rockwell ff dvc6000f-1 - fieldbus foundation · – dvc6000 – hart & fieldbus ... air mass...

FIELDVUE DVC6000f Delivering Digital InnovationFIELDVUE DVC6000f FIELDVUE DVC6000f Delivering Digital InnovationDelivering Digital Innovation

Sanjay K. Soni Sanjay K. Soni –– Fisher Sanmar Ltd.Fisher Sanmar Ltd.

Saurabh Pathak Saurabh Pathak –– Emerson Process Management (AP)Emerson Process Management (AP)

FF End User Event, 18FF End User Event, 18thth Nov 2010 Nov 2010

[File Name or Event]Emerson Confidential27-Jun-01, Slide 2

ContentsContentsContents

� Fisher FIELDVUE Range

� Introduction of DVC6000f

� Operating Principle

� Alerts & Advanced Diagnostics


FIELDVUE InstrumentationFIELDVUE InstrumentationFIELDVUE Instrumentation


FIELDVUE DVC6000f– Exploded ViewFIELDVUE DVC6000fFIELDVUE DVC6000f–– Exploded ViewExploded View

� Built on a proven platform

� Takes FIELDVUE Instruments to a new level

� Easy DVC


DVC6000f - Basic SpecsDVC6000f DVC6000f -- Basic SpecsBasic Specs

� Single or Double Acting

� Foundation Fieldbus Communication

� Common Hardware

– DVC6000 – HART & Fieldbus

– Valve mounted or Remote

� SST Construction Option

� Bus Powered - [polarity insensitive] - 19ma (30% less power)

� -40C to 85C (-52C with optional Fluorosilicone)

� Approvals & Certifications

– Exp. Proof, Div 2 (non-incendive), I.S., flameproof

– FM, CSA, ATEX, IECEx

– NEMA 4X, IEC IP66

– EMC Directive - EN61326-1


� Backup LAS capability

� Increased memory

– Stores Valve Specification Sheet

� Function Blocks Execute Faster– AO Block: 15 ms AI Block: 15 ms

– PID Block: 20 ms MAI Block: 35 ms

– ISEL Block: 20 ms DO Block: 15 ms

– OS Block: 20 ms DI Block: 15 ms

� Faster Control In The Field

– Potential for more and faster loops on segment

� Maximum Current to 19 mA

DVC6000f - Basic SpecsDVC6000f DVC6000f -- Basic SpecsBasic Specs

FOUNDATION™fieldbus

Fieldbus Device: Basic BlocksFieldbus Device: Basic BlocksFieldbus Device: Basic Blocks

BASIC COMPONENTS

FunctionBlock(s)

ResourceResourceBlockBlock

TransducerTransducer(Servo)(Servo)BlockBlock

Device characteristics:

_Name

_Manufacturer

_Serial number

_Enable Features

Device interface to user

_Calibration data

_Configuration information

Define Control System Behavior:

_AI, AO, DI, DO, PID, etc.

_Approx 30 Blocks Defined

_Blocks Configured by Host to

Implement a Control Strategy

Communication

Diagnostics

Electronic

Diagnostics

Control valve

Diagnostics


DVC6000f - Diagnostic SupportDVC6000f DVC6000f -- Diagnostic SupportDiagnostic Support

� Advanced Diagnostics -

– Pressure Sensors

– Valve Signature Test

– Step Response Test

– Dynamic Error Band Test

� PD One Button Sweep

– Embedded in instrument

– Runs - 24/7

– Become Instrument Alerts

– Integrated into PlantWeb Alarm Structure

� PD Friction / Dead band


DVC 6000f - Pressure FallbackDVC 6000f DVC 6000f -- Pressure FallbackPressure Fallback

� Three Modes

– Travel Control

– Pressure Control

– Travel Control with Fallback


Software Upgrades - on your schedule ONLINE Software Upgrades Software Upgrades -- on your schedule ONLINE on your schedule ONLINE

� Freedom to upgrade when you want

� Take advantage of firmware enhancements

� Upgrade during process operations


Pneumatic

Relay

I/P

Converter

Terminal

Box

Gauge

Gauge

Gauge

Printed Wiring Board (PWB)

Pressure

Sensors

Output A

Output B

Drive

Signal

I/P

Output

Pressure

Air Supply

Minor Loop

Feedback

Fieldbus Input Signal

Digital Signal

Travel Sensor

Provides Feedback

End Build

Basic Operation…Basic OperationBasic Operation……


Configurable Fisher DVC AlertsConfigurable Fisher DVC AlertsConfigurable Fisher DVC Alerts� Travel Deviation� Travel Hi

� Travel Lo

� Travel Hi Hi

� Travel Lo Lo

� Travel Accumulator

� Drive Signal

� Supply Pressure Alert� Cycle Count

� Valve Stuck high alert

� Ref. Voltage Failure

� Pressure Sensor Fail

� Drive Current Fail

� Temp Sensor Fail

� Travel Sensor Fail

� Output Block Timeout

� Bock Set to Default

� Auto Tvl Cal Failed

� Power Starvation Alert

� Calibration in Progress

� Variable Out of Range

� Diagnostic in Progress

� No Free Time

� Integrator Saturated Low

� Internal Sensor Out of Limits

� Flash Integrity Error

� Integrator Saturated High

� Configuration Changed

� Process Impaired

� Shutdown Alerts

� I/P Plugged alerts

� Relay Jammed

� Valve Stuck Low alert


Alerts Provide Visibility of ProblemsAlerts Provide Visibility of ProblemsAlerts Provide Visibility of Problems

Healthy DVC struggling to position the valve due to:

– loss of supply pressure

• Supply Pressure Alert

• Drive Signal Alert

• Travel Deviation Alert

• Online supply pressure trending

– air leak in actuator



• Online Air Mass Flow

– excessive valve friction



• Online Friction Trending


Alerts Provide Visibility of ProblemsAlerts Provide Visibility of ProblemsAlerts Provide Visibility of Problems

Non-Healthy DVC

– open circuit in the I/P coil

• Drive Current Readback Failure Alert

• Possibly also “Drive Signal” or “Travel Deviation”

– clogged I/P (due to dirty air) or pneumatic relay failure

• intermittent “Drive Signal” Alert

• Travel Deviation

• PD Inside – I/P alert

– travel sensor or linkage incorrect adjustment

• “Travel Sensor Error”

• “Travel Deviation” Alert

• “Travel Hi” or “Travel Lo” Alert


Status Monitor & AlertsStatus Monitor & AlertsStatus Monitor & Alerts


� Performance Diagnostics (PD) is an on-line/in-servicediagnostic tool.

� PD allows remote condition monitoring of a valve without disturbing the process.

• diagnostics and analysis.

– Relay Adjustment, I/P & Relay Integrity, Travel Deviation, Air Mass Flow, Supply Pressure.

• Friction/Deadband measurement and trending.

• Alerts (travel deviation, travel hi/low, supply pressure, internal failures, etc…).

� Automated analysis for predictive maintenance on control valves…information, not just data.

� Performance Diagnostics (PD) is an on-line/in-servicediagnostic tool.

� PD allows remote condition monitoring of a valve without disturbing the process.

• diagnostics and analysis.

– Relay Adjustment, I/P & Relay Integrity, Travel Deviation, Air Mass Flow, Supply Pressure.

• Friction/Deadband measurement and trending.

• Alerts (travel deviation, travel hi/low, supply pressure, internal failures, etc…).

� Automated analysis for predictive maintenance on control valves…information, not just data.

Sustaining Performance with Valve IntelligenceSustaining Performance with Valve IntelligenceSustaining Performance with Valve Intelligence

Y GR / /


Triggered ProfileTriggered ProfileTriggered Profile


Valve Friction& Dead band

Valve Friction& Dead band

Actuator PressureActuator Pressure Tracking valve

performance

Tracking valve

performance

On-Line Friction &

Deadband calculation (in-service), collect data on:

- Travel

- Travel Set-point

- Act. Press. A

- Act. Press. B

- A – B

- B – A

On-Line Friction &

Deadband calculation (in-service), collect data on:

- Travel

- Travel Set-point

- Act. Press. A

- Act. Press. B

- A – B

- B – A

Friction / Deadband AnalysisFriction / Deadband AnalysisFriction / Deadband Analysis


Trends for Detection of Valve DeteriorationTrends for Detection of Valve DeteriorationTrends for Detection of Valve Deterioration

Friction Estimate

Travel Range

Smoothed Fit

Select Frictionor Deadband

Select Frictionor Deadband

User defined

Hi/Low Thresholds

User defined

Hi/Low Thresholds


Types of tests:

– Dynamic Scan: (continuous bidirectional sweep)

• Valve Signature (Actuator Pressure vs Travel)

• Dynamic Error Band (Travel vs Input)

• Drive Signal (Drive Signal vs Input)

– Step Response

• Configurable up to 8 steps (End Point, Ramp Time, and Collection Time)

• Performance Step Test (25 predefined profile of ± 0.25%, 0.5%, 1%, 2%,

5%, and 10% steps with 10 second collection time/step)

NOTE: “Input” is really the digitally sequence of Travel Target values commanded to the DVC from the diagnostic test script. The other parameters are measured operational values.

Off-Line Valve DiagnosticsOffOff--Line Valve DiagnosticsLine Valve Diagnostics


Valve Signature BasicsValve Signature BasicsValve Signature Basics

Sliding stem

valve

Quarter turn valve


Components Tested With A Valve Signature TestComponents Tested With A Components Tested With A Valve Signature TestValve Signature Test

FF signalI/P DriveCurrent

I/PAO

FromControlRoom

pwbPressure

Relay

MechanicalMotionValve

Stem

Travel

SensorActuator


Valve Signature - Seating ProfileValve Signature Valve Signature -- Seating ProfileSeating Profile50 second scan – 250 ms interval 50 second scan – 75 ms interval


Valve Signature - Seating Profile Valve Signature Valve Signature -- Seating Profile Seating Profile


AMS ValveLink SoftwareSignature AnalyzerAMS ValveLink AMS ValveLink SoftwareSoftwareSignature AnalyzerSignature Analyzer

� User configurable travel and friction/torque percent boundaries, and a stick-slip test to determine if there is a problem with the performance of the valve and inform users with an overall PASS/ FAIL result.


AMS ValveLink SoftwareSignature Analyzer – Boundary EditorAMS ValveLink AMS ValveLink SoftwareSoftwareSignature Analyzer Signature Analyzer –– Boundary EditorBoundary Editor

� The Signature Analyzer Boundary Editor is used to modify the boundaries and settings for the Signature Analyzer.


AMS ValveLink SoftwareSignature Analyzer AMS ValveLink AMS ValveLink SoftwareSoftwareSignature Analyzer Signature Analyzer


AMS ValveLink SoftwareValve Signature Graph ViewsAMS ValveLink AMS ValveLink SoftwareSoftwareValve Signature Graph ViewsValve Signature Graph Views

� Pressure/Travel

� Pressure/Time

� Travel/Time

� Travel %/Time


Dynamic Error Band Test Graph Dynamic Error Band Test Graph Dynamic Error Band Test Graph


Components Tested With A Dynamic Error Band TestComponents Tested With A Components Tested With A Dynamic Error Band TestDynamic Error Band Test


I/PAO

FromControlRoom

pwbPressure

Relay


Stem

Travel

SensorActuator


Drive Signal Test GraphDrive Signal Test GraphDrive Signal Test Graph


Components Tested With A Drive Signal TestComponents Tested With A Components Tested With A Drive Signal TestDrive Signal Test


I/PAO

FromControlRoom

pwbPressure

Relay


Stem

Travel

SensorActuator


Step ResponseStep ResponseStep Response

“With FIELDVUE Instruments, we have reduced

process variability and can keep it in place”

- a major pulp and paper producer


Components Tested With A Step Response TestComponents Tested With A Components Tested With A Step Response TestStep Response Test


I/PAO

FromControlRoom

pwbPressure

Relay


Stem

Travel

SensorActuator


Use Off-line Advanced Diagnostics to DetectUse OffUse Off--line Advanced Diagnostics to line Advanced Diagnostics to DetectDetect

� Poor seat condition

� Internal galling

� Downstream restriction

� Crossover adjustment

� Feedback interference/loose linkages

� Actuator and tubing leaks

� Travel Sensor Failure

� Friction

� Bad pressure sensor

� Tuning

� I/P and relay problems

� Lever misalignment

� Supply pressure starvation


PW-101

FV-101

Diagnostics Methodology (Fieldbus)Diagnostics Methodology (Fieldbus)Diagnostics Methodology (Fieldbus)

Increasing Diagnostic Capability

PlantWeb Alerts

(on-line)

(alert notification)

Performance Diagnostics

(on-line)

(graphs, interpretation)

Dynamic Scan Diagnostics

(off-line)

(graphs, interpretation)


FIELDBUS FIELDVUE Value to you..FIELDBUS FIELDVUE Value to you..FIELDBUS FIELDVUE Value to you..

� Hardware Savings

Accessories such as limit switches and position transmitters can be eliminated because this information is available as function blocks.

� Increased Uptime

The self−diagnostic capability of the DVC6000f digital valve controller provides valve performance and health evaluation without shutting down the process or pulling the valve assembly from the line.

� Improved Maintenance Decisions

Digital communication provides easy access to the condition of the valve. Sound process and asset management decisions can be made by analysis of valve information through Fisher DVC’s and ValveLink software.

Thank you!!Thank you!!Thank you!!

rockwell ff dvc6000f-1 - fieldbus foundation · – dvc6000 – hart & fieldbus ... air mass...

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