective view of an actuator device for activating a valve,

[0066] FIG. 2, already described above, is a cross-sectional view of the central supporting body of the actuator device of FIG. 1, comprising the mechanism for transmitting the motion to the actuator rod of the valve,

[0067] FIGS. 3 and 4, already described above, are perspective views which illustrate some implementation details of the transmission mechanism of FIG. 2,

[0068] FIG. 5 is an exemplary block diagram of a monitoring system according to the invention,

[0069] FIG. 6 is a cross-sectional view of an actuator device according to the invention,

[0070] FIG. 7 is another cross-sectional view of an actuator device according to the invention, and

[0071] FIG. 8 is an exemplary flowchart of a method for monitoring an actuator for valves according to the invention.

[0072] In the non-limiting example illustrated in FIG. 5, a monitoring system 500 for an on/off actuator device 1 according to the invention comprises: [0073] a plurality of sensors mounted on the actuator device 1 and configured to detect a plurality of operating parameters of the actuator device 1, [0074] an electronic processing and control unit 50, [0075] a human-machine interface device (HMI) 52, [0076] an electro-pneumatic control unit 54, and [0077] optionally a remote plant control room 56.

[0078] According to the invention, the actuator device 1 can be of the type illustrated with reference to FIGS. 1 to 4, or rather comprising a single-acting fluid cylinder 6 normally active to keep the valve member in a first operating position (typically, completely open) and at least one spring element 18 which tends to move (e.g., rotate) the valve member towards a second safety operating position (typically, completely closed).

[0079] In an alternative embodiment, the actuator device 1 can comprise a double-acting fluid cylinder which can be activated in one direction to move (e.g., rotate) the valve member towards its first position, and in an opposite direction to move (e.g., rotate) the valve member towards its second position.

[0080] In yet another alternative embodiment, the actuator device 1 may comprise a first single-acting cylinder which can be activated to move (e.g., rotate) the valve member towards its first position, and a second single-acting cylinder can be activated to move (e.g., rotate) the valve member towards its second position.

[0081] The electronic processing and control unit 50 is configured to receive, from the plurality of sensors mounted on the actuator device 1, respective signals indicative of the values of the operating parameters detected on the actuator device 1.

[0082] Furthermore, the electronic processing and control unit 50 is configured to give the electro-pneumatic control unit 54 the commands necessary for activating the actuator device 1, such as, for example, an opening or closing command (total or partial) of the valve, or a set of commands that initiate and carry out a procedure for diagnosing the state of health of the actuator 1 as better described in the following part of the present description.

[0083] The electro-pneumatic control unit 54 comprises a set of electro-pneumatic valves which, controlled by the electronic processing and control unit 50, implement an electro-pneumatic circuit for controlling the fluid cylinder 6.

[0084] For example, the electro-pneumatic control unit 54 may comprise: [0085] an inlet duct for a pressurized fluid (for example, air) with a corresponding inlet filter, [0086] a pressure regulating device in the inlet duct downstream of the inlet filter, [0087] a pressure limiting device which performs a safety function by limiting the pressure downstream of the pressure regulating device, [0088] a (proportional) flow rate regulating device to regulate the introduction of fluid into the fluid cylinder 6, [0089] a flow amplifier device downstream of the flow regulator device, which feeds a pneumatic outlet duct coupled to an inlet of the fluid cylinder 6 to control its actuation, and [0090] a device for discharging the actuator 1 in emergency conditions.

[0091] In the following part of the present description, reference will be made, by way of non-limiting example, to an actuator device as illustrated in FIGS. 1 to 4, i.e. configured to impart rotational movements to the valve member, it being understood that the principles of the present invention are also equally applicable to actuator devices for gate valves.

[0092] According to the invention, the electronic processing and control unit 50 is configured to carry out a diagnosis procedure of the actuator 1 that includes: [0093] activating, by means of the electro-pneumatic control unit 54, the actuator device 1 to impart a micro-rotation to the actuator shaft 5 such as not to interfere with the flow of fluid controlled by the valve (possibly, a set or sequence of micro-rotations), [0094] detecting, by the plurality of sensors mounted on the actuator 1, signals indicative of the values of the operating parameters during the micro-rotation of the actuator shaft 5, and [0095] as a function of the values of said operating parameters detected during said micro-rotation of the actuator shaft 5, estimating whether said actuator device 1 is capable of applying a torque value sufficient to make the valve member perform the entire movement from the first position to the second position.

[0096] For example, this estimate can be carried out by: [0097] calculating a torque value that the actuator shaft 5 is able to apply to the valve member in case the actuator device 1 is controlled to make the valve member perform the entire movement from the first position to second position, and [0098] comparing the torque value thus calculated with a threshold torque value, which is required for the effective rotation of the valve member from the first position to the second position.

[0099] If it is detected that the actuator device 1 is not able to apply a torque value sufficient to make the valve member perform the entire movement from the first position to the second position (for example, because the calculated torque value is less than the threshold torque value), the monitoring system can generate a signal indicating an anomaly.

[0100] At the end of the diagnostic procedure described above, and in the event that no anomalies are detected, the electronic processing and control unit 50 can operate the actuator 1 to return the valve member to its normal operating position, if necessary.

[0101] In the embodiment exemplified here, the electronic processing and control unit 50 is mounted near the actuator device 1 and is configured to operate (i.e., to receive signals and issue commands) only on this actuator device 1.

[0102] Alternatively, the electronic processing and control unit 50 can be connected remotely to the actuator device 1, via a wired or wireless connection. For example, the electronic processing and control unit 50 can be located in the remote plant control room 56. In a still alternative embodiment, a single remote electronic processing and control unit 50 can be associated with a plurality of actuator devices 1 within a certain production plant.

[0103] In the case in which a single electronic processing and control unit 50 is associated with a plurality of actuator devices, the unit 50 can be configured to cyclically perform (“in rotation”) a diagnostic procedure on all the actuators associated therewith, or on a subset of them.

[0104] The human-machine interface device 52 associated with the electronic processing and control unit 50, in addition to providing the information and commands typically available for managing the actuators of a known type (for example: operating the actuator device to impart a partial rotation to the actuator shaft, and/or activating the actuator device to move the valve member from the first position to the second position), is configured for: [0105] communicating the values of the operating parameters detected on a respective actuator device 1 to an operator, [0106] providing a command to activate the actuator device 1 in order to carry out the diagnostic procedure described above, and [0107] communicating an alarm message corresponding to a signal indicative of anomaly generated in the event that the torque value that the actuator shaft 5 is able to apply to the valve member is less than a torque value required for the effective rotation of the valve from its first position to its second position.

[0108] The human-machine interface device 52 can be local, i.e. mounted near the actuator device 1 and accessible to an operator on the field, or remote (i.e., coupled to the electronic processing and control unit 50 via a wired or wireless connection) and located, for example, in the remote control room 56. The human-machine interface device 52 may also comprise a portable device such as a smartphone or tablet. Obviously, these interface devices are not mutually exclusive, and a certain actuator device 1 can be accessible both via a local interface device and via a remote interface device.

[0109] In addition, a single remote interface device 52 may allow access (i.e., receiving data and/or sending commands) to a plurality of actuator devices 1, located for example, within the same production plant. In the non-limiting example illustrated in FIGS. 6 and 7, the plurality of sensors mounted on the actuator device 1 comprises at least one of: [0110] a pressure sensor 60 for detecting the pressure in the fluid cylinder 6, [0111] a temperature sensor 61 for detecting the temperature in the fluid cylinder 6, [0112] a linear position sensor 62 for detecting the linear position of the actuator rod 8, [0113] an angular position sensor 63 to detect the angular position of the actuator shaft 5, [0114] a deformation sensor to detect deformation of one or more components of the actuator, [0115] a temperature sensor 65 for detecting the temperature at the spring element 18, and [0116] a load cell sensor 66 to detect a force exerted by the spring element 18 on the actuator rod 8′.

[0117] Each of the aforesaid sensors can be implemented according to any known technology. For example, temperature sensors may consist of thermocouples and position/deformation sensors may consist of laser sensors configured to detect the distance between the sensor and the controlled element.

[0118] In a preferred embodiment, the electronic processing and control unit 50 is further configured to estimate the time necessary for the valve member to complete the entire movement from the first position to the second position.

[0119] In a preferred embodiment, the electronic processing and control unit 50 is configured for: [0120] calculating an applicable torque or force value, which the actuator device 1 is able to apply to the valve member in case the actuator device is controlled to make the valve member perform the entire movement from the first position to second position, and [0121] calculating a resisting torque or force value, which is required for the actual movement of the valve member from the first position to the second position.

[0122] For example, calculating the applicable torque and the resisting torque can be carried out by determining a correlation between the values of the operating parameters detected during the micro-rotation of the actuator shaft 5 and values of the operating parameters that would be detected during a rotation imparted to the shaft actuator 5 for rotating the valve member from its first position to its second position.

[0123] In general, the diagnosis can be made by comparing the torque applicable by the actuator during the emergency maneuver with the resisting torque.

[0124] In a preferred embodiment, in the case in which the applicable torque value is lower than the resisting torque, the electronic processing and control unit 50 is configured to determine whether an increase in the dissipation sources internal to the actuator 1 has occurred (e.g., an increase in the friction of the seals, the initiation of mechanical clearances due to wear, the decrease in the thrust of the spring 18, etc.) which represents the cause of the non-satisfaction of the required performance, or if there has been no deterioration in the performance of the actuator 1, but a progressive increase in the resisting torque required by the valve has been detected, which is attributable to the non-satisfaction of the required performance.

[0125] Therefore, in a preferred embodiment the electronic processing and control unit 50 is configured for: [0126] comparing the applicable torque value to a minimum reference value, and/or comparing the resisting torque value to a maximum reference value, [0127] generating a signal indicative of anomaly of the actuator device 1 if the applicable torque value is lower than the minimum reference value, and [0128] generating a signal indicative of anomaly of the valve if the resisting torque value is higher than the maximum reference value.

[0129] In the case in which there has been an increase in the dissipation sources internal to the actuator 1 (i.e., in the case in which the applicable torque value is less than the minimum reference value), the electronic processing and control unit 50 can be configured to identify which of the main sub-systems of the actuator 1 (i.e., the fluid cylinder 6, the spring actuator unit 14 or the motion transmission mechanism contained in the supporting body 2) causes the performance of the actuator to decrease (i.e., a decrease in the actual deliverable torque).

[0130] As described previously, an electro-pneumatic control unit 54 may be associated with said actuator device 1. Therefore, in another preferred embodiment, the electronic processing and control unit 50 is configured to identify, as a result of the fact that the torque value applicable by the actuator shaft 5 is less than the minimum reference value, at least one component or sub-unit of the electro-pneumatic control unit 54 due to which the torque value applicable by the actuator shaft 5 to the valve member is lower than the minimum reference value, possibly discriminating whether the actuator device 1 or the electro-pneumatic control unit 54 causes this anomaly.

[0131] Of course, the monitoring system according to the invention can also allow maintenance operations to be carried out based on a continuous detection of the values of one or more operating parameters of the actuator 1, for example, to detect the occurrence of wear phenomena which do not affect the emergency function of the actuator. For example, the monitoring system can be configured to: [0132] continuously detect the values of one or more operating parameters of the actuator 1 and/or the respective variations (for example, taking advantage of the excitation of the mechanical system induced by any line vibrations, or by any changes in the ambient temperature, however without the need to introduce a disturbance of the static/dynamic state of the actuator such as a micro-rotation), [0133] carry out a self-diagnosis of the monitoring system, for example, by checking the health of the sensors and the communication system, and/or [0134] monitor the time evolution of the values assumed by one or more controlled parameters (for example, in order to detect drift errors).

[0135] A monitoring method according to the invention is exemplified in the flow chart of FIG. 8.

[0136] After a start step 800, at a step 801, the monitoring system imparts a command to the actuator device 1 to perform a micro-movement and starts detecting the values of the operating parameters.

[0137] At a step 802, the monitoring system checks, according to the values detected, whether there has been a transition from static conditions to dynamic conditions of the movable member of the valve, that is, if the actuation command given is sufficient to set in motion the movable member of the valve.

[0138] In the case of a negative outcome (N) of the verification step 802, indicative of the fact that the actuation command imparted has—at most—generated elastic deformations in the kinematic chain of the actuator device, without generating an effective movement of the movable member of the valve, at a step 803 the monitoring system processes the acquired data and, at a step 804, generates an anomaly signal, indicating, for example, which unit, sub-unit or sensor of the actuator device 1 is the cause of the anomaly detected. The monitoring method then ends at an end step 805.

[0139] In the event of a positive outcome (Y) of the verification step 802, indicative of the fact that the actuation command imparted has generated an effective micro-movement of the movable member of the valve, at a step 806 the monitoring system processes the acquired data, for example, by making a predictive estimate of at least one of: [0140] a torque or force value that the actuator device 1 is able to apply to the valve member when the actuator device 1 will have to move the valve member from the first position to the second position, [0141] a resisting torque or force value of the movable member of the valve, and [0142] a speed or angular speed value with which the actuator device 1 will move the valve member from the first position to the second position.

[0143] At a step 807, the monitoring system generates a status signal indicative of the fact that the diagnosis procedure can be carried out correctly.

[0144] At a step 808, the monitoring system verifies whether the estimated torque or force value applicable by the actuator device 1 to the valve member is greater than a torque or force value required for the effective movement of the valve member from the first position to the second position (resisting torque or force), and optionally checks whether the speed or angular speed value with which the actuator device 1 will move the valve member from the first position to the second position is greater than a reference speed or reference angular speed value.

[0145] In the event of a negative outcome (N) of the verification step 808, at a step 809 the monitoring system generates an anomaly signal, and the monitoring method ends at an end step 805.

[0146] In the event of a positive outcome (Y) of the verification step 808, at a step 810 the monitoring system generates a positive status signal, indicative of the fact that the actuator device 1 can carry out the emergency maneuver when required, and the monitoring procedure restarts from the beginning step 800, for example, to repeat the monitoring procedure at regular time intervals.

Definition of Micro-Movement, Micro-Rotation, Micro-Translation

[0147] In the context of the present description, the term “micro-movement” of the valve member (or rather, a micro-rotation of the actuator shaft 5 in the case of “quarter-turn” actuator devices, such as that exemplified in FIGS. 1 to 4, or a micro-translation in the case of linear actuator devices) indicates a movement sufficiently large to effectively set in motion the movable member of the valve (considering the presence of mechanical clearances and dissipative and deformation effects inside the actuator, such that a small linear movement of the actuator rods 8 and 8′ does not necessarily correspond to an effective movement of the movable member of the valve), but also small enough not to interfere in a perceptible way with the fluid dynamic characteristics of the valve (for example, leaving the flow rate of the pipeline at the valve substantially unaltered). It is therefore only the “start” of movement of the movable member of the valve, corresponding to the overcoming of mechanical clearances and dissipative and deformation effects internal to the actuator, such as not to substantially involve any alteration in the flow of fluid controlled by the valve. By this it must be understood that the aforesaid micro-movement, on the one hand, does not entail any significant, or noteworthy variation in the flow of fluid controlled by the valve, and on the other hand, it safeguards the reliability of the valve, since each opening/closing maneuver of the valve can lead to an accumulation of impurities between the valve member and the valve body.

Predictive Mathematical Model

[0148] In one example, the electronic processing and control unit 50 can be configured to calculate—according to the values of the operating parameters detected during a micro-movement of the valve member—the torque value that the actuator shaft 5 is able to apply to the valve member, by means of a mathematical model of the specific actuator 1, which can be stored in a memory of the processing and control unit 50.

[0149] In the event that a single electronic processing and control unit 50 is associated with a plurality of actuator devices, the electronic processing and control unit 50 can store a plurality of respective mathematical models of the actuator devices, for example, by associating a respective mathematical model with each actuator device, or by dividing the plurality of actuator devices into subsets (for example, with each subset comprising a certain number of similar actuators) and associating a respective mathematical model with each subset thus identified.

[0150] The inventors have noted that, in order to estimate the ability of the actuator device 1 to perform an emergency maneuver (i.e., estimate the performance of the actuator), it is useful to estimate the torque that the actuator can deliver at a given angular speed. This angular speed is determined by the maximum time allowed (predetermined) to rotate the movable member of the valve by about 90 degrees. In fact, the inventors have noted that the dynamic effects are not negligible.

[0151] With reference to a conventional actuator device 1, as illustrated in FIGS. 1 to 4, it is possible to study in detail the behavior of the various parts of the actuator and the possible consequences of a relative failure on the overall behavior of the actuator, for example, in terms of deliverable torque. Obviously, the same approach can also be applied, in various embodiments of the present invention, to linear actuators, estimating the possible consequences of a failure in terms of deliverable force or thrust.

[0152] A mathematical model that describes the behavior of an actuator device 1 for the purposes of the present invention can be determined according to different methodologies.

[0153] For example, the document “Models of control valve and actuation system for dynamics analysis of steam turbines”, M. Pondini, V. Colla, A. Signorini, Applied Energy 207 (2017), p. 208-217, doi: 10.1016/j.apenergy.2017.05.117, and the document “Parametric identification of a servo-hydraulic actuator for real-time hybrid simulation”, Y. Qian, G. Ou, A. Maghareh, S. J. Dyke, Mechanical Systems and Signal Processing 48 (2014), p. 260-273, doi: 10.1016/j.ymssp.2014.03.001, are examples of possible approaches to mathematical modeling and simulation of hydraulic actuator devices.

[0154] In addition to, or alternatively, a mathematical model of an actuator device 1 may also be determined using the “digital twin” technique. In this context, the document A Simulation-Based Digital Twin for Model-Driven Health Monitoring and Predictive Maintenance of an Automotive Braking System”, R. Magargle, L. Johnson, P. Mandloi, P. Davoudabadi, O. Kesarkar, S. Krishnaswamy, J. Batteh, A. Pitchaikani, Proceedings of the 12th International Modelica Conference, May 15-17, 2017, Prague, Czech Republic, p. 35-46, doi: 10.3384/ecp1713235 is an example of a “digital twin” modeling method of complex mechanical and hydraulic systems.

[0155] By way of example, the actuator device 1 of the example considered here can be conceptually divided into three main sub-systems, corresponding to the fluid cylinder 6, to the spring actuator unit 14 and to the pin-slot transmission mechanism contained in the supporting body 2.

[0156] Preferably, by means of a Failure Modes, Effect and Diagnostic Analysis (FMEDA), each of these three sub-systems can be further divided into a set of corresponding components (for example, within the pin-slot transmission mechanism it is possible to identify the actuator arm 10, the cam-follower pin 12, the block 13, the guide bar 19, and other components). It is then possible to analyze the possible failure modes of each of these components or sub-units (for example, sets of components), determining the effect they have on the behavior of the actuator as a whole (for example, in terms of variations of the torque delivered). The mathematical model can, therefore, allow characterization of the actuator device 1 at the level of sub-units or components.

[0157] Therefore, the inventors have noted that, from a maintenance point of view, it is useful to identify some operating parameters of the actuator device 1, indicative of the health status of one or more components or sub-units of the actuator 1, to be monitored by means of a plurality of sensors in order to evaluate the ability of the actuator to carry out an emergency maneuver in a certain defined time interval.

[0158] Generating the mathematical model of an actuator device 1 can be based on the following considerations, which take into account: deformability of the mechanical bodies in the actuator 1, effect of dynamic loads, dynamic response of the mechanical and electro-pneumatic systems, and real fluid-dynamic behavior.

[0159] To generate torque, an actuator device as exemplified in FIGS. 1 to 4 (with scotch-yoke architecture and single-acting cylinder) transforms the force generated by the fluid cylinder 6 and the spring element 18. This torque varies according to the angular position of the scotch-yoke kinematic mechanism, i.e., of the actuator arm 10. The module of the torque is a function of the “Gain” parameter of the kinematic mechanism, which amplifies the force.

[0160] When the actuator device 1 is required to perform an emergency maneuver, a depressurization of the fluid cylinder 6 is carried out such as to produce a reduction in the force of the piston (F.sub.piston) sufficient to generate, at the specific angular position (θ) of the actuator arm 10, a difference between the force generated by the spring 18 (F.sub.spring) and the resistance to rotation generated by the valve (for example, due to friction phenomena), equal to Δforce.

[0161] The component Δforce can be decomposed in the directions of interest, or rather in a first direction perpendicular to the axes 6X and 15X, and in a second direction perpendicular to the straight line tangent to the contact profile. The contact profile is a curve that depends on the geometry of the slots 11 formed in the actuator arm 10, and the direction perpendicular to this profile varies according to the angular position θ of the actuator arm 10. In the direction perpendicular to the axes 6X and 15X, a force is generated which is balanced by a reaction force (F.sub.reaction) in first approximation totally attributable to the guide bar 19. In the direction perpendicular to the contact profile, a force F.sub.resultant is generated.

[0162] Having identified the direction of the actuator arm 10 (i.e., the direction given by a straight line passing through the pin 12 and the rotation axis 4), it is possible to decompose F.sub.resultant into a component perpendicular to the direction of the arm (Arm) and into a component parallel thereto, determining the force (F.sub.torque) that generates an ideal torque (neglecting internal dissipations) Torque.sub.ideal equal to: Torque.sub.ideal=F.sub.torque×Arm, where Arm is the distance between the pin 12 and the rotation axis 4 which assumes different values as a function of the angular position of the actuator arm 10.

[0163] The transmission mechanism therefore produces a “multiplication” of the force that contributes to the development of torque from Δforce to F.sub.torque, whose ratio represents the “Gain” parameter, therefore a function of the angular position θ of the actuator arm 10.

[0164] The developed torque can be calculated by applying an efficiency coefficient η to the ideal torque Torque.sub.ideal, which takes into account the dissipations (in friction) internal to the actuator, estimated experimentally or defined by experience:

Torque.sub.real=η×Torque.sub.ideal.

[0165] Calculating the torque as described above does not take into account some real effects that allow a more precise estimate of the real torque developed by the actuator device 1 when operated to carry out an emergency maneuver.

[0166] For example, calculating the “Gain” parameter indicated above is based on the assumption that the force resulting from the contact between the pin 12 and the slot 11 is only dependent on the profile curve (see, in this regard, the aforementioned European patent EP 3 029 338 B1 owned by the same Applicant) understood as a set of positions that the center of the pin 12 assumes for each value of the angular position θ of the actuator arm 10. The geometry (in the plane) of the pin 12, which can generate actual contact points different from the theoretical ones, is not considered. The actual contact points may also depend on the deformation state of the components of interest (and, therefore, on the forces exchanged and, in cascade, on the operating conditions of the actuator 1). Still, it is not considered that the deformation state of the components (for example, of the pin 12, of the block 13, and of the actuator arm 10) leads to a variation of the value of the geometric arm Arm, and therefore of the developed torque.

[0167] Other real effects not considered in the above model concern estimating the efficiency coefficient n, for which an estimate of the effective dissipations, or rather, of the friction dissipations at the sliding surfaces, which are produced by the real contact pressures is preferable. The real contact pressures are influenced by the actual deformation/operating conditions of the actuator 1. It is also appropriate to consider other possible sources of loss of performance, for example possible variations in the rigidity of the spring 18 and/or leaks of the piston seal elements 7 due to wear.

[0168] Therefore, the predictive mathematical model can be developed in order to represent the operation of the actuator 1 in the most realistic way possible, and to estimate the performance of the actuator 1 as the operating conditions vary, and not just variation of the geometric and/or kinematic parameters.

[0169] According to the invention, the mathematical model allows an estimate of the real torque Torque.sub.real, which can be a function not only of the pressure in the fluid cylinder 6 and of the angular position θ of the actuator arm 10, but also of other parameters such as, for example, the linear position of the actuator rod 8, the temperature in the fluid cylinder 6 and/or in the spring container unit 14, the deformation of one or more components of the actuator, and possibly other operating parameters of the actuator 1.

[0170] Therefore, the monitoring system according to the invention includes a plurality of sensors that measure some parameters indicative of the operating conditions of the actuator 1, useful for estimating the actual torque Torque.sub.real.

[0171] In particular, the mathematical model is based on a lumped-parameter model wherein the mathematical laws that govern the operation of the actuator device 1 and its electro-pneumatic control unit 54 are represented. The lumped-parameter model is fed with information derived from simulations with specific software, for example, information obtained through finite element analysis (FEM) or Computational Fluid Dynamics (CFD) analyses of one or more components of the actuator 1. These simulations allow representation, and the capacity to numerically solve some three-dimensional phenomena such as stresses, deformations, distribution of contact pressure, etc.

[0172] The data provided by the software simulations (FEM and/or CFD) are processed in order to integrate them into the lumped-parameter model, for example, by generating interpolation curves, characterization matrices and transfer functions to be integrated into the lumped-parameter model.

[0173] The predictive mathematical model according to the invention therefore allows determination of a “transfer function” between a certain number of operating parameters of the actuator 1 (for example, pressure in the cylinder 6, temperature in the cylinder 6, thrust provided by the spring 18, angular position of the actuator arm 10, etc.) and the performance of the actuator 1, in terms of the torque that can be delivered during an emergency maneuver.

[0174] As previously described, a diagnostic procedure carried out by means of a monitoring system according to the present invention therefore envisages a controlled micro-movement of the actuator device 1, such as not to substantially entail any alteration of the process, but sufficient to bring the valve into a condition of only incipient movement.

[0175] The mathematical model of the actuator 1 stored in the processing and control unit 50 allows correlating the values of the operating parameters detected during this partial non-interfering micro-movement with those that it is estimated the actuator 1 would have during hypothetical execution of an emergency function. The mathematical model therefore allows estimating the real torque that the actuator 1 would be able to deliver during an emergency maneuver according to these estimated values of the operating parameters.

[0176] As anticipated, the example described here of a so-called “quarter turn” actuator device (i.e., an actuator device configured to transform a linear movement of the actuator rod 8 into a rotary movement of the actuator shaft 5 in order to rotate a valve member associated therewith) is not to be understood as limiting of the embodiments of the present invention. In fact, various embodiments can be equally applied to so-called “linear” actuator devices, in which the linear movement of the actuator rod 8 is directly transmitted to the movable member of a gate valve in order to make it move—indeed linearly, i.e., by means of a translation—from a first position to a second position.

[0177] Of course, without prejudice to the principle of the invention, the details of construction and the embodiments may vary widely with respect to those described and illustrated purely by way of example, without departing from the scope of the present invention.