In general, increasing the effectiveness of the control valve (uptime) requires revamping the maintenance program to ensure maximum performance of the instrument. Many factories use reverse thinking to solve this problem and switch to a device-based strategy that adjusts the maintenance workload based on the actual operation of the control valve. This strategy assumes that such "proactive" maintenance is far more cost effective than "reactive passive" maintenance, a corollary of the recently published article by FactoryMaintenance demonstrating that the cost of passive emergency maintenance "is proactive 4-10 times for a sexual maintenance solution ". However, to take advantage of the active preventive maintenance strategy for a control valve, it also needs to rely on another unobtrusive assumption that factory operations and maintenance personnel can accurately and real-time master the status of the control valve and help to develop the corresponding Practical measures to ensure the highest performance equipment. "Diagnostics" is a jargon often quoted in solutions that provide such data, but there are often a large distance from the ideal goal for two key reasons. Conventional Control Valve Diagnostic Methods First, valve and instrument diagnostics consistently require parking performance testing, which is likely to cause significant damage. Second, it is also time-consuming to inspect and maintain every valve in the equipment. Furthermore, the accuracy of the final data can vary based on the equipment used and the skill of the technician performing the test. In order to understand the state of the art currently used to evaluate the performance of control valves, it is necessary to review the implementation of this test. In the past, equipment to perform valve and instrumentation inspections typically consisted of a precision pressure regulator, a 0-0.2 Mpag manometer (0.25% accuracy) and a linear dial gauge (Figure 1). In the past, the equipment was pre-calibrated to a specific working range (eg 0.02-0.1Mpag, or 0.04-0.2Mpag), a high accuracy regulator was used to simulate the control command signal over the operating range, and the pressure gauge was used as its measurement point. The dial gauge shows the opening of the valve over a specific signal range. The process is executed in two working directions: the signal is off and the signal is on, and the starting valve has a 50% displacement positioning. Perform 3 consecutive complete cycles, report and calculate repeatability, hysteresis, and deadband. Deadband is the maximum difference between the two inputs in the upper and lower order for the same input over the full scale. The test data is then applied to the chart for performance analysis. The resulting "Valve Performance Curve" shows the characteristics of the control valve and related instruments and accessories. The data captured in these valve diagnostic tests provided useful information for understanding valve performance degradation (Figure 2). However, this diagnostic process takes a long time, requiring the valve to "park" (ie, stop working) from the pipeline, affecting the plant's production. In addition, the accuracy of the data results is heavily dependent on the skill of the measuring equipment and technician performing the test. Because the mechanical components and instruments associated with various valve designs and their accessories have their own complexities, the conversion of diagnostic data to maintenance measures is not only a science and technology, but also an art and skill; that is, it depends largely on Experience and knowledge of technicians. Performing "proactive" maintenance more economical than remediation while more effectively preventing unplanned downtime is our overall goal. Converting diagnostic data into executable maintenance advice that meets these goals often requires a deeper understanding of the purpose of the valve design, the manufacturing principles, and the mechanism of operation under the particular process conditions to determine if the valve's behavior is "normal." The International Association for Automation (ISA) has played an important role in this regard by setting performance standards for control valves and conventional instrumentation to provide outline guidance for the implementation of valve-related diagnostics. However, these guidelines address only certain aspects of the control valve health diagnosis and do not Involves Original Equipment Manufacturer (OEM) specific information. For example, on-site diagnostics can not determine non-conformance issues such as valve seat leaks, seat pull forces sufficient, or why a valve needs more maintenance. Some of these problems can be quickly resolved, such as whether the seat pull force is sufficient. The valve seat load (Fs) calculation is a function of force based on the actuator effective area (Af) times the applied load pressure (Ps), the reverse direction of the spring (Pf) and the actuator spring stiffness. However, this analysis requires knowledge of the actual hardware used to control the valve, such as the size of the valve actuator and the stiffness of the installed spring. In addition, a common algorithm for valve seat loading can be used to confirm that only this force is applied, and the actual physical surface finish and the mating contact angle of the valve plug determine if the control valve is normally closed under this valve seat load. In addition, the physical design of the valve plug (tap hole or pressure balance) must also be taken into account. The reality in many factories today is that a large number of knowledgeable and skilled maintenance personnel are being replaced by a handful of young workers who know little about modern control valve configurations, spooling and spool design. In addition, many modern devices are beginning to use Asset Management software to perform the heavy lifting of collecting, analyzing, and archiving large amounts of data generated by control valve diagnostic tools. Although these tools can play an important role in helping factories plan and prepare for overhaul cycles, they must never replace technicians with extensive experience and knowledge of control valves, as they are mostly from third-party providers rather than valve OEMs, The help of management is very limited. Finding the best answer Valve diagnostics and asset management tools have evolved to become powerful helpers for plant operations and maintenance staff. These tools include best practices for data management, valve validation, and on-line and off-line valve diagnostics. As a best practice, these solutions are integrated into the control valve positioner to collect data continuously, in real time, avoiding the need to remove the valve from the line when generating the valve performance profile (Figure 3). These advanced tools improve valve performance, greatly reducing downtime and valve maintenance costs. More importantly, a whole new generation of diagnostic tools from control valve OEMs is based on the manufacturer's long history of valve design, manufacture, operation and maintenance. In some cases, these tools can even rival the control diagnostics of experienced control valve technicians. Without the information provided by these state-of-the-art on-site diagnostics solutions, factories spend a lot of time and money wasting unnecessary periodic maintenance unplanned downtimes that can often be unavoidable. Based on feedback from the supplier and end-user diagnostics using advanced valves, typical valves require only simple valve mechanical adjustments or instrument recalibration. For example, a normal 3-inch globe valve will cost about $ 4,600. The cost of replacing the valve is much higher than the cost of repacking and reinstalling the old valve from the pipeline, using new gaskets and sealing rings. So the crux of the problem is knowing when maintenance is needed. Because the new generation of diagnostic tools is provided directly by the valve manufacturer, they analyze the valve-performance response curve and find any inconsistencies or pattern / trend deviations, such as excessive friction due to packing and guide sleeve, high hysteresis And dead zones, non-linear response, mechanical disorders, low friction due to filler wear, potential limit cycles and instrument calibration are not in place. These methods of analysis increase the accuracy of on-site diagnostics without disturbing the normal manufacturing process, reducing the amount of time it takes to diagnose, and keeping the valve in working condition. This diagnostic process helps the plant save manpower and eliminate the cost of production lost when the instrument is down. These solutions provide advance notice to concerned personnel about issues that allow plant operators plenty of time to take action to minimize downtime or eliminate them completely. Because the new generation of control valve diagnostic tools are built by valve manufacturers, they confirm the crux of the problem and provide guidance and advice. Allows operators to find out the root cause of the problem in time and correct maintenance processes, spare parts and special tools required to repair, which can further save time and money factory. Leading OEM Diagnostic Tools In summary, while there is great potential for valve diagnostic solutions to increase plant yields, the full potential benefits are often tied to the solution itself, failing to collect meaningful real-time diagnostic data, The unique combination of valve design and service conditions translate data into actionable maintenance recommendations. The good news for end users is that the latest generation of tools from Valve OEM make up these gaps and make significant strides. The Valve OEM's Best Diagnostic Solution Leverages the know-how and experience accumulated by valve manufacturers to overcome the inherent deficiencies of third-party "software" providers, improve the level of control valve performance analysis and speedup of maintenance advice, restore equipment to Highest performance. As a result, these solutions are better able to help factories achieve the original intention of the asset management strategy, which is to increase production capacity without increasing maintenance costs and labor. More Keyword Search: Control Valve
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