Diagnostic Software Supporting Condition-Based Maintenance of Control Valves

PublishTime：2022-05-10

◆To improve the stability of plant operation we developed PLUG-IN Valstaff, an application supporting the maintenance of control valves, which occupy an important place in plant maintenance operations. PLUG-IN Valstaff makes use of the diagnostic functions of Azbil Corporation's new Smart Valve Positioner 700 series, enabling advance detection of the symptoms of deterioration and abnormality. In addition, an analysis service for diagnostic data allows users to plan an appropriate maintenance schedule and effectively reduce maintenance costs and maintenance time.
●Introduction
▲Since control valves directly control the process fluid, if there is a problem with a valve, it will greatly affect plant operation. Thus, maintenance of control valves is very important for maintaining steady plant operation. On the other hand, changes in the economic situation due to global competition, industrial reorganization, etc., have heightened the need to cut equipment maintenance costs, putting pressure on plant maintenance departments to be more efficient.Generally, equipment failure rates change according to equipment age along what is called a “bathtub curve.” Failures can therefore be classified into three stages: the early failure period, random failure period, and wear-out failure period, the latter being the period when the failure rate increases as time passes. To prevent wear-out failures, time-based maintenance (TBM, periodic maintenance based on operating time) is usually used. However, a problem with TBM is that, if the maintenance interval is shortened to reduce the failure rate, maintenance costs and the risk of failure immediately after maintenance both increase.To avoid the problems with time-based maintenance, it is desirable to use condition-based maintenance (CBM), in which maintenance measures can be planned based on the monitoring of equipment condition and detection of symptoms of abnormality. Since, with CBM, unnecessary maintenance work is not done while the equipment is working reliably, a reasonable maintenance interval and reliable equipment operation can coexist, and maintenance costs can be cut.
▲With these considerations in mind, Azbil Corporation developed its 300 and 700 series smart valve positioners and equipped them with a control valve diagnostic function. In addition, the company developed a control valve maintenance support system, PLUG-IN Valstaff, to support condition-based maintenance that makes use of this diagnostic function. PLUG-IN Valstaff has functions that support the diagnosis of long-term deterioration based on history data collected during plant operation, as well as adjustment and test functions that help to prevent initial failures after shutdown maintenance. This paper describes the functions that are available to support CBM during both plant shutdown and plant operation. In addition, it explains Azbil Corporation’s valve diagnostic analysis service, which is based on the data collected by PLUG-IN Valstaff.

Brand of Product：	Azbil
Part#：	700 series 、 700 、 300 series 、 300 More Part#
Product Category：	smart valve positioners More
Application：	More
Data Type：	Supplier and Product Introduction More
Safety & Environment Standards：	More
Operating Temperature：	Please see the document for details
Qualification Grade：	More
Qualification Approval：	More
Package：
Language：	English Chinese Chinese and English Japanese
Date of Creation：	2015/6/23
Version Number：
Data Encoding：
Data Size：	4.2 MB

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