Life Cycle Benefits: Maintenace (Control Valve Diagnostic and Field Device Diagnostic Management)

Transcription

1 Life Cycle Benefits: Maintenace (Control Valve Diagnostic and Field Device Diagnostic Management) Yasushi Kudo Yamatake Corporation Aaron Chen Azbil Taiwan

2 Contents I. Prologue II. Possibilities of CV failure III. CV diagnoses (Three phases with field reports) IV. Conclusions V. Introduce other devices VI. Progress beyond conclusions 2

3 I. Prologue Output signal Valve Position Hey, Mr. Ching, something wrong with CV Tag # LIC013. Maintenance is required immediately! 3

4 I. Prologue Mr.Ching - An experienced maintenance engineer Our system operator tells me something wrong with this control valve but it is not so easy to find what 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? 4

5 I. Prologue No, it is not a dream! We can help you using Fieldbus technology. OK, Mr. Ching, we are pleased to explain how to do it but before let s think together why control valve is so important? Because control valve may give:- - severe damages onto process. - bad influences on production and safety of entire plant Control Valves are the HEART of the plant 5

6 II. Possibilities of CV failure Control valve failure might occur due to:- Trim part leak Stick by process Air leakage Actuator degradation Grand part degradation Others 6

7 III. CV diagnostics (Three phases) Phase-1: Real time diagnoses (online) Phase-2: Shutdown Maintenance (offline) Phase-3: Maintenance plan based on historical data 7

8 Zero drift (%) III. CV diagnostics Phase-1: Real time diagnoses Detect Zero Shift Alert (POS_ALERT_LO) Actual feedback position is +3% (shift) although Set Point goes below 0% /11/ /11/22 8 ゼロ点推移 Graph visualization 2006/11/ /12/6 2006/12/ /12/ /12/ /1/3 2007/1/ /1/ /1/ /1/ /2/7 2007/2/ /2/ /2/ /3/7 2007/3/ /3/ /3/ /4/4 2007/4/ /4/ /4/ /5/2 2007/5/9 2007/5/ /5/ /5/ /6/6 2007/6/ /6/ /6/ /7/4

9 Zero drift (%) III. CV diagnostics Phase-1: Real time diagnoses Detect Zero Shift Alert (POS_ALERT_LO) As a result of inspection, accumulated solid around plug and trim was found. Then the valve was cleaned up and safely re-installed to the process. Malfunction of Plug ゼロ点推移 /11/ /11/ /11/ /12/6 2006/12/ /12/ /12/ /1/3 2007/1/ /1/ /1/ /1/ /2/7 2007/2/ /2/ /2/ /3/7 2007/3/ /3/ /3/ /4/4 2007/4/ /4/ /4/ /5/2 2007/5/9 2007/5/ /5/ /5/ /6/6 2007/6/ /6/ /6/ /7/4 Sheet damage

10 III. CV diagnostics Phase-1: Real time diagnoses Summary System operators can realize some abnormal signals on control valves immediately using Foundation Fieldbus and CV s diagnostics. And, the signals not only notices but also it is understood what it is. Serious issues should be solved immediately Minor issues can be recorded to do overhauling during the next shutdown maintenance 10

11 III. CV diagnostics Phase-2: Shutdown Maintenance To check:- 1. Tightness of grand packing 2. Position according to air supply Stroke between 10% and 90% to record relation between position and air supply as historical data Automatically calculates spring range and friction Position (%) System Vender: Yokogawa Electric Supply (kpa) 18 11

12 III. CV diagnostics Phase-2: Shutdown Maintenance Various simulations:- 1. Travel vs. Actuator pressure 2. Travel & SP vs. Time 3. Actuator signature 4. Travel signature 1. Travel vs. Actuator Pressure Seating, Spring Range, 2. Travel & Set point vs. Time Overshoot, Resolution 3. Actuator Signature Friction, Spring Range, Pressure 4. Signature ( travel vs. set point) Hystersis, Dead band, Linearity System Vender : Dresser Masoneilan 12

13 III. CV Diagnostics Phase-2: Shutdown Maintenance Summary Compare data (valve signature, step response and etc.) with those previously collected. Contents of maintenance work can be decided efficiently. 13

14 III. CV Diagnostics Phase-3: Maintenance plan based on historical data A possible damage of bellows seal would be detected by Total_Stroke parameter. (TRAVEL_ACCUM) This TOTAL_STROKE is as same as 40,000 times full open and full close. 40,000times 35,000times Actual bellows seal after used Replacement period System Vender: Azbil (Yamatake) 14

15 III. CV Diagnostics Phase-3: Maintenance plan based on historical data Example (Chemical Plant-1) Operation failure was found in stick-slip diagnostic function of control valve:- According to index of gland packing deterioration:- 1. Detect abnormal sliding motion of plug guide 2. Detect plug bend, scratch & other mechanical damages Image Detect Stick Slip 15 System Vender: Azbil (Yamatake)

16 III. CV Diagnostics (Three phases) Summary Visualize various conditions of control valve through these analyses and historical data Plan CV maintenance efficiently according to present conditions of control valve. 16

17 IV. Conclusions Control valve diagnoses through Fieldbus are valuable. Fieldbus suits for real time notice since the data transmitting speed is much faster. Offline maintenance with various simulations is useful on data comparison with those collected in the past. Condition based maintenance, it is important to analyze historical data collected through valve positioner. Fieldbus is highly recommended collecting various data on control valve. 17

18 V. Other Devices(Transmitter Diagnosis) Impulse line Blocking Diagnosis method orifice Impulse line(l) Time Analyzing statistical values of the fluctuation signal from differential pressure(h,l). Compare each deviation of the fluctuation signals with threshold or value at normal condition. Fluctuation signal(l) Pressure TX Fluctuation signal(h) Impulse line(h) Normal signal Blocking signal Yokogawa Electric 18

19 V. Other Devices(Transmitter Diagnosis Example) A company: H side impulse line blocking 2 weeks Blue: DP change After cleaning, recover to normal Pink: DP fluctuation RED: Blocking degree 0.0 = normal 1.0 = (H) blocking -1.0 = (L) blocking Impulse line blocking grow in 3days Yokogawa Electric 19

20 V. Other Devices(Transmitter Diagnosis) Micro Motion Solution Test process Tones Response Field device display AMS display Start to damage Not Okay Emerson Japan 20

21 V. Other Devices (Rotating Machinery Diagnosis) FFT & Diagnosis contents Contents Misalignment Unbalance Bearing Gear Installation Cavitation Sensor Emerson Japan 21

22 V. Other Devices (ph sensor Diagnosis) conventional Information from sensor increase ph sensor signal ph sensor signal 1. mv -> ph 2. R -> temperature 1. ph 2. mv 3. Redox potential 4. Resistance of glass 5. Resistance of liquid 6. Temperature 7. Calibration data 8. Elapsed time (calibration) 9. Elapsed time (use) 10. Count of sterilization 11. Sensor degradation 12. Product number & serial number METTLER TOLEDO 22

23 V. Other Devices (Host System) Device diagnostic solution can be added to any host device management application. Maintenance Diagnosis Condition Maintenance Alarm PLUG-IN Event, Operation Calibration Yokogawa Electric 23

24 VI. Progress beyond conclusions a.) 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 24

25 VI. Progress beyond conclusions b.) Fieldbus Foundation works with NAMUR (FF912) Using the power of FOUNDATION Fieldbus, and considering NAMUR requirements, the new standard diagnostic profile aim to: Standardize the integration of diagnostic information Guarantee valuable information to the user 25

26 VI. Progress beyond conclusions c.) 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 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 26

27 VI. Progress beyond conclusions d.) Device diagnostic alarms (NE107) scope Device Diagnostics Support Function Device status Diagnostics to host system Device Diagnostics Step 3 Field Performance Diagnostics Step 4 Plant Diagnostics process and equipment Step 1 Communications Diagnostics Step 2 electronics actuators, elements valves, connections Fisher Device Management Asset Management FF Device Status communications Fisher Control System 27

28 Thank you for your attention!!