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SIS “Final Element” Diagnostics Including The SOV, Using A Digital Valve Controller

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Presented by C B Chakradhaar and Riyaz Ali at the 2010 Emerson Exchange in San Antonio, Texas.

Presented by C B Chakradhaar and Riyaz Ali at the 2010 Emerson Exchange in San Antonio, Texas.

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    SIS “Final Element” Diagnostics Including The SOV, Using A Digital Valve Controller SIS “Final Element” Diagnostics Including The SOV, Using A Digital Valve Controller Presentation Transcript

    • SIS “Final Element” Diagnostics Including The SOV, Using A Digital Valve Controller
      C B Chakradhaar– Instrument & Control Specialist
      Riyaz Ali – Director Instruments
    • Presenters
      • C B Chakradhaar- I & C Specialist
      • Riyaz Ali – CFSP
    • Introduction
      SIS “Final Control Element” Diagnostics by Digital Valve Controller
      Basic Concepts and Need
      Traditional Test Methods
      Present Field Issues & Pains
      Digital Valve Controller to the Rescue
      SOV Health Monitoring
      Critical Evaluation of Solution
      Ras Gas (End User) Field Experience
      Evaluation of Solution
      Lesson Learned
    • Basic Concepts and Need
      x x
      Plant and
      Emergency
      Response
      Emergency response layer
      Passive protection layer
      Mitigate
      Relief valve,
      Rupture disk
      Active protection layer
      Dike
      Emergency
      Shut Down
      Safety
      Instrumented
      System
      Safety layer
      Trip level alarm
      Prevent
      Process
      Shutdown
      Process control layer
      Operator
      Intervention
      Process alarm
      Basic
      Process
      Control
      System
      Process
      Value
      Process control layer
      Normal behaviour
      Safety Through Layers of Protection
    • Basic Concepts and Need
      Why Focus on the Final Element ?
      Safety Instrumented System
      Basic Process Control System
      50% failures are in Final Control Element
    • Typically operate in one position - only move upon an emergency
      Without mechanical movement, unreliability inherently increases
      Frequent testing ensures valve availability upon Demand
      Historically, inexpensive mechanical jammer or expensive labor intensive pneumatic testing methods are used
      Basic Concepts and Need
      Why does the SIS Final Element account for 50% of failures?
    • OFF LINE
      ON LINE
      Total Stroke
      Total Stroke
      By-Pass In Service
      Process Down
      Component Test
      Partial Stroke
      Solenoid (SOV)
      Traditional Test Methods
      Test Methodology
      • Objective:
      Reduce the Probability of Failure on Demand (PFD)
      • Traditional test methods (pneumatic local panels, pin retainers, by-passing, etc.) are difficult to operate and maintain with risks and high operational costs
    • Present Field Issues & Pains
      Existing Test Methods Have High Costs
      CAPEX
      LABOUR
      Pneumatic panels
      Mechanical retainers
      Logic Solver with Limit Switch
      CAPEX
      By-pass Valve

    • The Test objectives

      Maintaining the Process

      AvoidingAccidentalClosureTesting

      Final Element Variation

      Simple Operation

      Stroke Test Speed

      Ensures Valve Returns to Normal Position

      Safety Audit
      Digital Valve Controller to the Rescue

    • The Test objectives

      Maintaining the Process

      AvoidingAccidentalClosureTesting

      Final Element Variation
      IMPROVE PFD
      Reducelaborcosts
      Improveflexibility
      Valve exercised to an extent

      Simple Operation

      Stroke Test Speed

      Ensures Valve Returns to Normal Position

      Safety Audit
      Digital Valve Controller to the Rescue

    • The Test objectives

      Maintaining the Process

      AvoidingAccidentalClosureTesting

      Final Element Variation
      FIELDVUE Partial Stroke isdone on-line.
      FIELDVUE Partial Stroke capable of beingtrimmed to suit the process.

      Simple Operation

      Stroke Test Speed

      Ensures Valve Returns to Normal Position

      Safety Audit
      Digital Valve Controller to the Rescue

    • The Test objectives

      Maintaining the Process

      AvoidingAccidentalClosureTesting

      Final Element Variation
      FIELDVUE Partial Stroke Test avoid to casually close the valve

      Simple Operation

      Stroke Test Speed

      Ensures Valve Returns to Normal Position

      Safety Audit
      Digital Valve Controller to the Rescue

    • The Test objectives

      Maintaining the Process

      AvoidingAccidentalClosureTesting

      Final Element Variation
      FIELDVUE Partial Stroke Test checks valve movement and collectstravel and pressure data.

      Simple Operation

      Stroke Test Speed

      Ensures Valve Returns to Normal Position

      Safety Audit
      Digital Valve Controller to the Rescue

    • The Test objectives

      Maintaining the Process

      AvoidingAccidentalClosureTesting

      Final Element Variation
      FIELDVUE Partial Stroke couldbestartusing a simple push button

      Simple Operation

      Stroke Test Speed

      Ensures Valve Returns to Normal Position

      Safety Audit
      Digital Valve Controller to the Rescue

    • The Test objectives

      Maintaining the Process

      AvoidingAccidentalClosureTesting

      Final Element Variation
      FIELDVUE Partial Stroke test Speed canbevaried to Suit Process.

      Simple Operation

      Stroke Test Speed

      Ensures Valve Returns to Normal Position

      Safety Audit
      Digital Valve Controller to the Rescue

    • The Test objectives

      Maintaining the Process

      AvoidingAccidentalClosureTesting

      Final Element Variation
      FIELDVUE Partial Stroke Test takes valve to its original position. If stuck, willprovide an alert.
      Travel, pressure and devicecondtionmonitoredregularly.

      Simple Operation

      Stroke Test Speed

      Ensures Valve Returns to Normal Position

      Safety Audit
      Digital Valve Controller to the Rescue

    • The Test objectives

      Maintaining the Process

      AvoidingAccidentalClosureTesting

      Final Element Variation
      FIELDVUE Partial Stroke Test resultstored in the instrument.
      ValveLink Audit Trail & Documentation

      Simple Operation

      Stroke Test Speed

      Ensures Valve Returns to Normal Position

      Safety Audit
      Digital Valve Controller to the Rescue
    • Digital Valve Controller to the Rescue
      The Influence of Partial Stroke testing
      Increase SIL Level
      Implementation of Partial Stroking on Final Control Element improves PFD to achieve better SIL level
      Validation of SIS
      Partial Stroking Validates the proper operation of the FCE
      Final Control Elements are commonly untested and are inherently unreliable
      Maintains SIL Level
      Safely extend turnaround times
      PFDavg
      1/PFD(t)
      Test Interval
      Without testing the PFD increases
      Time
    • Digital Valve Controller to the Rescue
      Unique Alert Features
      Partial Stroke “Valve Stuck” ALERT
      If the valve does not move or sticks the Digital Valve Controller STOPS the test
      Valve returns to normal operation position and alert is generated
      The valve will not slam shut, causing a plant “Spurious Trip”
      Trigger ALERT
      Captures valve movement or pressure changes
      Automatically stores travel, pressure and deviation data in the digital valve controller Supply Pressure ALERT
      Low supply pressure causes an alert
    • Digital Valve Controller to the Rescue
      Specific Safeguards
      Any safety DEMAND overrides Partial Stroke Test Mode
      Remote push button test returns to normal operation if:
      partial stroke fails
      push button is held outside 3-5 seconds timeframe
      Safety DEMAND occurs
      Write Protection or ‘tamper-proof’ lock
      Deters local unauthorized access to calibration or configuration parameters
    • Digital Valve Controller to the Rescue
      Diagnostics
      Diagnose VALVE failures before they happen
      Moves the SIS valve into predictive maintenance regimes
      Additional diagnostics
      Friction buildup
      Valve shaft shear
      Air supply pressure deviations
      Option to collect data during a demand
    • Digital Valve Controller to the Rescue
      Diagnostics Enhancements
    • Companion Software Alert Log
      Companion Software Audit Log
      Companion Software Test DataBase
      Intrument Alert Log
      Last Partial Stroke Test Stored in the Intrument
      Digital Valve Controller to the Rescue
      Audit Documentation
    • Solenoid Valve Health Monitoring
      0-20 mA Point To Point
      Or 0-24 Volts Multidrop
      From Logic Solver
      0 mA or 0 Volt ESDV Closed
      20 mA or 24 Volts ESDV Open
      24 Volts DC From Logic Solver
      Supply Pressure
      Port A
      Port B
    • Solenoid Valve Health Monitoring
      0-20 mA Point To Point
      Or 0-24 Volts Multidrop
      From Logic Solver
      0 mA or 0 Volt ESDV Closed
      20 mA or 24 Volts ESDV Open
      24 Volts DC from Logic Solver
      Supply Pressure
      Port A
      Port B
      Pressure Measurement Downstream SOV
    • Solenoid Valve Health Monitoring
      0-20 mA Point To Point
      Or 0-24 Volts Multidrop
      From Logic Solver
      0 mA or 0 Volt ESDV Closed
      20 mA or 24 Volts ESDV Open
      24 Volts DC From Logic Solver
      PULSE
      Supply Pressure
      Port A
      Port B
    • Solenoid Valve Health Monitoring
      • The solenoid valve can be pulsed for a split second
      Long enough so that the solenoid vents (verification that the solenoid valve is functional)
      Short enough so that the actuator doesn’t bleed enough pressure to make the SIS valve move.
    • Critical Evaluation for Solution
      PST Scripted avoiding Human Error
      Chances of Spurious Trip Reduced during PST
      Demand Overrides PST
      “Valve Stuck” Conditions Alerted
      Health Detection of “Final Element”
      SOV Health Monitoring
      Trigger Capability to Capture Safety Demand Event
      Compare and Overlay Previous Results to Predict Valve state
      Audit Documentation by Date and Time Stamp
    • Real Life Examples from Ras Gas - Qatar
    • Real Life Examples from Ras Gas - Qatar
    • Real Life Examples from Ras Gas - Qatar
      AMS Valve Link Suite opened Via Pactware
    • Real Life Examples from Ras Gas - Qatar
      Digital Valve Controller access via AMS ValveLinkTM Software
    • Real Life Examples from Ras Gas - Qatar
      Full Stroke Test Initiated
    • Real Life Examples from Ras Gas - Qatar
      FST signature taken and saved
    • Real Life Examples from Ras Gas - Qatar
      Initiating a PST
    • Real Life Examples from Ras Gas - Qatar
      PST signature taken and saved
    • Real Life Examples from Ras Gas - Qatar
      SOV test setup
    • Real Life Examples from Ras Gas - Qatar
      SOV test initiated from DCS
    • Real Life Examples from Ras Gas - Qatar
      Response graph taken and saved
    • Real Life Examples from Ras Gas - Qatar
      Valve Step Response Test
    • Real Life Examples from Ras Gas - Qatar
      Benefits realized
      • FST and PST signatures taken during loop check
      • FST signature compared with Factory signature to study valve wear and tear
      • PST performed with 10% valve movement
      • PST – SOV test signature saved
      • Diagnostic errors assist in identifying issues and enable taking necessary corrective actions
    • Lesson Learned
      PST Recommendations / Learning
      Use the valve signature to refine the partial stroke test parameters, such as minimum pressure and upper operating pressure.
      When a valve fails to move, adjust the speed, minimum pressure or pause time.
      Map the HART bit of FIELDVUE Instruments to HOST for getting SOV Health
      Check travel deviation or pressure deviation alert point to ensure correct configuration, this can be the cause of failure.
      Enable pressure mode to reduce stroke time of valve.
      Test more often than required to exercise valves if necessary.
      Baseline data from initial valve signature is PRICELESS!!!
    • Business Results Achieved
      Testing valve On Line Improves Reliability and Plant Availability
      Trigger Data Available in case of “Safety Demand”
      Continuous Health Monitoring of Final Element
      SOV Integrity Check
      Predictive Maintenance
      Improved PST Flexibility
      Reduced Labor Cost
      Compliance to Regulatory Requirements
      Integration to Logic Solver Possible
    • Summary
      Possible Issues on Final Element Testing
      Customer Needs and Requirements
      Field Issue and Concerns
      Possible Remedy – Digital solution
      Critical Evaluation of Solution
      Field Experience from Ras Gas
    • Where To Get More Information
      IEC61508 – Functional Safety of Electrical / Electronic / Programmable Electronic Safety Related Systems
      IEC61511 – Functional Safety – Safety Instrumented Systems for Process Industry Sector
      ISA-TR84.00.02-2002 – Part 1 to 5
      Control System Safety Evaluation & Reliability – W M Goble
      Safety Integrity Level Selection – Ed Marszal and Eric Scharpf