Patent Application
20190120263
Flow controls are important in many industries. Whether found on process lines, distribution networks, or any system that carries flowing material, devices like valve assemblies are vital to regulate material flow within set parameters. Sometimes, these devices must operate in hazardous areas. Valve assemblies, for example, may mount onto process lines that carry flammable or combustible materials, like natural gas. In such cases, it is important that these devices meet certain design specifications to prevent ignition of the material.
The subject matter disclosed herein relates to improvements that meet these design specifications. Of particular interest are embodiments of control hardware that meets both explosion-proof and intrinsically-safe design standards. This control hardware, or “controller” or “valve positioner,” may integrate onto the flow device to control mechanical mechanisms to regulate this flow. For valve assemblies, these mechanisms may include an actuator, likely pneumatic, that manages movement of a closure member relative to a seat via a stem. During operation, the controller may receive and processes a control signal from a process control system (also “distributed control system” or “DCS system”). The control signal may define operating parameters for the valve assembly. These operating parameters may set an appropriate flow of material through the valve assembly and into the process line. The controller can translate the operating parameters, often in combination with the output from the position sensor, to regulate instrument gas into the actuator. The instrument gas may pressurize (or de-pressurize) the actuator in a way that moves the valve stem and, in turn, locates the closure member in position relative to the seat to coincide with the operating parameters.
Reference is now made briefly to the accompanying drawings, in which:
Where applicable, like reference characters designate identical or corresponding components and units throughout the several views, which are not to scale unless otherwise indicated. The embodiments disclosed herein may include elements that appear in one or more of the several views or in combinations of the several views. Moreover, methods are exemplary only and may be modified by, for example, reordering, adding, removing, and/or altering the individual stages.
The discussion that follows describes embodiments of a controller for use with flow devices and fluid control. The controller is shown to operate with a valve assembly, but the concepts may percolate to other fluid regulating devices (e.g., pressure regulators), particularly those that are for use in hazardous areas. The embodiments have a modular design that separates functional elements into independent, operative modules. Some of these modules may be configured to minimize operating power and temperatures to meet guidelines and requirements typical of “intrinsically-safe designs.” Other modules are built to satisfy explosion-proof standards. When combined, the modules adapt the controller to meet both intrinsically-safe and explosion proof standards and still have appropriate functionality so that the valve assembly can regulate fluids in hazardous areas. Other embodiments are within the scope of the subject matter herein.
Broadly, the controller 100 is configured to satisfy requirements for both explosion-proof and intrinsic-safety on a “single” device. These configurations separate operative functions into self-contained devices. Each device has functionality that comports with its respective safety characterization (whether explosion-proof or intrinsically-safe). These features may simplify design as compared to practices to date, often reducing burdens to appropriately arrange, size, and fit components to address both safety standards. The explosion-proof devices 128 may house power “hungry” functionality (like data processing and diagnostics) because these devices do not limit incoming energy. Further, unlike prior practices, the embodiments separate pneumatic functions from the explosion-proof devices 128 to the intrinsically-safe devices 130. This feature is beneficial because it eliminates “openings” in the explosion-proof devices 128 that would allow for ingress of pressurized, instrument air, which tends to complicate packaging design decisions in order to meet certifications for explosion protection.
The valve 106 is configured to regulate flow of material 118. Closure member 110 may embody a plug, a ball, a butterfly valve, and/or like implement that can contact a seat to prevent flow. A sensing mechanism may be useful to monitor the position of the closure member 110 relative to the seat 112. This sensing mechanism can have a position sensor and a mechanical linkage that couples the position sensor with the stem or other structure that moves in concert with the closure member. In some examples, the actuator 104 includes a pneumatic actuator that converts energy (e.g., compressed instrument air 126) into mechanical motion to cause the closure member 110 to move between an opened position, a partially opened position, and a closed position.
The safety barrier 132 may be configured to comport with “intrinsically-safe circuit designs.” These configurations may embody circuitry (or circuits) that are effective to power or “energy” limit signals, preferably those signals that enter areas that are not explosion-proof. In one implementation, the circuitry can ensure signals from the main control device 134 are at low voltages and low currents.
The main control device 134 may be configured to act as the central “brains” of the controller 100. These configurations may have functionality to control or instruct operation of the devices 136, 138, 140. Suitable functions may process signals, including the control signal C, and other inputs to the main control device 134. These inputs may correspond with signals that originate from the devices 136, 138, 140, which may also be at the voltage and current levels to meet intrinsically-safe environments. In this regard, the main control device 134 may be configured for the control signal C to assume any industrial automation protocols. Examples of these protocols include HART, 4-20 milliamp, FOUNDATION Fieldbus, or Profibus. In use, the main control loop 122 may provide the main control device 134 with proper control (via the loop control signal C) and power (via the power signal P). In one implementation, power available from the main control loop power 122 may be approximately 40 milliwatts.
The first peripheral device 136 may be configured to operate the actuator 104. This “pneumatic” configuration may include hardware and software to provide a pneumatic signal to the actuator 104. The pneumatic signal may be regulated instrument air 126 that effectively raises or lowers pressure at the actuator 104 to manage movement of the closure member 110 relative to the seat 112. Often, the pneumatic signal corresponds with a control signal from the main control device 136. This control signal may itself correspond with the loop control signal C, which the control system 122 uses to set flow of the material 120 through the valve assembly 102.
The second peripheral device 138 may be configured to allow an end user to interact with the main control device 136. This “interactive” configuration includes features to exchange information with the end user. Example features may incorporate display technology to visualize data and information. The features may also include various input devices (e.g., buttons, keyboards, touchscreens, etc.) that can allow the end user to input data, read data, or make selections that influence operation or modes on the controller 100.
The third peripheral device 140 may be configured expand functionality of the controller 100. This “options” configuration may provide certain functions that are not essential to the controller 100 to operate the valve assembly 102. Exemplary options may include sensor technology to detect leaks, vibrations, or position of the closure member 110. Other options may offer wireless communication technology. End users may select from among several available options to install onto the controller 100.
The housing structure allows devices 134, 136, 138, 140 to couple with one another to form the controller 100 as a functional, modular “unit.” Often, the enclosure 142 of the main control device 134 may operate as a “base” to receive the other, peripheral devices 136, 138, 140. Fasteners like bolts may be useful to ensure safe, secure attachment. When assembled, the pneumatic device 136 may receive instrument air 126 directly through pneumatic fittings 156. But the peripheral wall 146 prevents ingress of instrument air 126 into the interior space 148 of the main control device 134. This feature maintains the interior space 148 as safe for use with higher-power functions to occur or to house high-power devices.
Enclosures 142 may be configured to meet relevant operative standards for the respective devices 134, 136, 138, 140. For devices 136, 138, “first” enclosures may satisfy only “intrinsically-safe” designs, where the peripheral wall 146 may comprise plastic or metals, like sintered metals or formed metal sheets, often at the discretion of the install environment. Some designs may favor materials that are flame-retardant. It is recognized, as well, that the intrinsically-safe “first” enclosures 142 may not require any external structure at all. On the devices 134, 140, “second” enclosures may meet “explosion-proof” standards, where the peripheral wall 146 may comprise cast, machined, or formed metals with appropriate vents and like pressure-dissipating features built therein. Suitable materials may comport with U.L. 1203 standards, where applicable.
The peripheral wall 146 may adapt to provide ready access to the interior space 148. These adaptations may use multi-piece structures that include separable “sections” of the peripheral wall 146. The sections can connect together with fasteners (e.g., bolts, screws, etc.) or “quick-release” snaps, clips, or fittings. But care should be taken to ensure appropriate and secure fits that comport with explosion proof standards at least on the explosion-proof devices 128.
The communication interface 150 may facilitate communication across the modular architecture. The devices 134, 136, 138, 140 may incorporate appropriate computing components (e.g., processor, memory, sensors, etc.) to process and generate the digital signals S1, S2, S3. This feature allows the devices 136, 138, 140 to easily swap out of the controller 100 in lieu of, for example, a replacement device with comparable functionality. Connectors 152 may include pin-and-socket or like elements to enable this “quick release” capability. In lieu of wiring 154, preference may also be given to outfit the controller 100 with a circuitized substrate (e.g., a printed circuit board) with connections or connectors 152 and appropriate trace topology. This configuration could allow devices 136, 138, 140 to “plug” into the circuitized substrate to transmit signals S1, S2, S3, P1, P2, P3 among the devices.
The pneumatic fitting 156 can permit instrument air 126 to penetrate the enclosure 142 of the device 136. Quick-release fittings that engage tube or tubing are likely candidates for this design. The pneumatic fitting 156 resides separate or independent of the explosion-proof enclosures 128. This location prevents ingress of pressurized air into the explosion-proof housing of the main control device 134 (and from the options devices 140, as well). As noted above, this feature is beneficial because it reduces cost and complexity of the design of the enclosures 142 and allows the devices 134, 140 to operate at power levels that are greater than the devices 136, 138, thus allowing for enhanced or improved functionality.
In operation, the controller 100 may cause the actuator 104 to move the closure member 110 to an instructed position. The main control board on the main control device 134 can process the control signal C to generate an input signal Is, typically electrical current. The pneumatic control device 136 can use (or process) the input signal Is to stimulate the signal converter 186, such as a current-to-pneumatic (I/P) converter, to generate a proportional pneumatic pressure output Ps (also, “signal pressure Ps” or “pilot pressure Ps”). Flow modifying structure on the amplifier 188 may integrate components (e.g., diaphragms, valves, etc.) into a single or unitary package with, for example, an input for the instrument air 132, an input for the signal pressure Ps, and an output port. Collectively, these components may be analogous to pneumatic relays and like devices that, when combined together, can generate, a pneumatic actuator signal Pa to operate the actuator 104. In one implementation, the structure may leverage one or more diaphragms that move in response to the signal pressure Ps. This diaphragm may operate an internal valve (or valves) to modulate the instrument air 126 to generate the pneumatic actuator signal Pa that exits the output port. The pneumatic actuator signal Pa may have parameters that are proportional to the signal pressure Ps at balanced conditions. Sizing of internal components and flow coefficients (CV) for the flow modifying structure may influence parameters for the pneumatic actuator signal Pa.
The display 192 may be configured to provide visual representation or indication. These configurations may embody an LCD display, typically alpha-numeric, or like device. This display may present values for the control signal, valve position, or actuator pressure. For touchcreen implementations, the display 184 may further provide appropriate actuatable inputs, like icons, touch-sensitive buttons, and the like.
The pushbutton input 194 may operate as the primary local user interface to allow the end user (e.g., a technician) to change settings, readouts, and like operative features. Notably, practice to date may require the user interface to meet “explosion” proof standards, which may require stiffer more robust dials and actuatable member. The input 194 may offer better, easier actuation because it meets only “intrinsic-safety requirements. This feature may be important for regular maintenance, configuration, and setup, for example, to allow the end user to exit from valve operating mode and step through a menu structure to manually perform functions such as calibration, configuration, and monitoring.
Optional devices 196 may be configured to expand functionality on the controller 100. These configurations may include sensors that can monitor parameters of flow, whether of material 118 or instrument air 132. In some implementations, the sensor may be particularly configured to collect other operating date from the valve assembly 102. This operating data may be used in diagnostics that can help schedule preventive maintenance and like tasks. In this regard, the devices 196 may also include wireless technology, like antenna or receivers/transmitters, so as to property convey the data from the device.
In view of the foregoing, the embodiments offer proper safety measures for use on valve assemblies that operate in hazardous areas. But the concepts here also simplify the design by spreading functionality across differently-configured devices. In this way, the resulting controller may be built to be both intrinsically-safe and explosion-proof, but avoid the cost and time intensive design efforts that are often necessary to meet these standards at the time of this writing.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. An element or function recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural said elements or functions, unless such exclusion is explicitly recited. References to “one embodiment” of the claimed invention should not be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Furthermore, the claims are but some examples that define the patentable scope of the invention. This scope may include and contemplate other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
Examples appear below that include certain elements or clauses one or more of which may be combined with other elements and clauses describe embodiments contemplated within the scope and spirit of this disclosure.
