FOUNDATION™ FieldbusFOUNDATION FieldbusControl Valve
“Device diagnostics”“Device diagnostics”
Katsuhiko FujiiAzbil India Pvt.,Ltd.Azbil India Pvt.,Ltd.
Automation 2010
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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