intelligent valve control and monitoring - val controls valve control and monitoring ddp-pl-001-07 -...

Intelligent valve control and monitoring

DDP-PL-001-07 - Intelligent Diagnostic Positioner

IDP - Intelligent Diagnostic Positioner

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Val Controls® A/S Intelligent valve control based on the latest know-how concerning digital technology for advanced valve control, monitoring and testing suited for pneumatic and hydraulic actuators. Our key task is to assist valve and actuator manufactures in finding the optimal solution for control, monitoring or testing of their products. We discover the best solutions for hazardous areas and harsh environments combined with cost reduction potentials. Index Intelligent control and diagnostic positioner ready to suit the most extreme environments .......... 2

Standard Emergency Shutdown System vs. Val Controls Intelligent Diagnostic Positioner ......... 3

Models ............................................................................................................................................ 4

The Val Controls Intelligent Diagnostic Positioner ......................................................................... 5

Configurations ................................................................................................................................ 6

SIL .................................................................................................................................................. 7

System components ...................................................................................................................... 8

HART and Wireless HART ............................................................................................................. 9

Modbus ........................................................................................................................................ 10

Foundation Fieldbus .................................................................................................................... 11

Bluetooth PDA ............................................................................................................................. 12

Diagnostic .................................................................................................................................... 13

Partial stroke signature ................................................................................................................ 14

Full stroke signature ..................................................................................................................... 15

Val Controls Diagnostic Centre .................................................................................................... 16

Hardware features ....................................................................................................................... 18

Software features ......................................................................................................................... 18

Model selector .............................................................................................................................. 20


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Intelligent control and diagnostic positioner ready to suit the most extreme environments This Intelligent Diagnostic Positioner (IDP) from Val Controls offers the best control, monitoring and diagnostic in a very compact enclosure of all type of valve systems. Since no programming is needed for our customers, this product is “plug and play” and with the graphical display and the 4 buttons it is very user-friendly. The flexible software included in the IDP, makes it very easy for our customers, to configure this unit exactly for their specific valve system. This product is very unique because of following advantages:

- The units are already programmed - Very compact design - Cost saving for our customers - No extra cost for software, display etc. - Easy to install on existing valve systems

The positioner fits following actuators on the market:

- Hydraulic and pneumatic - Rotary and linear - Double acting and spring return

It offers further advantages:

- Control and diagnostic for hydraulic and pneumatic systems - Automatic intelligent calibration - Valve signatures with Val Controls Diagnostics Centre - Monitoring of auxiliary inputs and Dual solenoid configuration - Flexible and configurable with user- friendly menu - Local control panel - Multiple communication protocols - Ultra low power design - Installation on SIL systems without affecting the SIL level - Compact flameproof (Ex d) version in SS316 - All software for control and diagnostics included


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Standard Emergency Shutdown System vs. Val Controls Intelligent Diagnostic Positioner A standard ESD system is usually only tested during shutdown or when an emergency occurs. The problem is that the system cannot be tested when the factory is running. Since it can disturb the process and can give problems reaching the maximum production capacity. A standard ESD system can be designed as shown in the picture below. The controller sends a signal to the IO module that will de-energize the solenoid valve and the valve will close.

The IDP from Val Controls can be used on already installed systems with few modifications. It is easy to add the ability for extra testing, security and diagnostic. The picture below shows how the IDP can be added to an existing system or used on a new installation.


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Models The Val Controls Intelligent Diagnostic Positioner is available in two different hardware versions. We can offer these units in a flameproof version or in a version for DIN rail mounting. Both versions have the same flexible software.

IDP24-AF: The Val Controls Intelligent Diagnostic Positioner – Flameproof This model is designed in a SS316 flameproof enclosure approved for hazardous areas. With this compact design it is cost saving, it can be fitted on existing or on new systems. If needed we can offer this version with a customized local control panel.

- Dimensions: LxWxH 155 x 140 x130mm - Weight: 5kg - Gland entries: 6 x M20x1.5 - Ingress protection – IP68/66 - Flameproof version, ex d - SS316 enclosure - ATEX and IECEx approved - Compliance to EN 60079-0 and EN 60079-1

IDP24-A: The Val Controls Intelligent Diagnostic Positioner – Advanced The DIN rail housing is intended for already installed systems or customers who have their own housing and installation.

- Dimensions: LxWxH 157x86x57mm - 35mm DIN rail mounting according to EN50022 - Easy mounting of wires


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The Val Controls Intelligent Diagnostic Positioner This advanced IDP offers a large range of connection possibilities. By connecting a battery or separate power supply, the IDP can record a full stroke profile in case of an ESD for later analyzing. Features: - Valve testing and operation - Automatic intelligent calibration - Intelligent diagnostic - User-friendly menu - 4-20mA position transmitter - 4-20mA pressure transmitter - Val Controls Diagnostic Centre for configuration of IDP and analysis of valve

signature on PC - Store configuration and analysis data on a memory card (micro SD) - Local control panel with button to initiate a test - Multiple communication protocols - Multiple solenoid valves, i.e. one for ESD and one for diagnostic - Automatic detection of ESD signal - Battery backup or separate 24VDC to provide full stroke signature in case of ESD - Temperature sensor - Any 4-20mA sensor - Pump unit controller


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Configurations The IPD can be configured to use the ESD solenoid valve for the partial stroke testing. It can also be configured for a separate solenoid valve. The configuration with only one solenoid valve makes the IDP easy to install on existing systems. It does not require extra wiring to the control room. By adding an external power supply the IDP can record the full stroke signature during an ESD. This signature can then later be retrieved. The electrical circuit in the IDP which is connected to the ESD will not affect the SIL level The IDP can also be connected to a separate solenoid valve. This makes the IDP ideal for control and diagnostic for a large range of setups.


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SIL

The IVC is designed to be used in safety instrument systems for partial stroke testing of emergency shut-down valves with no negative impact on the safety function. The IVC does not adversely affect the execution of the safety function. There exist two types of SIL circuits, which both are optional.

IVC with SIL expansion card This solution makes it easy to retrofit the IVC as no extra wiring is required. The unit is powered through the ESD line, which means that the IVC will lose power during an ESD.

Emergency shutdown controller

Emergencyshutdown

solenoid operated valve

Intelligent Valve Controller

ESD SOV (+)

ESD SOV (-)

ESD 24 VDC (+)

ESD 24 VDC (-)

24 VDC (+)

24 VDC (-)

IVC with SIL expansion card + extra 24 VDC When using an external power supply then the IVC can measure performance data in case of an ESD. This is beneficial as data from ESDs can be used to verify the status of the valve system.

Emergency shutdown controller

Emergencyshutdown

solenoid operated valve

Power supply

Intelligent Valve Controller

ESD SOV (+)

ESD SOV (-)

ESD 24 VDC (+)

ESD 24 VDC (-)

24 VDC (+)

24 VDC (-)


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System components A typical ESD system with an IDP is shown here. This system has a local control panel and can communicate with VCDC in several ways.

Data can be transferred from the IDP in following ways: - HART - Wireless HART - Modbus - Foundation Fieldbus - Bluetooth PDA

Please see details of communication protocols on the next pages.


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HART and Wireless HART The IDP can be fitted with a HART protocol to communicate with the Val Controls Diagnostic Centre (VCDC) or other HART compatible programs. Both configuration and diagnostic can be performed from a remote location. The VCDC can connect to multiple IDPs through a HART multiplexer to provide an overview of all IDPs on a plant. The VCDC then runs on a separate computer to keep the diagnostic tool apart from the control safety system. It is also possible to connect directly to an IDP with a Laptop using a HART modem. All this makes it easy to install, maintain and operate one or more IDPs. Because the IDP communicates through a HART protocol, it is also possible to use different communication methods. This could be following:

- 375 Field Communicator - Siemens PDM - Emerson AMS - HART OPC server - National Instruments - LabVIEW - Or other HART compatible program and devices

Laptop with

Val Controls Diagnostic Centre

HART


I/O module

Controller

Multiplexer

IDP IDP

HART modem

I/O module

ESD signal


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Modbus

Another communication protocol which is available in VCDC and that can be added to the IDP is Modbus. Modbus is a simple and robust protocol which is the de facto standard for communication in the industry. The Modbus communication operates on an independent network.

- Siemens PDM - Emerson AMS - National Instruments - LabVIEW - Or other Modbus compatible program and devices


Controller

IDP IDP

I/O module

ESD signal

Modbus modem

Modbus RTU

Modbus RTU

Modbus terminstion

Modbus RTU


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Foundation Fieldbus The IDP can be configured to communicate through the FOUNDATION Fieldbus protocol.

- 375 Field Communicator - Siemens PDM - Emerson AMS - National Instruments - LabVIEW


Controller

IDP IDP

I/O module

ESD signal

Fieldbus PSU

Foundation fieldbus modem


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Bluetooth PDA On plants where IDP’s are to be retrofitted is the solution with a PDA communicating over Bluetooth often desired. This will not require new wiring as the IDP’s can be powered from the ESD line. The signatures are downloaded to the PDA using Bluetooth and then the signatures are transferred to a PC with VCDC where the analysis is performed and reports are generated. One PDA can be used to connect to multiple IDP’s. The PDA functions as a local control panel for the IDP's from which a partial stroke can be initiated and the valve can be opened and closed. The PDA is intrinsically safe for use in hazardous areas.


Controller

IDP IDP

I/O module

ESD signal

Val Controls Diagnostic Centre PDA

ESD signal

Bluetooth

Field

Safe area


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Diagnostic Basic diagnostic can be performed directly on the IDP. For more detailed diagnostic, the valve signature must be transferred to a PC installed with Val Controls Diagnostic Centre. The IDP can make a graph of the following tests:

- Partial stroke signature - Full stroke signature - SOV test signature

All graphs can show valve position, actuator pressure, media temperature etc. This makes the IDP able to find parameters that can show the condition of the valve. Some of the parameters, which can be used to detect possible problems, are:

- Breakaway time - Travel time - Breakaway pressure

The valve signatures can be displayed as travel/pressure vs. time and travel vs. pressure. Some of the problems that the IDP can be used to identify includes:

- Slow reacting or stuck solenoid valves - Slow moving or stuck valve - Increased stem friction - Broken spring in actuator - Long reaction time

The ability to add an auxiliary sensor enables the operator to include more information in the diagnostic, e.g. temperature or other 4-20mA sensors. On the following pages, some recorded signatures for a pneumatic actuator are shown.


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Partial stroke signature An example of a partial stroke signature for a pneumatic system is shown below. This signature contains both position and pressure. The breakaway occurs after 1.6 seconds when the position goes below 99%. Travel time for the partial stroke is 0.6 seconds, which is the time it takes the valve to move from 99% to 80%. Changes in these measured times indicates that there might be a problem with the valve or actuator. The pressure graph is another aid to diagnostic the system. Breakaway pressure shows if extra force is necessary to move the valve.

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1

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3

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20

40

60

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100

0 1 2 3 4 5 6 7 8

Pre

ssu

re [b

ar]

Po

siti

on

[%

]

Time [sec]

Position PressureBreakaway pressure

Breakaway time Travel time – Partial stroke


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Full stroke signature A full stroke signature of the same system as above is shown here. The breakaway is again measured to 1.6 seconds and the signatures are similar until the position reaches 80%. Travel time for the full stroke takes 3.0 seconds.

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1

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0

20

40

60

80

100

0 1 2 3 4 5 6

Pre

ssu

re [b

ar]

Po

siti

on

[%

]

Time [sec]

Position PressureBreakaway pressure

Breakaway time Travel time – Full stroke


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Val Controls Diagnostic Centre Val Controls Diagnostic Centre is a simple and user-friendly interface for analysis of the valve signatures. Signatures can be received directly from the IDP’s through one of the communications protocols. It is also possible to get the signatures by inserting the SD card in the. Partial Stroke Test A partial stroke test will de-energize the solenoid valve until the valve position is at a specified point. Then the solenoid is energize to return the valve to the normal operation. The factory default settings for the setpoint is 80%. This parameter is also user customisable. Full Stroke Test A full stroke test closes the valve completely and records the signature. Solenoid Valve Test The IDP includes a solenoid valve test function to diagnose the solenoid valve. This test de-energizes the solenoid valve for a short period while measuring the pressure drop in the hydraulic or pneumatic system. The test can be performed without moving the valve.


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Test Result Each recorded signature can be examined graphically by the operator. The recorded signatures can be selected from a list based on the date and time it was recorded. Comparison Up to six signatures can be visually compared by selecting them from the lists. This enables the operator to see how the system has performed compared to earlier tests. If the graphs evolve in one direction over time, the report indicates wear in the system. Reports The IDP records several performance information during the tests. Together with the signatures these can be compiled to test reports. The report generation is based on word documents with bookmarks. This makes it easy customise the report, with the needed data as well as logo and customised header and footer.


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Hardware features The IDP range comes with the following in- and out-puts. Model IDP24

A AF Analogue input

4-20mA sensors ●/2

Position feedback

- Position sensor - 3-wire potentiometer ●

- Position loop - 4-20mA ●

Analogue output

Advanced 4-20mA transmitter loop ●

Digital inputs

Digital inputs internal powered ●/4

Digital outputs

Digital outputs (Max power consumption per output) ●/6 (48W @24VDC)

Digital outputs – Emergency Shutdown Controller (SIL1-4)

Digital outputs (Max power consumption per output) ●/2 NO/NC (48W @24VDC)

Monitoring of power consumption ●

ESD detection ●

SIL1-4 according to IEC 61508 (TÜV certified) ●

Power supply Power supply to unit (Power consumption) 24VDC (2W @ 24VDC)

One power supply (ESD solenoid and unit) ●

Separated power supply (ESD solenoid and unit) ○

microSD card for log files and Internal watch with battery backup ●

User interface – Graphical display, 4xbuttons, 2LEDs ●

Communication

HART v.7 ○ Modbus RTU – RS-485 ○ Foundation Fieldbus H1 ○

Wireless communication Bluetooth V2.0 ○ Wireless HART ○

Design

Temperature range -40 to 85˚C -30 to 80˚C

IP protection IP20 IP66/68

Relative humidity < 95% (No condensation)

DIN-rail mounting EN 50022 ●

ATEX and IECEx - Ex II 2 GD - Ex-d IIC T4/T5/T6 Gb, Ex tb IIIC T135°C/T100°C/T85°C ●

Standard = ● Extra option = ○

Software features The IDP range comes with the following software functions.


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Model IDP24

AF F Functions

Automatic intelligent calibration ●

Manual calibration ●

Pneumatic and hydraulic systems ●

Valve action – Direct/reverse ●

Spring Return or Double Acting actuator ●

Manual control of valves and actuator ●

Error handling ●

Alarm and errors

Test alarm and errors configurable ●

System alarms and errors ●

Event log All events ●

Local control panel

Remote/local selector ●

Manuel open/close – Operational/fail position ●

Initiate test – PST, FST and SOT ●

Test in progress indicator ●

Open/Close indicator ●

Pass/fail test indicator ●

OK/error indicator ●

Partial stroke test

Configurable alarm and errors ●

PST scheduler – Stand alone ●

Valve signature of test ●

Full stroke test Configurable alarm and errors ●


Full stroke test starts automatically during ESD ●

Solenoid test

Configurable alarm and errors ●

Position ●

Pressure ●


Valve signatures All signatures stored locally ●

User programming Installation, control, monitoring and diagnostic using VCDC ●

User diagnostic FDT/DTM ●

VCDC ●



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Model selector The selector can be used for selecting the correct part number needed. Product name Type Communication 1 Communication 2 Expansion card 1 Expansion card 2 Expansion card 3

IDP24 - A - B1 B2 C1 C2 C3

A Type

A Advanced ○ ○ ● ●

AF Advanced Flameproof ○ ○ ● ●

AFL Advanced Flameproof - Local Control Panel

○ ○ ● ●

AFC Advanced Flameproof - Custom

○ ○ ● ●

B1 Communication

0 None

2 HART – Transmitter loop

3 Modbus RTU

4 Foundation Fieldbus

5 Wireless HART

B2 Communication 2

0 None

1 Bluetooth

C1 Expansion card 1

1 microSD and watch

C2 Expansion card 2

3 Emergency Shutdown Controller (SIL)

4 Emergency Shutdown Controller (SIL) + extra 24VDC power supply

C3 Expansion card 3

0 None


Subject to modifications. We are not responsible for any misprints.

For further information: www.valcontrols.com

intelligent valve control and monitoring - val controls valve control and monitoring ddp-pl-001-07 -...

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