StarPac Intelligent System

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Intelligent System

StarPac Intelligent System

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Components

IntroductionThe Kammer StarPac® intelligent system includes amicroprocessor-based controller and process sensorsmounted on a control valve. The system providessingle-loop measurement and control of flow, pressure,or temperature. It also allows data acquisition neces-sary for valve or process diagnostics.

Intelligent systems can improve plant operation at alower installed cost than conventional control systems.With flow, pressure and temperature sensors, and themicroprocessor mounted directly on the valve itself,installation of a total control loop is simplified by elimi-nating separate line taps. The overall complexity andpotential for leaks in a process system are reduced withfewer penetrations in the flow stream.

The StarPac unit can be programmed to operate as atraditional control valve (responding to a 4-20 mA con-troller) or as a stand-alone controller or transmitterrequiring only a 24 VDC power source and air supply. Inthe stand-alone (controller) configuration, StarPac re-sponds with PID action to: a 4-20 mA analog controlsignal, a digital signal through the serial data port, or a

preprogrammed setpoint that is held with no externalcommunication. A personal computer can be used toset operating and tuning parameters or reading diag-nostics; it is not needed for ongoing StarPac operation.DCS’s can be linked to the StarPac unit if they supportModbus or Fieldbus protocols.

Maintenance procedures are improved with StarPac’sability to record and report on valve or process equip-ment performance. For example, a signature of thevalve or process (using StarPac sensors) can be re-corded by a PC upon installation of the StarPac system.Later, using this signature, StarPac software can helpdetermine whether the valve or other process equip-ment needs servicing, reducing scheduled maintenance.In addition, the StarPac system provides self diagnos-tics with easy field replacement of modular parts.

The use of intelligent systems in hazardous applicationstart-ups and shutdowns provides process insight andcontrol – previously only available with expensive, com-plicated equipment installations. StarPac’s “intelligent”reaction to system failure can give the user that extrasafety edge over conventional control-loop systems.

Figure 1: StarPac ® Intelligent System Components

StarPacElectronicsModule

UserAccessTerminal

PositionFeedbackArm

ProcessDisplay

I/PPositioner

®

Electronics Conduits Pressure/TemperatureSensors

StarPac Intelligent System

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Benefits and Advantages

Enhanced Plant Operation

Better Process Operation Total installation costs can be as low as 20 percent of a conventionalcontrol systems. The high turndown results in better process control overthe operating range.

Real-time System Analysis StarPac’s ability to gather and send flow and process data allows up-to-the-minute, engineering analysis, aiding in reducing production costs andenhancing the process.

Wide Versatility Multiple control modes–including fluid flow, upstream pressure, down-stream pressure, differential pressure and temperature–permit StarPacsystems to be used in a wide variety of process applications. Remotesensors can be tied into the StarPac unit for control of other processparameters. Cascade action is also supported.

Simple System StarPac software is easy to use, allowing the system to be setup or recon-Configuration figured quickly as needed by the user to optimize the process system.

True Distributed Process The StarPac unit can take load off a DCS by distributing measurementControl and control to the field. This allows the DCS to function as a process

supervisor, acting on information from the whole system

Increased Safety

Fewer Line Penetrations Single-point installation limits line penetrations for sensors and reducespotential leaks to the environment, reducing EPA reporting requirements.

Continuous Monitoring StarPac system continuously monitors the valve position and the opera-tion of several critical internal parameters, notifying the user when im-proper operation occurs, before upsetting the process.

System Warnings Programmable settings permit the user to set process system parametersand to be notified when those limits are violated.

Improved Maintenance

Predictive Maintenance StarPac software allows the intelligent system to be used to diagnose thevalve operation as well as upstream and downstream equipment (such as:pumps, reactors, heat exchangers, etc.) while in operation to predict anacceptable performance or potential failure. Maintenance can then beperformed before process failure occurs.

Reduced Complexity With all functions located in one package, complexity of the total controlsystem is reduced. Locating, finding and troubleshooting the problemis easier.

Remote On-site Service StarPac’s modem capability means low-cost, on-site, factory service isavailable when needed, using telecommunication technology.

Features

Process Diagnostics –Evaluation of process equipment is possible with the StarPacintelligent system. By generating an initial signature of the process (and catalogued inan ASCII format) and then identifying a standard process signature, a pump, compres-sor, heat exchanger, reactor, etc. can be discovered to be defective and in need ofservicing. Process diagnostics can be performed with a personal computer or DCSconnected to the unit via its serial data port.

High Interchangeability - Since the Kammer 25000 series (split body),35000 series (top-entry) and other control valve series is the basis of the

StarPac system, most valve parts are interchangeable withother Kammer valves, reducing parts inventory.

Figure 2: StarPac Intelligent System Features

Connections to Operator Interface - The StarPac can be connected to anoperator interface (personal computer, DCS console, or hand station andrecorder) through three 4-20 mA analog channels, four discrete channels.Supervisory digital communications with control equipment can be estab-lished through gateways, Modbus ports, or Fieldbus ports. All process andconfiguration information is available through the digital channel.

User Friendly Software - Where the user is not connectingthe StarPac unit to a DCS, StarPac software can configure,operate, and diagnose the StarPac unit through a personal

computer. The software has a graphical user interface,allowing most users to operate their StarPac

systems with minimal training.

PID Controller - Systems are equipped with a self-containedPID controller that can use internal process parameters (or a

value from an external transmitter) as the control variable.The PID parameters can be tuned for tight process control.The ability to control flow, pressure, or temperature makes

StarPac intelligent systems appropriate for numerousprocess applications in diverse industries.

Process Transmitters - Sensors in the valve body measure processconditions, including upstream and downstream pressure, temperature,and flow. Locating pressure and temperature sensors in the valve bodyeliminates several process connections. All sensors have at least twoseals to reduce the possibility of leaks to the atmosphere. Remote-mounted pressure sensors can be fitted with isolation and/or purgevalves to aid maintenance of the sensors. Flush mounted sensorsare available for fluids that could plug the pressure sensor ports.

Local Display - Eight variables (P1, P

2, temperature, gas and liquid flow,

setpoint, stem position and total flow) can be displayed on an externally-visible display. An error indicator will show if the StarPac system

should fail any internal diagnostics or have active process alarms.

Multiple Failure Modes - StarPac technology allows multiplefailure modes to be set, including: power, air supply, command

signal, or process failure. This ensures greater reliabilityand consistency of the process in case of emergency

shutdowns, protecting the process and people.

Data Logger - The StarPac system can keep a record of processconditions at user-specified intervals (1 to 32,000 seconds) andstore them in its memory for later retrieval to aid in diagnosingprocess upsets. A flow totalizer is also available with reset action.

StarPac Intelligent System

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Configurations, Ordering Information

DCS Modbus RS-485

Modbus RS-485

PC RS-232

232 - 485 Interface box

PC Controller

Box

Batch Control

or

Controller

Analog Interface

Box

4 – 20 mA

Six 4 – 20 mA

Signals (isolated)

Multiple Analog Outputs Via Optional Analog Interface Box

Sample Analog Interface Box Application

Analog Interface

BoxRecorder

4 Wires

Output

Flow

P1

Temperature

Controller

RS-485

Ordering InformationThe following information must be provided when order-ing a StarPac intelligent system:

1. Control valve specifications: size, body pressurerating, material, etc.

2. Start-up and operating conditions: inlet/outletpressures, temperature, flow rate, fluid physicalproperties.

3. Maximum operating temperatures and pressures

4. Electrical classification requirements

5. Process control parameters and special softwarerequired

6. Pressure sensor material and configuration re-quired; pressure sensor mounting: close to valvebody (std.), remote-mounted or flush-mounted (opt.)

7. Piping installation at StarPac system

8. Valve accessories and options required: handwheel,certified drawings, power supplies, etc.

Figure 3: StarPac Intelligent System Configurations

StarPac Intelligent System

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2

4

6

8

10

0 10 20 30 40 50 60 70 80 90 100Flow (percent of maximum)

Err

or (

perc

ent o

f rea

ding

)

Specifications

Figure 4: Flow Accuracy

Table III: Electrical SpecificationsPower Supply 24 VDC +4 VDC (300 mA max.)Analog Command 4-20 mA (30 mA max.)Aux. Analog Input 4-20 mA (30 mA max.)Analog Output 4-20 mADiscrete Inputs 12 to 200 VAC or DCDiscrete 1 A, 110 VDC or 125 VAC;Outputs 350 mA/200 VDC or peak ACExplosion-proof Class I, Division I, Groups B-D

(FM listed)

Non-incendive Class I, Division II, Groups A-D(FM and CSA) (BS 6941, pending)

Overload Min. 500 volt isolation; 24 VProtection power fuse protected

Serial Interface RS-485 port, Modbus

Table II: Physical Specifications

Pressure 316L stainless steel, VitonSensors O-ring seal; others on request

Housing Cast, powder-coated aluminum

Tubing 316 Stainless steel

Environmental NEMA 4X

Pressure Sensor Two times maximum operatingOverrange pressure with negligible change

in output.

Table V: Valve SpecificationsBody Size 1/2 to 6-inches (standard)Pressures up to ANSI 2500

Table IV: Software SpecificationsComputer System MS-DOS 3.1 or higher, 80286

processor running at effectiverate of 12 MHz or greater

Drives Required Hard disk (approximate 5 Mb)StarPacs per link up to 31 (depending on protocol)

Table I: Performance SpecificationsMeasurement Repeatability

Flow 0.25% full scalePressure (max.) 0.1% full scaleTemperature 0.6° CDrift 1% full scale/6 monthsCalibration Independent zero and span

adjustment for all sensors.Vibration Up to 2 G’s - 30 to 500 Hz

Operating Temperature Range

Ambient -40 to 170° F (-40 to 76° C)Process Media -320 to 1020° F (-195 to 550° C)Temperature -23 to 65° C (0,0335%/° C)Effect -40 to 85° C (0,12 %/° C)

Other Features

Totalizer Totalizes mass flow until reset;available through digital link.

Data Logger 300 most recent samples atuser-defined intervals, from1 second to 9 hours.

StarPac Intelligent System

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FT PT TT

Conventional Gas Flow Loop

Turndown Ratio – 4:1 Straight Runs – 10 up, 6 down Pipe Insertions – 4 No Diagnostic Capabilities No Data Logging

DCS

DCSStarPac Gas Flow Loop Turndown Ratio – 30:1

Straight Runs – none needed Pipe Insertions – 1 Diagnostic Capabilities Data Logging Interlock Tie Ins Local Display

Figure 5: StarPac Flow Loop Comparison

Valtek Sulamericana Ltda. - Sao Paulo 09940, Brazil

Telefon: 11-745-1011, Telefax: 11-745-2477

Valtek India Ltd. - Ahmedabad, India

Telefon: 272-813319, Telefax: 91-22-623-1055

Durco Valtek Pte Ltd. - Jurong, Singapore 2261

Telefon: 261-2200, Telefax: 261-3935

Yokogawa *Kitz* Valtek - Tokyo 141, Japan

Telefon: 03-5434-5963, Telefax: 03-5434-5930

Valtek Controls Ltd. - Edmonton, Alberta T6P 1K6

Telefon: 403-449-4850, Telefax: 403-449-4851

Valtek Corpus Christi - Corpus Christi, TX 78408

Telefon: 512-289-6911, Telefax: 512-289-691

Valtek Houston - Deer Park, TX 77536

Telefon: 713-479-9500, Telefax: 713-479-8511

Valtek Los Angeles - Santa Fe Springs, CA 90670

Telefon: 310-946-0767, Telefax: 310-946-2776

Valtek Philadelphia - Boothwyn, PA 19061

Telefon: 215-497-8600, Telefax: 215-497-6680

Valtek Australia Pty. Ltd. - Scoresby, Victoria 3179

Telefon: 3-764-8522, Telefax: 3-764-0013

Valtek New Zealand Ltd. - East Tamaki, Auckland

Telefon: 9-274-1933, Telefax: 9-274-1812

While the information and specifications presented in this literature are believed to beaccurate, they are supplied for informative purposes only and should not be consideredcertified or as a guarantee of satisfactory results by reliance thereon. Nothing containedherein is to be construed as a warranty or guarantee, express or implied, regarding anymatter with respect to this product. Because Kammer is continually improving andupgrading its product design, the specifications and information included herein aresubject to change without notice. For further information or verification, consult factory orKammer representative. Specific instructions for the installation, programming, operation,troubleshooting and maintenance of Kammer StarPac intelligent control valve systems arecontained in the StarPac maintenance manual. Before the intelligent control valve systemis installed or operated, this manual should be read thoroughly and followed exactly by allpersonnel responsible for their operations. Maintenance manuals are available throughKammer representatives or by writing Valtek directly. MS-DOS, Teflon, Lotus 1-2-3 areregistered trademarks of their respective companies.Valtek Incorporated has established industry leadership in the design and manufacture of

its products. When properly selected, each product is designed to perform its intendedfunction safely during its useful service life. However, it is necessary that Valtek’scustomers be fully aware of its responsibilities when using these products.

Each Kammer product may be used in numerous applications under a wide variety ofindustrial service conditions. Although Kammer can, and often does, provide generalguidelines, it is not possible to provide application specific data and warnings for allconceivable applications. The purchaser must therefore assume the ultimate responsibil-ity for the proper selection, installation, operation and maintenance of the products. It isimperative that the purchaser obtain and read the appropriate Installation, Operation andMaintenance (IOM) manual and train its employees and contractors in the safe use of theproducts in connection with the purchaser’s manufacturing processes.

Kammer will continue to provide its customers with the best possible products and servicesavailable. Should you have questions about these provisions or about Kammer’s productsin general, contact your local Kammer representative or the factory directly for assistance.

Kämmer is represented by factory-trained manufacturer representatives worldwide:

Valtek International Headquarters - Springville, UT 84663

Telefon: 801-489-8611, Telefax: 801-489-3719

Kämmer Ventile GmbH - Manderscheidtstr. 19, 45141 Essen

Telefon: (0201) 2 94 07 - 0, Telefax: (0201) 29 72 51

Kämmer Vannes S.A., La Chaux-de-fonds, Schweiz

Telefon. (0 39) 26 44 33, Telefax: (0 39) 26 54 22

Valtek-Sereg - 91304 Massy Cedex - France

Telefon: (1) 64.47.21.29 - Telefax: (1) 64.47.20.94

Valtek Baton Rouge - Baton Rouge, LA 70809

Telefon: 504-751-9880, Telefax: 504-755-0728

Valtek Beaumont -Beaumont, TX 77705

Telefon: 409-842-0087, Telefax: 409-842-4444

Issue E 07.94