Online performance diagnostics of Fisher Fisher Valve Smart Positioners

Create Date: 2024-8-30 12:03:23|Source: Fisher

FIELDVUE Fisher DVC6200 Series Valve Positioners are FISHER's next-generation high-performance valve controllers in response to market demand and as an alternative to the DVC6000 Series, combining the technical expertise of the existing series, using 50,000 units of DVC2000 Series proven non-contact valve position feedback measurement and DVC6000 Series flameproof/intrinsically safe housings and pneumatic architecture, with electronic components that continue the existing on-board microprocessor, application software and functional modules. In addition, it can adapt to all installation connection modes, support mainstream fieldbus communication and use of embedded AMS ValveLink predictive maintenance, which is easy to integrate into the system, and has high applicability and high reliability, which can provide users with additional benefits.
Online performance diagnostics of Fisher Fisher Valve Smart Positioners
EMERSON-Fisher, a leader in the development of digital intelligent valve positioners, introduced the FIELDVUE DVC (Digital Valve Controllers, abbreviated for DVC) 20 years ago in 1992.

When the control valve is put into use, it is usually connected by flange or welded to different locations in the process pipeline. During the normal operation of the process system, it is difficult to obtain effective operating status information by observing the operating status of the control valve on site. As a result, it is difficult to predict possible problems with the control valve. When the control effect of the control valve is abnormal, it is difficult to obtain effective diagnostic information if the valve cannot be disassembled online or offline.

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 problem valve

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. Under the premise of not affecting the operation and cost of the process system, each problem valve has the best maintenance time.

As one of the key components affecting 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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