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

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

Final Control Elements (FCE) 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 19.09.2018, Event Your name

Life Cycle Care of This Critical Asset 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

Increase Safe Process Run-time 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

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

Two Types of FCE Asset Management Manual Automated

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

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

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

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

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

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)

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

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

FCE Monitoring Status Graphic

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

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 Partial Stroke Testing for ESD Valves Breakout Force Air Supply Leakage or Obstruction

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

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

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

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

PST Configuration Test Results Test Alarms/Errors

Reports and Instructions Commissioning Reports Diagnostic Reports

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

Streamlines FCE Asset Management Throughout Life Cycle 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

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

Detailed Live Demonstrations are Available at the FDT Group Kiosk and Members Tables

Open access to device intelligence www.fdtgroup.org info@fdtgroup.org Thank you for your attention! Open access to device intelligence www.fdtgroup.org info@fdtgroup.org 19.09.2018, Event Your name