PTQ Q4 2022 Issue

Figure 2 Emerson’s TopWorx DXP discrete valve controller contains

last open/close stroke time, internal device temperature, a n d cycle count, can be delivered to the appropriate per- sonnel via a handheld device or at a control room workstation.

sensing and feedback in a single housing. Suitable for use in SIL-3 applications, it is certified for use in hazardous areas. It tracks a wider variety of variables and is easier to set up and integrate into processes than other HART 7 technologies

As a critical part of the technology loop, integrated switchbox solutions can help refineries solve several challenges they face. One main challenge, as previ- ously stated, is maintaining uptime. By continuously monitoring performance and diagnostics in real-time, opera- tors can improve the visibility of the valve package condition, and the system can send preset, planned alerts directly to maintenance staff when necessary. This allows plants to shift from reactive to proactive maintenance.

temperature, contact status, and posi- tion, at the moment. These sensors are linked to technology that enables con- nectivity, such as a discrete valve control- ler (see Figure 2 ). In the ‘decide stage’, a discrete valve controller sends sensor data to a control device, such as a distributed con- trol system (DCS) or safety instrumented system (SIS) DCS. The DCS analyses and visualises the data, translating it into dashboards that operators can easily interpret and synthe- sise. By quickly and clearly understanding what data means for operations, operators gain the expertise that empowers them to make better and faster decisions with confidence. Mobility tools in the ‘act stage’ enable the appropriate per- sonnel to access preset alerts, information, and prescribed actions from multiple platforms. These critical actions spur personnel to repair an asset or replace a component and are a vital step that improves both safety and reliability. The collaboration of these layers provides valuable ana- lytics and services that enable device life-cycle manage- ment, position feedback, transition dwell time, and internal device temperature. This constant cycle of seeing, decid- ing, and acting creates a technology loop that continuously improves expertise and efficiency. Automating and optimising operational processes While sensing and feedback devices are avail-

Predictive and prescriptive maintenance analytics improve decisions around device and system replacement, reducing unplanned shutdowns while lowering scrap, repair and labour costs. When a single valve shutdown can cost $1.3 million a day just in lost output, and a plant may likely experience 27 days of unplanned shutdown a year, costs add up fast. Reducing unplanned downtime by 36% through proactive maintenance results in significant savings. 1 By automating and optimising maintenance as well as data collection and delivery, discrete valve controllers like this also enhance safety. Proactive maintenance and pre- set safety alerts and alarms reduce the frequency of main- tenance rounds, and remote monitoring of valve package conditions curtails the need for workers to be physically close to the asset. Fewer maintenance and troubleshoot- ing trips decrease the frequency of possible injury, and improved insights empower personnel to make better safety decisions. When properly networked, discrete valve controllers with a HART 7 module can also rescue stranded data,

able discretely, integrated solutions are also available. Some discrete valve controllers combine sensing technology and a HART 7 module, as well as other components, such as a solenoid valve for piloting, in a single housing. This switchbox sits on top of the valve package. While the position sensing switch monitors the valve position, the HART module captures data from the sensor and sends it to the control system, which analyses it and carries out appropri- ate actions in response to it. Analytics and diagnostics about valve condition, including position percentage, transition dwell time,

which can offer additional insights and fur- ther improve uptime and safety. An esti- mated 85% of HART devices in operation experience stranded information due to accessibility issues or legacy control sys- tems. 2 Capturing diagnostics and param- eters using traditional cabling may be too expensive or, in offshore applications, too heavy. As part of the integrated switchbox solu- tion, HART can be networked with gate- ways wired or wirelessly via an adapter and connected to stranded devices wirelessly or via a cable/wireless hybrid solution. 3 As a global standard to exchange digital infor- mation, HART undergoes revisions that enhance its capabilities and can absorb or umbrella the previous version, creating a long-term, future-proof investment.

Figure 3 Emerson’s magnetically driven TopWorx GO Switch provides reliable proximity sensing in extreme conditions

PTQ Q4 2022