Pros & Cons of Gas Flowmeters Evolution of Digital Valves Q&A: Understanding Mixing & Agitation

august 2011 Vol. XVII, No. 8 www.FlowControlNetwork.com

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technology spotlight

Evolution of Valve Diagnostics

Delivering Enhanced Process Control Under Increased Scrutiny

ontrol valves have drawn more and more attention in recent valve stem to feel the motion of the valve. This technique was,
years, and modern diagnostic technologies and techniques
certainly, more of an art than a science. Determining whether the
are helping them shine under this increased scrutiny.
motion of the valve was normal required a unique skill set and
For many years, end-users focused on infrastructure-related
significant experience. And unless the valves motion was jerky
assets, invested in advanced process control system equipment,
(sticking and slipping), this technique provided no clues as to
and, following the tragedy of 9/11, tightened plant security.
what might be wrong with the valve.
Meanwhile, control valves, while essential, were line items buried
Veteran technicians also will recall using pencil and paper to
in the maintenance budget.
record pressure readings from the gauge on a valves actuator
The script is different today, however, thanks to global comand valve positions from a dial caliper. These readings would then
petition and growing pressure to increase profits, boost plant
be used to calculate friction and spring range.
performance, and improve process reliability. The final control
element has a direct impact on a facilitys operational excellence
Valve Diagnostics Timeline: 1980s
a combination of profitability, plant efficiency, quality, and safety The 1980s saw the introduction of computers and portable data
putting it squarely on the radar screens of maintenance teams
acquisition systems into process control facilities. These portable
and reliability and process control engineers.
systems (Figure 1) used external sensors to measure the forces
This, in turn, has made valve diagnostics more important than
generated by a valves actuator and used a travel sensor to meaever. To keep a plants control valves performing optimally, the
sure the valves motion. It was the birth of the valve signature
end-user must be able to monitor each
concept.
valves performance and have actionable
These portable valve diagnostic tools
information to use in identifying which
were (and still are) highly effective for valivalves require maintenance, accurately
dating the health of a control valve before
diagnosing valve problems, and planning
putting it in service or for verifying a valves
maintenance activities. And they need to
condition post-repair. They also are still
have this information in hand before valve
successfully used to diagnose the health of
problems impact process performance.
control valves equipped with analog posiDiagnostic methodologies and technolotioners.
gies for control valves have evolved greatly
These tools are not, however, userin the past 20 years with the advent of
friendly. The diagnostic process is timemicroprocessor-based valve positioners
consuming, taking at least one hour per
and the introduction of user-friendly ways
valve. Personnel must be specially trained
to integrate the information into the superin installing the sensors. Analyzing the data
visory system. This article will review the
so that it becomes actionable information
milestones in this evolution and describe
involves significant number-crunching.
Personnel may be required to enter potenhow online valve diagnostics (OVD) can help
Figure 1. The 1980s saw the introduction of
tially hazardous areas to conduct tests. And
improve process integrity by giving operaportable data acquisition systems that used
tions personnel the information they need to external sensors to measure the forces gener- using these tools is more disruptive than
using newer options, as it requires that the
address problems early, before they become ated by a valves actuator and a travel sensor
process be shut down or the control valve
major issues. It also will discuss the various to measure the valves motion.
bypassed.
types of diagnostic information that can be
provided by digital valve positioners and explain how to integrate
Valve Diagnostics Timeline: 1990s
this information with a plant asset management solution.
The 1990s were marked by the introduction of microprocessors
Valve Diagnostics Timeline: Pre-1980
placed inside valve positioners the birth of digital valve posiPrior to the 1980s, control valves could not be monitored remote- tioners (DVPs). This decade also saw a transition from proprietary
ly and diagnosing a problem valve involved the use of mechanical field communication protocols to open digital communication
tools and techniques that could only be mastered through extenstandards such as the HART Protocol, the Foundation fieldbus,
sive hands-on experience.
and PROFIBUS.
It was not uncommon to see a technician apply a finger to a
The new DVPs had embedded sensors to measure the pressure
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Flow Control
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By Sandro Esposito

moving the actuator and a travel sensor to track valve motion. This
made them significantly more user-friendly, because the end-user
did not need to complete any mechanical setup in order to measure
the force that moved the valve and track the valves actual position.
In addition, the new DVPs allowed embedded test routines, in
which the positioner would modulate the valve while measuring data
from embedded sensors. This essentially eliminated the need for
portable data acquisition systems, allowing the masses to make their
own signatures. Yet skills in analyzing signatures were still necessary
and the tests were as intrusive as those completed with portable
diagnostic tools.
There also was no open standard that all valve manufacturers
used to analyze the signature results and display them to the
end-user. Each manufacturer had its own proprietary software
that required additional hardware and software if the user wanted
to remotely access the data. Equipment from various manufacturers could not be easily integrated, creating islands of information that were frustrating and costly to use and support.

Valve Diagnostics Timeline: 2000 Today

The early 21st century has been marked by two significant

advances that have helped process facilities address such
emerging challenges as reduced staffing, the location of facilities
in evermore remote places, and globalization.
First is the introduction of open standards that present diagnostic information to the end-user in a common fashion, allowing
devices from various manufacturers to communicate with each
other and allowing end-users to mix and match devices from
various manufacturers to best meet their needs.
Second is the advent of online valve diagnostics technology
that allows sensor and other data from DVPs to be gathered,
analyzed and delivered to the end-user all automatically and
all while the process continues running. Without disrupting the
process, valves can be tested and drifting Key Performance
Indicators (KPIs) can be identified before they begin impacting
production. And rather than raw data, the end-user receives
actionable information, eliminating the need for complex calculations and data analysis and helping the end-user more quickly
determine the appropriate course of action.

The Flavors of Diagnostic Information

While diagnostics for control valves have evolved significantly,

end-users can still be confused by the various flavors of diagnostic information that are available. Diagnostic information can
be divided into three general categories continuous, offline
and online based on the type of data provided and how it is
gathered.
Continuous: Continuous diagnostic information is defined as
data saved in the non-volatile memory of a digital positioner. It
can include cycle count (number of valve reversals); accumulated
travel; hours of operation closed, near closed and open, etc. It
also includes DVP alerts initiated by the positioner to notify the
end-user of device performance issues or abnormal conditions,
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such as low air supply or position deviation.

This data can be valuable in predicting eventual
failures or process control deficiencies, or in helping determine
whether a valve has been improperly selected for a given application.
In addition, because the values are continuously monitored
and the data is saved by the DVP, the integration to a historian
is seamless. In other words, continuous communication with the
DVP is not necessary in order to collect the data because the DVP
functions as a field server of control valve information.
Offline: Offline diagnostic information can only be obtained by
sending a command to the DVP using the vendors software to
initiate a test or to start the acquisition of specific data. The command triggers a routine inside the positioner that modulates the
valve and gathers data from the built-in sensors.
Typically, the valve must be isolated and bypassed in order to
allow the test to stroke the valve back and forth. The result is
a signature that will provide insight into the mechanical condition of the valve, including how well the valve closes and how
it responds to an input signal. Essentially, the offline signature
delivers the same results that are provided by portable data
acquisition systems, but it is much easier to execute a signature
with a DVP because the necessary sensors are built into the positioner, rather than installed separately to the outside of the DVP
by the end-user.
Online Valve Diagnostics: This type of diagnostic information
is described as online because it is gathered while the valve
is controlling a live process. The condition of a control valve can
be assessed without disabling the positioner and interfering with
plant operations.
Data is gathered from the DVPs built-in sensors as the DVP
modulates the valve. Once the data is gathered, fault-modeling
techniques are applied to quantify Key Performance Indicators
(KPIs), such as friction, initial and final spring settings, response
speed, positioning accuracy, and position lag. The KPIs are then
compared to the nominal values; if they are found to be outside
the desired range, fault-modeling techniques will identify the possible cause of the deviation.
In addition, KPIs are monitored and analyzed over time, allowing plant personnel to identify trends and estimate when the valve
will require attention. Predictive maintenance can then be completed before the valve malfunctions and impacts the process.
For example, steadily decreasing friction is a sign of packing and
stem wear that could result in fluid leaking to the atmosphere,
indicating to plant personnel that the packing should be tightened
to prevent leaking and that the valve should be flagged to receive
more comprehensive maintenance in the near future.
The table in Figure 2 offers a snapshot of the various aspects
of valve performance and condition that can be tracked using
each of the diagnostic flavors.

Diagnostic Capabilities & Limitations

Each of the three diagnostic information flavors offers a differAugust 2011

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technology spotlight

Capabilities of Various Diagnostic Tools

Key Performance
Indicator (KPI)

Offline
Diagnostics

Continuous
Diagnostics

Online Valve
Diagnostics

DVP Condition

Runtime Information

DVP Performance

Seat Profile

Seat Load

Static Performance

Packing Condition

Bellows Condition

Guide Friction

Spring Adjustment

Spring Integrity

Feedback Linkage

Air Leak

Dynamic Performance

Historical KPIs

Root Cause Analysis

Shutoff Classification
Figure 2. This diagnostics capabilities checklist summarizes the various
facets of valve performance and condition that can be monitored using
each of the three flavors of diagnostics technologies. All three types of
information are necessary to get a complete picture of a valves health.
Diagnostics cannot assess seat leakage (shutoff classification); it can only
be tested by closing the valve and measuring the flow going through it.

ent array of information and different insight into the corrective

action that should be taken to maintain the integrity of a control
valves overall performance (Figure 3). For example, the accumulated cycles and travel displacement data obtained via continuous
diagnostics can be used to determine when packing must be
maintained or replaced. Offline diagnostic information allows the
user to validate the valves response throughout its full range of
motion, as well as measure such performance characteristics as
valve friction, the spring setting, and the quality of the plug and
seat contact (also known as seating profile).
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Figure 3. DVPs capture valve performance data and then transfer it to an

asset management station using one of several communication protocols.
The asset management station then converts the data into actionable information that can be used by plant personnel in assessing and addressing
valve performance.

Online diagnostics tools combine the capabilities of their

continuous and offline counterparts while offering additional
advantages. There is no setup involved and the DVPs software
automatically captures the data, saving time and streamlining processes. Remote access means plant personnel are not
required to enter potentially hazardous areas. The historical data
captured allows plant personnel to see performance trends over
time. Finally, there is the significant advantage that the tools do
not interfere with the control valves operation.
One key performance characteristic that cannot be tracked
with a DVP or with a portable diagnostic tool is seat leakage.
To explain why, let us begin by reviewing how tight shutoff
is achieved. When the plug makes contact with the seat, the
force generated by the actuator is delivered through the stem,
compressing the plug against the seat. This metal-to-metal connection is what prevents the fluid from going through the orifice
(seat) of the valve. The surface finish of the two components
making contact is critical to shutoff. The smallest nick or scratch
can degrade the shutoff to the point that the valve does not
fulfill its ANSI (American National Standards Institute) shutoff
classification.
While DVPs can confirm that there is a firm and adequate
contact between the plug and seat, they cannot determine the
integrity of the surface finish. The only method to confirm that the
valve can achieve its shutoff classification is to run a seat leak
test, or close the valve and measure the flow going through it.

Usability of Diagnostic Tools

The usability of diagnostic technology has improved significantly

with the emergence of such integration standards as EDDL
(Electronic Device Description Language) and DTM (Device Type
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Manager). Prior to the introduction of such standards, the integration of field device diagnostics was complex and required
significant engineering because each vendor had proprietary,
standalone solutions. With EDDL and DTM, the diagnostics provided by DVPs are easily integrated with control systems and asset
management software that support such standards. The user can,
therefore, access the digital positioners diagnostics with commercially available software and without the need for software
engineering.
In cases in which the host system does not support EDDL or
DTM, the end-user can still integrate the information via the OPC
(OLE for Process Control) standard. OPC is a communication
protocol allowing the exchange of data between computers and
between software. It creates a pipeline to move data between
a computer (the server) that is connected digitally to the DVP and
the computer (the client) that uses the raw data to generate and
present the diagnostics.
The integration of diagnostics is straightforward with control
systems that embed the HART Protocol, Foundation fieldbus, or
PROFIBUS. These systems have an architecture in which diagnostic information is passed from a DVP to a user interface.
In the case of older systems that still use an analog signal,
such as 4-20mA, the DVPs diagnostic data cannot be communicated through the host systems architecture because the
systems analog output channels are not capable of reading
the HART data. The emergence of wireless standards, such as
WirelessHART and ISA100, bridge that gap by allowing the data to
be wirelessly communicated from the DVP to a centralized data
acquisition computer.
When it comes to presenting the information to
the user, there are two primary industry standards
for doing so in a common fashion, regardless of
the DVPs manufacturer ISA SP75.26 and NAMUR
NE 107. ISA SP75.26 applies to offline diagnostics,
defining the terminology for valve diagnostics and
the graphical representations of valve signatures.
NAMUR NE 107 applies to continuous and online
diagnostics. It categorizes various possible asset
conditions and their severities and uses a set of color-coded symbols to communicate these statuses
(Figure 4). The same symbols are used for devices
made by various manufacturers, making them easily
recognized and interpreted much like the Check
Engine light on a cars dashboard.

The Next Decade

Developments to Watch

power microprocessors and sensors. These technologies and tools

will have the potential for allowing additional measurements to be
taken at the control valve, thus enabling more precise prediction
of pending performance problems and the detection of additional
valve malfunctions, such as seat leakage.
Furthermore, wireless and cloud computing could allow
information to move seamlessly to specialized outside experts,
allowing users to tap into their knowledge and, therefore, fueling
the creation of an encyclopedia of valve symptoms, root causes
and cures.
If control valves have not yet affected a plants performance
and budget, it is likely only a matter of time before they do so.
Todays diagnostics technologies can help operations personnel
prepare, help them optimize their processes, and potentially help
them trim maintenance costs. FC
Sandro Esposito is global marketing manager at GE Energy for
digital and SMART products in the companys Masoneilan product
line. A 17-year veteran of the control valve and process automation industries, Mr. Esposito has extensive experience with control
valve diagnostics and system integration and has been granted
several patents related to digital valve positioners. He graduated
from Ahuntsic College in Montreal with a degree in instrumentation and process controls. Mr. Esposito can be reached at sandro.
esposito@ge.com or 281 671-1683.

www.ge-energy.com

Figure 4. The NAMUR NE 107 standard categorizes various possible asset conditions and
their severities and uses a set of color-coded symbols to communicate these statuses. The
same symbols are used for devices made by various manufacturers, making them easily
recognized and interpreted much like the Check Engine light on a cars dashboard.

Control valve diagnostics have evolved rapidly

over the past 30 years from manual readings with gauges and
calipers to artificial intelligence that can analyze a valves performance while the valve is in operation. Advances will come as
fast, if not more quickly, over the next decade thanks to continued
advances in artificial intelligence and the introduction of ultra-lowwww.FlowControlNetwork.com
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