FOUNDATION™ FieldbusFOUNDATION FieldbusControl Valve

“Device diagnostics”“Device diagnostics”

Katsuhiko FujiiAzbil India Pvt.,Ltd.Azbil India Pvt.,Ltd.

Automation 2010

© 1994 – 2009 Fieldbus Foundation

ContentsContents

I. PrologueII. Possibilities of CV failureIII. CV diagnoses (Three phases with field reports)IV C l iIV. ConclusionsV. Progress beyond conclusions

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I PrologueI. Prologue

Output signal

V l P itiValve Position

Hey, Mr. Ashok, something wrong with CV Tag # LIC013 Maintenance is required immediately!

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LIC013. Maintenance is required immediately!

I. PrologueI. Prologue

Mr.Ashok - An experienced maintenance engineerOur system operator tells me something wrong with this control valve but it is not so easy to find what is the nature of problemwhat is the nature of problem.If it is clear from the beginning, my work can be much faster and easier… Is it just a dream? j

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I. PrologueI. Prologue

No, it is not a dream!

We can help you using Fieldbus technology.p y g gyOK, Mr. Ashok, we are pleased to explain how to do it butbefore let’s think together why control valve is so important?

Because control valve may give:-- severe damages onto process.

Control Valves are the HEART of the plant

- bad influences on production and safety of entire plant

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Control Valves are the HEART of the plant

II. Possibilities of CV failureoss b t es o C a u e

Control valve failure might occur due to:-

Trim part leak CorrosionStick by processAi l kAir leakageActuator degradationGrand part degradationGrand part degradationOthers

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III. CV diagnostics (Three phases)III. CV diagnostics (Three phases)

Phase-1: Real time diagnoses (online)

Phase-2: Shutdown Maintenance (offline)( )

Phase-3: Maintenance plan based on historical dataPhase 3: Maintenance plan based on historical data

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III. CV diagnosticsPhase-1: Real time diagnoses

Detect “Zero Shift Alert”“Zero Shift Alert” (POS_ALERT_LO)A t l f db k iti i 3% ( hift) lth h S t P i t b l 0%

ゼロ点推移

4.000

Actual feedback position is +3% (shift) although Set Point goes below 0%

Graph visualization

1.000

2.000

3.000

%)

-2.000

-1.000

0.000

Zer

o dr

ift (

-4.000

-3.000

2006

/11/

15

2006

/11/

22

2006

/11/

2920

06/1

2/6

2006

/12/

13

2006

/12/

20

2006

/12/

2720

07/1

/320

07/1

/10

2007

/1/1

720

07/1

/24

2007

/1/3

120

07/2

/720

07/2

/14

2007

/2/2

120

07/2

/28

2007

/3/7

2007

/3/1

420

07/3

/21

2007

/3/2

820

07/4

/420

07/4

/11

2007

/4/1

820

07/4

/25

2007

/5/2

2007

/5/9

2007

/5/1

620

07/5

/23

2007

/5/3

020

07/6

/620

07/6

/13

2007

/6/2

020

07/6

/27

2007

/7/4

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III. CV diagnosticsPh 1 R l ti diPhase-1: Real time diagnoses

Detect “Zero Shift Alert”“Zero Shift Alert” (POS_ALERT_LO)As a result of inspection, accumulated solid around plug and trim was found.Then the al e as cleaned p and safel re installed to the process

ゼロ点推移

4.000

Mull function of PlugThen the valve was cleaned up and safely re-installed to the process.

1.000

2.000

3.000

Sheet damage%)

-2.000

-1.000

0.000

Zer

o dr

ift (

-4.000

-3.000

2006

/11/

15

2006

/11/

22

2006

/11/

2920

06/1

2/6

2006

/12/

13

2006

/12/

20

2006

/12/

2720

07/1

/320

07/1

/10

2007

/1/1

720

07/1

/24

2007

/1/3

120

07/2

/720

07/2

/14

2007

/2/2

120

07/2

/28

2007

/3/7

2007

/3/1

420

07/3

/21

2007

/3/2

820

07/4

/420

07/4

/11

2007

/4/1

820

07/4

/25

2007

/5/2

2007

/5/9

2007

/5/1

620

07/5

/23

2007

/5/3

020

07/6

/620

07/6

/13

2007

/6/2

020

07/6

/27

2007

/7/4

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III. CV diagnosticsgPhase-1: Real time diagnoses

Summary

• System operators realize some abnormal y psignals on control valves

• Serious issues should be solved immediately• Minor issues can be recorded to do overhauling

during the next shutdown maintenance

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III CV diagnostics

Standard diagnosis

III. CV diagnosticsPhase-2: Shutdown Maintenance

Standard diagnosisTo check:-1. Tightness of grand packing2 Position according to air supply

Stroke between 10% and 90% to record relation between position and air

2. Position according to air supply

P

between position and air supply as historical data

Automatically calculatesspring range and friction

osition (%spring range and friction %)

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18Supply (kPa)

System Vender: Yokogawa Electric

III. CV diagnosticsPh 2 Sh d M i

Advanced Diagnoses

Phase-2: Shutdown Maintenance

Advanced Diagnoses

Various simulations:-

1. Travel vs. Actuator pressure2. Travel & SP vs. Time3. Actuator signature4. Travel signature

1. Travel vs. Actuator Pressure

Seating , Spring Range ,

3. Actuator Signature

2. Travel & Set point vs. Time

Overshoot , Resolution

System Vender : Dresser Masoneilan4. Signature ( travel vs. set point)

Friction , Spring Range , Pressure

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Hystersis , Dead band , Linearity

III. CV DiagnosticsgPhase-2: Shutdown Maintenance

Summary

Compare data (valve signature, step response p ( g , p pand etc.) with those previously collected so that daily maintenance can be planned efficiently .

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III. CV Diagnostics

A possible damage of bellows seal would be detected byTotal_Stroke parameter. (TRAVEL_ACCUM)

Phase-3: Maintenance plan based on historical data

This TOTAL_STROKE is as same as 40,000 times full open and full close .

Actual bellows seal after used

System Vender: Azbil (Yamatake)

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Replacement period

System Vender: Azbil (Yamatake)

III. CV DiagnosticsPhase-3: Maintenance plan based on historical dataPhase-3: Maintenance plan based on historical data Example (Chemical Plant-1)

Operation failure was found in stick-slipdiagnostic function of control valve:-diagnostic function of control valve:

According to index of gland packing deterioration:-1. Detect abnormal sliding motion of plug guide2. Detect plug bend, scratch & other mechanical damages

Detect Stick Slip

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System Vender: Azbil (Yamatake)

III. CV DiagnosticsPhase-3: Maintenance plan based on historical dataPhase-3: Maintenance plan based on historical dataExample (Chemical plant-1)

Jun

Jul

S

Stick-slip

Stick-slip

Aug

Stick-slip oper

movem

ent ha

movem

ent ha

Stick-sli

Sep

ration has star

s been increa

as been increa

p is not operaOct

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rted.

sed.

ased.

ated.

III. CV DiagnosticsPhase 3: Maintenance plan based on Historical dataPhase-3: Maintenance plan based on Historical data Example (Chemical Plant-2)

Valve Travel Distribution support on Engineering & MaintenanceValve Travel Distribution support on Engineering & MaintenanceConfirm if the selected control valve size is appropriate or not by visualizing the stress index of inner valve on the condition of low travel operation

Images visualization

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System Vender: Azbil (Yamatake)

III. CV DiagnosticsPhase 3 Maintenance plan based on historical dataPhase-3: Maintenance plan based on historical data Example (Chemical Plant-2)

Valve Travel Distribution support Engineering & MaintenanceValve opening level is shifting from 20-30 % to 30-40% due to clogging of air filter or CV inner parts. End user can judge that it is the best timing for maintenance.

20-30% 30-40%Images visualization

30 40%

Boiler

Filter

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System Vender: Azbil (Yamatake)

III. CV DiagnosticsPhase 3: Maintenance plan based on historical data

A possible damage of bellows seal would be detected byT t l St k t (TRAVEL ACCUM)

Phase-3: Maintenance plan based on historical dataExample (Chemical Plant-3)

Total_Stroke parameter. (TRAVEL_ACCUM)

Sliding distance value could be applied as a reference value G h i li tiGraph visualization

High pressure Chlorine gas

Globe valve (Bellows seal type)

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Globe valve (Bellows seal type)System Vender: Azbil (Yamatake)

III. CV Diagnostics (Three phases)

Summary

Visualize various conditions of control valve through these analyses and historical dataPlan CV maintenance efficiently according to present conditions of control valve.

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IV. ConclusionsCo c us o s

• Control valve diagnoses through Fieldbus are valuable . Fieldbus suits for real time notice since the data transmittingFieldbus suits for real time notice since the data transmitting speed is much faster.

• Offline maintenance with various simulations is useful on dataOffline maintenance with various simulations is useful on data comparison with those collected in the past.

• Condition based maintenance, it is important to analyze , p yhistorical data collected through valve positioner. Fieldbus is highly recommended collecting various data on control valve.

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V. Progress beyond conclusions) D i di tia.) Device diagnostics

• Fieldbus Foundation has ever solved users’ requirements to define “Standard Diagnostic Profile” and “Standard Transducer Block”.

• Fieldbus Foundation wishes end users to try and evaluate fieldbus diagnoses more in order to improve functions on the basis of user-friendliness and interoperability.

Enhancement of device diagnostics for end users

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V. Progress beyond conclusionsg yb.) Fieldbus Foundation works with NAMUR (FF912)

Using the power of FOUNDATION Fieldbus, and considering NAMURrequirements, the new standard diagnostic profile aim to:

Standardize the integration of diagnostic information

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Standardize the integration of diagnostic informationGuarantee valuable information to the user

V. Progress beyond conclusions) NAMUR R d ti NE107c.) NAMUR Recommendation NE107

NE107: “Self-Monitoring and Diagnosis of Field Devices”

Diagnosis results must be reliable

The diagnosis results must always be viewed in the context of theThe diagnosis results must always be viewed in the context of the application.

Internal diagnosis categorized into 4 standard status signals

Configuration should be free, as reactions to a fault in the device may be very different depending on the user's requirements

The plant operator to see only these status signals

Detailed information can be read out by the device specialist

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y p

V. Progress beyond conclusionsd ) D i di ti l (NE107)d.) Device diagnostic alarms (NE107) scope

PlantDiagnostics

Device Diagnostics Step 4

Field PerformanceDiagnostics

gSupport Function•Device status•Diagnostics to host system

process and

equipment

actuators, elements

Step 3

Fisher

DeviceDiagnostics

Step 2Asset Management

,

valves, connections

l i

CommunicationsDiagnostics

S 1

Device Management

electronicsStep 1

Fisher

FF Device Status

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communications

Control System

Thank you for your attention!!

K t hik F jiiKatsuhiko FujiiAzbil India Pvt.,Ltd.

Automation 2010

© 1994 – 2009 Fieldbus Foundation