Fieldbus Foundation Fieldbus Foundation India Marketing Committee Technology Event ISA EXPO 2007, Pragati Maidan, New-Delhi Fieldbus Overview India
Fieldbus Overview India MFX: May 2007
What is Performance? the act of performing; of doing something successfully; using knowledge as distinguished from merely possessing it Therefore Overall Performance in relation to a plant with Valves, maybe could be defined as:- the act of using our knowledge (and experience) to operate and maintain the valves in a way that improves the success of the plant 3
Overall Valve Performance the act of using our knowledge (and experience) to operate and maintain m the valves in a way that improves the success of the plant. This is a reasonable and fair definition as our main interests are to:- Run the plant profitably and therefore also keep our costs as low as possible. Make a good product of predictable, consistent Quality and Quantity. Ensure Health and Safety avoiding accidents or failures that cause accidents. Reduce the risk of unplanned shut-downs and extra work. 4
Following this logic, in order to successfully Run the plant profitably and therefore keep our costs as low as possible. AND Make a good product of predictable and consistent quality and quantity. AND Ensure health and safety avoiding accidents or failures that cause accidents. AND Reduce the risk of unplanned shut-downs and extra work. Then knowledge, experience and investigation is needed. But where does this come from? What shape does this take? It feels like a huge task 5
But the solutions are available and are around us - Some are obvious and familiar and some are not so. Choosing the right Valves for the application. This is obvious and familiar and yet how often do we see the wrong Valves selected for an application! Following the recommended maintenance procedures and schedules. Again an obvious statement, but some plants are more dedicated to maintenance and safety than others. If you have any doubts here and think this is unlikely, just think of the news such as the problems and resultant court action at BP... 6
From Times Online August 15, 2006 BP sued over Prudhoe Bay By Michael Herman and Agencies Senior managers at BP are facing legal action in the US accusing them of breaching their duty to shareholders by allowing equipment at the Prudhoe Bay oil field in Alaska to deteriorate. A lawsuit filed in New York yesterday on behalf of a private investor claims that senior executives at the company, including the chief executive, Lord Browne of Madingley, failed to carry out essential repairs before the oil field, America s largest, had to be partially shut-down. The closure caused significant disruption to US oil supplies and caused BP shares to fall. "Despite their awareness of the dangerous effect of the corrosion in the pipeline, defendants repeatedly failed to fund the work necessary to correct the problem," the suit alleged. It did not specify an amount sought in damages. A spokesman for BP declined to comment, but the company has previously said it is expecting a repair bill of around $200 million ( 106 million) to fix the field. http://business.timesonline.co.uk/tol/business/law/corporate/article609577.ece 7
So if we want to ensure safe and successful operation, we could think about the following analogy. Running Valves on a plant can be likened to the careful training of an Olympic Athlete or a World-Class footballer. For the Athlete or Footballer, we need to ensure:- That there is a natural potential for the sport. There are no illnesses or physical damage. The correct training is followed. We use the best and most appropriate shoes, clothing, bats, balls or other necessary equipment. There is a good, healthy diet. Get a good amount of rest and sleep. A positive mental attitude. Emotional well-being. The development of Confidence. An excellent game-plan. 8
What you definitely would NOT do is:- Ignore illnesses and physical damage. Not bother to train. Use cheap and substandard shoes, clothing, bats, balls or other necessary equipment. Eat junk food. Think only about failing and just getting by. Feeling sad and low. Not bother to effectively plan. And of course this kind of approach is not good for improving Overall Valve and plant performance either! 9
The analogy is close to the situation of a Valve on a plant because:- For the Athlete or Footballer, we need to ensure:- For Overall Valve Performance, we need to ensure:- That there is a natural potential for the sport. > We select the right Valve and Positioner for the job. There are no illnesses or physical damage. The correct training is followed. We use the best and most appropriate shoes, clothing, bats, balls or other necessary equipment. There is a good, healthy diet. Get a good amount of rest and sleep. A positive mental attitude. Emotional well-being. The development of Confidence. An excellent game-plan. > > > > > > > > > The Valve and Positioner are in good condition. We operate them in the correct way. We utilise the right tools and prognostic systems. We ensure a clean air supply and an appropriate service. The valve has a regular maintenance schedule. Being pro-active in using the most advanced tools. Trust in our own abilities and training. There is confidence in the abilities of the suppliers. The plant is well-designed, controlled and operated. 10
Consider this.. Are you really concerned about the health and performance of your valves? 11
Surveys tell us that Sadly, Users are not concerned enough The majority of Users are only concerned with Critical valves Typically <20% of installed base Many control loops are left in manual. In case the valve is not in good shape. There isn t a Pro-active approach. The current philosophy is: If it isn t broken, don t fix it There is a slow take-up of new technologies and advanced prognostic tools. 12
As previously stated, the Top reasons to be concerned with Control valves are:- The mechanical nature = Which means a Higher failure rate. They are exposed to harsh processes and environments. To maintain and improve plant safety. To reduce operational and maintenance costs. e.g. air consumption, repairs, shut-down costs, eliminate failure risk etc. The potential for increased process efficiency / product yield. The possibility for increasing process Up-time. Control valves are one of the Most Expensive items of plant equipment to maintain. 13
The solutions are available and are around us - Some are obvious and familiar and some are not so. Having good information from our technology in order to See what is happening in our process. Using alarms and warning systems that give us a prediction of a problem/failure/plant upset. Reduce the risk of unplanned shut-downs and extra work Diagnostics and more importantly Prognostics gives us the essential tools for this but who uses them? Who understands them?too often they are seen as expensive, time-consuming extras rather than highly useful and beneficial tools. Definition: Prognosis (literally fore-knowing, foreseeing) is a medical term denoting the doctor's prediction of how a patient's disease will progress, and whether there is chance of recovery seeing ahead to predict the outcome before it happens. 14
So what may go wrong with a control valve and reduce overall performance? Actuation Broken Spring Air leakage (diaphragm, tubing) Bench Range Calibration Abnormal Friction Packing Guides / Trim Positioner Linkage Pneumatics (I/P, Relay) Calibration / Performance Loss of air supply Trim Wear (plug/seat) Seat leakage Body damage Packing Wear Fugitive Emissions Stem Wear/Corrosion Safety Hazards Application Problems Cavitation / Flashing Noise Vibration 15
Some of the key points we have identified so far in improving overall performance are:- The importance of selecting the right Valve and Positioner for the job. - This seems easy, but are all Positioners created equal? Making sure the Valve and Positioner are in good condition. - But how do we effectively and yet easily monitor this on a day-to-day basis without lots of extra work? We operate and monitor them in the correct way. - Wouldn t it be good if we had automated and simple to understand notification or warning if something was wrong? We utilise the right tools and prognostic systems. - To get the best advantages from our technology. The valve has a regular maintenance schedule. - But without unnecessary work, cost, effort or delays to production. 16
What do we need? To have good Valve performance, as a well as a good Valve we need a good Positioner. But what are the characteristics of a good Positioner? It must be Reliable. It has to be Accurate. Its performance must be Consistent/Repeatable. Easy to set-up and use. Provides additional Intelligent features such as diagnostics. Easily integrates with your DCS/Control strategy. Be Fit & Forget. 17
It is the needs of the User and the Plant that determine the final characteristics of a good Fieldbus Positioner. 18
More extensive features, such as diagnostics represent the key area that helps with overall performance improvements by identifying an impending problem before it becomes serious and has an impact on the plant. 19
One aspect of improving performance by reducing Plant Down-time - is the ability to quickly fix any fault that might occur. A Fieldbus Positioner designed with a small number of modular parts greatly assists in this task. 20
The key advantages of adding a Fieldbus Positioner:- It creates an information portal to monitor valve health. You can see exactly what is going on. Remotely Access the Control Valve. Improve Control Valve Performance. Monitor The Health Of Valves Online. Assess Mechanical Health Using Diagnostics. You can see if you are using the valve in the optimum way and if it is correct for the application. 21
Using Reliable and Highly Accurate Fieldbus technology enables you to increase the Total loop accuracy Dynamic Matrix Control Main Syngas Feed, Tag: X0F102 Valve: 2 41000 Series (ATO) Cv = 20, Stroke = 0.8 3-15 # Spring Actuator (ATC) 50 # Air Supply Dynamic Stem Load Range Control = 160 psi Seated = 3568 psi Dynamic Stem Control Accuracy Control = 0.4768 psi Seated = 10.623 psi Dynamic Control Ratio = 335.8:1 Controller Range = 0-30K#/Hr Setpoint=16.3623 K#/hr PV= 16.4517 K#/hr Stem Position Resolution = +/- 0.002384 (1/2 thickness of a human hair) Installed Total Loop Precision = +/- 0.298% Inlet Pressure = 3600 PSI Outlet Pressure = 3400 PSI 22
After installing a high quality Fieldbus Positioner it is possible to achieve something in the order of a 53% reduction in the standard deviation from the set-point. 23
Looking more closely. Installed Valve Performance + / - 55 Thousandths of a Percent 24
The Performance gains are also significantly enhanced within a Fieldbus Positioner through the complicated software algorithms. These are used to simplify otherwise difficult tasks that would be tedious, timeconsuming and frustrating to set-up manually. Fortunately, this is all handled automatically through the software and set-up wizards making life easier, quicker and less complicated. For example:- Auto-tuning the Positioner to match the Valve characteristics. Setting the aggressiveness of the Positioner response This adjusts the speed of response. If you had to do it manually, it would be like tuning a musical instrument instead of an electronic one. 25
The Auto-tune Wizard allows easy set-up. Progress Screen Timers Results Graph Export to Excel PID Comparison Table Progress Screen Timers 26
When we start to consider the Diagnostic abilities of Fieldbus equipment, we step into a bright, new world. It gives us the ability to be Electronic Doctors assessing the health and well-being of our equipment. The key is to do it in an easy to use and a comprehensible way. Of course the full benefit comes from integration into a DCS. 27
The Heart of Diagnostics is in the Positioner, not the DCS. 5 Pressure Sensors P Air Supply I/P Out P1 Relay Out P2 Relay Out Atmospheric Pressure 4-20 ma Setpoint C1 CPU T1 P5 I/P Servo C2 Air Filter / Regulator P1 Servo (I/P) P2 Pneumatic Relay P3 Actuator Valve H1 P4 28
Having a high number of sensors allows the detection of more Valve issues. 1 Temperature Sensor P5 Air Filter / Regulator T 2 Loop Current Sensor C 4-20 ma Setpoint C1 CPU T1 I/P Servo C2 P1 Servo (I/P) P2 1 Hall Travel Sensor H P3 Pneumatic Relay Actuator P4 P4 H1 Valve 29
Types of diagnostics, which assist in maintaining and enhancing performance are:- Continuous Diagnostic Data Time Open Time Close Time Near Closed Cycle Count Travel Odometer 30
More complicated and useful diagnostics are:- Off-Line Signature Diagnostics High Resolution Step Test High Resolution Extended Test Positioner Signature On-Line Valve Diagnostics 28 Alerts Including, Low Air Supply, Actuation Problem, Deviation, etc. Careful and thoughtful use of this data provides us with an invaluable insight into the workings and condition of our Valves. 31
On a more fundamental level, we can instantly see where the fault lies. Whether it is in regard to its Operation, its firmware or the electronics. Alarm Historian Current and Historical for Every Alarm. Stays in Memory Even after Loss of Power. 32
Accessing Diagnostic Data via a DCS allows the sharing of data. Control Station Monitor Station Operator Console Valve alarms Actual position Integrated logic Trends Valve timers database Asset Manager Asset Manager Calibration, Configuration, Literature Etc. Device Viewer FF Plug-In Quick Overview Of device/valve Condition. Valve Signature User Friendly Config. +Cal. Troubleshoot Commissioning High Speed Network Device alarms Historian timers Valve odometer Deviation alarm Condition monitoring H1 Segment FF I/O TB FF StandAlone 33
DeskPro L I F E B O O K Maintenance Station Operator s Console Ethernet Data Archiving Predictive Maintenance OPC Client FF OPC Handheld Calibrator I/O SUBSYSTEM Portable Maintenance Station FF COMMUNICATION ONLINE Valve Diagnostics CONTINUOUS Cycle Counter Travel Accumulator Time Closed Time Near Closed Time Open OFFLINE Positioner Sign. Actuator Sign. Step Sign. Overall Friction Spring Range Seat Load Process Trend Actual Travel Output Pressure Internal Set-point Device s Health Digital Positioner Fieldbus Valve Positioner 34
Being able to fully engage and interrogate your Fieldbus equipment from the control room is another great advantage. It encourages the User to carefully examine the health, configuration and performance status of the Positioner/Valve while it is in action backed-up by automated monitoring and self-checking features. Without this ability, the only way to get data on Valve behaviour would be by going onto site and watching it for a few days. 35
The data gives us access to the Process, Physical, Maintenance, Safety and Reliability information. 36
The clever part is to convert the sophisticated performance and diagnostic data into a simple to interpret way. In this case, a traffic light system is used Red standing for a major problem, Orange for a predicted problem and Green for all OK. 37
Creating Information From Data Built-In historian in the Fieldbus Positioner 80 Implementing Alarms in to the DCS 100 90 80 70 60 50 40 30 20 10 0 Historical Trace 20 15 92 8 80 Valve A Valve B Valve C Valve D 65 35 15 10 90 5 hrs open hrs closed hrs n.closed Valve not being Exercised = Possible Stiction High % time nearly closed = Trim Erosion, Oversized Valve 38
Case study Industry Request Read Field Device Data Into DCS Centralize Field Device Data Manage Assets Effectively Optimize Process Control The Results Increase Process Yield Reduce Maintenance Cycle Online Overview Of Valve s Health Better Utilization of Man / Hours Integrated Diagnostic In DCS Predict Valve Failure Monitor Health of Valve Analyze Applied Valves Remotely Troubleshoot Valves A high quality, digital Positioner Foundation Fieldbus protocol Digital I/O s or Multiplexors AMS, PRM and Plug-In Concept The Objectives The Tools 39
Prognostics in action Case study: BASF, Geismar, Lousiana Terminal Life Estimation - Bellows Seal 1) Total service Time = Time open + Time closed (59 + 6 hours = 65 Hours) 1000000 2) Cycles / Hour = Cycles / Service Time (5001/63 = 76.93 Cycles/Hour) Valve Cycles ( 000's ) 100000 Expected Cycle Life (000's) Masoneilan Design Criteria 3) Life Estimate = [Life Estimate/Cycles / Hour] Minus [Current Accumulated Time] 10000 1000 5.0% 4.0% 2.5% 0.30% Expected Cycle Life (000's) 1000 3500 10000 1000000 Masoneilan Design Criteria 3500 [8,000,000/76.93] - [65] = 103925 Hours = 4330 Days = 11.86 Years Valve Movement as a% of Free Travel 40
Translation to Operational Expenditure savings:- Power Plant: USA Industry Request 40% of industry costs relate to maintenance in some way Request :- Reduce maintenance costs on Power Plant 40 Valves Cost $110,000 every two years The Results Maintenance costs were reduced, as only 6 valves actually needed work: Thus, costs cut from $110, 000 To $30,000 Made up of:- Testing, field repair: $14,000 Removal, Reintstallation and shop repair: $16,000 Fieldbus technology was used to:- Predict valve failure Monitor health of the valves Analyze valve behaviour Remotely troubleshoot valves The Tools 41
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