The Future of Control Valve Maintenance: On Line 24/7

Diagnostics
2023

Predict Act Protect

© 2021 Flowserve Corporation. All rights reserved. 1

About the viewer panel
Today’s Presenter
Control Valves

Actuator

According to several studies performed by

the International Society of Automation
Positioner
(ISA) and API, control valve failure is
responsible for an estimated 25% of
unplanned shutdowns in the petrochemical
industry.
Valve Body
 Positioners

The function of a positioner

is simply that of an input vs.
an output. Think of it as the DIGITAL Positioner ANALOG Positioner
positioner being told to do
something, then reacting
based on a set of rules to
keep things in sync within
the media flowing system.

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 Digital Positioners - Evolution

1997 1999 2001 2004 2006 2009 2010 2013 2016 2018

Positioners evolved withing the years and now they are fully stack with sensors to provide
valve/actuator/control diagnostics.
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 Digital Positioner Diagnostics

Currently there are only two ways to fully access positioner diagnostics:
1) Hard wire (I.E. USB/HART modem) to a field PC with OEM software installed or handheld
Communicator
2) If the end user has a DCS with AMS, they can load DTMs and run the OEM Software.
Site specific view
• Alarms deeply embedded in DCS, AMS Post Diagnostic are usually accessed
by OEM field engineers to
Reactive • No easy way of determining health of all valves Failure perform RCA.
• People competency dependent
• Time consuming
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End-to-End, Complete Turnkey IoT Solution
Innovative sensors Application-specific analysis
Wired and/or wireless sensors collect vibration, pressure and Equipment performance data is analyzed with technology
temperature data for analysis. Long-range wireless sensors designed specifically for pumps, valves and seals, so you can
enable cost-effective monitoring of thousands of assets over gain a clearer understanding of how to increase the efficiency,
sprawling facilities. productivity and reliability of the particular equipment you use
every day.

Flowserve Monitoring Center

Secure communications Trend reporting and notifications

Our secure system architecture collects data from Trend reports provide insights into equipment performance
equipment sensors and transmits it via a secure over time, while emails and alerts inform you when an asset
encrypted network. experiences a problem, so you can take immediate action to
address it.

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 Communications - 3 options On-Premises/Cloud

/ DA

Wired
Logix 3800
IIoT
DCS/AMS Server
Edge Gateway

HART Wireless
Device

Wireless MQTT
Logix™ 3800 HART Wireless IIoT
Gateway Edge Gateway
Monitoring Center

Wired
MQTT
Logix 3800 HART Expansion HART IIoT
Module Multiplexer Edge Gateway
9
Multiple connectivity options.
 Security Outline – Best Practices

• Field Device (Positioner/Electric Actuator) with Write Protect (WP) Functionality which disables any external parameter change
requests from DTMs, DDs, Handhelds etc. All other functionality of the positioner remains intact.- control, alarms, diagnostics,
communications, etc.

• Edge Integrity - Hardened by IoT security software with the capability to monitor Hosted Intrusion Prevention, Approved Application
Listings, System Vulnerability Scan, and Web and IoT Reputation Service. Authenticate the field gateway.

• Cellular Modems or Routers - M2M SIM Whitelisted with dedicated IMSI, Data transferred via a dedicated, private APN, Endpoint
Authentication

• Communication Protocols – Use Industry Standard Reference backed and secured communication protocols

• Data Encryption – Use Data Encryption during transit and storage like Advanced Encryption Standard (AES) – 256-bit

• Portal – should provide configurable user roles, best practices of password policy to be followed, concurrent user login session should
be restricted, in case of inactivity – Portal logout.

• API Management – Use API gateways and Web Application Firewalls to filter out any malicious traffic. Use auditing and logging

• Update patches regularly and patch vulnerabilities quickly

Use cases - Common issues in a critical application

Failure / Issue Technology

Common factors affecting plant operation Friction indication
 High cyclical valves – wear & tear due to fatigue
 Mechanical damage, friction impacting time to open, time to close
 Packing leaks 30 % Pressure at
pressurization
 Exposure to solids in the process fluid (dust from adsorbent ) -
of failures port, Temperature
could cause damage to valve.

Hydrodynamic noise / cavitation /

mechanical failures due to vibration
15 % Vibration
of failures
e.g: Severe service – massive pressure spikes

Sensors Networks
Create Data Communicate Data

Positioners
Gateways
Limit switch Vibe, temp,
pressure

Monitor & receive early notifications 11

 Key Diagnostics / Analytics

# Failure Type Failure Modes and Fault Conditions Online /Offline

1 Mechanical Trim failure Online

2 Mechanical Packing wear / Adjustment Online

3 Mechanical Actuator wear / Air Leaks Online

4 Valve stability Signature analytics Offline

5 Electrical/Control Positioner failures Online

6 Mechanical Fail safe capability Online

7 Control Controllability Online

8 Mechanical / Control Linkage Online

9 Any Event & History capture Online

10 Control Hydrodynamic noise (Vibration) Online

You can use equipment you already have (150+ Diagnostics)

© 2022 Flowserve Corporation. All rights reserved. 12
 Unique Value Addition

Landing Page Detailed Valve Health Failure Modes & Solutions

Platform agnostic OEM Vendor Agnostic Insights and Solutions

• Existing plant control systems • Aggregate & standard parameters • Mouse over detailed information
• Standard industry protocols – FDT, • More detail for FLS equipment • Can build in analytics in future
OPC UA , MQTT, PA DIM

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Agnostic – connection, protocol, platform & vendor.
 What is different ?
Feature Generic Asset Management Systems OnLine Diagnostics Solutions

Data capture: Continuous Loss of Resolution intact

vs Snapshot Resolution over
time.

Expertise on demand Near real time monitoring & notifications,

Ability to service & support

AMS agnostic – multiple Single site only. Comprehensive asset health view across multiple sites &
sites No Comprehensive view of assets across multiple platforms
multiple sites and asset mgmt. platforms.

Trends / Event Log Positioner has finite memory – if many events Detailed historical information available – recorded continuously.
occur, first event gets overwritten
Early Failure detections & Existing Positioners: Packing leaks in Control valves,
Analytics Time to fail, Time to maintain
Additional Sensors - Aerodynamic noise,
Valve documentation Links to birth certificate, repair history, interactive parts search,
IOM

Pumps, Valves , Seals Proprietary – Expensive to customize, integrate Non Proprietary - Easy integration / customization.
& limited to number of users Independent of connection, protocol, platform & vendor !

Agnostic – Connection, Protocol, Platform, Vendor.

 Summary

On Line Diagnostic Solutions enables you to transition

from a reactive to proactive approach to:
• Reduce costs by avoiding unexpected downtime and emergency
repairs
• Empower maintenance staff via “expertise on demand”
• Improve plant efficiency, productivity and profitability through
more optimized equipment
• Reduce equipment lifecycle costs through improved equipment
efficiency
• Engage Service & repair support

© 2022 Flowserve Corporation. All rights reserved. 16

 Questions?

Predict Act Protect

© 2021 Flowserve Corporation. All rights reserved. 17

 Submitting Questions, Exit Survey and Archive
Questions?
Type your question in the “Ask a Question” box on the Webcast Console and click
“Send.” We will get to as many questions as we have time for. Questions that are for
today’s presenters will be answered verbally during the Q&A session.

Exit Survey:
Please take a moment to answer a few questions on our exit survey that will pop up on
your screen at the conclusion of the webcast. We use the answers to help make
improvements to our webcast program.

Archive:
 Within 7 days, an archive with Q&A will be posted

 We will send an email to registered attendees with hyperlink

 Can also access from the plantengineering.com home page

 The Future of Control Valve Maintenance: On Line 24/7
Diagnostics
2023

Predict Act Protect

© 2021 Flowserve Corporation. All rights reserved. 19