Fisher's Fisher Valve DVC6200 &DVC2000 Smart Positioners allow users to configure, calibrate, and adjust their instruments, bringing a new level of reliability to the range of products through years of experience in the control industry. This helps to accurately identify problems and avoid equipment failures without interrupting the process. Fisher's intelligent locator liberates front-line workers from heavy work, reduces front-line maintenance personnel and reduces labor intensity.
Through the monitoring of valve operating status parameters, combined with the valve information preset in the positioner at the factory, the performance diagnostic test and its functions mainly include:
(1) Diagnosis of air supply pressure
Through the diagnostic analysis of the air supply pressure, it is possible to know whether the air supply pressure of the actuator meets the requirements of use, and at the same time, it can monitor and quantitatively analyze the degree of instantaneous air supply pressure drop of the actuator when the valve is moving in large displacement, so as to help determine whether the flow rate of the air supply pipeline is sufficient.
(2) Relay adjustment diagnosis (for cylinder actuators)
This function can monitor the cross pressure of the upper and lower cylinders of the double-acting actuator in real time. At the same time, it also helps to reasonably set the cross-pressure of the large-volume actuator. Too small cross pressure will cause the stiffness of the actuator to deteriorate, and the valve stem and spool assembly are prone to abnormal vibration under the action of fluid force, resulting in the difficulty of stabilizing the spool position. Excessive cross pressure will cause the pressure in the upper and lower cylinders to be close to the supply pressure, so that the piston will be very close to the upper and lower forces, the spring force will play a dominant role, and the actuator will move towards the spring failure position.
(3) Electrical converter I/P and relay integrity diagnosis
This diagnostic function can detect problems with the internal components of electrical converters and amplifiers in a timely manner. For example, if the nozzle of the electrical converter is clogged, if the sealing diaphragm is failing, if the O-ring is failing, and if the I/P calibration drifts. This diagnosis helps to detect problems caused by contamination of the supplied air and excessive temperatures.
(4) Diagnosis of stroke deviation
This diagnostic function is primarily used to monitor actuator pressure as well as differences in stroke feedback and set points. Diagnostics can help identify control trim sticking or wear that is causing the valve to not close properly, or to have internal leaks, or drift in stroke calibration.
(5) Air flow diagnosis
This diagnostic function measures the flow of air through the control valve assembly. With the help of multiple sensors in the positioner, it is possible to detect both positive (supply) and negative (exhaust) pressure from the DVC. This diagnostic not only detects leaks in the actuator and associated air supply lines, but also in the case of cylinder-piston actuators, air flow diagnostics can effectively detect leaks in piston seals or damage to O-rings.
(6) One-click scanning
This feature automates all advanced performance diagnostic tests and provides analysis results that can help identify health issues with the base stations themselves and recommend maintenance.
(7) Valve friction analysis
This diagnostic function analyzes the friction and dead zone of the valve online to help detect changes in packing friction. Severe packing wear can lead to less friction and therefore a risk of leakage. Wear or sticking of the spool sealing rings can also cause friction to change. A change in the dead band can severely affect the overall control performance of the valve, and the response speed may be slower.
By running the advanced diagnostic functions of the smart locator described above, its diagnostic results can provide users with a comprehensive and reliable comprehensive solution from the following five aspects:
(1) Identification of problem valves
Combined with the diagnostic results, the user can locate in advance valves in the process system that are not functioning properly, or that are starting to degrade/deteriorate in performance.
(2) Analysis of problem valve trims
Based on the diagnostic results, the user can identify the health status of the valve trim and whether it needs to be repaired or replaced.
(3) The person in charge of the maintenance of the valve in question
Based on the diagnostic results, the user can identify the complexity of the problem.
(4) Problematic valve maintenance time
The user determines the appropriate maintenance time based on the severity of the diagnosis results and the availability of spare parts in the factory, the parking schedule or the maintenance personnel arrangement. Without compromising process system operation and cost optimization, each problem valve has the best repair time.
Then, as one of the key components that affect the control accuracy of the process system, the health status of the control valve has a decisive impact on the stable operation of the process system. The intelligent positioner can perform online performance diagnosis and evaluate the health status of the control valve, helping users to achieve the goal of further reducing the maintenance cost of the control valve and making the process system more efficient and safe.
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