Configuring FISHER SMART

Positioners for Optimum

Diagnostics
Tim Jentz

Control Valve Performance:

What Makes a Good Control Valve?
How Fast Does the Valve Move?
Does the Valve Move?
Does the Valve Give the Right Loop Gain?

Flow Geometry Design

Stability is critical
Friction - controlled & consistent
Seal design impacts
Packing load and type
Linkages, lost motion
Impact of actuator design type
Positioner Design - sensitive & responsive
Feedback scheme used
Capability of tuning
Ability to diagnose/monitor
Must be matched to valve/actuator

Hart Protocol
Key Features

Compatible with Existing 4-20 mA systems

Protects investment in current systems
Wide breadth of products on the market today
Non-Proprietary -- Open and available for all

Other Compelling Benefits

Fieldvue helps to optimize Maintenance

The diagnostics capability of the FIELDVUE instrument

optimizes control valve assets and provides:

Increased availability
Increased uptime
Decreased unscheduled outages for control valve problems
Faster problem identification and resolution
Increased maintenance effectiveness
Lower maintenance costs by pinpointing problems and eliminating
unnecessary expenditures on parts, labor, or downtime
Increased plant safety.

DVC5000 & DVC5000f Series Instruments

First Generation & Obsolete
First Generation DVCs for HART &
Fieldbus
Introduced in 1994(HART),
1998(Fieldbus)
Over 237,000 HART & 15,600
Fieldbus units sold

DVC6000 Series Instruments

Available till Oct 1, 2013
Introduced in 2000
Over 1,000,000 sold
Utilizes linkages to pick up valve
movement
Single and Double acting actuators
Extremely rugged
Modular design with
encapsulated/Isolated electronics
NEMA 4X enclosure
Common I/P module
Explosion Proof & Intrinsically Safe

DVC2000 Series Instruments

Introduced in 2004
Over 100,000 units sold
Utilizes linkage-less mounting
technology
Same firmware technology as the
DVC6000
Common I/P module
Compact with local display
Single acting only
Intrinsically-safe & Non-Incendive
only
Has the option of position
transmitter and software limit
switches

DVC2000 Series
Linkage-Less Feedback Sliding Stem
Linear stem movement
No linkages
No contacting parts

Magnetic
Array
On Valve
Stem

Hall Effect
Sensor
in DVC

DVC6200 Series Instrument

Non-Contact Feedback
Introduced in Dec 2009
Over 300,000 sold
Uses linkage-less feedback similar to DVC2000
and an extension of the DVC6000 family
Single and Double acting actuators
Extremely rugged
Modular design with encapsulated/Isolated electronics
(same as DVC6000)
NEMA 4X enclosure
Common I/P module

Explosion Proof & Intrinsically Safe

DVC6200 HW 2 With I/O Package

Capabilities

4-20 mA position transmitter or 1 amp

discrete switch
Selectable HART 5 or HART 7

HART 7 - Long Tag (32 Characters)

Pushbutton autocal (travel)

Simplified protection removal
HART variable assignments

Remote Mount Option

Over 300 ft distance

High Temperature
Up to 257 deg. F
Isolates the I/P and electronics from
temperature

High Vibration
Inaccessible Valves

Review All Fieldvue Products

Basic Operation
Input Signal (4 to 20 mA)
Digital Signal (HART Protocol)
Terminal
Box

Printed Wiring Board (PWB)

Pressure
Sensors

Minor Loop
Feedback

Drive Signal
Output A
Gauge
I/P Converter

Air Supply

Pneumatic
Relay

Travel Sensor Provides

Feedback

Gauge
Output B

I/P Output
Pressure
Gauge

End Build

Its all about the tiers

Customized Diagnostic Functionality
HC - HART Communicating
AD - Advanced Diagnostics
PD - Performance (On-Line) Diagnostics

Fisher Fieldvue Products

Diagnostic Capabilities - HC
HART Communications
Configuration
Calibration
Alerts (travel deviation, travel hi/low, internal device failures, cycle count,
etc)
No Valve Diagnostics
Works with all HART Communication tools

Fisher Fieldvue Products

Diagnostic Capabilities - AD
Advanced Diagnostics
Configuration
Calibration
Alerts (travel deviation, travel hi/low,
supply pressure alert, internal device
failures, cycle count, etc) Alerts
Valve Diagnostics (Signature, Step
Response, Drive Signal, Dynamic Error
Band)
Works with all HART Communication
tools

Quick Tutorial
Valve Signature Basics

Fisher Fieldvue Products

Diagnostic Capabilities - PD
Performance Diagnostics (On-line/In-Service )

Configuration
Calibration
Alerts (travel deviation, travel hi/low, supply pressure, internal device failures,
cycle count, etc) Alerts
Valve Diagnostics (Signature, Step Response, Drive Signal, Dynamic Error Band)
Suite of On-line/In-Service Tests with real-time trending of critical variables to
help pin-point problems

I/P and Relay Integrity

Supply Pressure
Air-Mass Flow
Relay Adjustment
Travel Deviation

On-line/In-Service Friction/Deadband Calculation

Trending of Friction/Dead band Calculations

PD Diagnostics
On-Line (In Service) Pre-configured tests
PD One Button

On-Line In-Service
24/7 access
Non-Intrusive
Easy

Problem Description
Possible Cause
Recommended Action

Red , Yellow , & Green Light

Quick ly I ndicates
issue and severity

PD Diagnostics
On-Line (In Service) Friction Test
Friction/Dead Band Test

Friction is a key indicator of valve assembly

degradation
Possible early indication of

Stem deformation
Rotary plug wear
Packing issue
Trim damage

Calculates average

Friction (sliding stem)

Torque (rotary)
Dead Band

Friction/Dead Band Trend

User configurable Max/Min

Trend line to determine urgency

PD Diagnostics
Triggered Profile & Profiler
Triggered Profile
Profiler

Fisher Fieldvue Products

Communication with DVC6000
LETS REVIEW ALL THE TOOLS FOR UNDERSTANDING!
HART 375 & 475 HART Communicator with base HART Communication
and ValveLink Mobile.
AMS ValveLink Solo Software (Fisher positioners only)
AMS Device Manager software (communicates with all HART devices)
and the companion software ValveLink Snap-ON

Getting at the Fieldvue Diagnostics

Point to Point or ONLINE
Point to Point Architecture
AMS Device Manager with companion software AMS ValveLink Snap-ON
with a HART modem OR ValveLink Mobile on a 475 Communicator
Go from valve to valve and monitor alerts, perform PD diagnostics as required and
doing Advanced Diagnostics (including Valve Signatures, Step Tests and Dynamic
Error Band test) during outages or when valve is offline

Online Architecture
AMS Device Manager with companion software AMS ValveLink Snap-ON
connected to a HART network using Multiplexers or pass-through
technology in the DCS.
Talking to all devices and monitoring alerts in real-time and scheduling PD
diagnostics

Diagnostic Planning
Configuring the Smart Positioner
The following items needed to be accounted for, to get the
most out of an Online system:

Setting up the alerts (Travel Deviation Alert, Drive Signal Alert and Supply
Pressure Alert) these alerts are NOT configured by the factory (all Tiers)
Setting up the Alert Record (data buffer in the device) so that events can
be captured 24/7 (all Tiers)
Setting up the specification sheet in the device so that Advanced
Diagnostics can performed and analyzed properly (AD or PD Tier &
ValveLink Snap-ON)
Schedule PD One Button Sweeps which are predetermined Inline Service
tests to verify the condition of valve and positioner (PD Tier & ValveLink
Snap-ON)
Schedule PD Friction Test (PD Tier & ValveLink Snap-ON)
Setting up Triggered Profile to capture 4 HART variables based on travel
deviation (PD Tier & ValveLink Snap-ON)

Diagnostic Planning
Other Considerations
Other things to consider that are important:
Also, the assets need to be configured in Alert Monitor in AMS
Device Manager and it will be based on criticality ranking as
well
Work practices need to change to incorporate an Online AMS
Device Manager package and hopefully trips to the field are
minimized
During outages, valves should be scanned (Valve Signature) by
ValveLink Snap-ON and this should minimize the numbers of
valves for overhaul KEY POINT, BASELINE DATA SHOULD BE
COLLECTED SO THAT VARIATIONS ARE NOTICED!

Fieldvue Diagnostics
Typical Alerts
Valve Alerts
Travel Deviation
Travel Hi
Travel Lo
Travel Hi Hi
Travel Lo Lo
Travel Accumulator
Drive Signal
Supply Pressure
Cycle Count
ESD Valve Stuck
ESD Pressure Deviation
Ref. Voltage Failure
Pressure Sensor Fail
NVM Fail
Drive Current Fail
Temp Sensor Fail
Travel Sensor Fail
Auto Tvl Cal Failed
Power Starvation Alert
Calibration in Progress
Alert Record Not Empty
Alert Record Full
Variable Out of Range
Diagnostic in Progress
No Free Time
Integrator Saturated Low
Internal Sensor Out of Limits
Flash Integrity Error
Integrator Saturated High
Configuration Changed
Aux Input
Analog Input Saturated

Travel Deviation
Drive Signal
Supply P ressure

Fieldvue Diagnostics
Diagnostics Methodology

Network Alert Scan

(on-line)
(alert log & trending)

Performance Diagnostics
(on-line)
(graphs, interpretation)

Dynamic Scan Diagnostics

(off-line)
(graphs, interpretation)

Incorporating the 475 Communicator

Diagnostic Testing at the Valve ValveLink Mobile

Out Of Service Diagnostics

Total Scan
Step Response
Stroke Valve
Analyzed Data

In Service Diagnostics
Device Status
PD One Button
PD Traces

Red , Yellow , & Green Light

Quick ly I ndicates
issue and severity

Final Control & Regulate

Additional Learning - Control Valves
Links
Control Valve Training
PlantWeb University
Suggested Emerson Courses
e9020 Control Valve Fundamentals
1451 Valve Maintenance FIELDVUE Digital Valve Controller
1759 ValveLink Software for Diagnostics of FIELDVUE Digital Valve Controller
7022 Fisher FIELDVUE Digital Valve Controller with AMS ValveLink SNAP-ON