Positioner type 3730-5

S t V l P iti ithSmart Valve Positioner with diagnostic functions

Presented By: Mr. Gourishankar Saharan

Product managementJens Bargon / V42

Product overviewP V lProcess Valves

Control Valves

Positioner and Accessories

Control Valves & FF Smart PositionersControl Valves & FF Smart Positioners

Control Valves are the “work horses”in every process plant

They are subject to wear and tearand therefore an important targetfor asset management and predictivefor asset management and predictivemaintenance procedures

Smart positioners with integrated diagnosticfunctions and FOUNDATIONTM Fieldbus technology d li ti l l tideliver optimal solution

Control Valves & FF Smart PositionersControl Valves & FF Smart Positioners

Typical valve failuresTypical valve failures

Eroded seat and plug → internal leakage

Erosion of valve body → finally external leakage

Leaking stuffing box → external leakage

Increased / decreased friction → higher / lower hysteresisIncreased / decreased friction → higher / lower hysteresis

Closing (Zero) point shifting → deposits on sealing edge

Change in opening / closing breakaway torque (e.g. ball valves)

Poor control performance → External leakages in the pneumatic supply

What is diagnosis?

Usually the term diagnostic“ is used in the medicine and means

What is diagnosis?

Usually the term „diagnostic is used in the medicine and means interpretation of symptoms with the target to get information about the actual status or reasons of a malfunction.

1 step: condition monitoring → measuring different process parametersDeliver symptoms of expected or existing malfunctions

2 step: diagnosis → interpretation of the process parameters By experienced service personalBetter: via software, based on experienced algorithms

3 step: maintenance requirements / measures → constructive stepsService-> Keep the working conditionR diti R t th ki ditiRecondition-> Restore the working condition

Where do the diagnostic messages appear?Where do the diagnostic messages appear?

Type 3730-5

Condensed state acc. to NAMUR recommendation NE 107

Classified status messages (forms & colors):goodmaintenance required / demandedfailure Internal device failurefailurefunction checkout of specification

GOOD_MAINT_REQ

Perhaps not enough airWorking at full capacity

N /di ti ti

Classification by End User

Highest rated message determines

Perhaps bias reduced TESTShifting working range closeNo message/diagnostic active

Highest rated message determines the condensed state

Condensed state acc. to NAMUR recommendation NE 107

Condensed state acc. to NAMUR recommendation NE 107

So far the DI function block of the positioner type 3730-5 is used to read in the condensed state into the host

Condensed state configuration

Examples: M/s. Bayer, China.Plant is in Caojing and has nearly 11.000 FF devices with around 3000 of positioner type 3730-5 running well in the plant also using the positioner diagnosis.yp g p g p g

Condensed state acc. to NAMUR recommendation NE 107

In future devices and systems are working according to Specification FF 912 “Field Diagnostic Profile” (required for devices tested with ITK6.0)

Source: FF-912 chapter 1.3

Monitoring functions during the running processMonitoring functions during the running process

General requirementsDiagnostics should be realized without any additional sensor systems

The valve is in controlled operation and the process may not be to interrupted!

Histograms allow to evaluate the valve travel [x], the set point deviation [e] and the valve cycle counter as an automatic function without any setup in the backgroundThe valve signature function allows …

to detect possible changes in friction

to detect possible changes in the supply pressure or maybe leakages in the pneumatic supply to detect poss b e c a ges t e supp y p essu e o aybe ea ages t e p eu at c supp y

The Final position trend monitoring function allows to detect a fluctuating or creepingzero point due to seat & plug wear or material between seat and plugDynamic Stress factor to monitor the stuffing boxDynamic Stress factor to monitor the stuffing box

Partial Stroke Test for on/off applications

Leakage sensor to detect inner leakages between seat & plug

Cycle counter detailsCycle counter details

The operator needs to differentiate the stuffing box! The corresponding values are based on experiences in the SAMSON development department!development department!

Self-adjustingAdjustable packingBellows sealBellows sealOther adjustable threshold

Dynamic stress factor [%]y a c st ess acto [%]The rate of wear of the selected stuffing box will be calculated

New: 0%Statistical defect 100%Above 90% a message will be generated

Long-term histogramo g e s og a

Cycle counter in practiceCycle counter in practice

Parex ProcessThe pump around valve sees every two minutes new process conditions, when the Rotary Valve has been switched and two new column beds are connected to each other.The process requires a fast and precise response of the control valve controlling the flow to the adsorption chambers, leading to a high number of cycles.

Source: UOP LLC 25 East Algonquin Road, Des Plaines, IL 60017-5017

Cycle counter in practiceCycle counter in practice

Parex ProcessValve requirementsOptimized pneumatic Hook-up to achieve high accuracy for …g y

… small steps (0.5 %)as well as

… large steps (50 – 100%)

Consequence after some years…The stuffing box has reached the tolerable number of cycles (dynamic stressfactor > 90%) and needs replacement at the next service interval

R lt C t ti i t i d t t “P di ti M i t ”Result: Cost optimizatoion due to smart “Predictive Maintenance”

Step response 50%Step response 0,3%

Partial Stroke TestPartial Stroke Test

Especially for on/off applications (critical ball or butterfly valves, maybe safety related)Partial Stroke Test without disrupting plantPartial Stroke Test without disrupting plant operation (e.g.: 100% to 90% and backwards to theoperation point)Prevent the valve from becoming stuck Starting time scheduled or manuallyStep or ramp function (adjustable ramp to prevent overshoot)Configurable test abortion conditions

PFD

test intervall without PST

Configurable test abortion conditionsCondensed/test status acc. to NE 107Documentable & reliableGoal: maximize the time between full proof

SIL thresholdtest tintervall with PST

Goal: maximize the time between full proof tests -> Cost optimizationFull Stroke Test over the entire travel range is always required! 1

months126 18 24

PRTPFD DU ⋅= λ2

Partial Stroke Test examplesPartial Stroke Test examples

1 2

1 Ramp with low friction1. Ramp with low friction No noticeable problems

2. Ramp with increased breakaway torqueSlightly overshooting

3. Ramp with high breakaway torque Extreme overshooting could cause problems for the running process!Therefore cancellation conditions travel & drive signal y

3g y

FF specification work for end user benefitFF specification work for end user benefit

Fi ldb FOUNDATION h dd d d i t i tFieldbus FOUNDATION has added end user requirements into their specifications for interoperable use of diagnostic functions

FF-912 “Field Diagnostic Profile” according to NAMUR recommendation NE 107“Self-Monitoring and Diagnosis of Field Devices”

FF-906 “Positioner Transducer Block” parameters for diagnosis testFF-906 Positioner Transducer Block parameters for diagnosis test

CYCLE_CNTR, CYCLE_CNTR_LIM, …

VST_MODE → Partial Stroke or Full Stroke Test

PST BREAKOUT TIME PST RAMP RATEPST_BREAKOUT_TIME, PST_RAMP_RATE, …

Th k YThank You

for your attention!