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DTM's Streamline Asset Management for Final Control Elements. Leo Hughes. Topics. Final Control Elements (FCE) Asset Management DTM Technology Streamlining FCE Asset Management. Basic Process Control Systems Traditional Globe Style Control Valves ¼ Turn Valves Damper Drives

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DTM's Streamline Asset Management for Final Control Elements


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    1. DTM's Streamline Asset Management for Final Control Elements Leo Hughes

    2. Topics Final Control Elements (FCE) Asset Management DTM Technology Streamlining FCE Asset Management

    3. Basic Process Control Systems Traditional Globe Style Control Valves ¼ Turn Valves Damper Drives Pneumatically Operated with Digital Positioners Safety Instrumented Systems ESD ¼ Turn Valves Pneumatically Operated Digital Positioners for Partial Stroke Testing Final Control Elements (FCE) Your name

    4. FCE Asset Management • Life Cycle Care of This Critical Asset • Commissioning • Monitoring • Maintenance and Repair • De-commissioning • Reduce the Cost of Ownership of Asset • Predictive Rather than Preventative Maintenance • Reduce man-hours Required to Maintain FCE

    5. FCE Asset Management • Increase Safe Process Run-time • Avoiding Unscheduled Down-time • Extending Scheduled Maintenance Cycles • Maximize Efficiency of Scheduled Down-time • Safety Instrumented System Monitoring • Increase Process Quality and Efficiency • Tight Valve Control Yields Tighter Process Control • Increased Process Yields by De-bottlenecking • Increase Product Quality Leads to Higher Profitability

    6. Why Automated Asset Management? • Reduced Staff • Man-hours Available to Required Ratio Worsens • Increasing Demands • Higher Volume and Quality of Output • Higher Profitability • Environmental Monitoring and Control • Plant Safety • Automation is the Only Solution • Embeds Efficiency in the Digital Positioner • Provides Access to That Capability

    7. Two Types of FCE Asset Management • Manual • Automated

    8. Asset Management for FCE - Manual • Mechanical/Pneumatic Positioners • Manual Calibration • Scheduled Preventative Maintenance • Written Documentation • Requires Man Power • Digital Positioners • Employs Local User Interface – LED’s, LCD & Pushbuttons • Employs Device Descriptors (DD) & Handhelds • Automated Commissioning • Limited Monitoring • Limited Diagnostics • Written Manual Documentation

    9. Asset Management for FCE - Automated • Digital Positioners and Asset Management Software – Stand Alone • Stand Alone PC Software • Digital Positioner Manufacturer Specific Software • Asset Management Software • Individual Connection • Direct to Device • Output Signal Wire (HART) • Network Wire (fieldbus) • May Employ a HART Multiplexer (MUX) • Digital Positioner with Asset Management Software Integrated into Control or Safety Instrumented System • Requires HART Analog Output Card for HART Installation • All Valve Parameters Available All the Time

    10. What is FDT DTM Technology? • Field Device Tool – Device Type Manager • Standardized Digital Interface Technology • FDT Frame • Device Type Manager (Device Driver) • Uses Style Guide as a Template • No Limit on Graphics • Manufacturers are Free to Give User Best Access to Their Key ROI Features • Protocol Independent • Frame Independent

    11. Field Device Tool Advantages for FCE • Applicable to all 3 Protocols • HART • Foundation Fieldbus • Profibus • Global Support • Majority of Control Systems • Majority of Field Device Manufacturers • Asset Management Software Programs • Endress+Houser/Metso – FieldCare • Yokogawa – PRM and FieldMate • Honeywell – Field Device Manager • ABB – Smart Vision • Foxboro - ValCare • Endorsed by Growing Number of Global End Users • Some Make DTM’s a Requirement

    12. DTM’s • Device Type Manager (DTM) • Designed by Manufacturer • Ease of Use of Device • Employs Graphics to Maximize Value of Key Features

    13. FDT DTM Streamline Asset Management • Commissioning • Set-up Wizards • Automated Tuning • Baseline Diagnostics • Documentation • Monitoring • Alarm Monitoring • Valve Trend – Command vs. Position • Diagnostics • Continuous Diagnostics • On-Line Diagnostic Analysis • Off-line Signatures • Partial Stroke Tests (ESD)

    14. Commissioning • Set-up Wizards • Calibration Wizards • Auto Tuning • Custom Characterization • Baseline Diagnostics Signatures

    15. FCE Monitoring • Status at a Glance • Operational • Electronics • Pneumatics • Alarms Errors or Alerts • Current and Historical • All Sensor Outputs • Max/Min Temperatures

    16. FCE Monitoring • Status Graphic

    17. FCE Monitoring • Trend Graphs • Command Signal • Valve Position • Actuator Pressure • Historical Views

    18. Diagnostics • Continuous – Valve Activity Totalizers • Travel and Cycle Counters with Limit Alerts • Deviation Histograms • Position Timers • Off-line – Diagnostic Tests (Signatures) • Friction • Spring Range • Histerisis • Linearity • Step Tests • On-line – Normal Operational Condition Analysis • Friction • Partial Stroke Testing for ESD Valves • Friction • Spring Range • Breakout Force • Air Supply Leakage or Obstruction

    19. Continuous Diagnostics • Valve Histograms • Position Timers • Cycles Travel • Position Timers • Time Open • Time near Closed

    20. Off-line Valve Signatures • Actuator Signatures • Total Valve Friction • Spring Range • Stroking Speeds • Step Signatures • Two Way • Overshoot

    21. On-line Valve Diagnostics • Calculates Valve Parameters • Friction • Performs Analysis • Suggests Recommend Action

    22. Partial Stroke Testing (For ESD Valves) • Partial Stroke Test Configuration • Range of Movement • Duration and Speed • Alarm and Failure Parameters • PST Activation • PST Alarm/Error/Alert Notification • Pass/Fail • PST Data Collection and Graphical Display • Trends Position vs Pressure

    23. PST • Configuration • Test Results • Test Alarms/Errors

    24. Reports and Instructions • Instructions • Commissioning Reports • Diagnostic Reports

    25. Summary • FCE Asset Management is Critical in Today’s World • Commissioning - Monitoring – Diagnostics • Basic Process Control Systems • Safety Instrumented Systems • Automation is a Necessity • Given Man-hours Available to Required Ratio • FDT DTM Technology • Widely Supported Global Standard • Widely Supported by FCE Manufacturers • Dresser Masoneilan • Flowserve Valtek & Limitorque • Metso Neles • Foxboro Eckhart • ABB • Siemens • Samson • Yamatake • Yokogawa • Auma

    26. Summary • Streamlines FCE Asset Management Throughout Life Cycle • Commissioning • Monitoring • Diagnostics, Maintenance and Repair • Reduce the Cost of Ownership of Asset • Increase Safe Process Run-time • Increase Process Quality and Efficiency

    27. Questions? For further information please visit www.fdtgroup.org and Members web sites

    28. Detailed Live Demonstrations are Availableat the FDT Group Kiosk and Members Tables

    29. Thank you for your attention! Open access to device intelligence www.fdtgroup.org info@fdtgroup.org Your name