Great potential with intelligent valve controllers. Janne Laaksonen Metso Automation Finland

Transcription

1 Great potential with intelligent valve controllers Janne Laaksonen Metso Automation Finland

2 Second-generation diagnostics as vital maintenance tool Neles ND9000 Online monitoring and testing of ESD valves Neles ValvGuard VG9000

3 ND9000 Intelligent valve controller

4 Neles ND9000 in nutshell The Neles ND9000 is a top class field proven intelligent valve controller that operates on all control valve packages and in all industry areas. With benchmark control accuracy, diagnostics features enabling true predictive maintenance and versatile features our customers can achieve a well performing process and full transparency to valve assembly. 4

5 Optimum process performance with Neles ND9000 ND9000 has benchmark control accuracy Control accuracy has direct effects on process variability Process variability has then again cost effects through Production quality Amount of production losses Chemical consumption Raw material consumption Energy consumption Process variability with average control accuracy 3,1 % Process variability with Neles ND9000 s control accuracy 0,6 %

6 Reliability The most important feature Why is reliability so important? - Cost of lost production - Cost of maintenance - Safety ND9000 reliability facts - Robust and thoroughly tested design - Extensive field experience - Comprehensive diagnostics improve reliability - Contactless position sensor

7 Diagnostics Predictive maintenance strategy compared to corrective and preventive Enhanced field device availability - No unplanned shutdowns - Reduced unexpected downtime More effective maintenance resource allocation - Concentrating on the devices that really need to be maintained Efficient maintenance planning - Work lists in advance - Human resources, spare parts and equipment

8 First generation diagnostics UNCLASSIFIED Analysis Signature? = OPEX Signature = OPEX StartUp Plant is running Shut Down Based on tests that are run during start-up and shut down - any view of this test is an instant in time, it does not give predictive value and you can not plan the maintenance activities and need of spare parts in advance Valve is not under true process conditions and the analysis result does not reflect the real situation. Users do not have time to test, analyze and make decisions on every valve package during the shut-down 8

9 Second generation diagnostics UNCLASSIFIED Data analysis StartUp Plant is running Shut Down Valve performance is assessed during the run-time Valve controller measures and stores the diagnostic data - best possible resolution and accuracy of information - constant understanding of valve condition No extra work during start-up or shut down 9

10 Third generation diagnostics 10 Start-up Plant is running Data analysis Shut down No extra work during start-up or shut down No extra costs for diagnostics features Know your valve condition in the past, present and in the future. Correct focus for the shut down maintenance Valve performance is assessed during the run-time Metso smart products measures and stores the diagnostic data by itself Best possible resolution and accuracy of information Time Plant is running

11 What does the diagnostics of ND9000 include? Third generation diagnostics - User friendly metrics for control performance, valve, actuator, positioner and external factors - Deviation and pressure ratings graphically - Trouble shooting guide Second generation diagnostics - Lifecycle diagnostics example: control valve stiction - Counter diagnostics example: actuator full strokes count - Online diagnostics example: pneumatics problem - Event log of 8000 events First generation diagnostics - Offline tests 11

12 Advanced diagnostics made easy Performance view of Metso Valve Manager Advanced diagnostics helps to make correct decisions fast Metso Valve Manager with ND9000 makes valve diagnostics more user friendly than ever before Unique and easy segmentation of control valve condition Statuses according to Namur NE107 12

13 Example of troubleshooting with the help of ND9000 s diagnostics Condition monitoring screen Performance view with recommended actions Actuator membrane has failed, leakage increasing! 13

14 Selected references Site Country Industry H/F/P DCS ND9000 Smart products Shell Nanhai China Refining FF Yokogawa 2500 VG Sabic UK Petrochemical H Honeywell 200 Neste Oil Finland Refining H metsodna FieldCare, devices Goliath Norway Upstream Gas, offshore H ABB 200 VG9300, SG9300 Botnia Uruguay P&P H Honeywell 700 Mangalore India Refining &Petrochemical IOCL Paradeep H / F Yokogawa 600 India Refining F Yokogawa Date/Title/Author

15 ValvGuard VG9000 Intelligent safety solenoid

16 Neles ValvGuard VG9000 in nutshell Neles ValvGuard VG9000 is a new generation intelligent safety solenoid and partial stroke testing device for emergency shutdown valves (ESD) and emergency venting valves (ESV). With market leading pneumatics capacity and enhanced features, VG9000 takes partial stroke testing to a completely new level and mitigates the safety risks

17 Metso s intelligent safety solenoids VG800 (HART) First ever SIL 3 certified PST device in the market VG9000F (FOUNDATION fieldbus) 17 VG9000H VG9000 (HART) Stainless Steel

18 VG9000 is SIL3 certified by TÜV Neles ValvGuard VG9000 is TÜV certified up to and including SIL 3 to comply with IEC61508 standard Type A device 18

19 VG9000 key features Most extensive ESD valve diagnostics - Internal pneumatics testing - Automatic safety electronics testing - Emergency trip testing - Partial stroke testing Collects valve diagnostics also during the trip Easy to use user interface Largest pneumatics capacity on the market One device for single and double acting operation Available for FF and HART Internal integrated limit switches Full interoperability with all the main safety and asset management systems

20 Safety View For easy first look of the diagnostics Safety View in ValveManager TM (DTM) is showing the main diagnostics at once Tells the condition of the safety valve Indices are based on the measurements and the test data in VG

21 VG9000 internal pneumatics test Tests VG9000 pneumatic operation without moving the safety valve Safety action is available during the testing Test is controlled by VG9000 and is cancelled if the valve moves Automated or manual Can be run very often, because it does not affect the process at all Safety loop failure sources by OREDA 35 % 15 % 42 % 8 % SOLENOID VALVE FAILURES OTHER FINAL ELEMENT FAILURES SENSOR FAILURES SAFETY SYSTEM FAILURES

22 Partial stroke test (PST) Tests the whole safety valve assembly Manual or automatic with adjustable testing frequency Pressure and time based position measurement Breakaway pressure and load factor measurements 22

23 Diagnostics trends for predictive maintenance Load factor and breakaway pressure trends - Based on partial stroke testing - Trends are test based Latest 10 individual tests and after that averaged data 23

24 Assured success ValvGuard technology proven worldwide Aramco, Saudi Arabia BP, UK (include HIPPS) Borealis, Finland / Sweden Conoco, UK ENI, Norway Ineos, UK / Sweden KNPC, Kuwait KOC, Kuwait Lotos, Poland Man Turbo, Germany Neste Oil, Finland Oman, LNG (incl. HIPPS) Petrobras, Brazil Preem, Sweden Qatar Gas, Qatar Qatar Petroleum, Qatar Rasgas, Qatar SABIC, Germany / Saudi-Arabia Shell Nanhai, China Shell, NL / Singapore / UK (incl. HIPPS) Sasol, South Africa Statoil, Norway (incl. HIPPS) Total, France / UK / Nigeria / Angola Woodside Energy, Australia

25 Summary Top class control accuracy of ND9000 enables better control loop performance True predictive maintenance with the help of ND9000 s superior diagnostics features Most extensive ESD valve testing capabilities with Neles ValvGuard VG9000 ValvGuard VG9000 has the highest pneumatic capacity on the market

26 CONFIDENTIAL - DRAFT