Optimizing valve maintenance using condition analysis

IPPTA seminar 17-18th July, 2014

Optimizing valve maintenance using condition analysis

IPPTA seminar 17th July, 2014

Speaker:

Jarkko RätyDirector, Services, Business Solutions

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Typical Maintenance Issues

• Unexpected failures− Production breaks cause loss of

revenue

− Safety and environmental issue

• Lack of targeted maintenance− Unnecessary maintenance costs

− Unnecessary risk of damage

− Are the right issues tackled ?

• Typical Performance Statistics− 30 % of controls increases process

variability

− 10-30 % of controls in Manual

− 30 % of valves with problems

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Traditional ways of selecting Valves for shutdown maintenance

• Certain Critical always

• Operator indications

• Grouping for each shutdown

• No actions if by-pass available

• Run to failure (=no actions)

Typically one rule is not directly followed, reality is more like combinations of the rules

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Operational History

Making a maintenance recommendationDevice history and present condition defines the action

ConditionAnalysis

Service History

Maintain in Place

Remove & Maintain

OK

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Maintenance decision makingDefining the actions is a continuous process

Prioritize

Analyse

PlanRepair

Report

Filter

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Maintenance based on known conditionMay reduce valve shutdown cost by up to 50 %

Field Work• Removal, reinsertion• Lifting, scaffolding• Transportation

Traditional Shutdown

Maintenance• Refurbishment• Spare parts• Testing

Condition Analysis• Visual Inspection• Diagnostic Analysis• Devices Testing

Adjustments• Calibrations• Preventive Actions• Tightening

Shutdown with Condition Analysis

70 % reduction in Field Work cost30+ % reduction in Maintenance costs

Typically30% valves require no action40% valves can be maintained in place30% valves require removal for maintenance

Up to 50 % reduction in Shutdown

Condition AnalysisKnown device conditions – makes maintenance intelligent

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Various intelligent analysis tools and methods are available to reveal field device conditions.

The suitable tools are sellected according to the existing installed device base and control system infrastructure.

Intelligent Maintenance

Device analyses are scheduled according the criticality. The known device conditions and criticality are used to prioritize daily maintenance actions.

Intelligent Shutdown

Devices are sellected for maintenance based on known device conditions and unnecessary maintenance can be avoided.

Condition Analysis ToolsRemote performance and diagnostics analysis

Smart Device Check

One-shot diagnostic analysis of large amount of devices for Shutdown planning purposes

Smart Device Monitoring

Continuous diagnostic analysis architecture for Maintenance and Shutdown planning

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Control Device Monitoring

Use the loop monitoring system to identify underperforming valves and identify probable root causes

Control Device MonitoringAn example: Detecting oscillations caused by a sticky valve

1. Graphical view to illustrate Valve Health

2. Deeper analysis reveals valve stiction

3. Process trend confirms typical sticky valve behavior- Process Value remains steady despite of changes in

Control actions until it moves

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SP = SetPointPV = ProcessValue (a flow meter)

CO = Control (to valve)

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ENGHIS

PCS

OPC

Contol Loop Monitoring

Smart device diagnostics utilizationAn example: Detecting air leakage in valve actuator

1. Condition Monitoring alarms malfunction

2. Remote analysis reveals excessive air consumption

- Gradual chance in Spool Valve Position

3. Actuator membrane failure (a hole) was discovered in devices maintenance

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Utilizing diagnostic information:

• Trouble Shooting (one device at the time)• Analysis of 10’s or 100’s of devices• 24/7 monitoring

Condition Analysis ToolsPortable testing devices

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Control Valve Testing

Testing of valve condition with portable testing system for Shutdown and Maintenance planning

Safety Valve Testing

Testing of safety relief pressure valves in process to determine if they are operating correctly at correct pressure setting

Valve Leak Testing

Testing of valves in process to determine if they are leaking when shut

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Control Valve TestingDetecting sticky valve by ramp movement

PC

Measurement system

1. Testing system connection to valve

2. Attachment options for external potentiometer

3. Testing results revealed valve sticking - while leaving the seat

- in the upper half of the stroke

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Valve Leak TestingLeakage detection and leak rate estimation

1. Acoustic measurement on predefined spots of valve assembly

2. A leak detected by acoustic signal

3. Estimation of leakage rate

4. Reporting devices conditions and recommended actions

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GAS LEAK ESTIMATIONContact: JR

COMPANY: Customer LOCATION: Site Date: 13/05/2013Valve Signal Pressure Inlet Gate Ball Leak Fluid LossI.D. Level Difference Size Valve Valve Rate Density Estimation

(dB) (bar) (ins NB) (y/n) (y/n) (l/min) (kg/m 3̂) (Tonnes/yr)PV-1280601A 23 13 2,0 N Y 0,7 1,2 0,46PV-1280601B 32 13 6,0 N Y 4,8 1,2 3,01PV-1290501 28 21 4,0 N N 3,5 1,25 2,29PV-1310702 18 5 1,0 N N 0,5 0,8 0,21PV-1470601A 17 9 5,0 N Y 0,9 1,25 0,62PV-1470601B 22 9 8,0 N Y 2,4 1,25 1,61

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A leak detected

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Safety Valve TestingTesting verifies pressure setting of safety valves

1. Setting up of testing system

2. Automatic testing run

3. Test report and pressure setting certificate with Maintenance recommendations

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Condition Analysis

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Analysis for different field device types

Device Type Vendor independent Vendor dependent Continuous / networked Off-line (portable) Bulk analysis

Sensors • Control Device Monitoring

• Smart Device Monitoring   

Valves

• Control Device Monitoring

• Smart Device Monitoring

•Control Valve testing

•Valve leak testing

•Safety valve testing

• Smart Device Check

Suzano BA Shutdown 2012, Brazil Company profile

Suzano- 2nd largest eucalyptus pulp producer in the world (8th in market pulp)- Pulp production costs is one of the lowest in the world- Six industrial units in Brazil

Suzano BA (Mucuri)- Pulp production 1.540 ktons yearly- Uncoated paper 250 ktons yearly

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Suzano BA Shutdown 2012 Results through Condition Analysis

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232 pcs

Preliminary list for

valve maintenance

153 pcs

Condition analyses

bySmart Device

Check

79 pcs

Visual inspectionand

Operational tests

22 pcsMaintenance

131 pcsOK

44 pcsMaintenance

35 pcsOK

66 pcs Maintenanc at

workshop

93 pcsAdjusment and

preventive actionon pipeline

73 pcsNo action

Customer Request Testing Plan Test Results Shutdown Actions

Shutdown time Shutdown 11 daysStart-up 3 days

Manning 33 Metso Professionals 2 Partner Professionals

for electrical actuators

Shutdown activities• 66 pcs maintenance of automatic valves• 7 pcs maintenance electric actuators • 93 pcs positioners adjustments and preventive tasks • 5 pcs extra activities requested by Suzano.

Suzano BA Shutdown 2012Maintenance Execution

Planning & Execution

• Activities included in the master schedule

• Monitoring the progress of activities

• Implementation of maintenance actions according to company procedures

Smart Device Check

Maintenance Planning ShutdownStart-

upVisual & Operational

CheckingOperational &

Maintenance History

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Suzano BA Shutdown 2012Direct reduction in maintenance costs 44 %

100 %

Preliminary Estimation

Condition Analysis• Visual Inspection• Diagnostic Analysis• Devices Testing

Adjustments• Calibrations• Preventive actions• Tightening

56 %

Actual

44 % reduction in Maintenance costs

Results31% valves required no action40% valves adjusted in place29% valves required removal for maintenance

50 + % reduction in Shutdown costs when Field Work taken into account

Field Work• Removal, reinsertion• Lifting, scaffolding• Transportation

Maintenance• Refurbishment• Spare parts• Testing

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Condition AnalysisThe way to optimize valve maintenance

“Don’t fix if its not broken”

Gather and collect information

Pinpoint the issues

Prioritize actions

“Tackle the right issues”