Instrument Performance Audit

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Instrument Performance AuditInstrument Performance Audit

(Control Valve Perspective)(Control Valve Perspective)

Establishing and Sustaining Valve Performancefor World-Class Process Plants

Wisnu Anggoro



[File Name or Event]Emerson Confidential27-Jun-01, Slide 2

What is Instrument Performance Audit ?What is Instrument Performance Audit ?What is Instrument Performance Audit ?

An activity to audit the performanceof instrument to get best practice formaintenance and/or increasing theequipment performance andreliability




Business

Systems

ProductionManagement

Real-Time Optimization

Monitoring and Analysis

AdvancedProcess Control

Control Loop Performance(Includes Instrumentation) Level 1

Level 2

Level 3

Level 4

Level 5

Performance Optimization Initiatives

To Address These Demands,

Investment is Being Made at

Many Levels in the Business

Today’s Business Environment Has

Ever Increasing Performance Demands

TodayToday’’s Business Environment Hass Business Environment Has

Ever Increasing Performance DemandsEver Increasing Performance Demands

Reduce Manufacturing Costs

Increase Revenues

Achieve Positive Growth

Widen Profit Margins

Increase Shareholder Earnings

Where Should InvestmentBe Made

to Get the Best Return?

Where Should Investment

Be Madeto Get the Best Return?

Control Loop Performance(Includes Instrumentation) Level 1Control Loop Performance(Includes Instrumentation) Level 1




Control Valve

Performance

Tuning

Design

Loops

IncreasesVariability

20%

30%

30%

20%

Source: Entech---Resultsfrom audi ts of over 5000loops in Pulp & Paper Mills

“ The undesirable behavior of controlvalves is the biggest contributor topoor loop performance and thedestabilization of product uniformity” .

W. L. Bialkowski , President

EnTech Control Engineering

Loop Audit Studies:

Pulp and Paper Industries

Loop Audit Studies:Loop Audit Studies:

Pulp and Paper IndustriesPulp and Paper Industries




Gas Plant with advanced control

65% of loops > 2% process dead band


Blending Unit


Hydro cracker with advanced control 50% of loops > 2% process deadband

Overall statistics > 6000 control loops

54% of loops need valve/instrumentation help

Performance Audit Results:

Hydrocarbon Industries

Performance Audit Results:Performance Audit Results:

Hydrocarbon IndustriesHydrocarbon Industries




Leaders in Optimization Recognize

the Value of “ The Basement”

Leaders in Optimization RecognizeLeaders in Optimization Recognize

the Value ofthe Value of ““ The BasementThe Basement””

15-30% of control loopsimpact business

profitability. > 50% of critical loops

need valve attention.

“ Over half the value in

APC comes frompaying attention to thefield controlequipment”

ExxonMobil

Planning and Scheduling System

RTO System

APC System

Primary

Controls

Control Valves

I n c r e a s i n

g l y C r i t i c a l

f o r O

p t i m

i z a t i o n

Performance Monitoring is Applicable

to All Levels of Control & Optimization

1999 NPRA Presentation by Aspen Tech

“Optimal performance of the regulatorycontrol layer is a prerequisite for plants torealize the financial benefits of businessoptimization applications such as

advanced control, real-time optimization,and planning and scheduling.”

Honeywell Hi-Spec




When do we need Instrument

Performance Audit ?

When do we need InstrumentWhen do we need Instrument

Performance Audit ?Performance Audit ?1. Plant was operated for more than

5 years operation

2. Many issues for maintenance3. Alteration of the operation /

service condition

4. Obsolete issue for the equipment5. Advanced Process Control

Planning

6. Predictive maintenance planning




Which instrument are required to audit ?Which instrument are required to audit ?Which instrument are required to audit ?1. Critical or Severe application such as

Compressor anti surge, Main Oil Line

Pump, Separator application, Flareheader/vent application, water injectionapplication, pump recycle applicationetc.

2. Instrument that has many issue formaintenance

3. High pressure, high temperature and

high flow application4. Overall final control element




Friction - controlled & consistent

Seal design impacts Packing load and type Linkages, lost motion Impact of actuator design type

Positioner Design - sensitive & responsive Feedback scheme used Capability of tuning Ability to diagnose/monitor Must be matched to valve/actuator

Flow Geometry Design Stability is critical

Does the Valve Move?

How Fast Does the Valve Move?

Does the Valve Give the Right Loop Gain?

Control Valve Performance:

What Makes a Good Control Valve?

Control Valve Performance:Control Valve Performance:

What Makes a Good Control Valve?What Makes a Good Control Valve?




Reduce Manufacturing Costs

Increase Revenues

Achieve Positive Growth

Widen Profit Margins

Increase Shareholder Earnings

Business

Systems

ProductionManagement

Real-Time Optimization

Monitoring and Analysis

AdvancedProcess Control

Control Loop Performance(Includes Instrumentation) Level 1

Level 2

Level 3

Level 4

Level 5

Performance Optimization Initiatives

To Address These Demands,

Investment is Being Made at

Many Levels in the Business

Control Loop Performance

(Includes Instrumentation)Level 1

Once Achieved Best Performance, need to

Monitor & Maintain this Best Performance

Once Achieved Best Performance, need toOnce Achieved Best Performance, need to

Monitor & Maintain this Best PerformanceMonitor & Maintain this Best Performance“ The cost of predictive maintenance

on valves is 5 times less expensive

than scheduled maintenance and

ten times less expensive than

corrective maintenance, even

before the costs of down time are

figured in.”

From ARC Insights: July 14, 1999

Monitoring and Analys is Level 2

On-Line Diagnostics for

Process Optimization

Monitor Process Improvement




Maintaining Best Performance:

Predictive Maintenance

Maintaining Best Performance:Maintaining Best Performance:

Predictive MaintenancePredictive Maintenance

Time

T h r o u g h p u t

Practical plant limitsPractical plant limits

Comfort Zone: Operate here to make profit .

Safety Band: Operate into this area and make more profi t.

Typical OperatingTypical OperatingPointPoint – – devicesdevices

deteriorate withdeteriorate withtimetime

UnscheduledUnscheduledShutdown =Shutdown =

Lost RevenueLost Revenue

Quickly have theQuickly have theproblem fixed =problem fixed =Lost RevenueLost Revenue ScheduledScheduled

Shutdown =Shutdown =

Lost RevenueLost Revenue

Rebuild toRebuild toimproveimprove

throughputthroughput

Comfort Zone: Operate here to make profit .

Safety Band: Operate into this area and make more profi t.

Predictive maintenance can keep the plant operate at

a higher Prof itable level

Predictive maintenance can keep the plant operate at

a higher Prof itable level

AMS ValveLink® and Fisher control valves with

FIELDVUE® DVC are the right tools to monitor and

diagnose valve performance for Predictive

Maintenance

AMS ValveLink® and Fisher control valves with

FIELDVUE® DVC are the right tools to monitor and

diagnose valve performance for Predictive

Maintenance




The Advantage of Fisher Valves, DVC 6000 and

ValveLink Software on the loop performance :

The Advantage of Fisher Valves, DVC 6000 andThe Advantage of Fisher Valves, DVC 6000 and

ValveLinkValveLink Software on the loop performance :Software on the loop performance : To Establish Best PerformanceTo Establish Best Performance

To Maintain Best PerformanceTo Maintain Best Performance

To Retrieve Best PerformanceTo Retrieve Best Performance




Optimized control valve response:

Able to tune the valve to meet the exactrequirement of the process controlthrough DVC tuning

Optimized control valve response:

Able to tune the valve to meet the exactrequirement of the process controlthrough DVC tuning

Fisher Digital Valves and AMS ValveLink

Software Achieve Best Performance

Fisher Digital Valves and AMSFisher Digital Valves and AMS ValveLinkValveLink

Software Achieve Best PerformanceSoftware Achieve Best Performance

An X-ray to diagnose the valveconditions on: Packing wear, Seat

load, Actuator leakage, Valve

leakage, Insufficient air supply

An X-ray to diagnose the valveconditions on: Packing wear, Seat

load, Actuator leakage, Valve

leakage, Insufficient air supply

Valve Signature

Step Response

Dynamic Error Band

Overall control valve performance

indications: Able to provide

information on when to service and

when to recalibrate a control valve

Overall control valve performance

indications: Able to provide

information on when to service and

when to recalibrate a control valve





Software Maintaining Best Performance


Software Maintaining Best PerformanceSoftware Maintaining Best Performance

On-line trending graphscould reveal loop related to

control valve problems

On-line trending graphscould reveal loop related to

control valve problemsOn-line trending

Off-line analysis

On-line analysis of frict ionand deadband can be

compared with the off-line

data for potential valveperformance deterioration

On-line analysis of frictionand deadband can be

compared with the off-line

data for potential valveperformance deterioration





Software Retrieving Best Performance


Software Retrieving Best PerformanceSoftware Retrieving Best Performance

Current diagnostics graph data

can be overlaid on previous

graph data for comparison anddetection of potential control

valve deterioration

Current diagnostics graph data

can be overlaid on previous

graph data for comparison anddetection of potential control

valve deteriorationValve hunting at closing

due to galled bearing

Extended Valve Signaturedue to damage valve seat

Positioner gain is too highcausing hunting coulddue to wear in packing




Control valve performance is a critical factor inprocess optimization.

Optimization of the control valve is essential forsuccessful Advanced Process Control.

Large economic returns result from proper sizing,selection, and maintenance of the control equipment.

Predictive monitoring of loop equipment is a keyelement for total asset optimization.

Process Optimization andProcess Optimization and

the Control Valvethe Control Valve

Instrument Performance Audit

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