Great potential with intelligent valve controllers

Janne Laaksonen

Metso Automation

Finland

© Metso

Online monitoring and

testing of ESD valves

Neles® ValvGuard VG9000

Second-generation diagnostics

as vital maintenance tool

Neles® ND9000

ND9000 Intelligent valve controller

© Metso 4

Neles ND9000 in nutshell

The Neles ND9000 is a top class field proven intelligent valve

controller that operates on all control valve packages and in all

industry areas.

With benchmark control accuracy, diagnostics features enabling true

predictive maintenance and versatile features our customers can

achieve a well performing process and full transparency to valve

assembly.

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Optimum process performance with Neles ND9000

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• ND9000 has benchmark

control accuracy

• Control accuracy has direct

effects on process variability

• Process variability has then

again cost effects through

• Production quality

• Amount of production

losses

• Chemical consumption

• Raw material consumption

• Energy consumption

Process variability with

average control

accuracy

Process variability

with Neles ND9000’s

control accuracy

3,1 % 0,6 %

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Reliability The most important feature

6 12.6.2013

• Why is reliability so important?

- Cost of lost production

- Cost of maintenance

- Safety

• ND9000 reliability facts

- Robust and thoroughly tested design

- Extensive field experience

- Comprehensive diagnostics improve reliability

- Contactless position sensor

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Diagnostics Predictive maintenance strategy compared to corrective and preventive

• Enhanced field device

availability

- No unplanned shutdowns

- Reduced unexpected

downtime

• More effective maintenance

resource allocation

- Concentrating on the devices

that really need to be

maintained

• Efficient maintenance planning

- Work lists in advance

- Human resources, spare parts

and equipment

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UNCLASSIFIED

• Based on tests that are run during start-up and shut down

- any view of this test is an instant in time, it does not give predictive value and you can not plan the maintenance activities and need of spare parts in advance

• Valve is not under true process conditions and the analysis result does not reflect the real situation.

• Users do not have time to test, analyze and make decisions on every valve package during the shut-down

Plant is running StartUp Shut Down

Analysis

Signature Signature ? = OPEX = OPEX

First generation diagnostics

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UNCLASSIFIED

Plant is running StartUp Shut Down

Data analysis

• Valve performance is assessed during the run-time

• Valve controller measures and stores the diagnostic data

- best possible resolution and accuracy of information

- constant understanding of valve condition

• No extra work during start-up or shut down

Second generation diagnostics

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Data analysis

Time

10

• No extra work during start-up or shut down

• No extra costs for diagnostics features

• Know your valve condition in the past, present and in the future. Correct focus for the shut down maintenance

− Valve performance is assessed during the run-time

− Metso smart products measures and stores the diagnostic data by itself

− Best possible resolution and accuracy of information

Third generation diagnostics

Plant is running Start-up

Shut down Plant is running

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What does the diagnostics of ND9000 include?

Third generation diagnostics

- User friendly metrics for control performance, valve,

actuator, positioner and external factors

- Deviation and pressure ratings graphically

- Trouble shooting guide

Second generation diagnostics

- Lifecycle diagnostics

example: control valve stiction

- Counter diagnostics

example: actuator full strokes count

- Online diagnostics

example: pneumatics problem

- Event log of 8000 events

First generation diagnostics

- Offline tests

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Advanced diagnostics made easy Performance view of Metso Valve Manager™

• Advanced diagnostics helps to make correct decisions fast

• Metso Valve Manager™ with ND9000 makes valve diagnostics more user friendly than ever before

• Unique and easy segmentation of control valve condition

• Statuses according to Namur NE107

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Example of troubleshooting with the help of ND9000’s diagnostics

Actuator membrane has

failed, leakage increasing!

Condition monitoring screen Performance view with recommended actions

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Selected references

14 Date/Title/Author

Site Country Industry H/F/P DCS ND9000 Smart

products

Shell

Nanhai

China Refining FF Yokogawa 2500 VG

Sabic UK Petrochemical H Honeywell 200

Neste Oil Finland Refining

H metsoDNA FieldCare,

5000+

devices

Goliath Norway Upstream Gas,

offshore

H ABB 200 VG9300,

SG9300

Botnia Uruguay P&P H Honeywell 700

Mangalore

India Refining

&Petrochemical

H / F

Yokogawa

600

IOCL

Paradeep

India Refining

F Yokogawa

500

ValvGuard VG9000 Intelligent safety solenoid

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Neles ValvGuard VG9000 in nutshell

Neles ValvGuard VG9000 is a new generation intelligent safety

solenoid and partial stroke testing device for emergency shutdown

valves (ESD) and emergency venting valves (ESV).

With market leading pneumatics capacity and enhanced features,

VG9000 takes partial stroke testing to a completely new level and

mitigates the safety risks.

16 2013

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Metso’s intelligent safety solenoids

VG800 (HART)

First ever SIL 3 certified

PST device in the market

VG9000F

(FOUNDATION fieldbus)

VG9000H

(HART) 17 VG9000

Stainless Steel

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VG9000 is SIL3 certified by TÜV

Neles ValvGuard™ VG9000 is TÜV certified up to and including SIL 3 to comply with IEC61508 standard

Type A device

18

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VG9000 key features

• Most extensive ESD valve diagnostics

- Internal pneumatics testing

- Automatic safety electronics testing

- Emergency trip testing

- Partial stroke testing

• Collects valve diagnostics also during the trip

• Easy to use user interface

• Largest pneumatics capacity on the market

• One device for single and double acting

operation

• Available for FF and HART

• Internal integrated limit switches

• Full interoperability with all the main safety and

asset management systems

2012 19

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Safety View For easy first look of the diagnostics

2009 20

• Safety View in

ValveManagerTM

(DTM) is showing the

main diagnostics at

once

• Tells the condition of

the safety valve

• Indices are based on

the measurements and

the test data in VG

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VG9000 internal pneumatics test

• Tests VG9000 pneumatic operation

without moving the safety valve

• Safety action is available during

the testing

• Test is controlled by VG9000 and

is cancelled if the valve moves

• Automated or manual

• Can be run very often, because it

does not affect the process at all

21 2009

15 %

35 % 42 %

8 %

Safety loop failure sources by OREDA

SOLENOID VALVE FAILURES

OTHER FINAL ELEMENT FAILURES

SENSOR FAILURES

SAFETY SYSTEM FAILURES

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Partial stroke test (PST)

• Tests the whole safety valve assembly

• Manual or automatic with adjustable testing frequency

• Pressure and time based position measurement

• Breakaway pressure and load factor measurements

22

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Diagnostics trends for predictive maintenance

• Load factor and breakaway pressure trends

- Based on partial stroke testing

- Trends are test based

• Latest 10 individual tests and after that averaged data

23

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Assured success –ValvGuard technology proven worldwide

• Aramco, Saudi Arabia

• BP, UK (include HIPPS)

• Borealis, Finland / Sweden

• Conoco, UK

• ENI, Norway

• Ineos, UK / Sweden

• KNPC, Kuwait

• KOC, Kuwait

• Lotos, Poland

• Man Turbo, Germany

• Neste Oil, Finland

• Oman, LNG (incl. HIPPS)

• Petrobras, Brazil

• Preem, Sweden

• Qatar Gas, Qatar

• Qatar Petroleum, Qatar

• Rasgas, Qatar

• SABIC, Germany / Saudi-Arabia

• Shell Nanhai, China

• Shell, NL / Singapore / UK (incl. HIPPS)

• Sasol, South Africa

• Statoil, Norway (incl. HIPPS)

• Total, France / UK / Nigeria / Angola

• Woodside Energy, Australia

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Top class control accuracy of ND9000 enables better control loop performance

True predictive maintenance with the help of ND9000’s superior diagnostics features

Most extensive ESD valve testing capabilities with Neles ValvGuard VG9000

ValvGuard VG9000 has the highest pneumatic capacity on the market

Summary

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CONFIDENTIAL - DRAFT