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The number of fault samples for the new nuclear valve is commonly rare; thus, the machine learning algorithm is not suitable for the fault prediction of this kind of equipment. In order to overcome this difficulty, this paper proposes a novel method for the fault critical point prediction of the gate valve based on the characteristic analysis of the operation process variables. The operation process of gate valve switch often contains various fault characteristics and information, and this method first adopts the Shannon entropy to describe the power spectrum of vibration signal relevant to the operation process of gate valve switch, and then employs the mean value of the power spectrum entropy as an indirect process variable and further investigates the differences between the indirect process variable under the healthy state and the fault state with a different fault degree. In addition, the power signal of the gate valve is also employed as the direct process variable and the features of the direct process variable under the healthy state and the fault state with different fault degrees are also investigated. Based on the previous indirect process variable and direct process variable, the prediction approach for the critical point of the gate valve fault is established by analyzing the change in the indirect process variable and direct process variable before and after faults. Finally, the data of a nuclear gate valve experiment are employed to demonstrate the feasibility of the proposed method and the results show that the proposed method can effectively predict the fault critical point of the mentioned nuclear gate valve. If the diagnostic threshold is set properly, the critical point prediction of a nuclear gate valve fault can be realized as 100% or close to 100%. Furthermore, the proposed method can be directly applied to the nuclear gate valve in a nuclear power plant to improve the operation reliability of the valve. At the same time, the method can be applied to the fault diagnosis and prediction of valves in other fields, such as the chemical industry.

Fault Critical Point Prediction Method of Nuclear Gate Valve with Small Samples Based on Characteristic Analysis of Operation