Control Valve Opening Research Articles

Fault Detection Technology for Ultrapure Water Plant using Virtual Sensors for Pressure Control Valve and Indicators in Return Line

Objectives:This study aims to propose a technology that utilizes virtual sensors to quickly and accurately diagnose faults in valves and measurement devices that may occur in the return line of an ultrapure water plant.Methods:The empirical equations were derived, and the error range was calculated using operational data collected from three pieces of equipment (pressure control valve, pressure transmitter, and flow transmitter) in the recovery system of the ultrapure water process. Based on this, a virtual sensor is established.Results and Discussion:It was confirmed that the utilization of 24-hour data collected from the operation of the ultrapure water plant was enough to establish virtual sensors and could also estimate monthly data with high accuracy. In Phase 1, the fault diagnosis technology was found to estimate values more accurately and had a meaningful margin of error compared to Phase 2.Conclusion:It was possible to develop a fault detection technology using the virtual sensor derived from the empirical equation. The technology showed high performance in detecting anomalies in the flow meter and pressure control valve opening but had limitations in estimating consistently pressure values. Additionally, considering that there was no issue in estimating monthly data using the equations derived using 24 hours operational data. The fault detection algorithm could be used continuously if the empirical equations are updated by collecting a day's data when operating conditions change.

Advanced Study: Improving the Quality of Cooling Water Towers’ Conductivity Using a Fuzzy PID Control Model

Cooling water towers are commonly used in industrial and commercial applications. Industrial sites frequently have harsh environments, with certain characteristics such as poor air quality, close proximity to the ocean, large quantities of dust, or water supplies with a high mineral content. In such environments, the quality of electrical conductivity in the cooling water towers can be significantly negatively affected. Once minerals (e.g., calcium and magnesium) form in the water, conductivity becomes too high, and cooling water towers can become easily clogged in a short time; this leads to a situation in which the cooling water host cannot be cooled, causing it to crash. This is a serious situation because manufacturing processes are then completely shut down, and production yield is thus severely reduced. To solve these problems, in this study, we develop a practical designation for a photovoltaic industry company called Company-L. Three control methods are proposed: the motor control method, the PID control method, and the fuzzy PID control method. These approaches are proposed as solutions for successfully controlling the forced replenishment and drainage of cooling water towers and controlling the opening of proportional control valves for water release; this will further dilute the electrical conductivity and control it, bringing it to 300 µS/cm. In the experimental processes, we first used practical data from Company-L for our case study. Second, from the experimental results of the proposed model for the motor control method, we can see that if electrical conductivity is out of control and the conductivity value exceeds 1000 µS/cm, the communication software LINE v8.5.0 (accessible via smartphone) displays a notification that the water quality of the cooling water towers requires attention. Third, although the PID control method is shown to have errors within an acceptable range, the proportional (P) controller must be precisely controlled; this control method has not yet reached this precise control in the present study. Finally, the fuzzy PID control method was found to have the greatest effect, with the lowest level of errors and the most accurate control. In conclusion, the present study proposes solutions to reduce the risk of ice-water host machines crashing; the solutions use fuzzy logic and can be used to ensure the smooth operation of manufacturing processes in industries. Practically, this study contributes an applicable technical innovation: the use of the fuzzy PID control model to control cooling water towers in industrial applications. Concurrently, we present a three-tier monitoring checkpoint that contributes to the PID control method.

Water Level Control in Coupled Tank System with PLC and IoT-Based PID Method

There are many advanced technological discoveries in industry, including the coupled tank. Coupled tanks are several tanks connected to each other. One of the quantities that is often controlled in the industry is the control of water levels. Water level control in a PLC and IoT-based coupled tank system is a medium for controlling and monitoring water levels remotely in real-time. The sensor used is a Differential Pressure Transmitter (DPT) with a pump motor actuator which is connected to an Omron PLC using an inverter. There is a disturbance in the form of setting the control valve opening. The control method used is the PID method with Ziegler-Nichols tuning and trial and error. Both methods analyzed which performance of the system response characteristics was better. It is proven that PID tuning is suitable for water level control of coupled tank systems.

Design of Fluid Control Valve Opening Control System

Technical problems such as the limited control times and time of existing fluid control valves and the inability to accurately control the control opening limit the long-term economic development of deep shale gas. This design is mainly based on PID control algorithm to control the opening of fluid control valve. It has the advantages of unlimited control times, high control precision and strong reliability.

Effect of spool posture on control valve performance considering outlet shape and large fit clearance

The control valve serves as a crucial component of the downhole integrated water distributor in water injection oilfields, enabling waterflooding into oil reservoirs. However, the control valve opening cannot be adjusted in the practical environment, resulting in ineffective injection, which means that the spool is stuck. Furthermore, it is difficult to observe the details of the spool sticking and reproduce this phenomenon during testing. To reveal the mechanism of sticking, this paper establishes a CFD model, which considers the spool posture, large fit clearance and outlet shape, to study the spool performance. Additionally, the proposed model is demonstrated experimentally and theoretically. It is found that larger fit clearances result in significant distortion of the flow characteristic curve, with a flow regulation rate of only 90.87% observed when the fit clearance is 0.25 mm. Furthermore, the lateral outlet causes a reduction of 77.27% and 69.15% in radial forces for eccentricity or inclination angles changed from 0° to 180°, respectively. Sticking is strongly correlated with radial forces, the axial force is contingent upon the spool end face area. These findings provide crucial theoretical guidance for the design of control valves.

Research on intelligent control theory and strategy of gas drainage pipe network based on graph theory

To address the issues related to the working conditions of the mine gas drainage system and achieve adaptive adjustment of negative pressure during gas drainage, this study proposes a gas drainage pipe network structure model based on graph theory principles. The model is built upon the air-gas mixed flow model of the pipe network. The boundary conditions of the pipe network are determined, and both the pipe network flow model and resistance model are constructed. An assignment iterative adjustment method is used to establish the pipe network solution model, enabling the solution of the gas drainage pipe network. The mathematical model for regulating and controlling the gas drainage pipe network is formulated, considering the objective function, decision variables, and constraint conditions based on the drainage parameters. The control model, along with the flow calculation model of the gas drainage pipe network system, is employed to calculate the optimal gas control scheme. This scheme enables remote intelligent control of the control valve opening on the ground, significantly improving the safety and efficiency of the gas drainage system. The engineering application of Liuzhuang Coal Mine demonstrates the successful realization of the rational distribution of negative pressure and intelligent dynamic control of the drainage pipe network. As a result, the total gas concentration in the drainage pipe network has increased by 12%, yielding favorable outcomes. The findings of this study have significant theoretical and practical implications for the design, development, and improvement of intelligent control systems for mine drainage pipe networks.

Development and analysis of the loading characteristic of accumulate fuel injection system Common Rail of the engine 50 RT-flex

The object of research are hydrodynamical processes in fuel delivery system of marine diesel engine of type RT-flex with accumulate fuel injection system of type Common Rail. The problem, being solved, is maintenance of an effective operation of the specified diesel engines due to perfection work of their fuel equipment. The results of simulation modeling of the injection process by accumulator fuel delivery system Common Rail of the 50RT-flex engine are presented. On the basis of the functional diagram of system, a calculation model has been compiled that provides a description of the operation of the systems main blocks. The load characteristic of the fuel equipment is built in the traditional version – the dependence of the fuel delivery parameters from the engine load at a constant speed. For the system under consideration, the control element is the valve assembly connecting the injection control unit (ICU) with injectors. The parameters of the load characteristic in this study are modes with a constant engine speed n=124 rpm and a change in the opening angle of the control valve in the range – jv=6.6–14.4 °CA. The parameters of the devices that largely determine the characteristics of the fuel delivery and the quality of the working processes of a diesel engine are considered in more details. Such an element of the system is ICU, the working body of which is the dosing piston. The main parameters of its operation when delivering fuel are the magnitude and speed of the stroke. For the load characteristics in the accepted range of the valve control valve opening angle jv from 6.6 to 14.4 °CA (2.18 times), the piston stroke was hp=4.29–8.61 mm (2.0 more). In this case, the dependence of hp on jv is linear. Area of use of the data received during research, ship crews and the shore services providing operation of vessels are. A material is applied in process of high school and is already used in various educational forms. The given researches are useful to developers and builders of marine diesel engines of a considered class.

Sistem Kendali Hidrogen Pada HCl Burner Menggunakan Controller Yokogawa

The hydrogen control system is a hydrogen control system in the HCl manufacturing process. This control is needed to control the presence of hydrogen over capacity or low capacity in the HCl burner, resulting in product failure. Hydrogen is one of the first steps for making HCl, which needs to be considered for its parameters, consisting of a control valve, flow transmitter, and pressure transmitter. In this study, a controller can be operated to adjust the hydrogen control valve line opening on the HCl burner. Then to find out the set point value of hydrogen entering the HCl burner, 2 transmitters measure flow and pressure. Furthermore, the signal measured by the transmitter will provide feedback so that the flow and pressure values appear on the controller. To ensure that the parameter data has been observed by comparison between the data on the system and the actual data in the field. From the observational data of this control system, the need for hydrogen for the initial stage of HCl production can be carried out within 1 hour with the control valve opening parameter of 34%, so that by opening the control valve it is known that the flow transmitter indication is 34 kg/hour and the transmitter pressure is 9kPa, so from flow and pressure indications can be used for later stages of the HCl manufacturing process.

Parametric modeling of flow characteristics in reciprocating pump-pipe interaction system

The flow characteristics in reciprocating pump-pipe system are inevitably subject to the interaction effects between pump and pipeline. In this paper, a parametric interaction model of flow characteristics in reciprocating pump-pipe system is presented by considering the coupling effect and leakage characteristics. The analytical solutions of the proposed interaction equations are deduced with the aid of the harmonic balance method. A testing platform of a simplex plunger reciprocating pump-pipe system is employed for validating the proposed model. The experimental tests under different operating conditions are used to compare the pressure pulsations and discharge flow rates from analytical solutions. It is observed that the analytical solutions are in good agreement with the test data and numerical results, and the prediction error is within 13%, thus validating the presented interaction model and analytical solutions. The interaction effects as well as the flow characteristics in reciprocating pump-pipe system are analyzed and discussed using the proposed model. It is found that the opening of flow control valve has remarkable influence on the relationship between flow rate and operating speed of reciprocating pump. The pressure pulsation within a pipe is closely related to and significantly affected by the plunger-to-cylinder clearance and the plunger stroke.

Experimental and Numerical Research on Fluid Dynamic Interaction Effects of Reciprocating Pump–Pipeline System

AbstractThe performance of a reciprocating pump–pipeline system is often limited by the fluid dynamic interaction between pump, pipeline, and valves. In this paper, the fluid dynamic characteristics of a reciprocating pump–pipeline system are investigated via experiments and numerical analysis. A simple experimental platform consisting of a reciprocating pump, suction and discharge pipes, and flow control valve are offered and the experimental tests under multiworking conditions are carried out to explore the fluid dynamic interaction of the reciprocating pump–pipeline system. Combined with theoretical analysis and computational fluid dynamics (CFD) simulations, a dynamic model of the pump–pipeline system is presented with considering the fluid dynamic interaction effect of pump valves, plunger stroke, and flow control valve. All of the predicted results coincide well with the experimental data, and the inherent mechanism and the feature of the fluid dynamic interaction are revealed by experiments and numerical analysis. It is shown that the fluid dynamic characteristics of pipeline significantly influence the lag phenomenon and the motion behaviors of pump valves. The discharge flowrate rises nonlinearly with the increase of plunger stroke and the leakage rate is associated with the resistance of flow control valve. The pressure pulsation in discharge pipe is directly related to and markedly impacted by the control valve opening and the plunger stroke. However, the influence of the reservoir liquid-level on the system dynamic behavior is relatively slight. This work would give information for the optimum design and operation maintenance of reciprocating pump–pipeline system.

Supervision and Control System of the Operational Variables of a Cluster in a High-Pressure Gas Injection Plant

The objective of this research was to develop a technological architecture proposal that allows for the supervision and control of the operational parameters of gas injection (flow, temperature, and pressure) in a cluster of a high-pressure gas injection plant. The proposal provides a supervision and control system for the HPGIP I high-pressure gas injection plant that includes instrumentation equipment (transmitters and actuators), a remote terminal unit (RTU) as a control device, and the creation of a control logic as the basis for the development of the SCADA GALBA®, through which the operational variables involved in the process of the gas injection plant can be visualized and controlled, allowing the automatic regulation of the flow of gas that enters the deposits. Automatization of the process allows for the elimination of the average error differential that increases from 2 to 5% when the control valve is opened manually. Currently, the MUC-67 and MUC-68 wells that make up cluster 5 require a control valve opening of 20% and 5%, respectively, and this percentage is directly affected by the average valve opening error when performed manually. In addition, there is a savings of around 40 min in the response time by the operators for the adjustment of the opening or closing parameters of the control valve manually. The proposal allows for the different control actions on the variables or parameters of gas injection present in the clump to be carried out from a control room.

Nonlinear dynamic verification of the boron injection lances for the Atucha-I Nuclear Power Plant

This work deals with the nonlinear transient dynamic verification of the boron injection lances for the Atucha-1 Pressurized Heavy Water Reactor backup shutdown system. The lances inside the moderator tank constitute the end part of the fast boron injection piping. The current dynamic verification of the lances is performed in the context of modifications in the piping and valve configuration for Atucha-I Long Term Operation (LTO). It is intended to ensure the structural integrity of the lances in the event of Loss of Coolant Accidents (LOCA) and spurious opening of level control valves (Spurious) scenarios. All boundary conditions have been provided by Nucleoeléctrica Argentina S.A. (NA-SA), and a 3-D numerical model of the lances was built and analyzed with the open-source suite Salome-Meca v2019 using the Code_Aster finite element solver. Results indicate that the displacement of the lances does not produce collisions with other reactor internals and that stresses on the lances and their fastening bolts are low enough to ensure the correct function of the system during LTO period.

Valve control of a hydraulically interconnected suspension system to improve vehicle handling qualities

This paper deals with the control of a hydraulically interconnected suspension system to improve the handling performance of the vehicle. A seven-degrees-of-freedom MATLAB/Simulink vehicle model and an Adams/Car model are used for simulation purposes. A Simscape model for analysing the hydraulic subsystem is also employed. It was observed that the yaw rate and roll responses of the vehicle are influenced to a large extent by the flow control valve opening values. The handling performance of the vehicle was investigated by the control of the orifice valves and their adjustment according to the lateral acceleration inputs. Considerable improvements were obtained in the handling qualities without sacrificing the ride responses, compared to the responses of a passive interconnected suspension.

드럼보일러 증기발생기 수위 안정을 위한 급수펌프 유량제어특성 개선

In Korea, since the beginning of the 1990s, there has been a surge in the construction of high-efficiency coal-fired once-through boilers for 500 MW standard thermal power plants rather than drum (D/M) type steam generators. Furthermore, Old D/M type boilers have been retired without life extensions, and the capacity factor of remaining coal-fired power plants has been lowered owing to a government emission regulation policy on coal-fired power plants to reduce particulate matter since 2019. Recently, several issues with control systems of D/M type steam generators have been reported, including weekly start-up and shut-down and large-rapid load swings rather than constant operating patterns. The D/M level control system is one of the most important control systems in power plants, as it is directly influenced by the performance of the feedwater (FW) flow control system in terms of pump speed, flow control valve opening, and load runback controls, all of which affect FW flow and D/M level status. This study demonstrates how to reduce the parasitic power consumption during normal operating and regulate the steam generator level during runback operation by incorporating differential pressure control logic for flow compensation.

Development and Test of a Novel Electronic Radiator Thermostat with a Return Temperature Limiting Function

Automated hydronic balancing in space heating systems is crucial for the fourth-generation district heating transition. The current manual balancing requires labor- and time-consuming activities. This article presents the field results of an innovative electronic radiator thermostat tested on two Danish multi-family buildings. The prototypes had an additional return temperature sensor on each radiator and an algorithm was used to accurately control valve opening to ensure automated hydronic balancing. The results highlighted that the new thermostat performed as expected and helped secure the cooling of district heating temperatures —defined as the difference between supply and return temperature—4–12 °C higher during the test compared to results obtained in 2020, when the prototypes were replaced with state-of-the-art thermostats in the first building. The measurements from the other building illustrated how only two uncontrolled radiators out of 175 could contaminate the overall return temperature. The remote connection of the thermostats helped pinpoint the faults in the heating system, although the end-users were not experiencing any discomfort, and secure, after fixing the problems, a return temperature of 35 °C. Future designs may consider integrating a safety functionality to close the valve or limit the flow in case of damage or malfunction to avoid a few radiators compromising the low-temperature operation of an entire building before the cause of the problem has been identified.

Analysis of Flow Torques During Opening and Closing of High-Frequency Rotary Directional Control Valve

Analysis of Flow Torques During Opening and Closing of High-Frequency Rotary Directional Control Valve

Experimental Study on Performance Assessment of Hydraulic Power Take-off System in Centipede Wave Energy Converter Considering Caspian Sea Wave Characteristics

Considering the characteristics of the Caspian Sea waves, using a centipede wave energy converter might lead to satisfactory performance. The present paper introduced a pilot wave energy converter (WEC) called IRWEC2. Moreover, the performance of the hydraulic power take-off (PTO) system developed for the WEC was assessed experimentally in the wave tank of Babol Noshirvani University of Technology (BNUT). The Simcenter Amesim software was used so as to design the hydraulic PTO system and to initially evaluate the system performance. For two separate buoys were used, different series and parallel configurations were employed for the separate hydraulic cylinders connected to each buoy to achieve the optimum performance of the PTO system. The characteristics of input wave, resistant load, and flow control valve opening were defined as the most important parameters affecting the converter performance. Accordingly, the maximum value of generator output was obtained based on the certain values of these parameters. To validate the processes defined, the simulation results obtained through the Simcenter Amesim software were compared to the experimental ones and a good agreement was found. According to the results, the maximum power of the PTO system was 46 watts (for laboratory scale), which is related to the parallel configuration. In this case, the efficiency of the PTO system was 23%. Moreover, the output of the generator increased by about 12% compared to the case where only one buoy was used.

Lab performance testing of a small Banki-Michell hydraulic turbine for remote applications

For decades, hydropower has been the most important renewable energy source in the world. The use of Banki-Michell turbine (B-M) in small hydropower constitutes an attractive solution for rural electrification in developing countries and off-grid applications. This robust turbine is easy to design and to construct and not expensive. A test bench (JLA 29) for remote applications was installed at the Aero-Thermo-Mechanics Department of the Brussels Polytechnic School of ULB to test this type of turbine. This paper aimed to present the efficiency results of the installed Banki-Michell turbine test bench for remote applications and these results helped to design a typical turbine adapted for remote sites such as the Ryamukona site located in Burundi. Two series of B-M turbine tests were carried out, by varying the flow rate using the turbine control valve opening placed inside the distributor and also by controlling the turbine speed using a Sinamics S 120 drive. The efficiency of the turbine varies between 40 and 60% for a flow range varying between 15 and 20% of the nominal flow. According to the tests made with a discharge above 20%, the efficiency of the turbine can reach easily 75 %. Based on this turbine efficiency, a typical B-M turbine of an electric power of 79.5 kWe turbine was designed for Ryamukona site which is a remote site located in Burundi.

Fuel Rail Pressure Control Characteristics of a GDI High-Pressure Fuel Pump Using a Newly Developed Experimental System Controlled with a Microcontroller

An experimental system was developed to evaluate the fuel injection parts of a gasoline direct injection engine. An AC motor and an inverter were used to rotate the camshaft in the engine cylinder head. A single plunger high-pressure fuel pump (HPFP) driven by a square cam at the end of the camshaft was used in the gasoline direct injection engine. The rotation position of the square cam was measured by a rotary encoder. The developed system allows control of the camshaft rotation speed, the HPFP pressure control valve (PCV) opening and closing timing, and the fuel injection duration, which are three important factors affecting the fuel rail pressure (FRP). It is confirmed that the fuel rail pressure can be made to vary wit different combinations of these three factors. By using the experimental system developed in this study, the fuel rail pressure can be effectively controlled in the range of 3 MPa to 20 MPa. The most influential factor for control of the fuel rail pressure was the HPFP PCV opening and closing timings. With the proposed using the experimental system, the rail pressure, fuel rail pressure wave characteristics, and the injector drive characteristics can all be assessed under various fuel injection conditions.

Computer simulation and full-scale measurements of the load flow in a functioning heating network

The article aims to identify patterns in the distribution of heating energy to consumers with a varying availability of regulation equipment under real conditions of a central heating network, as well as to compare the results of computer simulation with full-scale measurements. For computer simulation, well-known mathematical methods for calculating the load flow in hydraulic circuits were used. Experimental studies of the operation modes of heat supply systems were carried out using the data of the control and monitoring systems of thermal power plants using the Siemens Simatic PCS7 software, a Portaflow 300 ultrasonic flow meter, stationary electromagnetic flow transducers, verified and certified manometers and thermometers. The graphs of the actual hydrodynamic modes of the heating network under study were obtained at outdoor air temperatures from +8 to -37°C, as well as under abnormal conditions (temperature drop in the supply pipeline and pressure drop at the heating network input). It was proposed to use jointly the simulation by means of the JA_Net software and full-scale measurements of the thermohydraulic operating modes of a centralised heat supply system, whose consumers have a various degree of regulation equipment. It was shown that the proposed complex method of qualitative and quantitative assessment of the efficiency of district heating networks makes it possible to identify the features of control of their hydraulic modes when connecting new consumers with a varying degree of automation. According to the obtained characteristics of changes in the flow rate of the coolant in the consumers’ internal systems depending on the pressure drop at the tie-in point, the lack of response to emergency situations on part of the consumers whose heat supply systems are equipped with the means of qualitative and quantitative regulation of the heat load, is associated with the process of automatic adjustment of the degree of opening of flow controllers and control valves at individual points. In future work, we will develop guidelines for levelling the imbalance of the heating network under the conditions of uneven provision of facilities with automation equipment when implementing projects for the complex modernisation of heat consumers or connecting new facilities to existing heat supply networks.