DEVELOPMENT OF A CONTROLLER AND PERFORMANCE TESTING FOR PARTIAL STROKE TESTING (PST) OP FISHER ESD VALVES By SHAHIDA FARHANA BINTI SALUDIN Dissertation submitted in partial fulfillment of the requirements for the Degree Bachelor of Engineering (Hons) (Electrical & Electronics Engineering) JUNE2009 Universiti Teknologi Petronas Bandar Seri Iskandar 31750 Tronoh Perak Darul Ridzuan CERTIFICATION OF APPROVAL DEVELOPMENT OF A CONTROLLER AND PERFORMANCE TESTING FOR PARTIAL STROKE TESTING (PST) OF FISHER ESD VALVES Approved: By Shahida Farhana binti Saludin A project dissertation submitted to the Electrical & Electronics Engineering Programme Universiti Teknologi PETRONAS in partial fulfillment of the requirement for the Bachelor Engineering (Hons) (Electrical & Electronics Engineering) (AP Dr Nordin Saad) Project Supervisor UNIVERSITI TEKNOLOGI PETRONAS TRONOH, PERAK JUNE 2009 CERTIFICATION OF ORIGINALITY This is to certify that I am responsible for the work submitted in this project, that the original work is my own except as specified in the references and acknowledgements, and that the original work contained herein have not been undertaken or done by unspecified sources or persons. iii ABSTRACT This report essentially discusses the work on the Development of a Controller and Performance Testing for Partial Stroke Testing of FISHER ESD Valves which deals with Y okogawa F A-M3 Controller and the FISHER Emergency Shutdown valves. The objectives of the project are on developing a controller to the Partial Stroke Testing (PST) using Programmable Logic Controller (PLC) and software tools; and conduct performance testing on the ESD valves. This report also explains the valve components and the fundamentals of PLC. The methodology explains in detail about developing the routine for PST and also the construction of ladder logic diagram using WideField2 software. The setting of AMS V alveLink software is also explained in this chapter. The data gathered from the 35 days of testing are presented in Chapter 4. Besides, the Valve Signature, PST Analyzed Data, and Digital Valve Controller (DVC) installation are also explained in details. Chapter 5 concludes what has been achieved in this project and the recommendation for future works. Throughout the project, sharing of ideas with PETRONAS engineers from the Improvement Working Group (IWG) of Skill Group 14 (SKG14) are also conducted to compare the performance of various valves for use in PETRONAS plants. The outcome of this project would be very useful for the PETRONAS to adopt on the PST strategy in their plant nationwide. IV ACKNOWLEDGEMENT First and foremost, I am very grateful to God the Almighty for His mercy as He gave me the strength and ability to complete the final year project throughout the year. I also would like to take this opportunity to thank all parties involved in making to final year project a great educational session and a success. Deepest gratitude goes to my parents, Saludin Sulong and Norpiah Sidik for their continuous motivation and moral support. I would like to thank the following for their respective professionalism and contribution to the program. There were plenty of names though, but my special thanks go to all the names mentioned below:-AP Dr Nordin Saad Mr Azhar Zainal Abidin Ir Mohd Rashdan Mahmood Mr M. Firdhaus M. Hasani Mr Sinivasen Sevalingam FYP Supervisor, UTP Technician, UTP Lead Engineer, PETRONAS GTS Engineer, PETRONAS Gas Berhad Senior Engineer, TRANSWATER Tenaga SdnBhd I'd like to thank everyone for their continuous support especially my colleagues and fellow friends. These elements have successfully assisted me to do my best and effort in upholding the individual learning spirit during my final year in UTP. Thank you once again to everyone involved. v TABLE OF CONTENTS CERTIFICATION OF APPROVAL CERTIFICATION OF ORIGINALITY ABSTRACT ACKNOWLEGDEMENTS. LIST OF FIGURES . LIST OF TABLES LIST OF ABBREVIATIONS CHAPTER!: INTRODUCTION 1.1 1.2 Backgro1111d of Study Problem Statement CHAPTER2: 1.3 Objectives and Scope of Study 1.3.1 1.3.2 Objectives Scope of Study LITERATURE REVIEW 2.1 Rotary Valve 2.1.1 Ball Valve 2.1.2 Butterfly Valve 2.1.3 Actuator 2.1.4 Limit Switch 2.1.5 Digital Valve Controller VI 11 111 IV v X xm XIV I 2 3 3 4 4 5 6 7 7 8 2.1.6 Pressure Regulator 9 2.1.7 Solenoid Valve 9 2.2 Programmable Logic Controller. 10 2.2.1 Advantages of PLC 10 2.2.2 Construction of a PLC 11 2.2.3 PLC Languages l3 CHAPTER3: METHODOLOGY I PROJECT WORK 15 3.1 Project Process Flow 15 3.2 Procedure Identification 16 3.2.1 Understand the Project Requirement 17 3.2.2 Design the PST Sequences 17 3.2.3 Program the PLC 18 3.2.4 Setting the AMS ValveLink Software.23 3.2.5 PST Execution 26 3.2.6 Data Logging and Analysis 27 3.3 Tools Required 28 3.3.1 Hardware Requirement 28 3.3.2 Software Requirement 30 3.4 Hardware Preparation 31 Vll CHAPTER4: RESULTS AND DISCUSSION 33 4.1 Partial Stroke Testing 33 4.2 PST Coincides with FST 35 4.3 DVC Installation 36 4.3.1 4-wire system . 36 4.3.2 2-wire system . 38 4.4 Analyzed Data of PST for Ball Valve 40 4.4.1 Average Dynamic Error 40 4.4.2 Maximum Dynamic Error 40 4.4.3 Minimum Dynamic Error 41 4.4.4 Dynamic Linearity 42 4.4.5 Zero Ranged Travel 43 4.4.6 Fnll Ranged Travel 44 4.4.7 Lower Bench Set 45 4.4.8 Upper Bench Set 45 4.5 Analyzed Data of PST for Butterfly valve 47 4.5.1 Average Dynamic Error 47 4.5.2 Maximum Dynamic Error 48 4.5.3 Minimum Dynamic Error 49 4.5.4 Dynamic Linearity 50 4.5.5 Zero Ranged Travel 51 4.5.6 Fnll Ranged Travel 52 4.5.7 Lower Bench Set 53 4.5.8 Upper Bench Set 54 vm CHAPTERS: REFERENCES APPENDICES CONCLUSION AND RECOMMENDATIONS 5.1 Conclusion 5.2 Recommendations IX 55 55 57 58 60 LIST OF FIGURES Figure 1.1 ESD valve in a pipeline I Figure 2.1 Typical butterfly valve and its major components 4 Figure 2.2 Controlling device of ball valve 5 Figure 2.3 Flow movement through ball valve 5 Figure 2.4 Typical butterfly valve 6 Figure 2.5 Typical rack and pinion actuator 7 Figure 2.6 VAL VETOP DXP Limit Switch 7 Figure 2.7 DVC6000 Digital Valve Controller 8 Figure 2.8 Pressure Regulator 9 Figure 2.9 Solenoid Valve 9 Figure 2.10 PLC architecture 11 Figure 2.11 Type of programming languages 13 Figure 3.1 Process flow of the project 15 Figure 3.2 Procedure identification and flow diagram 16 Figure 3.3 WRITE Symbol 19 Figure 3.4 Rung 1 for ball valve program 19 Figure 3.5 Rung I for butterfly valve program 19 Figure 3.6 Rung 2 and 3 for ball valve program . 20 Figure 3.7 Rung 2 and 3 for butterfly valve program 21 Figure 3.8 Rung 4 for ball valve program 21 Figure 3.9 Rung 4 for butterfly valve program 21 Figure 3.10 Rung 5 for ball valve program 22 X Figure 3.11 Rung 5 for ball valve program 22 Figure 3.12 Ball valve and butterfly valve are connected to the network 23 Figure 3.13 Instrument Mode setting 23 Figure 3.14 Instrument Protection setting 24 Figure 3.15 Input current to the butterfly valve 24 Figure 3.16 Input current to the ball valve 25 Figure 3.17 Flow chart of PST execution • 26 Figure 3.18 Steps taken to analyzed the PST data 27 Figure 3.19 Valves arrangement for this project . 29 Figure 3.20 Y okogawa F A-M3 Controller configurations 30 Figure 3.21 Hardware connections between valves, PC, PLC and multiplexer 31 Figure 3.22 Wiring connection for power supply and pressure supply 32 Figure 4.1 Valve signature for ball valve. 33 Figure 4.2 Valve signature for butterfly valve 34 Figure 4.3 Valve signature for PST coincides with FST on ball valve 35 Figure 4.4 Valve signature for PST coincides with FST on butterfly valve 35 Figure 4.5 4-wire system . 36 Figure 4.6 Bypass the solenoid valve 37 Figure 4.7 2-wire system 38 Figure 4.8 Average Dynamic Error versus No of PST 40 Figure 4.9 Maximum Dynamic Error versus No of PST. 40 Figure 4.10 Minimum Dynamic Error versus No of PST . 41 Figure 4.11 Dynamic Linearity 42 Figure 4.12 Zero Ranged Travel versus No of PST 43 XI Figure 4.13 Full Ranged Travel versus No of PST 44 Figure 4.14 Lower Bench Set versus no of PST 45 Figure 4.15 Upper Bench Set versus no of PST 45 Figure 4.16 Average Dynamic Error versus No of PST 47 Figure 4.17 Maximum Dynamic Error versus No of PST. 48 Figure 4.18 Minimum Dynamic Error versus No of PST . 49 Figure 4.19 Dynamic Linearity 50 Figure 4.20 Zero Ranged Travel versus No of PST 51 Figure 4.21 Full Ranged Travel versus No of PST 52 Figure 4.22 Lower Bench Set versus No of PST 53 Figure 4.23 Upper Bench Set versus No of PST 54 Xll LIST OF TABLES Table 3.1 Time allocation for PST on ball valve 17 Table 3.2 Sections in PLC program 18 Table 3.3 Data location number when CPU failure 18 Table 3.4 Data location nusmber for scaling 20 Table 3.5 Parameters setting in Partial Stroke menu 25 Table 3.6 General specification for valves 27 Table 3.7 General specification for Yokogawa F A-M3 Controller 29 Table 3.8 Software use in this project . 30 xiii LIST OF ABBREVIATION UTP Universiti Teknologi PETRONAS GTS Group Technology Solutions ESD Emergency Shutdown DVC Digital Valve Controller PST Partial Stroke Valve Testing FST Full Stroke Valve Testing PLC Programmable Logic Controller I/0 Input I Output CPU Central Processor Unit XIV CHAPTER I INTRODUCTION 1.1 Background of Study Emergency Shutdown (ESD) valve is a fmal defense element in a pipeline of a process plant. Nowadays, the ESD valve is connected to the PLC and sensors as shown in Figure 1.1. Whenever the sensor identifies the abnormalities in the pipeline, it sends a signal to the PLC and PLC disconnects the power supply to the ESD and solenoid valve. Therefore, the valve will fully close or fully open, depending on the process loop. ~"romDCS --- PneumatlcSupply Sensor Proces.sf ow Figure 1.1: ESD valve in a pipeline Due to the continuous process in the plants, ESD valve usually remains set in one position for a long time, thus reduce the efficiency of the valve. In addition to that, a harsh process inside the pipeline can cause the valve to stick. Therefore, the valve fails to move to safety state during emergency shutdown. This could cause a potentially dangerous condition leading to catastrophic events. 1 As a solution, FST and PST are introduced to exercise the valve. FST technique strokes the valves from 0% to 100% of valve travel. Implementation of this technique requires the shutdown of the process. The alternative testing is an online FST but it requires bypassing the flow to the other pipeline or reducing the flow rate which may disturb the other loop if the procedures are not properly followed [1]. The PST is an online SIS testing which involves partial stroking of the valve movement. The valve travel is set between 10%-30% of the opening or closing of the valve. This method does not require to shutdown the process. 1.2 Problem Statement Current method applied in process plant to initiate the PST is by using mechanical devices such as mechanical limiting, position control and solenoid valves. The implementation of this method has its own pros and cons. The use of mechanical limiting does not allow the process shutdown when emergency occurred. The position control method requires an analog positioner installation on the valve. The positioner guides the valve travel as set by pre-determined point. The disadvantage of this method is the positioner may fail during the stroking. The solenoid valve method requires the operators to hold the switch to de-energize the solenoid coil. The operators need to short certain terminals in the field with push button located at special device. Once initiated, the automated test moves the valve to the pre-determined value then returns the valve to its original position [2]. PST enters new domain in industrial automation technology. Programmable Logic Controller (PLC) based systems appear to play a central role concerning initiating, registering, and responding to PST [3]. The 2 implementation of PLC will not require the operators to go to the field or hazardous area just to initiate the PST. Besides, the PLC is designed for multiple inputs and outputs arrangements in a compact size which is not require large space for installation and requires much less wiring. Therefore, the usage of PLC will bring in a new chapter for PST technology. 1.3 Objectives and Scope of Study 1.3.1 Objectives The objectives of the project are:-• To develop a controller to perform PST and FST • To compare the PST performance of various valves • To study the failure mode of the valves during the test 1.3.2 Scope ofStudy There are two parts of this project. The first part is the development of PLC programming to power up the valve. Therefore, it is necessary to have a broad knowledge in constructing ladder logic diagram for PLC programming. The second part of the project is to execute the PST for 90 days, gather the data and analyze the performances of the valves. The reliability and feasibility study will be carried out to achieve the objectives. Experiences during industrial internship at one of PETRONAS plants would be very helpful to relate the project to the real application in plant. 3 2.1 Rotary Valve CHAPTER2 LITERATURE REVIEW There are two types of valves - sliding stem valve and rotary valve. The major different between these two types is the way it works when responding to signals. The sliding stem valve controls the flow of the fluids by sliding up and down of the stem. The rotary valve is controlled by a rotary motion. The butterfly valve and ball valve are from rotary type. Usually, the butterfly valve and ball valve act as a block valve. In the process plant, the block valves are located at the beginning and ending of the process flow. The function of the block valve is to stopping or starting the flow. Its features - tight shut-off and fire-safe design make it suitable for emergency shutdown valve in the process plant since it can react very fast as soon as it receives the signals. There are varieties of block valve in the market, manufactured by different vendors with different specifications and hence will result to different performances. Actua.tot V llrt body m cnbly Figure 2.1: Typical butterfly valve and its major components [4] 4 Figure 2.1 shows two major components in a valve; actuator and valve body assembly. The valve assembly typically consists of the valve body, an actuator to provide motive power to operate the valve, and a variety of additional valve accessories, which can include positioner, transducer, supply pressure regulators, and limit switch [5]. 2.1.1 Ball Valve Figure 2.2 shows a typical ball valve with its controlling device, a ball. The opening and closing of the ball valve is controlled by a handle that is attached inside the ball valve. Inside the middle of the ball valve body is a hole, which will allow the flow of the fluid if the hole is in line with both end of the valve. Referring to Figure 2.3, when the valve is closed, the hole is perpendicular to the ends of the valve, and flow is blocked. The straight through design of ball valve will reduce the pressure drop. The characteristic of ball valve allows the quickness of operation, require no lubricants and give tight sealing with low torque [4]. Figure 2.2: Controlling device ofball valve [6] A;;TLJATOR OPtN lHIIOTTU:O CLOSC:O Figure 2.3: Flow movement through ball valve [7] 5 2. I. 2 Butlerjly valve Figure 2.4 shows the typical butterfly valve. The controlling device of a butterfly valve is a circular disk at the center of the valve body. The operation of the valve is either parallel or perpendicular to the flow. The valve is in fully open position when it turns 90 degrees, which is parallel to the flow. When the valve is fully closed, the disk is turned so that it completely blocks off the passageway [7] . t I Ol't 'fATOR I / $EAT ' Figure 2.4: Typical butterfly valve [7] • 6 2.1.3 Actuator An actuator is a powered device that supplies force and motion to open or close the valves. The power sources are from pneumatic, hydraulic, or electrical. The actuator use in this project is rack and pinion actuator and is supplied by pneumatic air as shown in Figure 2.5 [4]. Actuator Figure 2.5: Typical rack and pinion actuator [4] 2./ . .J Limit Switch Limit switch in Figure 2.6 is installed to signal when a valve is at or beyond a predetermined position. It is also operates discrete inputs to a distributed control system, signal lights, small solenoid valves, electronic relays, or alarms. Besides, it combines bus networking, pilot valve, and position sensor into a single globally certified, flammable and explosion proof enclosure, that can be attached to any automated valve [8]. Figure 2.6: VAL VETOP DXP Limit Switch [8] 7 2.1.5 Digital Valve Controller Figure 2.7 shows a digital valve controller or also known as smart positioner. It is a microprocessor-equipped device. It controls the opening and closing of the valve by converting the 4-20mA DC current signal input from process controller and converts it to pnewnatic output signal to the actuator. Besides, it communicates via Highway Addressable Remote Transducer (HARn communication protocol to provide instrument and valve diagnostic information. The smart positioner plays an important role in Emergency Shutdown (ESD) application. It will reduce the testing time taken and manpower requirement, thus it will reduce cost. The diagnostic capability of the smart positioner reports the health of the valve, thus reducing the need for scheduled maintenance and increasing process availability. Figure 2.7: DVC6000 Digital Valve Controller 8 2.1.6 Pressure Regulator Pressure regulator in Figure 2.8 is used to regulate or reduce air pressure so that it achieves the desired value. Also known air-sets, it will reduce plant air supply to valve positioner and other control equipment. Common reduced-air-supply pressures are 20, 35 and 60 psig. The regulator mounts integrally to the positioner or nipple-mounts or bolts to the actuator (4).The parameters that limit adjustment control on the pressure range are the regulating and adjustment range. Figure 2.8: Pressure Regulator [4] 2. 1. 7 Solenoid Valve Figure 2. 9 shows a solenoid valve. The functions of solenoid valve are to operate on/off pneumatic actuator and to interrupt the action of modulating valves by switching air or hydraulic pressure [4]. The solenoid valve requires power supply for it to energize. If there is no power supply. the solenoid valve will be de-energized. Thus, it will affect the state of the valve whether fully open or fully close. Figure 2.9: Solenoid Valve (4] 9 2.2 Programmable Logic Controller The Programmable Logic Controller (PLC) is in essence a device that is specifically designed to receive input signals and emit output signals according to the program logic. PLCs come in many shapes and sizes from small, self-contained, units with very limited input/output capacity to large, modular units that can be configured to provide hundreds or even thousands of inputs/outputs [9]. The PLC-based system becomes the most common choice for manufacturing controls including process plant since it can cut production cost and increase quality. 2.2.1 Advantages of Programmable Logic Controller I. Cost effective for controlling complex system - one PLC can run on many machines [10) 2. Easily programmed and reprogrammed- can alter its sequence of operations [II] 3. Large quantities of contacts - PLC memory is getting bigger and thus can generate more contacts, coils, timers, sequencers, counters and so on 4. Maintainability - less maintenance required and PLC can live longer without failure [ 11] 5. Reliability- can sustain the industrial environment that has extreme temperature (typically up to 160°F, high humidity (up to 95%), electrical noise, electromagnetic interference, and mechanical vibration.[!!] 10 2. 2. 2 Construction of a Programmable Logic Controller Basically, most of the PLC in the market has several common functional parts. Figure 2.10 shows a central processor, memory, I/0, power supply, programming and peripheral device subsection [12]. ,-------------------' ' • Programming : ' ' : device : ' -------- ----------· f Power supply l ~~ CPU -,. ~~ Memory j I '4 ... .......................... Input I Output Bus r Input I Output System Module I Output device Input device --------------- --------------Solenoid Switch motor starters pushbuttons Figure 2.10: PLC architecture [12] 11 1. Central Processor Unit (CPU) Module Perform necessary tasks to fulfill PLC functions. The tasks are scanning, I/0 bus traffic control, program execution, peripheral and external device communications, data handling execution (enhancement), and self diagnostic. [12] 2. Memory In PLC, the memory section acts as a library. It has Read Only Memory (ROM) and Random Access Memory (RAM). The ROM memory can be read but user can not modify the contents. It stores PLC operating system, driver programs, and application programs. The RAM memory can be read and written which mean user can modify the contents, but the memory contents will be lost when supply voltage fails. The user-written programs and working data are stored in RAM memory [12]. 3. Input and Output Module (I/0 Module) Connect between PLC and sensors or actuators. Each module can be connected to multiple outputs of similar characteristics. Besides, it can isolate the low signals of current and voltage which have been used by PLC internally from the higher-power electrical circuit [12]. 4. Power Supply Module Convert available power to de power at the levels required by the CPU and I/0 module internal circuitry. The power supply drives the I/0 logic signals, the central processor unit, the memory unit and also peripheral devices. Besides, it also protects the PLC internal circuitry from high-voltage line spikes [12]. 12 2.2.3 Programmable Logic Controller Languages There are two methods of programming language - text and graphic language. The text languages are the Instruction List and the Structured Text type. The examples of graphic languages are Sequential Function Charts, Function Block Diagrams and Ladder Logic. Different PLC can support different languages. There are certain types of PLC that can support more than one language. These languages have their own limitation, and they complement one another to provide programmers with more programming power. [13]. Figure 2.11 shows type of programming languages for PLC. ~'~ ~ Figure 2.11 : Type of programming languages 1. Structured Text ~Til--~ '· •' ' .·. ~:·.:::--] ' ;~ High-level structured language designed for automation process. Statements can be used to assign values to the variables. 2. Instruction List Low-level programming language for smaller applications or for optimization parts of an application. It is much more like assembly language programming. 13 3. Sequential Function Chart Use graphic to describe sequential operations. It is very useful for describing sequential type processes. 4. Functional Block Diagram Use in applications involving the flow of signals between control blocks 5. Ladder Logic Diagram It is the most popular and widely used progranuning. It applies Boolean mnemonics to represent the process, before converting into logic diagram. 14 CHAPTER3 METHODOLOGY I PROJECT WORK 3.1 Project Process Flow Figure 3.1 shows the flow chart of the project which is then applied throughout the project. I Start I l Se:ection of project topic ! Pre:iminary :reiearch ~~vo:rk and ·:iterature reYiev: ~ Understanding project and :earning pro c-e:;:; i PLC deve:opment and software app:ication i Simu:ation works and ana:ysis J Preparing tlae project report and p.resemation ! I End I Figure 3.1: Process flow of project 15 The first step is to select the project topic and conduct the preliminary researches and literature review. Journals, conference papers, books and internet are referred. As the information is available, it is very crucial for the author to undergo the learning process as the valve, PST and PLC are not a familiar area to her. From the data gathered, the author gets the overview about the project. The next step is development programming for the PLC and setting the valve's software. Then, the simulation works and analysis are conducted. The following step is preparing the report that need to be submitted to the Final Year Project Committee. There is also an oral presentation which will take place towards the end of the semester. 3.2 Procedure Identification Understand the project requirement Design the PST sequences Program the PLC to perform FST Setting the valve software to perform PST Execute the PST and FST Data gathering and analysis Figure 3.2: Procedure identification and flow diagram 16 3.2.1 Understand the Project Requirement The main task beforehand is to understand the project requirement. This project is technology collaboration between PETRONAS Group Technology Solutions (GTS) and Universiti Teknologi PETRONAS. Besides, there are several vendors involve this project~ Fisher, Metso Automation, Masoneilan, and Yokogawa Electric Corporation. Each vendor supplied the emergency shutdown valves which are ball valves and butterfly valves, while Yokogawa provided the PLC for this project. In the mean time, PETRONAS GTS has specified that for each ball and butterfly valve, the PST is to be executed 6 times a day, including 1 time PST coincides with FST. For the data to be accurate and valid, the test needs to be executed for 90 days. 3.2.2 Design the Partial Stroke Testing Sequences The time allocate for each PST is 1 0 minutes. Therefore, the time taken to complete the 6 PST on a valve is 60 minutes. Table 3.1 shows the time allocation for the testing on ball valve. Table 3.1: Time allocation for PST on ball valve IOmin IOmin IOmin IOmin IOmin IOmin PST 1 PST2 PST3 PST4 PSTS PST+FST The test is executed separately for ball and butterfly valve. The PST for the butterfly valve is executed right after the PST on ball valve. The time allocation for PST on butterfly valve is the same as ball valve. 17 3.2.3 Program the Programmable Logic Controller Using the ladder logic diagram progrannning language, the program is developed on the Yokogawa FA-M3 PLC using the WideField2 software. The position of the Analog Input Module of the PLC consists of 4 sections as shown in Table 3.2. Table 3.2: Sections in PLC Program Section Areas of data Program Section I Operation The area which the operation mode of each channel is stored mode Section II Operation The area in which the upper and lower limit of the scaling are details data installed Section III Input data The area which the input voltage data of each channel is installed Section IV Program The area which the internal relay is used to execute the program execution 3.2.3.1 Section 1- Operation Mode In Section I, the operation mode when the sequence CPU fails is developed on a channel-by-channel basis. Charmel 1 and 2 refers to FISHER ball valve and butterfly valve respectively. To set output values in a sequence CPU failure, a data location number is set to 1. The set items in operation mode in a sequence CPU failure are canceled when the power is turned off [14]. Table 3.3 shows the data location number in operation mode in a sequence CPU failure. Table 3.3: Data location number in operation mode in a sequence CPU failure Set items Channel 1 Channel2 Operation mode 501 502 18 For this setting, a special module WRITE instruction is used. Figure 3.3 shows a WRITE symbols. WRITE I s SL n2 ~ I 1 r First device for Slot number First data Data writing data position for transfer reading count Figure 3.3: WRITE symbols Figure 3.4 and Figure 3.5 show the WRITE instruction for power failure in rung 1 for ball valve program and butterfly valve program, respectively. I vol'r-r-------------l.l\!'•\Rlt.:l 'lE _j__gsc_L_J.j _ _;;~ :u_l .l__.L_; ~ Figure 3.4: Rung 1 for ball valve program Figure 3.5: Rung 1 for butterfly valve program 19 3. 2. 3. 2 Section II- Operation Details Data Digital input values corresponding to upper-and-lower limit values in the output signal range is set to 0 and 10000, which 0 is 4mA and 10000 is 20mA [15]. Besides, the data location numbers for scaling have been set on a channel-by-channel basis. Table 3.4 shows the data location numbers for scaling. Table 3.4: Data location numbers for scaling Set Items Channel Channel 1 2 Digital input values corresponding to upper 520 530 limit values in the output signal range Digital input values corresponding to lower 521 531 limit values in the output signal range Figure 3.6 and Figure 3. 7 shows the rung 2 and rung 3 for ball valve program and butterfly valve program, respectively. .,. liv'· y· I ''W' fl do luuul i m if-l"t ' i !11 : • Figure 3.6: Rung 2 and 3 for ball valve program 20 Upper limit scaling for channel l Lower limit scaling for channel 1 w ( I 1\lii"E I!!!; ~ ~!IJ 'Ml·e " ~ ·~1! Figure 3.7: Rung 2 and 3 for butterfly valve program Upper limit scaling for channel 2 Lower limit scaling for channel 2 The M003 5 used in rung I, 2 and 3 is a special relay. It has a specific function such as indicating operation and error states of the CPU [14]. M0035 enables I scan when operation is started. 3.2.3.3 Section III- Output data In rung 4, the output data is pointed to data register, DOOOOI. Channell is used for input signal range from 4-20 rnA. Figure 3.8 and Figure 3.9 show the rung 4 for ball valve program and butterfly valve program, respectively. Figure 3.8: Rung 4 for ball valve Figure 3.9: Rung 4 for butterfly valve Output writing to Channell Output writing to Channell The special relay, M0033 is used to initialize the program and give a permanent high level (always ON). 21 Section 3.2.3.4: Section IV- Program Execution In rung 5, the Internal Relay 10002 is used to move the lower limit value of output signal (0) to the data register, DOOOl. By forced set the 10002, PLC energizes the solenoid valve and sends 4mA to the DVC. Figure 3.10 shows the rung 5 for ball valve programming. ~; il\' I Figure 3.10: Rung 5 for ball valve ,] r.·~lt' ~~-~~~ 4mAis sent to D0001 At rung 6 as shown in Figure 3.11, by forced reset the 10020, the valve opened. To send the FST signal, the 10020 is forced set and PLC sends the 20mA to DVC the valve closed. 0~~ I W'" " Figure 3.11: Rung 6 for ball valve I . .., I ow·· ....• .. 71: v 20mAis sent to D0001 Refer to Appendix I and II for a complete programming for ball valve and butterfly valve, respectively. 22 3.2..1 Setting the AMS ValveLink Software The instrument must be configured to run the PST. Below are the basic requirements to perform the PST. Figure 3.12 to Figure 3.16 shows the screenshots to setting the AMS ValveLink software. 1. Instrument is connected to the network • ·--h ~ -............. .. ~:.!·~:.:"'----------------Ball and butterfly valve is connected to the network Figure 3.12: Ball and butterfly valve are connected to the network 11. Instrument Mode set to Out of Service Qn • w • ~a / R/ 4k - ~ -----·· .__ -·-----.... - · __ .,...._ ::1-·-· ··- ·--........ Choose Instrument Mode: Set to Out of Service .. Figure 3.13: Instrument Mode setting 23 m. Instrument Protection set to NONE. _._ .... ~.,.. ... --·--Instrument Protection: Choose NONE ···"'--" -Figure 3.14: Instrument Protection Setting 1v. A 4 rnA current is supplied to the Digital Valve Controller (DVC) of butterfly valve and 24VDC is supplied to ball valve DVC • Butterfly valve ..... -----Input Current= 3.99 rnA C'\ ~--.. ,, ..... Figure 3.15: Input current to the butterfly valve 24 'I J - J • Ball valve ·-· ··- . - .... - ~ - - ~ Input current = 8.07 mA (Equal to 24 VDC) ... . ._ ___ ... , ___ .... .. _ Figure 3.16: Input current to ball valve Besides, the Partial Stroke Parameters are set to get in order to do PST. Table 3.5 shows the parameters setting in Partial Stroke menu. Table 3.5: Parameters setting in Partial Stroke menu No Parameter Setting I Partial Stroke Enabled Enabled 2 Test Start Point Valve Open 3 Maximum Travel Movement 20% 4 Test Speed 0.5%/s 5 Test Pause Time 5 sec 6 Auto Test Interval (day) 0 25 3.2.5 Partial Stroke Testing Execution Figure 3.17 shows the flow of PST execution. Download ball valve program to the PLC from WideField2 software J Forced reset 100020 to energize the solenoid valve __j ()pen AMS ValveLink software ) Right click 'Local Machine' icon on the left pane of the window _j Choose 'Network Scan' to search for valves connected to the software Valves connected to the software are shown at window's left pane J Double click the valve that needs to be tested __j Choose 'Read Instrument' from Instrument menu __j Set the PST parameters at the Partial Stroke/SlS menu _] Click on the PST icon on the AMS ValveLink software too~ When PST window appears, click ' Run Diagnostic' PST progress bar appears on screen. Wait until PST is completed J Figure 3.17: Flow of PST execution 26 3. 2. 5 Data gathering and analysis AMS ValveLink has a feature that able to generate the report of the testing after the testing was conducted. Figure 4.8 shows the steps taken to analyze the data. The Analyzed Data Section in PST report was generated from the AMS ValveLink software. The report provides the testing result in graphs such Valve Signature, Dynamic Error Band and Travel Signal. These graphs were also represented in numerical value as shown in Analyzed Data section (red circle). The Analyzed Data section consists of the Dynamic Error, Dynamic Linearity, Ranged Travel and Bench Set. The value of the errors was varied according to the valve specification and condition. Then, the data were converted to table form. Next, the graphs were plotted according to the value of the parameters in Analyzed Data section, and the valve performances are analyzed. (Note that the graphs on the next pages are not generated from the software. Refer to Appendix V and VI for the summary of Analyzed Data values in table form for PST on ball and butterfly valves) • • Figure 3.18: Steps taken to analyzed the PST data 27 Graphtorwh ...... ..... Daa 3.3 Tools Required 3.3.1 Hardware Requirement The hardware requirements for this project are as follow:-1. Valves There are 2 types of valves use throughout this project; ball valve and butterfly valve. Table 3.6 shows the general specification for each valve. Table 3.6: General Specification for Valves Manufacturers Valves Size Input Minimum Operational (inch) Pressure Temperature (psi) ("C) FISHER Ball 6 24VDC 5 psi -40-+80 Butterfly 4 4-20mA 5 psi -40-+80 METSO Ball 6 4-20mA 36 psi -40-+85 Butterfly 6 4-20mA 36psi -40-+85 MASONEILAN Ball 6 24VDC 3 psi -40-+85 Butterfly 6 4-20mA 3 psi -40 -+85 28 Figure 3.19 shows the configuration for the Yokogawa F A-M3 Controller. 110 modules and special modules CPU module Power supply module Figure 3.20: Yokogawa FA-M3 Controller configuration 3. Personal Computer 4. 24 VDC Power Supply 5. Multiplexer 6. Pressure supply 3.3.2 Software Requirement Table 3.8 lists out the softwares use in this project. Table 3.8: Softwares use in this project Software Vendor Application 1 WinField2 Yokogawa Yokogawa FA-M3 Controller 2 ValveLink Fisher Fisher Ball Valve and Butterfly Valve 3 Field Care Metso Metso Ball Valve and Butterfly Valve 4 Valvue ESD Masoneilan Masoneilan Ball Valve and Butterfly Valve 30 -3.4 Hardware Preparation This project involves 6 valves from different manufacturers. The valves will be controlled by PLC and Personal Computer (PC). The PLC is needed to trigger the demand and execute the FST according to the project requirements. Thus, it is important to develop the right hardware system between input and output devices. A complete wiring connection will ensure the communications between each device are successful. Figure 3.20 shows the hardware connections between PLC, PC, valves and multiplexer. Fisher vaJyesskid :\t etsO \·alves skid :\iasoneilan yal\·esskid Figure 3.21: Hardware connection between the valves, PLC, PC and multiplexer 31 Figure 3.22 shows the hardware connection for power supply and pressure supply to the valves. 24VDC Power Supply Figure 3.22: Wiring connection for power supply and pressure supply Legends:-D FISHER6. ' Ball \'alH! FISHER .f' Butterdy Yal\·e 32 Pressure Supply CHAPTER4 RESULTS & DISCUSSION 4.1 Partial Stroke Testing The PST has been executed for 35 days, which means each valve has perfonned 175 times PST and 35 times PST coincides with FST. Figure 4.1 shows the valve signature of a PST executed on ball valve on 151 February 2009. (Refer to Appendix III and IV for full report (software generated) on PST testing for ball valve and butterfly valve). • i J • J J • .l • .. .. . .. 2"d travel . ,. • a I I .. • .. --Figure 4.1: Valve signature for ball valve Best fit 1st travel • .. The y-axis of the graph is the actuator pressure and the x-axis is the travel in degree. The valve is in fully open position at 90 degree and according to Partial Stroke parameters setting; the maximum travel is 20% which is 18 degree. 33 Referring to Figure 4.1, the first travel is from 90.5 degree to 72.5 degree. At 90.5 degree, the actuator pressure dropped abruptly from 52.5 psi to 41.5 psi. It is because the valve needs much torque to overcome the break force in order to cause the valve to move. In order to perform PST, the valve bleed out the air and the pressure is continuously dropped until it reached the maximum travel set earlier in Section 3.2. At the starting point of second travel, the pressure is increased from 38.8 psi to 43.8 psi. Then, the pressure is steadily increased until it reached 100% opening. ---- I ... 2"d travel ~ / Best fit 1st travel -. . ..Figure 4.2: Valve signature for butterfly valve Referring to Figure 4.2, the pattern of the signature is the same as the ball valve. The valve started its first travel at 90 degree with 54 psi and drop 41 psi. The pressure drop occurred to cause the valve to move from its seat. The pressure dropped steadily until it reached 80% of travel. Then, the pressure is increased from 37 psi to 44.5 psi when the valve started to move from 80% to I 00% during second travel. The pressure is continuously increased until it reached 100% opening. 34 4.2 Partial Stroke Testing Coincides with Full Stroke Testing For this test, the FST signal is given to the valve when the valve is 90% opened during first travel. Figure 4.3 and Figure 4.4 show the graph of the test for ball and butterfly valve. I st travel / ·- .. --Figure 4.3: Graph for PST coincides with FST on ball valve / !"travel • Figure 4.4: Graph for PST coincides with FST on butterfly valve The maximum travel setting for this test was the same as the PST which is 20%. When the valve started to move, it released the pressure for the valve to move. The FST signal is sent at 81 degree cause the valve to automatically close once it received the signal. 35 4.3 DVC6000 Installation There are 2 types ofDVC6000 installation:-a) 4-wire system b) 2-wire system 4.3.1 4-wire system The 4 wire system installation allows the DVC6000 to continue to communicate even dru:ing emergency shutdown condition. The advantage of 4-wire system is it has 2 different sources being supplied to instruments. The 24 volts is supplied to power up the solenoid valve and the 4-20mA is supplied to the DVC. During shutdown, the voltage supply will be cut off and hence there is no power supply to the solenoid valve. The analog signal to the digital valve control enables the operators to monitor the current information of the valve although the valve is not operating. 4-20 ll"'A ,~----·-/;!---• • ----------------------· Porta Figure 4.5: 4-wire system 36 2.-4-vol:te On 261h February 2009, the solenoid valve on FISHER Ball Valve was removed from the valve actuator. Then, a 24 VDC is supplied to the valve instead of the current. As a result, the FISHER ball valve will no longer operate using the 4-20 mA current. With the solenoid valve bypassed, the pressure line A was eliminated as shown in Figure 4.13. The middle gauge at the DVC6000 measures the pressure supplied to the actuator. The output pressure A energizes the solenoid valve and the output pressure B measures the pressure drops. OutputB Output A Figure 4.6: Bypass the solenoid valve 37 4.3.2 2-wire system The DVC installation became a 2-wire system when solenoid is bypassed. Figure 4.7 shows the 2-wire system with line conditioner connected to the DVC. The line conditioner acts as a barrier because the valve cannot receive 24VDC supply directly from the PLC. LC340 PLC 0.24 Volts Line Conditioner Preaaure Supply Figure 4.7: 2-wire system 38 Parallel with the bypassing of solenoid valve and the operating mode of the valve, there were some changes of the instrument parameters as shown in Table 4.1. Table 4.1: Parameters change of the ball valve Group Parameters Before( Analog) After(Digital) Initial Setup Restart Cont Mode AnalogRSP Dioital Zero Power Condition Valve Open Valve Closed Travel/ Pressure Cutoff Lo (%}_ 0.5 so Relay Type RelayB Relay A orC Travel Sensor Motion Clockwise Counter-clockwise Travel Cycle Count 331 338 History Travel Accumulator(%) 22576 23243 Alerts Deviation& Drive Signal Alert Enable Yes No Other Alerts Supply Pressure Alert Enable Yes No SIS/Partial Partial Stroke Pressure Limit 16 psi 18 psi Stroke 5 sec 5 sec 10 sec Action on Failed Test Ramp Back Step Back Alert Instrument Clock 24Feb 25 Feb 2009,2:26 Records & 2009,1:50 Commands Alert Record Not Empty Enable Yes No Alert Record Full Enable Yes No Travel/ Travel/Pressure Cutoff Lo (%) 0.5 50 Pressure Travel/Pressure Cutoff High(%) 99.46 50 Control Pressure Set Point 52.1 psi 51.8 psi Information lnst Time Invalid Enable Yes No al Status Diag Data Avail Enable Yes No Integrator Sat Hi Enable Yes No Integrator Sat Lo Enable Yes No Press Ctrl Active Enable Yes No Electronics Shutdown Activated Alert Enable Yes No Alerts Actuator Volume Booster/Quick Release - No The parameters in blue are the parameters that changed when the valve operation mode is changed from analog operated to digital operated mode. The Relay Type is changed from Relay Type A to Relay Type B. The Relay Type B allows the valve to automatically close during the power failure. Previously, the valve is set to open whenever the power fails. This setting is not suitable for the emergency shutdown valve because the valve is in fully open during normal operation. 39 4.4 Analyzed Data of Partial Stroke Testing for BaD Valve 4.4.1 Average Dynamic Error 3 Average Dynamic Error l i c 2.5 ... 0 ... 2 ... .... • !:! E 1.5 "' c> c .. .. 1 ....... seriesl "' ... .. ,. 0.5 1.5 c "!---- --seriesl " i "' 1 :!: f"'" 0.5 ···----------·--··· 0 J PST Figure 4.9: Maximum Dynamic Error versus no of PST 40 4.4.3 Minimum Dynamic Error ~----1 Minimum Dynamic Error 2.5 2 1 -t-Sericsl 0.5 0 -'-. ............................. . PST Figure 4.10: Minimum Dynamic Error versus no of PST AMS V alveLink software analyzed the dynamic error curve from 5% travel to 95% travel and calculates the average, maximum and minimum difference between opening and closing curves. Referring to Figure 14, the plot shows that initially the valve Average Dynamic Error was around 2.75%. Referring to Figure 4.8, after the 951h testing (red circle), the Average Dynamic Error reduced to around 2.25% in total reduced to 0.5% error. For the Maximum Dynamic Error, the reading was reduced from 3.7% to 3.1% as shown in Figure 4.9. This happened because previously, the DVC output was connected to the solenoid and the solenoid was connected to the actuator. During the operation, the DVC has a restriction when air goes through the solenoid and to actuator. After removing the solenoid, the output of DVC become smooth where there is no restriction in between the actuator and the DVC 41 4.4.4 Dynamic Linearity Dynamic Linearity 0.8 0.7 ~ 0.6 -> ·£: 0.5 .. .. :5 0.4 .!:! e 0.3 "' -+-Seriesl c > 0.2 c 0.1 0 ··--·---·~--- ·-·· ·-···--------- -PST _________ _j Figure 4.11: Dynamic Linearity versus No of PST Linearity is the maximum deviation from a straight line best fit to the opening and closing curve and line representing the average value of those curves. Based on Figure 4.11, the Dynamic Linearity varies along the number of PST executed and does not affected by the solenoid. 42 4.4.5 Zero Ranged Travel -----Zero Ranged Travel 25 15 .. ~ , ., 1!!' 10 ,. a: 0 .. .. 5 "' 0 PST Figure 4.12: Zero Ranged Travel versus No of PST ....-seriesl ' I ~~----I j AMS V alveLink Software establishes a best fit line through the Dynamic Error Band and projects this to a ranged travel of zero. It converts the X-axis point where the ranged travel is zero, from input percent to milliamps (rnA). The Zero Ranged Travel was ranging from 19.92mA to 20.04 rnA. Referring to Figure 4.12, at 95th PST the values were dropped to 4.21 rnA and continued stabilizing. This drop was due to the changed of operating mode from analog to digital. Initially, the valve was configured at zero ranged valve opens. This is only applicable for Relay Type B special. This relay has been removed when the solenoid was bypassed and being replaced by Relay Type A. For Relay Type A, it is configured that valve close when zero power condition occurred. Therefore, the 4-20 mA signal changed at the plot. 43 4.4. 6 Full Ranged Travel Full Ranged Travel 25 20i····························································l1~~~-----------15 ; .............. . --seriesl 0 ~ C'l ~ ~ ~ !; ~ c; :2 ~ e;j gj ~ (j ~ ~ ~ ~ ~ r;:: ~ $ 1'"1 'F"f M M '!""! 1"1 f""! l""'f 1'"1 Axis Title Figure 4.13: Full Range Travel versus No of PST Full Ranged Travel is the point where the travel no longer increases with an increase in current. There was a sudden rise at 95th PST as shown in Figure 4.13. Previously, the Zero Power Condition was set the valve to open when power fails. After changing the operation mode of the valve (from analog operated to digital), the Zero Power Condition is set to close which cause the valve to fully close when power fails. Initially, at full range the valve was configured closed position. After changing the setting of Zero Power Condition, the valve goes to open position as it is configured as open at full range 44 Lower Bench Set is the amount of pneumatic pressure required to begin actuator movement. For air-to-open valve, it is the pressure required to begin valve opening travel. Figure 4.14 and 4.15 show that the pressure reading is reduced after 95th PST. Upper Bench Set displays the amount of pneumatic pressure required to drive the actuator through the full range of travel. For air-to-open valve, it is the pressure required to move the valve to the fully open position. Note that the pressure required to moving the valve is also reduced after 95th PST. The valve requires less pressure to move from its seat when the solenoid is bypassed. Previously, the pressure is supplied to both solenoid valve and DVC to operate the valve. After bypassing the solenoid valve, the pressure is only supplied to the DVC. 46 4.5 Analyzed Data of Partial Stroke Testing for Butterfly Valve 4.5.1 Average Dynamic Error r I 1.8 Average Dynamic Error 1.7 ~ --0 1.6 -"' ·~ 1.5 .. " > c ~ 1.4 .. ., > <( 1.3 41-"''--- --------····· ·- - ....................... ······--·· .. - .. ···-······· .. ·- ·-····. -···-··· ----·-·-··· -·-···--------··--·- -··· ----"' "" Nl 0 ..... ... .... ., "' N "' Cl\ 0 .... M N M ... ... "' "' "' i .... ,... .... rl rl ,... ,... .... ,... .... I PST I _j Figure 4.16: Average Dynamic Error versus no of PST Dynamic Error Curve is the difference between opening and closing curve from 5% to 95% of valve travel. From the curve, the AMS ValveLink software calculates the average, maximum and minimum difference of the opening and closing curve. The graphs are plotted to observe the differences and its effect to the valve. Figure 4.16 shows the Average Dynamic Error plot which ranging from 1.2% to 1.8%. With 0.6% variation, the graph is acceptable. 47 4.5.3 Minimum Dynamic Error -~ 1.1 ~ 1 I i!!i 0.9 E Minimum Dynamic Error ::J 0.8 I 0.7 L ___ -o.6 r---- ------------------------------------------------------ ------o.s _, ---·---------·--··------------·-·-· ··----- ···--··----·· -------·--·--···--------.... 00 PST Figure 4.18: Minimum Dynamic Error versus no of PST Figure 4.18 shows the Minimum Dynamic Error graph of PST. The variation is ranging from 0.9% to 1.7%. The spike at 21st PST is 0.73%. Tightening valve packing cause one of the minimum dynamic error overshoot. 49 4.5.4 Dynamic Linearity o.7 -,------ _________ --~~--namic ~~-~~-arity~ _. __ .. ~ 0.6 ~ 0.5 i-····- --lf-1· , __ - ------- --------------------------- ----------- --------------- ---~ :. 0.4 +-------- --1---111----------------- ------------------ ----------··-------- -------- -. ------~ -~ 0.3 c---------tc·ft 1--- -- -- ----------------------- ---_.---------------- --------------------------~ ~ 0.2 ! 0 _j----~-------~----~-----------------------------------···---------------~--------rl ~ ~ N m ~ M 0 ~ ~ M 00 ~ N m W M 0 ~ q M ~ ~ N m rl N N ~ ~ ~ ~ ~ ~ ~ 00 m m 0 ~ N N M ~ ~ ~ ~ ~ ~ rl M rl rl rl rl rl rl rl PST Figure 4.19: Dynamic Linearity graph versus no of PST Figure 4.19 shows the Dynamic Linearity graph. Linearity is the maximum deviation from a straight line best fit to the opening and closing curves and a line representing the average value of those curves. The readings are ranged from 0.1% to 0.3%. Tightening the valve packing causes the value of dynamic linearity at 21 '' PST to be out of range. 50 4.5.5 Zero Ranged Travel Zero Range Travel 20.6 20.5 4: ! 20.4 ;; ,. ,. ~ ~ 20.3 .... ., ... c "' "' 0 20.2 ~ .. N I I PST !___ Figure 4.20: Zero Range Travel versus no of PST Using the Dynamic Error Band, the AMS ValveLink software establishes a best fit line and projects this to a ranged travel of zero. AMS ValveLink Software converts the X axis point of dynamic band graph where the ranged travel is zero, from input percent to milliamps. Referring to Figure 4.20, the Zero Range Travel is ranging from 20mA to 20.5 rnA. The reading at 21'' PST is the highest among all due to tightening the valve packing. 51 4.5.6 Full Ranged Travel <( E -Full Range Travel 3. 75 -r ---~--------·-----------~----------~· ···-----·-·--------- ---··-···------------' ' Figure 4.21: Full Range Travel versus no of PST I _I Full Range Travel is the point where the travel no longer increases with an increase in current. The value of full range travel is between 3 .5mA to 3. 7mA. At 81 st and 161 '1 PST, the value is out of ranges which are 3.54 rnA and 3.46 rnA, respectively as shown in Figure 4.21. 52 4.5. 7 Lower Bench Set Lower Bench Set 26 ,----·····-···---·-------·····-·-··-~--~----·--··-··--···-···---··---·--·--········ ! 2 4 +--'l'l:c-. ll 23 ~ 22 ~--~·--1-H···II·-····-·---·-----~--~----·------·-·----·-···········~····-~··-·-··--~--··· ~ h 21 i--~··+·-11- ···-·-------··~····-······-~··-·-··----·-~·-·····---·~---··-···~-···· ~ - 20 +-···-··1-l~,f--~···------·-·-·-·-·-------~---------~~--~·-···········~·· 18 I ' PST I .. --~--- ·--~--- --··--·-·· ·-··· ·- .... ··-··~----····--- ...... _.! Figure 4.22: Lower Bench Set versus no of PST Figure 4.22 shows the Lower Bench Set plot. Lower Bench Set is the amount of pnuematic pressure required to begin actuator movement. For air-to-open valves, it is the pressure required to begin valve-opening travel. The reading is ranging from 22 psi to 25 psi. The overshoot occurred at 21 51 PST due to tightening the valve packing. 53 4.5.8 Upper Bench Set 46 ·------·-' Upper Bench Set ·-l ], 45.6 +----- ---1-1- ·-------------------------------------- -- -- ---------------------------1--1--11 !_ ____ _ 3l .s: ::! 8l PST Figure 4.23: Upper Bench Set Upper Bench Set displays the amount of pnuematic pressure required to drive the actuator through the full range of travel. For air-to-open valve, it is the pressure required to move the valve to the fully open position. The reading ranges from 44.6 psi to 45.2 psi which varies about 0.6 psi. Figure 4.23 shows the overshoots occurred at 21th PST due to tightening the valve packing activities. 54 CHAPTERS CONCLUSION & RECOMMENDATIONS 5.1 Conclusion Below is the summary of the project outcomes:-5.1.1 Development of a controller to perform PST and FST • Programming was developed in order to perform PST and FST. The functions of the programming are to initiate the PST and execute the FST. The programming was built separately for each ball valve and butterfly valve. 5.1.2. Compare the PST performance of ball valve and butterfly valve 5.1.2.1 Valve Signature of Partial Stroke Testing • Ball valve requires much pressure at the beginning of the openmg compared to butterfly valve. It is because the actuator size of ball valve is bigger than butterfly valve. Inside the actuator, there is a spring to control the ball or disk movement. The spring inside the ball valve is bigger; hence it needs much torque to cause the valve to move. 5.1.2.2 Bypass the solenoid valve • Bypass the solenoid valve reduced the pressure supplied to the DVC. The value of dynamic error and bench set proved that the pressure supplied to the ball valve was reduced after removing the solenoid valve from the actuator. It is because air can go through the actuator from DVC without restriction from solenoid valve. 55 5.1.2.3 2-wire system versus 4-wire system • Removing the solenoid valve make the DVC installation became a 2-wire system which requires less wiring and would reduce the cost, but the 2-wire system also requires installation of line conditioner which would add up to the total cost of installation. 5.1.3 Failure mode of the valves during the test • Tightening quarterly the gland packing would require much pressure to be supplied to the valve. It is because the valve needs to overcome higher torque in order to cause the valve to move. 56 5.2 Recommendations 5.2.1 Continuous Testing • Currently, the author has executed the PST for 35 days. It is highly recommended to continue the testing to gather 90-days data in order to get a better and accurate result. 5.2.2 Varying the PST parameters • As being discussed in Section 4.5: Analyzed Data for PST of Butterfly Valve shows that tightening the valve packing has an effect on the valve performance. Therefore, the future work the author would suggest varying the PST parameters such as the stroking travel and testing speed to determine their effect in valve performance. 57 REFERENCES [1] Angela E. Summers, "Partial Stroke Testing of Block Valves", Instrument Engineers Handbook, Volume 4, Chapter 6.9, 2006. [2] Emerson Process Management, Sept 2006, "FIELD VUE DVC6000 Series Digital Valve Controller for Safety Instrumented System (SIS) Solutions", Product Bulletin, 62.1:DVC6000 SIS. [3] Bert Knegtering, March 2005, "Partial valve stroke testing enters new domain", http:/ /www.isa.org [4] Emerson Process Management, 2005, "Chapter 4: Control Valve Accessories, Control Valve Handbook", Fourth Edition [5] Emerson Process Management, 2005, "Chapter]: introduction to Control Valve. Control Valve Handbook", Fourth Edition [6] Personnel Training. "Control Valve Presentation", PETRONAS Gas Berhad [7] Personnel Training. "Control Valve Technical Sharing", PETRONAS Gas Berhad [8] Topworx,"ValveTop, Valve Control Solution", http://www.topworx.com 58 [9] K.Clements-Jewery, 1996, "The PLC Workbook" K.Clements-Jewery and W.Jeffcoat, "Programmable Logic Controller Made Easy", Prentice Hall Europe; Simon & Schuster International Group. [10] KronoTech, Instrumentation & Control, "Programmable Logic Controller" http:/ /www.kronotech.com/PLC/ Advantages.htm [11] Kelvin T.Erikson, 1996, "Programmable Logic Controller", IEEE POTENTIALS [12] W. N. Clare, G. T. Kaplan, D. R. Sadlon, A. C. Wiktorowicz (1985), R. A. Gilbert (1995) C. W. Wendt (2005), "PLC: Programmable Logic Controller", Process Control & Optimization, Volume II [13] V.A.Bhavsar, 2005, "PLC Programming", Process Control & Optimization, Volume II [14] Yokogawa Electric Corporation, October 2002, "User Manual: FA-M3 Programming Tool", 1 ''Edition. [15] Yokogawa Electric Corporation, Feb 1999, "Instruction Manual: Analog Input I Output Module", 1st Edition 59 APPENDIX I Ladder Logic Diagram for Ball Valve Circuit:FISHER Power Fai I ur e Condition~ 1st eye I e~ module 5 M00035 '---i 1-------- I J035 { Fl SHER, 00001N,LD), ( Fl SHER, 00003N, LO) Upper Li mi and Lower Li mi t Set t i n g 4 & 2 0 rnA 1 s t c y I c e ~ --···n''-r -----.. ----.-1-.. ~.TE-·~--1000~-. ·-·~---- ~·--- ., __________________ ,.Q _ L___ _ __ _p_j__ _o _ !l_L _________ L_j l ___ . ____ _ 0035 (FISHER,00001N,LD), (FISHER,00003N,LO) l M00033 N--11 00:!3 ( Fl SHER, 00006N, LD) 0001 (FlSHER,00009N,\o\fliTE), (FlSHER,00011N,MOV), (FISHER,00014N,MOV) I) I 00002 IN -·11----l0002 l 0 0 0 1 B) 2N 0) 00201 0 0 0 2 0 00001 ( Fl SHER, 0001 ON, LD) (FISHER, 00009N, 'M.I TE), ( Fl SHER, 00011N, MOV), ( Fl SHER, 00014N, MDV) I 00020 '1 I FISHER, 00016N, OUTN) (FISHER,00012N,LD) (FlSHER,00009N.~ITE), (FISHER,00011N,MOV), (FISHER,00014N,MOV) Y00201 -----0--APPENDIX II Ladder Logic Diagram for Butterfly Valve l -~~-r~ ·~--------------------ji__, .. ~ITIJEL__l_ __ .tsoLL __ L__L _ _j5 02 __L __ ._L__jl 1035 ( BFLY, 00001 N, LD), ( BFL Y, 00003N, LD) M00035 0035 ( BFLY, 00001N, LD), 'l"i"," ( BFL Y, OOOOJN, LD) 0033 ( BFLY, 00008N, LD) 0001 (BFLY,00009N,v.RtTE), (8FLY,00011N,MOV), (BFLY,00014N,MOV) ) I 00002 N~ I---------------~ 0002 ( BFLY, 00010N, LD) 0001 (BFLY,00009N,IJI.fttTE), (BFLY,00011N,MOV), (BFLY,00014N,MOV) N 'l l 0 20 2 J 0 02 0 J 0 0 0 1 (BFLY, 00016N, OUTN) ( BFLY, 00012N, LD) (BFLY,00009N,v.RITE), (BFLY,00011N,MOV), (BFLY,00014N,MOV) ~I TE 530 ---r:=c.__oD~L~D~D~D~D~DJl1 _ji 000001 Y00202 APPENDIX III Daily Report of PST for Ball Valve (Software generated) ValveLink Custom Repott I February 01, 2009 14:06:13 BALL VALVE DVC&OOO SIS HARTT ag Name PST Valve Style ROTARY Actuator Style Piston - Sgl w/ Spring Instrument 5/N 18477410 Valve 5/N 18477410 Firmware Revision 7 Hardware Revision 1 PETROi,lt}5 UTF trument Confi uration [BALL VALVE]- Basic 01 Feb 2009 11:52:29 General Pressure Travel/Pressure Control HART Tag PST Max Supply PreSS\Jre 60 psi Travel/Pressure Control Message Pressure Units psi Travel/ Pressure Select Travel Descriptor 18477410 Tuning Travel I PreSS\Jre Cutoff Lo 0.5 Date 02/18/08 Travel Control (%) Valve Serial Number 18477410 Travel Control Tuning Set H Travel/ PreSS\Jre Cutoff Hi 99.46 1strument Serial Number 18477410 Proportional 8.4 (%) Polling Address 0 Enable Integral Control No End Point Press. Control Initial Setup Integral Gain (reps/min) 9.4 End Point Control Enable Enabled Control Mode Analog (RSP) Integral Settings Control End Restart Cont. Mode Analog (RSP) Integral Dead Zone (%) 0.26 Pressure Set Point 52.1 psi Zero Power Condition Valve Open Integral Umit (%) so Pressure saturation Time 45 avel/ PreSS\Jre Cutoff Lo o.s Pressure Control (sec) (%) Pressure Control Tuning Set H Dynamic Response Valve Style Rotary Shaft Proportional 4.2 Set Point Rate Umits Actuator Style Piston - Sgl w/ Enable Integral Control Yes SP Rate Open (%/sec) 0 Spring Integral Gain (reps/sec) 0.1 SP Rate aose (%/sec) 0 Relay Type Relay B SIS I Partial stroke Set Point Alter Feedback Connection Rotary-All/55- Partial Stroke Lag lime (sec) 0 Roller Enable Enabled Travel Sensor Motion Oockwise Test Start Point Aux Terminal Mode Push Button Partial Stroke Press Umit 16 psi Partial Stroke Max. Travel Movement(%) 20 Test Test Speed 0.5%/s Partial Stroke Start Pt. Valve Open Test Pause lime 5 sec Inputs Auto Test Interval (days) o.oo Analog Input Units mA SIS Options Temperature Units F DVCPowerUp Auto Reset InputCha~zation Action on Failed test Ramp Back In Characteristic Unear Page l of 19 ValveLink Custom Report February 01, 2009 14:06:13 trument Confi uration [BALL VALVE]- Alerts Self Test Shut Down Flash ROM Fail Enable No No Free Time Enable No Reference Voltage Fail No Enable NVM Fail Enable No remp Sensor Fail Enable No ·ravel Sensor Fail Enable No lrive CUrrent Fail Enable No Travel History Alerts Cycle Count Alert Enable No ~e Count Deadband (%) 2.93 Cycle Count Alert Point 2147483646 Cycle Count 300 Trav Ace Alert Enable No vi Accum Deadband (%) 2.93 Tvl Accum Alert Pt (%) 2147483646 Travel Accumulator(%) 21655 01 Feb 2009 11:52:29 Deviation &. Other Alerts Travel Dev Alert Enable Yes Travel Dev Alert Pt (%) 5 Travel DevTime (sec) 9.99 Pressure Dev Alert Enable Yes Pressure Dev Alert Pt 2 psi Pressure Dev Time (sec) 9.99 Drive Signal Alert Enable Yes Supply Pressure Alert Point 0 psi SUpply Pressure Alert Yes Enable Travel Alerts Tvl Alert lo Enable No Tvl Alert Hi Enable No Tvl Alert lo La Enable No Tvl Alert Hi Hi Enable No lo Point(%) -25 Hi Point(%) 125 lo lo Point(%) -25 Hi Hi Point(%) 125 Deadband (%) 1 Tvl Umit/Cutoff lo Enable No Tvl UmitjCutoff Hi Enable No trument Confi uration [BALL VALVE]- 5 ec Sheet 01 Feb 2009 11:52:29 Spec~Unlts Trim Pressure Units psi Seat Type Metal Travel Units deg leak aass v length Units in Port Diameter 6.0in Area Units in2 Actuator Torque Units lbf.in Actuator Mfg. Fisher Controls Spring Rate Units lbf/in Actuator Model 1035 Valve Actuator Size 40 Valve Mfg. Fisher Controls Effective Area 0.0 in2 Valve Model V-250 Air Closes Size 6in Volume Booster/Quick Unknown aass 300 Release Rated Travel 90.0 deg Lower Bench Set O.Opsi Actual Travel 90.0 deg Upper Bench Set 0.0 psi Stem Diameter 2.0in Nominal Supply Pressure 70.0 psi Packing Type TFE/ Single Spring Rate 0.0 lbf/in Inlet Pressure 100.0 psi lever Style Rack and Pinion Outlet Pressure 0.0 si Moment Arm 0.0 In Page 2 of 19 PETRQI\1/-\S ur.o Alert Record and Commands Instrument Ooci< 01 FEB 2009 11:52 Valve Alerts Enable No Failure Alerts Enable Yes Mise Alerts Enable No Burst Mode Enable No Burst Command 3 Cmd #3 (Trending) A Pressure Alert Record Nat Empty Yes Enable Alert Record Full Enable Yes Informational status Inst Time Invalid Enable Yes Cal in Progress Enable No Autacal in Progress Enable No Diag in Progress Enable No Diag Data Avail Enable Yes Integrator Sat Hi Enable Yes Integrator Sat lo Enable Yes Press Ctrl Active Enable Yes Multi-Drop Alert Enable No Electronic Alerts Shutdown Activated Alert Yes Enable Power Starvation Alert No Enable Non-Critical NVM Alert No Enable Reference Trim Style 1 Trim Style 2 Stroking Time Open (sec) 0 Stroking Time Oosed (sec) 0 Dynamic Torque O.Oibf.in Breakout Torque O.Oibf.in ValveLink Custom Report I February 01, 2009 14:06:13 rtial Stroke [BALL VALVE) ~ "' ~, • • e a. li • ~ 60 50 40 30 20 10 a- --------------"--10-t-1--i~----r---t -20 0 150- -----100 ----·----1 I ~ ~ ! ~r~ .~·~·-···+-, _~ ~--_-~---~~._ ~ --= . , .-c~-,~~~-~---~--1 150 100 50 0 -50 Input(%) 150 --~-T---------- ,____ -+- ---~~---~ ~ --~-~-~------ I -50 --+--------t----t---------r----1-~~~~--:i----+--• -~~+-~~-~-- -r--------j -50 0 50 100 150 100 ~ .. ~ 0 • I 50 ___ II) __ tJ ~ '0 0 0··-Input(%) Valve Trim Manufacturer: Fisher Controls Seat Type: Metal Type: V-250 Leakage Class: v Size: 6in Port Diameter: 6.0000 in Oass: 300 Rated Travel: 90.00 deg Actual Travel: 90.00 deg Shaft Diameter: 2.0000 in Packing Type: TFE I Single Inlet Pressure: 100.0000 psi OUtlet Pressure: O.OOOOpsi Page 3 of 19 PETI1_(Jt\!fl5 UTP 01 Feb 2009 11:52:44 Inputs Input Start: Input End: Stroke Speed Test Pause lime: Collection Interval: 100.0% 80.0% 0.5%/s 5 sec 150.0 msec. Analyzed Data Avg. Dynamic Error: 2. 71% Min. Dynamic Error: 1.99% Max. Dynamic Error: 3.47% Dyn. Linearity {Ind.): 0.48% Zero Ranged Travel at: 20.00 rnA Full Ranged Travel at: 4.05 rnA Average Torque: NA Minimum Torque: NA Maximum Torque: NA Spring Rate: NA Bench Sel: 25.9-44.89 psi Partial Stroke Test initiated HART Command by: Partial Stroke Test -us: Completed Successfully Tuning Set Tuning Set: H Gains Proportional: 8.40 Velocity: 4.20 MLF: 31.00 Integral Control: Disabled Integral Gain: 9.4 Notes Actuator Manufacturer: Fisher Controls Type: 1035 Size: 40 Effective Area: 0.00 in2 Air: aoses Bench Sel: 0.0000 psi-0.0000 psi Nominal Supply Pressure: 70.0000 psi Spring Rate: 0.0000 lbf/in Style: Rack and Pinion Moment Arm: 0.0000 in Va/veLink Custom Report February 01, 2009 14:06:13 trument Confi uration [BALL VALVE -Basic 01 Feb 200912:11:03 General Pressure HART Tag PST Max Supply Pressure 60 psi Message Pressure Units psi Descriptor 18477410 Tuning Date 02/18/08 Travel Control Valve Serial Number 18477410 Travel Control Tuning Set H 1sbument Serial Number 18477410 Proportional 8.4 Polling Address 0 Enable Integral Control No Initial Setup Integral Gain (reps/min) 9.4 Control Mode Analog (RSP) Integral Settings Restart Cont. Mode Analog (RSP) Integral Dead Zone(%) 0.26 Zero Power Concltion Valve Open Integral Umit (%) so !Vel/ Pressure Cutoff Lo 0.5 Pressure Control (%) Pressure Control Tuning Set H Valve Style Rotary Shaft Proportional 4.2 Actuator Style Piston - Sgl w/ Enable Integral Control Yes Spring Integral Gain (reps/sec) 0.1 Relay Type Relay B SIS I Partial stroke Feedback Connection Rotary-All/55- Partial Stroke Roller Enable Enabled Travel Sensor Motion Clockwise Test Start Point Aux Terminal Mode Push Button Partial Stroke Press Umit 16 psi Partial Stroke Max. Travel Movement(%) 20 Test Test Speed 0.5%/s Partial Stroke Start Pt. Valve Open Test Pause Time 5 sec Inputs Auto Test Interval (days) 0.00 Analog Input Units mA SIS Options Temperature Units F DVCPowerUp Auto Reset InputCharadb!rization Action on Failed test Ramp Back In t Characteristic Unear Page 4 of 19 PtTROi\JP.S UT? Travel/Pressure Control Travel/Pressure Control Travel/ Pressure Select Travel Travel/ Pressure Cutoff Lo 0.5 (%) Travel/ Pressure Cutoff Hi 99.46 (%) End Point Press. Control End Point Control Enable Enabled Control End Pressure Set Point 52.1 psi Pressure Saturation lime 45 (sec) Dynamic Response Set Point Rate Umits SP Rate Open (%/sec) 0 SP Rate aose (%/sec) 0 Set Point Filter Lag Time (sec) 0 ValveLink Custom Report February 01, 2009 14:06:13 trument Confi uration [BALL VALVE]- Alerts Self Test Shut Down Flash ROM Fail Enable No No Free Tlme Enable No Reference Voltage Fall No Enable NVM Fail Enable No remp Sensor Fall Enable No ·ravel Sensor Fall Enable No lrive Current Fail Enable No Travel History Alerts ::ycte Count Alert Enable No :le Count Deadband (%) 2.93 Cyde Count Alert Point 2147483646 Cyde Count 296 Trav Ace Alert Enable No .-1 Accum Oeadband (%) 2.93 Tv! Accum Alert pt (%) 2147483646 Travel Accumulator(%) 21351 01 Feb 2009 12:11:03 Deviation a other Alerts Travel Dev Alert Enable Yes Travel Dev Alert pt (%) 5 Travel Dev Tlme (sec) 9.99 Pressure Dev Alert Enable Yes Pressure Dev Alert pt 2 psi Pressure Dev Tlme (sec) 9.99 Drive Signal Alert Enable Yes Supply Pressure Alert Point 0 psi Supply Pressure Alert Yes Enable Travel Alerts Tv! Alert La Enable No Tv! Alert Hi Enable No Tv! Alert La Lo Enable No Tv! Alert Hi Hi Enable No La Point(%) -25 Hi Point(%) 125 La La Point(%) -25 Hi Hi Point(%) 125 Deadband (%) 1 Tvl Umit/Cutoff La Enable No Tv! Umit/Cutoff Hi Enable No trument Confi uration [BALL VALVE]- Spec Sheet 01 Feb 2009 12:11:03 Spec Sheet Units Trim Pressure Units psi Seat Type Metal Travel Units deg LeakOass v Length Units in Port Diameter 6.0in Area Units in2 Actuator Torque Units lbf.in Actuator Mfg. Fisher Controls Spring Rate Units lbf/in Actuator Model 1035 Valve Actuator Size 40 Valve Mfg. Fisher Controls Effective Area O.Oin2 Valve Model V-250 Air Oases Size 6in Volume Booster/Quick Unknown Oass 300 Release Rated Travel 90.0deg Lower Bench Set O.Opsi Actual Travel 90.0 deg Upper Bench Set 0.0 psi stem Diameter 2.0in Nominal Supply Pressure 70.0 psi Packing Type TFE I Single Spring Rate 0.0 lbf/in Inlet Pressure 100.0 psi Lever Style Rack and Pinion OUtlet Pressure o.o Moment Arm O.Oin Page 5 of 19 PETROl,! AS UTP Alert Record and Commands Instrument Oock 01 FEB 2009 11:52 Valve Alerts Enable No Failure Alerts Enable Yes Mise Alerts Enable No Burst Mode Enable No Burst Command 3 Cmd #3 (Trending) A Pressure Alert Record Not Empty Yes Enable Alert Record Full Enable Yes Informational status lnst Tlme Invalid Enable Yes cal in Progress Enable No Autocal in Progress Enable No Diag in Progress Enable No Diag Data Avail Enable Yes Integrator Sat Hi Enable Yes Integrator Sat La Enable Yes Press Ctr1 Active Enable Yes Multi-Drop Alert Enable No Electronic Alerts Shutdown Activated Alert Yes Enable Power Starvation Alert No Enable Non-critical NVM Alert No Enable Reference Trim Style 1 Trim Style 2 Stroking Tlme Open (sec) 0 Stroking Tlme Oosed (sec) 0 Dynamic Torque 0.0 ibf.in Breakout Torque o.o lbf.in ValveLink Custom Report February 01, 2009 14:06:13 tial Stroke BALL VALVE] 150 --- -- --~~-~---- -------r I 100----- ____ J_ +- -~~ --- _ 1 -~- __ 1 -~-~-----1 I I I I ..so -----+---t------t---t----+---t---+----;----------t----+--·1--..--.-t-----1--t-----"l--------t-------+----t----1------l 0- ---150 100 50 0 -50 Input(%) Valve Trim Manufacturer: Fisher Controls Seat Type: Metal Type: V-250 Leakage Class: v Size: 6in Port Diameter: 6.0000 in Class: 300 Rated Travel: 90.00 deg Actual Travel: 90.00 deg Shaft Diameter: 2.0000 in Packing Type: TFE I Single Inlet Pressure: 100.0000 psi Outlet Pressure: 0,0000 psi Page 6 of 19 'Y:' '\0\'t\S r·) 01 Feb 2009 12:11:24 Inputs Input Start: Input End: Stroke Speed Test Pause Time: Collection Interval: 100.0% 80.0% 0.5%/s 5 sec 150.0 msec. Analyzed Data Avg. Dynamic Error: 2. 71% Min. Dynamic Error: 1.81% Max. Dynamic Error: 3.22% Dyn. Linearity (Ind.): 0.44% Zero Ranged Travel at: 19.94 mA Full Ranged Travel at: 4.05 mA Average Torque: NA Minimum Torque: NA Maximum Torque: NA Spring Rate: NA Bench Set: 25.48-44.92 psi Partial Stroke Test initiated HART Command by: Partial Stroke Test status: Completed Successfully Tuning Set Tuning Set: H Gains Proportional: 8.40 Velocity: 4.20 MLF: 31.00 Integral Control: Disabled Integral Gain: 9.4 Notes Actuator Manufacturer: Fisher Controls Type: 1035 Size: 40 Effective Area: 0.00 in2 Air: Oases Bench Set: 0.0000 psi-0.0000 psi Nominal Supply Pressure: 70.0000 psi Spring Rate: 0.0000 lbf/in Style: Rack and Pinion Moment Arm: 0.0000 in ValveLink Custom Report February 01, 2009 14:06:13 trument Confi uration [BALL VALVE]- Basic 01 Feb 2009 12:22:15 General Pressure HART Tag PST Max Supply Pressure 60psi Message Pressure Units psi Descriptor 18477410 Tuning Date 02/18/08 Travel Control Valve Serial Number 18477410 Travel Control Tuning Set H roument Serial Number 18477410 Proportional 8.4 Polling Address 0 Enable Integral Control No Initial Setup Integral Gain (reps/min) 9.4 Control Mode Analog (RSP) Integral Settings Restart Cont. Mode Analog (RSP) Integral Dead Zone(%) 0.26 Zero Power Condition Valve Open Integral Umit (%) 50 !Vel/ Pressure Cutoff La 0.5 Pressure Control (%) Pressure Control Tuning Set H Valve Style Rotary Shaft Proportional 4.2 Actuator Style Piston - Sgl w/ Enable Integral Control Yes Spring Integral Gain (reps/sec) 0.1 Relay Type Relay B SIS I Partial stroke Feedback Connection Rotary-All/55· Partial Strol ·c " 150 ---~ ·----~-------r -----~-- .. --T- -~-- --l- .. ----l ~------- --1---- -~~ - -1 50 {-------~J --i -~ 1- ----1 100-- I_ _I_ _ ___ !~-----~---- ___ I ~I~--~~--+-1 ~--~+----+-~r-+-,~,_J 150 100 50 0 -50 Input(%) 15T- ---1-- I ,. --~- -r 50 -so-t-~-~~~-1 -50 0 50 Valve Manufacturer: Type: Size: aass: Rated Travel: Actual Travel: Shaft Diameter: Packing Type: Inlet Pressure: Outlet Pressure: Fisher Controls V-250 6in 300 90.00 deg 90.00 deg 2.0000 in TFE/ Single 100.0000 psi 0.0000 psi Input(%) -----"- ------ - --1 ___ j --- --1 -~-- _____ j I -[-- --- I 100 Trim Seat Type: Leakage Oass: Port Diameter: Page 9 of 19 Metal v 6.0000 in 150 PETHOi\1/\S UTP 01 Feb 2009 12:24:06 Inputs Input start: 100.0 % Input End: 80.0% Stroke Speed 0.5%/s Test Pause Time: 5 sec Collection Interval: 150.0 msec. Analyzed Data Avg. Dynamic Error: 2. 75% Min. Dynamic Error: 1.67% Max. Dynamic Error: 3. 71% Dyn. Unearity (Ind.): 0.59% Zero Ranged Travel at: 19.93 rnA Full Ranged Travel at: 4.06 mA Average Torque: NA Minimum Torque: NA Maximum Torque: NA Spring Rate: NA Bench Set: 26.16 - 44.69 psi Partial Stroke Test initiated HART Command by: Partial Stroke Test status: Completed Successfully Tuning Set Tuning Set: H Gains Proportional: 8.40 Velodty: 4.20 MLF: 31.00 Integral Control: Disabled Integral Gain: 9.4 Notes Actuator Manufacturer: Fisher Controls Type: 1035 Size: 40 Effective Area: 0.00 in2 Air: aoses Bench Set: 0.0000 psl-0.0000 psi Nominal Supply Pressure: 70.0000 psi Spring Rate: 0.0000 \bf/in Style: Rack and Pinion Moment Arm: 0.0000 In ValveLink Custom Report February 01, 2009 14:06:13 trument Confi uration [BALL VALVE]- Basic 01 Feb 2009 12:32:09 General Pressure HART Tag PST Max Supply Pressure 60psi Message Pressure Units psi Descriptor 1B4n410 Tuning Date 02/18/08 Travel Control Valve Serial Number 1B4n410 Travel Control Tuning Set H 1strument Serial Number 1B4n4to Proportional 8.4 Polling Address 0 Enable Integral Control No Initial Setup Integral Gain (reps/min) 9.4 Control Mode Analog (RSP) Integral Settings Restart Cont. Mode Analog (RSP) Integral Dead Zone(%) 0.26 Zero Power Condition Valve Open Integral Um~ (%) so avel/ Pressure Cutoff La 0.5 Pressure Control (%) Pressure Control Tuning Set H Valve Style Rotary Shaft Proportional 4.2 Actuator Style Piston - Sgl w/ Enable Integral Control Yes Spring Integral Gain (reps/sec) 0.1 Relay Type Relay B SIS I Partial stroke Feedback Connection Rotary-All/55- Partial Stroke Roller Enable Enabled Travel Sensor Motion Oockwise Test Start Point Aux Terminal Mode Push Button Partial Stroke Press Um~ 16 psi Partial Stroke Max. Travel Movement(%) 20 Test Test Speed 0.5%/S Partial Stroke start Pt. Valve Open Test Pause lime Ssec Inputs Auto Test Interval (days) 0.00 Analog Input Units mA SIS Options Temperature Units F DVCPowerUp Auto Reset Input Characterization Action on Failed test Ramp Back In ut Characteristic Unear Page 10 of 19 PETRON:\S UTP Travel/Pressure COntrol Travel/Pressure Control Travel/ Pressure Select Travel Travel/ Pressure Cutoff La 0.5 (%) Travel/ Pressure Cutoff Hi 99.46 (%) End Point Press. Control End Point Control Enable Enabled Control End Pressure Set Point 52.1 psi Pressure Saturation lime 45 (sec) Dynamic Response Set Point Rate Umits SP Rate Open (%/sec) 0 SP Rate aose (%/sec) 0 Set Point Filter Lag lime (sec) 0 ValveLink Custom Report I February 01, 2009 14:06:13 trument Confi uration [BALL VALVE] -Alerts self Test Shut Down Aash ROM Fail Enable No No Free lime Enable No Reference Voltage Fail No Enable NVM Fail Enable No Temp Sensor Fall Enable No rravel Sensor Fail Enable No ilrive Current Fail Enable No Travel History Alerts Cycle Count Alert Enable No :le Count Deadband (%) 2.93 Cyde Count Alert Point 2147483&46 Cyde Count 300 Trav Ace Alert Enable No \il Accum Deadband (%) 2.93 Tvl Accum Alert pt (%) 2147483646 Travel Accumulator(%) 21430 01 Feb 2009 12:32:09 Deviation & Other Alerts Travel Dev Alert Enable Yes Travel Dev Alert pt (%) 5 Travel Dev lime (sec) 9.99 Pressure Dev Alert Enable Yes Pressure Dev Alert pt 2 psi Pressure Dev lime (sec) 9.99 Drive Signal Alert Enable Yes supply Pressure Alert Point 0 psi Supply Pressure Alert Yes Enable Travel Alerts Tvl Alert lo Enable No Tvl Alert Hi Enable No Tvl Alert lo Lo Enable No Tvl Alert Hi Hi Enable No lo Point(%) -25 Hi Point (%) 125 lo lo Point(%) ·25 HI Hi Point(%) 125 Deadband (%) 1 Tvl Umit/Cutoff Lo Enable No Tvl Umit/Cutoff Hi Enable No trument Confi uration [BALL VALVE]- Spec Sheet 01 Feb 2009 12:32:09 Spec Sheet Units Trim Pressure Units psi SeatType Metal Travel Units deg Leak Oass v Length Units in Port Diameter 6.0in Area Units in2 Actuator Torque Units lbf.in Actuator Mfg. Fisher Controls Spring Rate Units lbf/in Actuator Model 1035 Valve Actuator Size 40 Valve Mfg. Fisher Controls Effective Area O.Oin2 Valve Model V-250 Air doses Size 61n Volume Booster/Quick Unknown Class 300 Release Rated Travel 90.0 deg Lower Bench Set O.Opsi Actual Travel 90.0 deg Upper Bench Set 0.0 psi Stem Diameter 2.0in Nominal Supply Pressure 70.0 psi Packing Type TFE/ Single Spring Rate 0.0 lbf/in Inlet Pressure 100.0 psi Lever Style Rack and Pinion Outlet Pressure o.o Moment Arm O.Oin Page 11 of 19 PETRONi\S UTP Alert Record and Commands Instrument Oock 01 FEB 2009 12:12 Valve Alerts Enable No Failure Alerts Enable Yes Mise Alerts Enable No Burst Mode Enable No Burst Command 3 Cmd #3 (Trending) A Pressure Alert Record Not Empty Yes Enable Alert Record Full Enable Yes Informational status Inst lime Invalid Enable Yes Cal in Progress Enable No Autocal in Progress Enable No Diag In Progress Enable No lliag Data Avail Enable Yes Integrator Sat Hi Enable Yes Integrator Sat lo Enable Yes Press Ctr1 Active Enable Yes Multi-Drop Alert Enable No Eledronlc Alerts Shutdown Activated Alert Yes Enable Power Starvation Alert No Enable Non-Critical NVM Alert No Enable Reference Trlm Style 1 Trim Style 2 Stroking lime Open (sec) 0 Stroking lime Oosed (sec) 0 Dynamic Torque o.o lbf.in Breakout Torque 0.0 lbf.ln Va/veLink Custom Report February 01, 2009 14:06:13 rtial Stroke [BALL VALVE] Travel (deg) 100- -~~--- ~-r --T- -----1 ------~-- ----1--7- -~- ' I I ' -------1-~~- -r -500[-~---.·-.---r-+---~~---~·--___,--~~····" ~·· --.~ --- I --, -·-----r--------- f---~---------+-----~·----t------1 150 100 50 0 -50 Input(%) . ·- ---,--------t~-· I i .. il i 50 ----~---" -~-- .. ---~--- -··--· --1--· ·- ----· -... 0 -··--r-- ------- 1 -soL-~~~-+~-~-~~-L~~-~+-~~~- -,____j -50 0 50 100 150 Valve Manufacturer: Type: Size: Oass: Rated Travel: Actual Travel: Shaft Diameter: Packing Type: Inlet Pressure: outlet Pressure: Fisher Controls V·2SO Gin 300 90.00 deg 90.00 deg 2.0000 in lFE/ Single 100.0000 psi 0.0000 psi Input(%) Trim Seat Type: Leakage Oass: Port Diameter: Page 12 of 19 Metal v 6.0000 in PETROi\l.JS UTP 01 Feb 2009 12:32:22 Inputs Input Start: Input End: Stroke Speed Test Pause Time: Collection Interval: 100.0% 80.0% 0.5%/s 5 sec 150.0 msec. Analyzed Data Avg. Dynamic Error: 2. 72% Min. Dynamic Error: 1.81% Max. Dynamic Error: 3.43% Dyn. Unearity (Ind.): 0.45% Zero Ranged Travel at: 20.00 mA Full Ranged Travel at: 4.05 mA Average Torque: NA Minimum Torque: NA Maximum Torque: NA Spring Rate: NA Bench set: 27.06- 44.65 psi Partial Stroke Test initiated HART Command by: Partial Stroke Test status: Completed Successfully Tuning Set Tuning set: H Gains Proportional: 8.40 Velodty: 4.20 MLF: 31.00 Integral Control: Disabled Integral Gain: 9.4 Notes Actuator Manufacturer: Fisher Controls Type: 1035 Size: 40 Effective Area: 0. 00 in2 Air: Ooses Bench set: 0.0000 psi-0.0000 psi Nominal Supply Pressure: 70.0000 psi Spring Rate: 0.0000 lbf/in Style: Rack and Pinion Moment Arm: 0.0000 in Va/veLink Custom Report February 01, 2009 14:06:13 trument Confi uration [BALL VALVE -Basic 01 Feb 2009 12:42:30 General Pressure HART Tag PST Max Supply Pressure 60 psi Message Pressure Units psi Descriptor 18477410 TUning Date 02/18/08 Travel Control Valve Serial Number 18477410 Travel Control Tuning Set H 1strument Serial Number 18477410 Proportional 8.4 Polling Address 0 Enable Integral Control No Initial Setup Integral Gain (reps/min) 9.4 Control Mode Analog (RSP) Integral Settings Restart Cont. Mode Analog (RSP) Integral Dead Zone (%) 0.26 Zero Power Condition Valve Open Integral Umlt (%) so avel/ Pressure Cutoff 1..o 0.5 Pressure Control (%) Pressure Control Tuning Set H Valve Style Rotary Shaft Proportional 4.2 Actuator Style Piston - Sgl w/ Enable Integral Control Yes Spring Integral Gain (repS/sec) 0.1 Relay Type Relay B SJS I Partial Stroke Feedback Connection Rotary-All/55- Partial Stroke Roller Enable Enabled Travel Sensor Motion Oockwise Test Start Point Aux Terminal Mode Push Button Partial Stroke Press Um~ 16psi Partial Stroke Max. Travel Movement(%) 20 Test Test Speed 0.5%/S Partial Stroke Start Pt. Valve Open Test Pause Time Ssec Inputs Auto Test Interval (days) 0.00 Analog Input Units mA SIS Options Temperature Units F DVCPowerUp Auto Reset Input Characterization Action on Failed test Ramp Back In ut Characteristic Unear Page 13 of 19 PETROW-'.S UW' Travel/Pressure Control Travel/Pressure Control Travel/ Pressure Select Travel Travel/ Pressure Cutnff l..o 0.5 (%) Travel/ Pressure Cutoff HI 99.46 (%) End Point Press. Control End Point Control Enable Enabled Control End Pressure Set Point 52.1 psi Pressure Saturation Time 45 (sec) Dynamic Response Set Point Rate Umits SP Rate Open (%/sec) 0 SP Rate aose (%/sec) 0 Set Point Fdter Lag Time (sec) 0 Va/veLink Custom Report • February 01, 2009 14:06:13 trument Confi uration BALL VALVE]- Alerts Self Test Shut Down Rash ROM Fail Enable No No Free lime Enable No Reference Voltage Fail No Enable NVM Fail Enable No Temp Sensor Fail Enable No rravel sensor Fail Enable No Jrive CUrrent Fail Enable No Travel History Alerts Cycle Count Alert Enable No :le Count Deadband (%) 2.93 Cyde COUnt Alert Point 2147483646 Cyde COUnt 302 Trav Ace Alert Enable No \il Accum Deadband (%) 2.93 Tvl Accum Alert Pt (%) 2147483646 Travel Accumulator(%) 214n 01 Feb 2009 12:42:30 Deviation • other AI-Travel Dev Alert Enable Yes Travel Oev Alert Pt (%) 5 Travel Oev lime (sec) 9.99 Pressure Oev Alert Enable Yes Pressure Dev Alert Pt 2 psi Pressure Oev lime (sec) 9.99 Drive Signal Alert Enable Yes SUpply Pressure Alert Point 0 psi Supply Pressure Alert Yes Enable TraveiAI-Tvl Alert Lo Enable No Tvl Alert Hi Enable No Tvl Alert Lo Lo Enable No Tvl Alert Hi HI Enable No Lo Point(%) -25 Hi Point(%) 125 Lo Lo Point(%) ·25 Hi Hi Point(%) 125 Deadband (%) 1 Tvl Umit/Cutoff Lo Enable No Tvl Umit/Cutoff Hi Enable No trument Confi uration [BALL VALVE]- Spec Sheet 01 Feb 2009 12:42:30 Spec Sheet u- Trim Pressure Units psi 5eatType Metal Travel Units deg Leak Oass v Length Units in Port Diameter 6.0in Area Units in2 Actuator Torque Units lbf.in Actuator Mfg. Asher Controls Spring Rate Units lbf/in Actuator Model 1035 Valve Actuator Size 40 Valve Mfg. Asher Controls Effective Area O.Oin2 Valve Model V·250 Air aoses Size Gin Volume Booster/Quick Unknown Oass 300 Release Rated Travel 90.0 deg Lower Bench Set 0.0 psi Actual Travel 90.0 deg Upper Bench Set 0.0 psi Stern Diameter 2.0 in Nominal Supply Pressure 70.0 psi Packing Type TFE I Single Spring Rate 0.0 lbf/in Inlet Pressure 100.0 psi Lever Style Rack and Pinion OUtlet Pressure o.o Moment Arm 0.0 in Page 14 of 19 PETRCi\Jf·S UTP Alert Record and Commands 1-ument Oock 01 FEB 2009 12:22 Valve Alerts Enable No Failure Alerts Enable Yes Mise Alerts Enable No Burst Mode Enable No Burst Command 3 Cmd #3 (Trending) A Pressure Alert Record Not Empty Yes Enable Alert Record Full Enable Yes Informational status Inst lime Invalid Enable Yes Cal in Progress Enable No Autocalln Progress Enable No Diag In Progress Enable No lliag Data Avail Enable Yes Integrator Sat Hi Enable Yes Integrator Sat Lo Enable Yes Press art ActiVe Enable Yes Multi-Drop Alert Enable No Electronic AI-Shutdown Activated Alert Yes Enable Power Starvation Alert No Enable Non-Critical NVM Alert No Enable Reference Trim Style 1 Trim Style 2 Stroking lime Open (sec) 0 Stroking lime Oosed (sec) 0 Dynamic Torque 0.0 lbf.in Breakout Torque 0.0 lbf.in ValveLink Custom Report February 01, 2009 14:06:13 rtial Stroke BALL VALVE 150- ·- ~-~ ~--- - -~-~-. -1- ---- --]-- --- -~-- I 100- -----, : I ---t -~--- - 1 r- 1 t +----~-----------1 [ " l 50 -* tl 0-------.so -~-+----i-!---i-------t-·+------t------··+--t--r·--j--------·1-- ~--------+------t---------t-----1 150 100 50 0 -50 150 -----· 100 ~--[ i 50 -~ 0 0 --··- -------- ·-Valve Manufacturer: Type: Size: Oass: Rated Travel: Actual Travel: Shaft Diameter: Packing Type: Inlet Pressure: Outlet Pressure: Fisher Controls V-250 61n 300 90.00 deg 90.00 deg 2.0000 in lFE/ Single 100.0000 psi 0.0000 psi Input(%) 50 Input(%) 100 Trim Seat Type: Leakage Oass: Port Diameter: Page 15 of 19 Metal v 6.0000 in 150 PETRO~U\S 01 Feb 2009 12:42:48 Inputs Input Start: Input End: Stroke Speed Test Pause lime: 100.0% 80.0% 0.5%/s 5sec UT? Collection Interval: 150.0 msec. Analyzed Data Avg. Dynamic Error: 2. 74% Min. Dynamic Error: 1.76% Max. Dynamic Error: 3.51% Dyn. Unearity (Ind.): 0.50% Zero Ranged Travel at: 19.98 mA Fuii·Ranged Travel at: 4.05 mA Average Torque: NA Minimum Torque: NA Maximum Torque: NA Spring Rate: NA Bench Set: 26.66- 44.65 psi Partial Stroke Test initiated HART Command by: Partial Stroke Test status: Completed Successfully Tuning Set Tuning Set: H Gains Proportional: 8.40 Velocity: 4.20 MLF: 31.00 Integral Control: Disabled Integral Gain: 9.4 Notes Actuator Manufacturer: Type: Size: Effective Area: Air: Bench Set: Nominal Supply Pressure: Spring Rate: Style: Moment Arm: fisher Controls 1035 40 0.00 in2 doses 0.0000 psi-0.0000 psi 70.0000 psi 0.0000 lbf/in Rack and Pinion O.OOOOin ValveLink Custom Repott I February 01, 2009 14:06:13 trument Conti uration [BALL VALVE -Basic 01 Feb 2009 12:53:25 General Pressure HART Tag PST Max Supply Pressure 60 psi Message Pressure Units psi Descriptor 1B4n410 Tuning Date 02/18/08 Travel a>ntrol Valve Se~at Number 1B4n410 Travel Control Tuning Set H 1strument Selia! Number 1B4n410 Proportional 8.4 Polling Address 0 Enable Integral Control No Initial Setup Integral Gain (reps/min) 9.4 Control Mode Analog (RSP) Integral Settings Restart Cont. Mode Analog (RSP) Integral Dead Zone(%) 0.26 Zero Power Q>ndltion Valve Open Integral Um~ (%) so avel I Pressure Cutoff Lo 0.5 Pressure Control (%) Pressure Control T unlng Set H Valve Style Rotary Shaft Proportional 4.2 Actuator Style Piston - Sgl w/ Enable Integral Control Yes Spring Integral Gain (reps/sec) 0.1 Relay Type Relay B SIS I Partial Stroke Feedback Connection Rotary-All/55- Partial Stroke Roller Enable Enabled Travel Sensor Motion Oockwise Test Start Point Aux Terminal Mode Push Button Partial Stroke Press Urn~ 16 psl Partial Stroke Max. Travel Movement(%) 20 Test Test Speed 0.5%/s Partial Stroke Start Pt. Valve Open Test Pause llrne 5 sec Inputs Auto Test Interval (days) 0.00 Analog Input Un~ rnA SIS Options Temperature Units f DVCPowerUp Auto Reset Input Characterization Action on Failed test Ramp Back In ut Characteristic Unear Page 16 of 19 PETRON/~5 UTP TraVel/Pressure Control Travel/Pressure a:mtrol Travel I Pressure Select Travel Travel I Pressure Cutoff Lo 0.5 (%) Travel I Pressure CUtoff Hi 99.46 (%) End Point Press. Q>ntrol End Point Control Enable Enabled Control End Pressure Set Point 52.1 psi Pressure Saturation lime 45 (sec) Dynamic~ Set Point Rate Urn~ SP Rate Open (%/sec) 0 SP Rate aose (%/sec) 0 Set Point Fl~ Lag llrne (sec) 0 ValveLink Custom Report February 01, 2009 14:06:13 trument Confi uration [BALL VALVE]- Alerts Self Test Shut Down Flash ROM Fail Enable No No Free lime Enable No Reference Voltage Fail No Enable NVM Fail Enable No remp Sensor Fail Enable No rravel Sensor Fail Enable No Jrive CUrrent Fail Enable No Travel History Alerts Cyde Count Alert Enable No :Je Count Deadband (%) 2.93 Cyde Count Alert Point 2147483646 Cyde Count 304 Trav Ace Alert Enable No \II Accum Deadband (%) 2.93 Tvl Accum Alert P! (%) 2147483646 Travel Accumulator(%) 21511 01 Feb 2009 12:53:25 Deviation 8L Other Alerts Travel Dev Alert Enable Yes Travel Dev Alert pt (%) 5 Travel Dev lime (sec) 9.99 Pressure Dev Alert Enable Yes Pressure Dev Alert pt 2 psi Pressure Dev lime (sec) 9.99 Drive Signal Alert Enable Yes Supply Pressure Alert Point 0 psi Supply Pressure Alert Yes Enable Travel Alerts Tvl Alert Lo Enable No Tvl Alert HI Enable No Tvl Alert Lo Lo Enable No Tvl Alert Hi Hi Enable No Lo Point(%) -25 HI Point(%) 125 Lo Lo Point(%) -25 Hi Hi Point(%) 125 Deadband (%) 1 Tvl Limit/CUtoff Lo Enable No Tvl Limit/CUtoff Hi Enable No trument Confi uration [BALL VALVE]- Spec Sheet 01 Feb 2009 12:53:25 Spec Sheet llnlts Trim Pressure Units psi Seat Type Metal Travel Units deg leak aass v Length Units in Port Diameter 6.0in Area Units in2 Actuator Torque Units lbf.in Actuator Mfg. Asher Controls Spring Rabo Units lbf/in Actuator Model 1035 Valve Actuator Size 40 Valve Mfg. Asher Controls Effective Area 0.0 in2 Valve Model V-250 Air aoses Size Gin Volume Boosbor/Quick Unknown aass 300 Release Rated Travel 90.0 deg lower Bench Set 0.0 psi Actual Travel 90.0 deg Upper Bench Set O.Opsi Stem Diameter 2.0in Nominal Supply Pressure 70.0 psi Packing Type TFE I Single Spring Rate 0.0 lbf/in Inlet Pressure 100.0 psi lever Style Rack and Pinion Outiet Pressure 0.0 Moment Ann O.Oin Page 17 of 19 PETRONJ\S UYP Alert Record and Commands Instrument aock 01 FEB 2009 12:33 Valve Alerts Enable No Failure Alerts Enable Yes Mise Alerts Enable No Burst Mode Enable No Burst Command 3 Cmd #3 (Trending) A Pressure Alert Record Not Empty Yes Enable Alert Record Full Enable Yes Informational status lost lime Invalid Enable Yes C.l in Progress Enable No Autocal in Progress Enable No Diag In Progress Enable No Diag Data Avail Enable Yes Integrator Sat Hi Enable Yes Integrator Sat lo Enable Yes Press Ctrt Active Enable Yes Multi-Drop Alert Enable No Electronic Alerts Shutdown Activated Alert Yes Enable Power Starvation Alert No Enable Non-Critical NVM Alert No Enable Reference Trim Style 1 Trim Style 2 Stroking lime Open (sec) 0 Stroking lime Qosed (sec) 0 Dynamic Torque 0.0 lbf.in Breakout Torque 0.0 lbf.in ValveLink Custom Report February 01, 2009 14:06:13 rtial Stroke [BALL VALVE] 'i" a ~ , • il Q_ s • , li 60 -- I~ - 1-:-~- ~ i -=-=-~ ~-------1 _:__---:l- -=-1 - ---1-----'-- __ I_--~- I --~--- ~ -1- I :==: ~= I - --~- .==t =-j 50-40 30 i3 --~: - --~ . _j__ _ __ ,__ - -+ I -------~--- -1-- !~- J ___ , __ _______ j_____ ' _ l -· _ . I I I -~~- - --~ ----1 - -~ 20· 10 0 -20 -t---i-t---t---T--+-i-t--i--+--+--1--r-----r-+-+-T-----t------t---·t- t-~-t-i-----1--{ - 0 W • 00 00 ~ 1W Travel (deg) 150 ---100 ---~ "$! -~ l =-1== r----1 ~----! 1---.. 50 -,_,~ ~ l-- ---r-- ___ jl I 1 i -t-----+----f------t----+ ~+-~....-.r--t---------t---l 0 100 50 0 -50 Input(%) 150 ------- I -- -- --~-----~ 100 _ ~- _______ r--- __ __ _1 _____________ 1 50 -r ------~-- ---1-- ------ I o~ -- --~--so -1-+----1 ___,'---~"-~~ j---------+----+- -------t----1 -50 0 50 100 150 Input(%) Valve Trim Manufacturer: Fisher Controls Seat Type: Metal Type: V-250 Leakage dass: v Size: 61n Port Diameter: 6.0000 in dass: 300 Rated Travel: 90.00 deg Actual Travel: 90.00 deg Shaft Diameter: 2.0000 in Packing Type: TFE I Single Inlet Pressure: 100.0000 psi Outlet Pressure: 0.0000 psi Page 18 of 19 PETROi\ii\S UTP 01 Feb 2009 12:54:14 Inputs Input Start: Input End: Stroke Speed Test Pause lime: Collection Interval: 100.0% 80.0% 0.5%/5 5 sec 150.0 msec. Analyzed Data Avg. Dynamic Error: -10000.00% Min. Dynamic Error: -10000.00% Max. Dynamic Error: -10000.00% Dyn. Unearity (Ind.): -10000.00% Zero Ranged Travel at: -10000.00 rnA Full Ranged Travel at: -10000.00 rnA Average Torque: NA Minimum Torque: NA Maximum Torque: NA Spring Rate: NA Bench Set: NA Partial Stroke Test initiated HART Command by: Partial Stroke Test status: Failed -Emergency Occurred Tuning Set Tuning Set: H Gains Proportional: 8.40 Velodty: 4.20 MLF: 31.00 Integral Control: Disabled Integral Gain: 9.4 Notes Actuator Manufacturer: Fisher Controls Type: 1035 Size: 40 Effective Anea: 0.00 in2 Air: doses Bench Set: 0.0000 psi-0.0000 psi Nominal Supply Pressure: 70.0000 psi Spring Rate: 0.0000 lbf/in Style: Rack and Pinion Moment Arm: 0.0000 in Va/veLink Custom Report • February 01, 2009 14:06:13 Page 19 of 19 PETRQi\!/\5 UTY APPENDIX IV Daily Report of PST for Butterfly Valve (Software generated) 1/a/veLink Custom Report 1 February 01, 2009 14:12:21 BunERfLYVALVE bVC6000 SIS HART Tag Name DEMO.SIS Valve Style ROTARY Actuator Style Piston - Sgl w/ Spring Instrument 5/N 16013812 Valve 5/N 16013812 Firmware Revision 7 Hardware Revision 1 PETROI\!/\5 UTP trument Confi uration [BUTIERFLY VALVE]- Basic 01 Feb 2009 13:06:33 General Pressure Travel/Pressure Control HART Tag DEMO.SIS Max Supply Pressure 70 psi Travel/Pressure Control Message Pressure Units psi Travel/ Pressure Select Travel Descriptor DEMO. SIS Tuning Travel/ Pressure Cutoff lo 50 Date 01/23/06 Travel Control (%) Valve Serial Number 16013812 Travel Control Tuning Set c Travel/ Pressure Cutoff HI 50 IStrUment Serial Number 16013812 Proportional 4.4 (%) Polling Address 0 Enable Integral Control No End Point Press. Control Initial Setup Integral Gain (reps/min) 9.4 End Point Control Enable Enabled Control Mode Analog (RSP) Integral Settings Control End Restart Cont. Mode Analog (RSP) Integral Dead Zone(%) 0.26 Pressure Set Point 54.9 psi Zero Power Condition Valve Open Integral Umit (%) 30 Pressure Saturation lime 45 avel/ Pressure Cutoff lo so Pressure Control (sec) (%) Pressure Control Tuning Set c Dynamic Response Valve Style Rotary Shaft Proportional 2.2 Set Point Rate Umits Actuator Style Piston - Sgl w/ Enable Integral Control Yes SP Rate Open (%/sec) 0 Spring Integral Gain (reps/sec) 0.1 SP Rate aose (%/sec) 0 Relay Type Relay B - Special SIS I Partial stroke Set Point Alter App. Partial Stroke Lag lime (sec) 0 Feedback Connection Rotary-All/55- Enable Enabled Roller Test Start Point Travel Sensor Motion Counter- Partial Stroke Press Umit 17 psi clockwise Max. Travel Movement(%) 20 Aux Terminal Mode Push Button Test Speed 0.5%/S Partial Stroke Test Pause lime 10 sec Test Auto Test Interval (days) 0.00 Partial Stroke Start Pt. Valve Open SIS Options Inputs DVCPowerUp Auto Reset Analog Input Units mA Action on Fa lied test Ramp Back Temperature Units F Input Characterization In ut Characteristic Unear Page 1 of 19 Valvelink Custom Report February 01, 2009 14:12:21 rument Confi uration [BUTTERFLY VALVE]- Alerts Self Test Shut Down Rash ROM Fail Enable No No free lime Enable No Reference Vokage Fail No Enable NVM Fail Enable No emp Sensor Fail Enable No -avel Sensor Fail Enable No rive CUrrent Fail Enable No Travel History Alerts :yele count Alert Enable No le Count Deadband (%) 3 Cycle Count Alert Point 2147483647 Cyde Count 2147483647 T rav Ace Alert Enable No I Accum Deadband (%) 3 Tvl Accum Alert pt (%) 2147483647 rravel Accumulator(%) 2147483647 01 Feb 2009 13:06:33 Deviation • other Alerts Travel Dev Alert Enable Yes Travel ilev Aiert Pi(%) 6.91 Travel Devlime (sec) 9.99 Pressure Dev Alert Enable Yes Pressure Dev Alert pt 2 psi Pressure Dev lime (sec) 9.99 Drive Signal Alert Enable Yes Supply Pressure Alert Point 9 psi Supply Pressure Alert Yes Enable Travel Alerts Tvl Alert La Enable No Tvl Alert Hi Enable No Tvl Alert La Lo Enable No Tvl Alert Hi HI Enable No La Point (%) 2 HI Point(%) 9 La La Point(%) 1 Hi Hi Point(%) 98.97 Deadband (%) 3 Tvl Umit/Cutoff La Enable No Tvl Umit/Cutoff HI Enable No trument Confi uration [BUTTERFLY VALVE]- Spec Sheet Spec Sheet Units Pressure Units psi Travel Units deg Lengtll Units in Area Units in2 Torque Units lbf.in Spring Rate Units lbf/in Valve Valve Mfg. Fisher Controls Valve Model 6560 Size 4in aass 300 Rated Travel 90.0 deg Actual Travel 90.0 deg Stem Diameter 2.0 In Packing Type TFE I Single Inlet Pressure 100.0 psi Outlet Pressure 0.0 01 Feb 2009 13:06:33 Trim SeatType Leak Oass Unknown Port Diameter 0.0 in Actuator Actuator Mfg. Fisher Controls Actuator Model 1035 Actuator Size 20 Effective Area 0.0 in2 Air aoses Volume Booster/Quick Unknown Release Lower Bench Set 0.0 psi Upper Bench Set 0.0 psi Nominal Supply Pressure 0.0 psi Spring Rate 0.0 lbf/in Lever Style Rack and Pinion Moment Ann 0.0 in Page 2 of 19 PETROl\! AS UTi., Alert Record and Commands Instrument aock 01 FEB 2009 01:06 Valve Alerts Enable Yes Failure Alerts Enable Yes Mise Alerts Enable Yes Burst Mode Enable No Burst Command 3 Cmd #3 (Trending) B Pressure Alert ReCOiil Not Empty Yes Enable Alert Record Full Enable Yes Infonnatlanal status Inst lime Invalid Enable Yes cal in Progress Enable No Autocal in Progress Enable No Diag in Progress Enable Yes Oiag Data Avail Enable Yes Integrator sat Hi Enable Yes Integrator Sat La Enable Yes Press Ct~ Active Enable Yes Multi-Drop Alert Enable No Electronic Alerts Shutdown Activated Alert Yes Enable Power Starvation Alert No Enable Non-critical NVM Alert No Enable Reference Trim Style 1 Trim Style 2 Stroking lime Open (sec) 0 Stroking lime Oosed (sec) 0 Dynamic Torque 0.0 lbf.in Breakout Torque 0.0 lbf.in ValveLink Custom Report February 01, 2009 14:12:21 tial Stroke (BUTTERFLY VALVE] 1E -~-1 -~~ ... ··~.~----·· ·-:- ~--1 ···-·-t--0 ---I I I 1 --- - --1 --- +- --· ·---· I I I I -50 ---t-------------~-~+-~ 1----t----"-t--f-----i-f----t----------t~-r------+--+--------~--r---t-·--l 150 100 50 0 -50 Input(%) 150 -· 1--100 --·~--1- - ~-J 50 -- - 1--t. .~ c j---·-·-·- ---~- -~ r~ -----1 .00 Valve Manufacturer: Type: Size: dass: Rated Travel: Actual Travel: Shaft Diameter: Packing Type: Inlet Pressure: Outlet Pressure: FISher COiltrOIS 8S60 4in 300 90.00 deg 90.00 deg 2.0000 in TFE/ Single 100.0000 psi 0.0000 psi i 50 Input(%) 100 Trim seat Type: Leakage dass: Port Diameter: Page 3 of 19 150 0.0000 in PtTROi'~,<\S \JTP 01 feb 2009 13:07:22 Inputs Input Start: Input End: Stroke Speed Test Pause Time: Collection Interval : 100.0% 80.0% 0.5%/s 10 sec 150.0 msec. Analyzed Data Avg. Dynamic Error: 1.63% Min. Dynamic Error: 1.24% Max. Dynamic Error: 1. 98% Dyn. Unearity (Ind.): 0.22% Zero Ranged Travel at: 20.39 rnA Full Ranged Travel at: 3.64 rnA Average Torque: NA Minimum Torque: NA Maximum Torque: NA Spring Rate: NA Bench Set: 23.37 - 45.01 psi Partial Stroke Test initiated HART Command by: Partial Stroke Test status: Completed Successfully Tuning Set Tuning Set: C Gains Proportional: 4.40 Velodty: 3.00. MLF: 35.00 Integral Control: Disabled Integral Gain: 9.4 Notes Actuator ManufactUrer: FISher COntrOls Type: 1035 Size: 20 Effective Area: 0.00 in2 Air: O!lSeS Bench Set: 0.0000 psi-0.0000 psi Nominal Supply Pressure: 0.0000 psi Spring Rate: 0.0000 lbf/in Style: Rack and Pinion Moment Arm: 0.0000 In Valvelink Custom Report February 01, 2009 14:12:21 trument Confi uration [BUTIERFLY VALVE]- Basic 01 Feb 2009 13:16:04 General Pressure HAATTag DEMQ-SIS Max Supply Pressure 70 psi Message Pressure Units psi Descriptor DEMQ-SIS Tuning Date 01/23/06 Travel Control Valve Serial Number 16013812 Travel Control Tuning Set c 1strument Serial Number 16013812 Proportional 4.4 Polling Address 0 Enable Integral Control No Inlti .. $etJip lntegn!l Gain (reps/min) 9.4 Control Mode Analog (RSP) Integral SettJngs Restart Cont. Mode Analog (RSP) Integral Dead Zone(%) 0.26 Zero Power Condition Valve Open Integral Umit (%) 30 ovel/ Pressure Cutoff Lo so Pressure Control (%) Pressure control Tuning Set c Valve Style Rotary Shaft Proportional 2.2 Actuator style Piston - Sgl w/ Enable Integral Control Yes Spring Integral Gain (reps/sec) 0.1 Relay Type Relay B - Spedal SIS I Partial Stroke App. Partial Stroke Feedback Connection Rotary-AIVS5- Enable Enabled Roller Test Start Point Travel Sensor Motion Counter- Partial Stroke Press Umit 17 psi dockwise Max. Travel Movement(%) 20 Aux Terminal Mode Push Button Test Speed O.S%/S Partial Stroke Test Pause lime 10 sec Test Auto Test Interval (days) 0.00 Partial Stroke Start pt_ Valve Open SIS Options Inputs DVCPowerUp Auto Reset Analog Input Units mA Action on Failed test Ramp Back 'Temperature Units F Input Characterization In Characteristic Unear Page 4 of 19 PET!(Qf\J/\5 UTP Travei/Preaure control Travel/Pressure Control Travel I Pressure Select Travel Travel/ Pressure CUtoff Lo 50 (%) Travel I Pressure Cutoff Hi so (%) End Point Press. Control End Point Control Enallle Enabled control End Pressure Set Point 54.9 psi Pressure Saturation lime 4S (sec) Dynamic~ Set Point Rate Umits SP Rate Open (%/sec) 0 SP Rate aose (%/sec) 0 Set Point Filter Lag lime (sec) 0 ValveLink Custom Report February 01, 2009 14:12:21 Self Test Shut Down Flash ROM Fail Enable No No Free Time Enable No Referer.ce Vortoge Foil No Enable NVM Fail Enable No remp Sensor Fail Enable No ~rave! Ser:St.-r Eai! Enab!~ No )rive Current Fail Enable No Travel History Alert$ Cyde Count Alert Enable No ::!e Ccn.mt Dead band (%,) 3 Cycle Count Aiert Point 2i47483647 Cyde Count 2147483647 Trav Ace Alert Enable No vl Aa:um o~adband (0/.-;} Tvi AcoJm Alert Pt (%) Travel Accumulator(%) 3 2147483647 2147483647 Spec Sheet Units Pressuie Units psi Travel Units deg L~r.gth U!1its Area Units Torque Units Spring Rate Unils valve Valve Mfg. Valve ~lode! Size Ciass Rated Travel Actual Travel Stem Diameter Packing Type Inlet Pressure Outlet Pressure in in2 lbf.in lbf/in Fisher Controls 8560 4 in 300 90.0 deg 90.0 deg 2.0in TFE I Single 100.0 psi 0.0 si 01 Feb 2009 13:16:04 Deviation &. other Alert$ Travel Dev Alert Enable Yes Travel Dev Alert pt (%) 6.91 Travei nev lime (sec} 9.~";/ Pressure Dev Alert Enable Yes Pressure Dev Alert Pt 2 psi Pressure Dev Time (sec) 9.99 t:.,.!vf' S~gr:r::! Alert Enab!e Yes Supply Pressure Alert Point 9 psi Supply Pressure Alert Yes Enable Tvi Aiett Lo Enable No Tvl Alert Hi Enable No Tv! Alert Lo Lo Enable No Tv! Atert Hi Hi En3b!e No La Point ("/o) 2. Hi Point(%) 9 Lo Lo Point(%) 1 H! Hi Point(%) 98.97 Dead band ('%) 3 Tv! limit/Cutoff Lo Enable No Tv! Umit/Cutoff Hi Enable No 01 Feb 2009 13:16:04 Trim Seat Type leak Class Unknown Port Diameter Actuator Actuator Mfg. Actuator Model Actue~tur Size Effective Area Air Volume Booster/Quick Reiease Lower Bench Set Upper Bench Set Nominal Supply Pressure Spdng Rate Lever Style Moment Arm Page 5 of 19 O_O!n Fisher Controls 1035 10 0.0 in2 Closes Unknown O.Opsi 0.0 psi o.o psi 0.0 ibff!n Rack and Pinion O.Oin PCfRO~if-\S UT? -- ---=-==--=--.=...- ~ Alert Record and Commands Instrument Oock 01 FEB 2009 01:14 Vaive Aier-..s Enabie Yes Failure Alerts Enable Yes Mise Alerts Enable Yes Burst Mode Enable No Burst O.Jrnrnand 3 Cmd #3 (Trending) B Pressure Alert Record Not Empty Yes Enable Aiert Record Fuii Enabie Yes Informational Status Inst Time Invalid Enable Yes C;::! in Progre.<;.s Enab!e No Autocai in Progress Enabie No Oiag in Progress Enable Yes lliag Data Avail Enable Yes Integrator Sat H! Enable Yes Integrator Sat Lo Enable Yes Press Ctr1 Active Enable Yes Multi-Drop Alert Enable No El@dmnic Alert_s Shutdov·-m Activated Alert Yes Enable Power Starvation Alert No Enable Non-Crlt!ca! !'!VM ,AJert No Enable Reference Trim Style 1 Trim Style 2 Stro!cjng Time Open (sec) Stroking Time Oosed (sec) Dynamic Torque Breakout Torque 0 0 0.0 lbf.in 0.0 lbf.in Valvelink Custom Report February 01, 2009 14:12:21 rtial Stroke [BUTTERFLY VALVE] 150 -~ _] ___ -- T--~---- I ~ 100 ~ ! ~----i---l ~ 50 -~-- -r r-···· ---r------l ~ .. c ~ • > 'C c 0 -··---.. ----.. 1-- ···-- ·-,-------·--~-----1 I I I 11 -50;------t----t-----+-----+-+---t----t---------~~-+-~- 1--t---f---------ji--~-t---+·----1 150 100 50 0 ·50 Input(%) 150··--·-·--···· r ____ -1--~- ·----·--· l 100 --···-- --~- -1- _____ ) 50 ··1----~ ----~-------1~----- I 0 ~- ~-- -c -50+-~-r~-~~r--~-r-4-~--~--T-~~~-~~~ -50 0 Valve Manufacturer: Type: Size: Oass: Rated Travel: Actual Travel: Shaft Diameter: Packing Type: Inlet Pressure: Outlet Pressure: Fisher Controls 8560 4in 300 90.00 deg 90.00 deg 2.0000 in TFE I Single 100.0000 psi 0.0000 psi 50 Input(%) 100 Trim seat Type: leakage Oass: Port Diameter: Page 6 of 19 150 0.0000 in PETROW\S UTP 01 Feb 2009 13:16:15 Inputs Input Start: Input End: Stroke Speed Test Pause lime: Collection Interval: 100.0% 80.0% O.S%/5 10 sec 1SO.O msec. Analyzed Data Avg. Dynamic Error: 1.62% Min. Dynamic Error: 1.33% Max. Dynamic Error: 1.98% Dyn. Unearity (Ind.): 0.18% Zero Ranged Travel at: 20.25 rnA Full Ranged Travel at: 3.70 rnA Average Torque: NA Minimum Torque: NA Maximum Torque: NA Spring Rate: NA Bench Set: 23.64- 4S.02 psi Partial Stroke Test initiated HART Command by: Partial Stroke Test status: Completed Successfully Tuning Set Tuning Set: C Gains Proportional: 4.40 Velocity: 3.00 MlF: 3S.OO Integral Control: Disabled Integral Gain: 9.4 Notes Actuator Manufacturer: Type: Size: Effective Area: Air: Bench Set: Nominal Supply Pressure: Spring Rate: Style: Moment Ann: Fisher Controls 1035 20 0.00 in2 Ooses 0.0000 psi-o.oooo psi o.oooo psi 0.0000 lbf/in Rack. and Pinion o.oooo in ValveLink Custom Report February 01, 2009 14:12:21 trument Confi uration BUTIERFLY VALVE -Basic 01 Feb 2009 13:25:33 General Pressure HART Tag DEMQ-SIS Max Supply Pressure 70 psi Message Pressure Units psi Descriptor DEMQ-SIS Tuning Date 01/23/06 Travel Control Valve Se~al Number 16013812 Travel Control Tuning Set c strument ~al Number 16013812 Proportional 4.4 Polling Address 0 Enable Integral Control No Initial setup Integral Gain (reps/min) 9.4 Control Mode Analog (RSP) Integral Settings Restart Cont Mode Analog (RSP) Integral Dead Zone(%) 0.26 Zero Power Condition Valve Open Integral Umit (%) 30 1vel/ Pressure CUtoff lo 50 Pressure Control (%) Pressure COntrol Tuning Set c Valve Style Rotary Shaft Proportional 2.2 Actuator Style Piston - Sgl w/ Enable Integral Control Yes Spring Integral Gain (reps/sec) 0.1 Relay Type Relay B - Special SIS I Partial Stroke App. Partial Stroke Feedback Connection Rotary-All/55- Enable Enabled Roller Test Start Point Travel Sensor Motion Counter- Partial Stroke Press Umit 17 psi dockwise Max. Travel Movement(%) 20 Aux Tenninal Mode Push Button Test Speed 0.5%/s Partial Stroke Test Pause lime !Osee Test Auto Test Interval (days) 0.00 Partial Stroke Start Pl Valve Open SIS Options Inputs DVCPowerUp Auto Reset Analog Input Units rnA Action on Failed test Ramp Back Temperature Units F Input Characterization In Characteristic Unear Page 7 of 19 PETROf\]!\S UTP Travel/Pressure Conlrol Travel/Pressure Control Travel/ Pressure Select Travel Travel/ Pressure CUtoff lo 50 (%) Travel/ Pressure CUtoff Hi 50 (%) End Point Press. Control End Point COntrol Enable Enabled Control End Pressure Set Point 54.9 psi Pressure Saturation lime 45 (sec) Dynamic Response Set Point Rate Umits SP Rate Open (%/sec) 0 SP Rate aose (%/sec) 0 Set Point Riter lag lime (sec) 0 ValveLink Custom Report I February 01, 2009 14:12:21 trument Confi uration [BUTTERFLY VALVE]- Alerts 5elfTest Shut Down Rash ROM Fail Enable No No Free lime Enable No Reference Voltage Fail No Enable NVM Fail Enable No Temp Sensor Fail Enable No rravel Sensor Fail Enable No Drive Current Fail Enable No Travel History Alerts Cyde Count Alert Enable No ~e Count Deadband (%) 3 Cyde Count Alert Point 2147483647 Cyde Count 2147483647 Trav Ace Alert Enable No \II Accum Deadband (%) 3 Tvl Acrum Alert Pt (%) 2147483647 Travel Accumulator(%) 2147483647 01 Feb 2009 13:25:33 Deviation • Other Alerts Travel Dev Alert Enable Yes Travel Dev Alert Pt (%) 6.91 Travel Dev lime (sec) 9.99 Pressure Dev Alert Enable Yes Pressure Dev Alert Pt 2 psi Pressure Dev lime (sec) 9.99 Drive Signal Alert Enable Yes SUpply Pressure Alert Point 9 psi Supply Pressure Alert Yes Enable Travel Alerts Tvl Alert Lo Enable No Tvl Alert Hi Enable No Tvl Alert Lo lo Enable No Tvl Alert Hi Hi Enable No lo Point(%) 2 Hi Point (%) 9 Lo Lo Point(%) 1 Hi Hi Point(%) 98.97 Deadband (%) 3 Tvl Umit/Cutoff lo Enable No Tvl Umit/Cutoff Hi Enable No strument Confi uration [BUTTERFLY VALVE]- Spec Sheet 01 Feb 2009 13:25:33 Spec Sheet Units Trim Pressure Units psi Seat Type Travel Units deg leakOass Unknown length Units in Port Diameter O.Oin Area Units in2 Actuator Torque Units lbf.in Actuator Mfg. Fisher Controls Spring Rate Units lbf/in Actuator Model 1035 Valve Actuator Size 20 Valve Mfg. Fisher Controls Effective Area 0.0 in2 Valve Model 8560 Air Ooses Size 4in Volume Booster/Quick Unknown Oass 300 Release Rated Travel 90.0 deg Lower Bench Set 0.0 psi Actual Travel 90.0 deg Upper Bench Set O.Opsi Stem Diameter 2.0in Nominal SUpply Pressure 0.0 psi Packing Type TFE/ Single Spring Rate 0.0 lbf/in Inlet Pressure 100.0 psi lever Style Rack and Pinion Outlet Pressure 0.0 Moment Arm O.Oin Page 8 of 19 PETRON/\S L'TP Alert Record and Commands Instrument Oock 01 FEB 2009 01:23 Valve Alerts Enable Yes Failure Alerts Enable Yes Mise Alerts Enable Yes Burst Mode Enable No Burst Command 3 Cmd #3 (Trending) B Pressure Alert Record Not Empty Yes Enable Alert Record Full Enable Yes Informational Status Inst lime Invalid Enable Yes Cal in Progress Enable No Autocal in Progress Enable No Diag in Progress Enable Yes Diag Data Avail Enable Yes Integrator Sat Hi Enable Yes Integrator Sat Lo Enable Yes Press Ctrl Active Enable Yes Multi-Drop Alert Enable No Electronic Alerts Shutdown Activated Alert Yes Enable Power Starvation Alert No Enable Non-Critical NVM Alert No Enable Reference Trim Style 1 Trim Style 2 Stroking lime Open (sec) 0 Stroking lime Oosed (sec) 0 OVnamic Torque 0.0 lbf.in Breakout Torque 0.0 lbf.in ValveL/nk Custom Report February 01, 2009 14:12:21 tial Stroke [BUTIERFLY VALVE] 60r- ---- . -~. - ---r -l c-- . -,- i _J ~----:·-~ -, l I ::,-- --1-- I_ -,11-=-- _I_=-~ --=[_-; ~ 20--L _,_ -_j__ ---- ___ J. -- 1-- ~~- ____ I t I I j "' 10- --- -- -- --- --- ----J __ T- + --~- --]-- +---~-··--~~ ·1 o Lt--t-f----+---+-t--i---+--1-t-----t-----+--j---t----+-----+---l--!------t------t-t--+---t--t ~ ~ 0 W ~ 60 60 100 1W Trawl (d'11) 150- ~-- --- 1 - -- ---r--·--- --~ 100 -··-- +----1- ---~-------! i so- l-- -I- l_ ----1-- ------1 ~ - I I ' ! 0. -------+ -- --+--··· ··---~---·' -I I : I I -50 -!---l------+--··t-------+--l-------+--1--+--f-----+--t-··---j----+--· j----------1-1 150 100 50 0 -50 Input(%) :]_------~C-- ~---~~--I ~ L "":'= II ' f ··t a-- -- - --r .. - -- :- ---- ---1 . - ------ -- 1-- I Ji---+-----+' ~~+----+-----+-~~~ -50 0 Valve Manufacturer: Fisher Controls Type: 8560 Size: 4 in aass: 300 Rated Travel: 90.00 deg Actual Travel: 90.00 deg Shaft Diameter: 2.0000 in Packing Type: TFE I Single Inlet Pressure: 100.0000 psi Outlet Pressure: 0.0000 psi 50 Input{%) 100 Trim Seat Type: Leakage Oass: Port Diameter: 0.0000 in Page 9 of 19 150 PETRONAS UTP 01 Feb 2009 13:25:43 Inputs Input Start: Input End: Stroke Speed Test Pause Time: Collection Interval: 100.0% 80.0% 0.5%/s 10 sec 150.0 msec. Analyzed Data Avg. Dynamic Error: 1.45% Min. Dynamic Error: 1.06% Max. Dynamic Error: 1.86% Dyn. Unearity (Ind.): 0.16% Zero Ranged Travel at: 20.27 rnA Full Ranged Travel at: 3.68 rnA Average Torque: NA Minimum Torque: NA Maximum Torque: NA Spring Rate: NA Bench Set: 23.5-44.99 psi Partial Stroke Test initiated HART Command by: Partial Stroke Test status: Completed Successfully Tuning Set Tuning Set: C Gains Proportional: 4.40 Velocity: 3.00 MLF: 35.00 Integral Control: Disabled Integral Gain: 9.4 Notes Actuator Manufacturer: Fisher Controls Type: 103S Size: 20 Effective Area: 0.00 in2 Air: aoses Bench Set: 0.0000 psi-0.0000 psi Nominal Supply Pressure: 0.0000 psi Spring Rate: 0.0000 lbf/in Style: Rack and Pinion Moment Arm: 0.0000 in ValveLink Custom Report February 01, 2009 14:12:21 trument Confi uration [BUTTERFLY VALVE] - Basic 01 Feb 2009 13:35:46 General Pressure HART Tag DEMD-SIS Max Supply Pressure 70 psi Message Pressure Units psi Descriptor DEMD-515 Tuning Date 01/23/06 Travel Control Valve 5erial Number 16013812 Travel Control Tuning Set c ostrument 5erial Number 16013812 Proportional 4,4 Polling Mdress 0 Enable Integral Control No Initial Setup Integral Gain (reps/min) 9.4 Control Mode Analog (RSP) Integral settings Restart Cont. Mode Analog (RSP) Integral Dead Zone(%) 0.26 Zero Power Condition Valve Open Integral Umit (%) 30 avel/ Pressure Cutoff La so Pressure Control (%) Pressure Control Tuning Set c Valve Style Rotary Shaft Proportional 2.2 Actuator Style Piston - Sgl w/ Enable Integral Control Yes Spring Integral Gain (reps/sec) 0.1 Relay Type Relay B - Special SIS I Partial stroke App. Partial Stroke Feedback Connection Rotary-All/55- Enable Enabled Roller Test Start Point Travel sensor Motion Counter- Partial Stroke Press Umit 17 psi docl 6 e ,_ 150 100 50 0 -50 Input(%) 150r ---- T-------~ ----------~--- ------~ 100··· ----~-- ---- ' _____ ·-·----r- ---~--- _] ~ __ ---~-- _ -~---- _I _ _ ___ [:. --~--- _ i ~-- I I ; I . o ---------- ------- -- ------ T - I - - -I I I ~ ~ J 50 • -~ " 0 50 100 150 Input(%) Valve Trim Manufacturer: Fisher Controls SeatType: Type: 8560 Leakage aass: Size: 4in Port Diameter: 0.0000 in aass: 300 Rated Travel: 90.00 deg Actual Travel: 90.00 deg Shaft Diameter: 2.0000 in Packing Type: lFE/ Single Inlet Pressure: 100.0000 psi Outiet Pressure: 0.0000 psi Page 12 of 19 PE:-fROi\!1-'tS UTP 01 Feb 2009 13:36:04 Inputs Input Start: Input End: Stroke Speed Test Pause Time: Collection Interval: 100.0% 80.0% 0.5%/s 10 sec 150.0 msec. Analyzed Data Avg. Dynamic Error: 1.49% Min. Dynamic Error: 1.06% Max. Dynamic Error: 1.87% Dyn. Unearity (Ind.): 0.17% Zero Ranged Travel at: 20.18 rnA Full Ranged Travel at: 3.66 rnA Average Torque: NA Minimum Torque: NA MaXimum Torque: NA Spring Rate: NA Bench Set: 24.13-44.89 psi Partial Stroke Test initiated HART Command by: Partial Stroke Test status: Completed Successfully Tuning Set Tuning Set: C Gains Proportional: 4.40 Velodty: 3.00 MLF: 35.00 Integral Control: Disabled Integral Gain: 9.4 Notes Actuator Manufacturer: Fisher Controls Type: 1035 Size: 20 Effective Area: 0.00 in2 Air: aoses Bench Set: 0.0000 psi-o.oooo psi Nominal Supply Pressure: 0.0000 psi Spring Rate: 0.0000 lbf/ln Style: Rack and Pinton Moment Ann: 0.0000 in Va/veLink Custom Report February 01, 2009 14:12:21 trument Confi uration [BUTTERFLY VALVE]- Basic 01 Feb 2009 13:45:21 General Pressure HART Tag DEMQ-SJS Max SUpply Pressure 70 psi Message Pressure Units psi Descriptor DEMQ-SIS TUning Date 01/23/06 Travel Control Valve Serial Number 16013812 Travel Control Tuning Set c wument Serial Number 16013812 Proportional 4.4 Polling Address 0 Enable Integral Control No Initialse:tup Integral Gain (reps/min) 9.4 Control Mode Analog (RSP) Integral Settings Restart Cont. Mode Analog (RSP) Integral Dead Zone (%) 0.26 Zero Power Condition Valve Open Integral Umit (%) 30 wei/ Pressure CUtoff Lo 50 Pressure Control (%) Pressure Control Tuning Set c Valve Style Rotary Shaft Proportional 2.2 Actuator Style Piston - Sgl w/ Enable Integral Control Yes Spring Integral Gain (reps/sec) 0.1 Relay Type Relay B - Special SJS I Partial stroke App. Partial Stroke Feedback Connection Rotary-All/55- Enable Enabled Roller Test Start Point Travel Sensor Motion Counter- Partial Stroke Press Umit 17 psi dockwise Max. Travel Movement(%) 20 Aux Terminal Mode Push Button Test Speed 0.5%/S Partial Stroke Test Pause lime 10 sec Test Auto Test Interval (days) 0.00 Partial Stroke Start pt Valve Open SIS Options Inputs OVCPowerUp Auto Reset Analog Input Units rnA Action on Failed test Ramp Back Temperature Units F Input Characterization In Characteristic Unear Page 13 of 19 PETROI\JA.S UTP Travel/Pressure Control Travel/Pressure Control Travel/ Pressure Select Travel Travel/ Pressure CUtoff Lo 50 (%) Travel/ Pressure Cutoff Hi 50 (%) End Point Press. Control End Point Control Enable Enabled Control End Pressure Set Point 54.9 psi Pressure Saturation lime 45 (sec) Dynamic Response Set Point Rate Umits SP Rate Open (%/sec) 0 SP Rate aose (%/sec) 0 Set Point Filter Lag lime (sec) 0 Va/veLink Custom Report I February 01, 2009 14:12:21 trument Confi uration [BUTTERFLY VALVE]- Alerts Self Test Shut Down Rash ROM Fail Enable No No Free lime Enable No Reference Voltage Fail No Enable NVM Fail Enable No remp Sensor Fail Enable No ·ravel Sensor Fail Enable No lrive CUrrent Fail Enable No Travel History Alerts ::yde Count Alert Enable No le Count Deadband (%) 3 Cycle Count Alert Point 2147483647 Cycle Count 2147483647 T rav I>« Alert Enable No Ill ~>«urn Deadband (%) 3 Tvl ~>«urn Alert Pt (%) 2147483647 Travel l>«umulator (%) 2147483647 01 Feb 2009 13:45:21 Devlatian &. Other Alerts Travel Dev Alert Enable Yes Travel Dev Alert Pt (%) 6.91 Travel Dev lime (sec) 9.99 Pressure Dev Alert Enable Yes Pressure Dev Alert Pt 2 psi Pressure Dev lime (sec) 9.99 Drive Signal Alert Enable Yes Supply Pressure Alert Point 9 psi Supply Pressure Alert Yes Enable Travel Alerts Tvl Alert La Enable No Tvl Alert Hi Enable No Tvl Alert La La Enable No Tvl Alert Hi Hi Enable No La Point(%) 2 Hi Point(%) 9 La La Point(%) 1 Hi Hi Point (%) 98.97 Deadband (%) 3 Tvl Umit/CUtoff La Enable No Tvl Umit/CUtoff Hi Enable No trument Confi uration [BUTTERFLY VALVE]- Spec Sheet 01 Feb 2009 13:45:21 Spec Sheet Units Trim Pressure Units psi Seat Type Travel Units deg Leakaass Unknown Length Units in Port Diameter O.Oin Area Units in2 Actuator Torque Units lbf.in Actuator Mfg. Asher Controls Spring Rate Units lbf/in Actuator Model 1035 Valve Actuator Size 20 Valve Mfg. Asher Controls Effective Area O.Oin2 Valve Model 8560 Air Closes Size 4in Volume Booster/Quick Unknown aass 300 Release Rated Travel 90.0 deg Lower Bench Set O.Opsi Actual Travel 90.0 deg Upper Bench Set O.Opsi Stem Diameter 2.0 in Nominal Supply Pressure 0.0 psi Packing Type TFE /Single Spring Rate 0.0 lbf/in Inlet Pressure 100.0 psi Lever Style Rack and Pinion OUtlet Pressure o.o Moment Arm O.Oin Page 14 of 19 Pt: I f\ONAS VfP Alert Record and Commands Instrument Oock 01 FEB 2009 01:44 Valve Alerts Enable Yes Failure Alerts Enable Yes Mise Alerts Enable Yes Burst Mode Enable No Burst Command 3 Cmd #3 (Trending) B Pressure Alert Record Not Empty Yes Enable Alert Record Full Enable Yes Informational Status Inst lime Invalid Enable Yes Galin Progress Enable No Autocal in Progress Enable No Dlag in Progress Enable Yes Diag Data Avail Enable Yes Integrator Sat Hi Enable Yes Integrator Sat Lo Enable Yes Press ctrl Active Enable Yes Multi-Drop Alert Enable No Electronic Alerts Shutdown Activated Alert Yes Enable Power Starvation Alert No Enable Non-Critical NVM Alert No Enable Reference Trim Style 1 Trim Style 2 Stroking lime Open (sec) 0 Stroking lime Qosed (sec) 0 Dynamic Torque 0.0 lbf.in Breakout Torque 0.0 lbf.in ValveLink Custom Report February 01, 2009 14:12:21 tial Stroke [BUTTERFLY VALVE] 60 -~~ , ------- ,---- I ---- , ----~----' . - ±=,t:_ l- ~:=--fj_:_ ••. I= r-·- ± l-1- -- ~--=~ .. 10 -------i ~----! - --T ----~ 50 0 --1----: 1- -- -; ----~ r----1 ·1 0 f--t--t-t-!-j·----t-+---+------T---i---+---1--"f 1·--t-t------1 -20 0 20 40 60 80 100 120 Travel (deg) 150r- r--- I ----------~-----1001 ____ 1! ___ __ ___ ~-- -x-----~ ., - I l 50 -t -r-- ---r~ -----~ 0 ---- --1~------ -~[ ----I -60 ,~-t---t-----+------~-+---~--150 100 50 Input(%) 150 i -----r--100 -- - --------~-------~ ' ~ a: ~ 50 . -~------- .-,- ------- . ~ 0 --- ----------. -------Valve Manufacturer: Asher Controls Type: 8S60 Size: 4 in Oass: 300 Rated Travel: 90.00 deg Actual Travel: 90.00 deg Shaft Diameter: 2.0000 In Packing Type: TFE I Single Inlet Pressure: 100.0000 psi OUtlet Pressure: 0.0000 psi Input(%) 0 Trim 5eatType: leakage Oass: +·-----t--------1--·-1 -50 Port Diameter: 0.0000 in Page 15 of 19 P~TRONt\S 01 Feb 2009 13:45:33 Inputs Input start: Input End: 100.0% 80.0% O.S%/s UTP Stroke Speed Test Pause lime: Collection Interval: 10 sec 1SO.O msec. Analyzed Data Avg. Dynamic Error: 1.47% Min. Dynamic Error: 1.10% Max. Dynamic Error: 1.82% Dyn. Unearity (Ind.): 0.18% Zero Ranged Travel at: 20.03 rnA Full Ranged Travel at: 3.69 rnA Average Torque: NA Minimum Torque: NA Maximum Torque: NA Spring Rate: NA Bench Set: 24.18- 44.92 psi Partial Stroke Test initiated HART Command by: Partial Stroke Test -us: Completed Successfully Tuning Set Tuning Set: C Gains Proportional: 4.40 Velocity: 3.00 MLF: 35.00 Integral Control: Disabled Integral Gain: 9.4 Notes Actuator Manufacturer: Asher Controls Type: 103S Size: 20 Effective Area: 0.00 ln2 Air: Oases Bench Set: 0.0000 psi-0.0000 psi Nominal SUpply Pressure: 0.0000 psi Spring Rate: 0.0000 lbf/in Style: Rack and Pinion Moment Arm: 0.0000 in Va/veLink Custom Report February 01, 2009 14:12:21 trument Confi uration [BUITERFLY VALVE]- Basic 01 Feb 2009 13:55:07 General Pressure HART Tag DEMD-SIS Max SUpply Pressure 70 psi Message Pressure Units psi Descriptor DEMD-SIS Tuning Date 01/23/06 Travel Control Valve Serial Number 16013812 Travel Control Tuning Set c IStrument Serial Number 16013812 Proportional 4.4 Polling Address 0 Enable Integral Control No Initial Setup Integral Gain (reps/min) 9.4 Control Mode Analog (RSP) Integral Settings Restart Cont. Mode Analog (RSP) Integral Dead Zone(%) 0.26 Zero Power Condition Valve Open Integral Umlt (%) 30 avel/ Pressure Cutoff Lo so Pressure Control (%) Pressure Control Tuning Set c Valve Style Rotary Shaft Proportional 2.2 Actuator Style Piston - Sgl w/ Enable Integral Control Yes Spring Integral Gain (reps/sec) 0.1 Relay Type Relay B - Spedal SIS I Partial stroke App. Partial Stroke Feedback Connection Rotary-All/55- Enable Enabled Roller Test Start Point Travel Sensor Motion Counter- Partial Stroke Press Umlt 17 psi dockwise Max. Travel Movement(%) 20 Aux Terminal Mode Push Button Test Speed O.S%/s Partial Stroke Test Pause lime 10 sec Test Auto Test Interval (days) 0.00 Partial Stroke Start Pt. Valve Open SIS Options Inputs DVC Power Up Auto Reset Analog Input Units mA Action on Failed test Ramp Back Temperature Units F Input Characterization In 1)er (psi) . 44.89 44.7 44.62 44.71 44.6 DaylO Parameter PSTl PST2 PST3 PST4 PST5 1 Average Dynamic Error(%) 2.65 2.71 2.79 2.73 2.72 2 Minimum Dynamic Error(%) 1.90 1.94 1.94 2.07 1.87 3 Maximum Dynamic Error (%) 3.34 3.49 3.61 3.57 3.53 4 Dynamic Linearity (Ind.) (%) 0.42 0.46 0.59 0.61 0.38 5 Zero Ranged Travel at (rnA) 19.95 19.96 19.87 19.90 19.99 6 Full Ranged Travel at (rnA) 4.00 3.99 4.01 4.03 4.02 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 Spring Rate NA NA NA NA NA 11 Bench Set Lower (psi) 25.78 26.1 26.19 26.3 25.84 12 Bench Set Upper Jj>si) 44.84 44.56 44.56 44.58 44.59 -··- ··----Parameter PST 1 PST2 PST3 PST4 PSTS l AverageD ·c Error(%) 2.71 2.74 2.77 2.76 2.73 2 Minimum Dynamic Error(%) 1.78 1.97 1.77 1.53 1.84 3 MaximumD ·c Error(%) 3.56 3.74 3.63 3.77 3.80 4 Dynamic Linearity (Ind.) (%) 0.43 0.69 0.69 0.68 0.55 5 Zero Ranged Travel at (rnA)_ 20.02 19.94 19.95 19.93 20.08 6 Full Ranged Travel at (rnA) 4.01 4.02 4.04 4.05 4.02 7 Average Torque NA NA NA NA NA 8 Maximum Tofring Rate NA NA NA NA NA 11 B_ei1ch Set (psi) 18.79-45.79 23.1-45.1 22.95-45.35 23.24-45.08 23.53-45.08 Day6 Parameter PST 1 PST2 PST3 PST4 PSTS 1 Average Dyuw,.;c Error(%) 1.55 1.50 1.51 1.52 1.56 2 Minimum Dynamic Error(%) 1.24 1.19 1.11 1.12 1.25 3 MaximumD 'c Error(%) 1.87 1.89 1.86 2.01 1.90 4 Dynamic Linearity (Ind.)(%) 0.15 0.15 0.15 0.22 0.20 5 Zero Ranged Travel at (mA) 20.31 20.31 20.31 20.24 20.27 6 Full Ranged Travel at (rnA) 3.63 3.64 3.64 3.68 3.66 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 Spring Rate NA NA NA NA NA 11 Bench Set (psi) 23.32-45.03 23.56-45.19 ' 22.63-45.14 22.97- 45.06 22.87-45.03 Parameter PSTl PST2 PST3 PST4 PSTS 1 Average Dynamic Error (%) 1.50 1.58 1.60 1.41 1.49 2 Minimum Dynamic Error(%) 1.25 1.18 1.14 1.10 1.06 3 Maximum Dynamic Error(%) 1.77 1.88 1.97 1.82 1.91 4 Dynamic Linearity (Ind.) (%) 0.18 0.14 0.18 0.18 0.18 5 Zero Ranged Travel at (rnA) 20.21 20.20 20.26 20.28 20.28 6 Full Ranged Travel at (rnA) 3.64 3.67 3.65 3.64 3.64 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 Spring Rate NA NA NA NA NA 11 Bench Set (psi) 23.2-45.02 24.32-45.01 24.07-45.01 23.24-45.09 23.72-44.99 - -------------DayS Parameter PSTl PST2 PST3 PST4 PSTS 1 AverageD ·c Error(%) 1.58 1.47 1.64 1.57 1.51 2 Minimum Dynamic Error(%) 1.31 1.14 1.35 1.18 1.09 3 Maximum Dynamic Error (%) 1.95 1.79 1.95 1.95 1.95 4 Dynamic Linearity (Ind.)(%) 0.17 0.18 0.17 0.19 0.14 5 Zero Ranged Travel at (rnA) 20.23 20.16 20.31 20.18 20.22 6 Full Ranged Travel at (rnA) 3.66 3.67 3.67 3.66 3.66 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 Spring Rate NA NA NA NA NA 11 Bench Set (psi) 23.54-45.03 23.77-45.01 23.79-45.05 23.67- 45.04 23.87-44.91 Parameter PSTl PST2 PST3 PST4 PSTS 1 Average Dynamic Error (%) 1.57 1.49 1.52 1.45 1.42 2 Minimum Dynamic Error (%) 1.17 1.15 1.26 1.09 1.13 3 MaximumL ·c Error(%) 2.09 1.94 1.82 1.85 1.91 4 Dynamic Linearity (Ind.)(%) 0.20 0.15 0.15 0.20 0.14 5 Zero Ranged Travel at (rnA) 20.16 20.24 20.24 20.19 20.25 6 Full Ranged Travel at (rnA) 3.64 3.64 3.66 3.66 3.66 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 Spring Rate NA NA NA NA NA 11 Bench Set (psi) 24.73-44.84 24.66-45.01 23.92-45.05 24.05-44.76 24.46- 44.80 . DaylO Parameter PSTl PST2 PST3 PST4 PSTS 1 AverageD ·c Error(%) 1.55 1.60 1.47 1.56 1.49 2 Minimum Dynamic Error(%) 1.10 1.23 1.20 1.09 1.07 ! 3 Maximum Dynamic Error(%) 1.97 2.00 1.89 1.93 1.80 4 D · c Linearity (Ind.) (%) 0.18 0.22 0.16 0.23 0.19 5 Zero Ranged Travel at (rnA) 20.18 20.12 20.17 20.05 20.16 6 Full Ranged Travel at (rnA) 3.58 3.60 3.60 3.64 3.60 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA I 9 Minimum Torque NA NA NA NA NA I 10 Spring Rate NA NA NA NA NA 11 . Bench Set . (psi) 24.46-45.16 24.32- 45.09 23.40- 45.07 24.02- 45.03 23.97-45.02 • -- ---------------------., --Parameter PST 1 PST2 PST3 PST4 PSTS I Average Dynamic Error(%) 1.60 1.46 1.46 1.46 1.56 2 Minimum Dynamic Error(%) 1.29 l.l2 l.l5 l.l4 1.26 3 Maximum Dynamic Error(%) 1.99 1.73 1.82 1.82 1.81 4 Dynamic Linearity (Ind.) (%) 0.16 0.17 0.15 0.16 0.19 5 Zero Ranged Travel at (rnA) 20.20 20.17 20.29 20.26 20.21 6 Full Ranged Travel at (rnA) 3.58 3.62 3.61 3.67 3.67 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 Spring Rate NA NA NA NA NA 11 Bench Set (psi) 24.49- 45.07 24.13 - 44.96 ' 23.07 :-_45.04 23.98-45.06 23.48-45.05 -··· ----- --···- --Day 12 Parameter PST1 PST2 PST3 PST4 PSTS I Average Dynamic Error (%) 1.40 1.40 1.56 1.54 1.49 2 Minimum Dynamic Error(%) l.l1 1.06 1.22 1.25 l.l8 3 MaximumD 'c Error(%) 1.79 1.74 1.91 1.94 1.89 4 Dynamic Linearity{Ind.) (%) 0.23 0.20 0.23 0.19 0.24 5 Zero Ranged Travel at (rnA) 20.06 20.19 20.21 20.18 20.26 6 Full Ranged Travel at (rnA) 3.61 3.62 3.64 3.62 3.63 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 Spring_ Rate NA NA NA NA NA 11 Bencll~~e_t (psi) 23.94- 44.98 23.83-45.05 24.23 - 44.99 23.22-45.20 24.04- 44.99 Parameter PSTl PST2 PST3 PST4 PSTS 1 Average Dynamic Error (%) 1.60 1.50 1.44 1.53 1.43 2 Minimum Dynamic Error (%) 1.25 1.17 0.87 1.18 1.14 3 MaximumD ·c Error(%) 1.91 1.89 1.81 1.92 1.84 4 Dynamic Linearity (Ind.) (%) 0.23 0.20 0.19 0.18 0.15 5 Zero Ranged Travel at (rnA) 20.19 20.14 20.14 20.29 20.22 6 Full Ranged Travel at (rnA) 3.67 3.65 3.67 3.66 3.67 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 Spring Rate NA NA NA NA NA 11 Bench Set -~L 23.76-44.88 23.93-44.88 23.56-44.80 23.45-44.89 23.71-44.98 Day14 Parameter PST 1 PST2 PST3 PST4 PSTS 1 Average Dynamic Error (%) 1.46 1.50 1.48 1.57 1.42 2 Minimum Dynamic Error(%) 1.13 1.14 1.17 1.21 1.14 3 Maximum Dynamic Error (%) 1.93 1.84 2.01 1.97 1.74 4 Dynamic Linearity (Ind.)_(%) 0.18 0.23 0.17 0.16 0.21 5 Zero Ranged Travel at (rnA) 20.29 20.13 20.24 20.21 20.27 6 Full Ranged Travel at (rnA) 3.65 3.64 3.65 3.67 3.69 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 Spring Rate NA NA NA NA NA 11 Bench Set (psi) 23.28-45.12 23.20- 45.07 . '23.43- 45.0~ - 22.88- 45.14 23.47-44.99 Parameter PSTl PST2 PST3 PST4 PSTS 1 Average Dynamic Error (%) 1.56 1.40 1.50 1.49 1.55 2 Minimum Dynamic Error(%) 1.14 1.03 1.22 1.14 1.25 3 Maximum Dynamic Error (%) 1.82 1.87 1.87 1.86 1.98 4 Dynamic Linearity (Ind.) (%) 0.19 0.16 0.21 0.21 0.20 5 Zero Ranged Travel at (rnA) 20.14 20.26 20.31 20.31 20.42 6 Full Ranged Travel at (rnA) 3.65 3.64 3.64 3.65 3.67 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 Spring Rate NA NA NA NA NA 11 Bench Set (psi) 23.48 - 45.05 23.13-45.03 22.96- 45.00 22.72- 45.03 22.96-45.01 Day16 Parameter PSTl PST2 PST3 PST4 PSTS 1 Average Dynamic Error (%) 1.39 1.34 1.50 1.52 1.52 2 Minimum Dynamic Error (%) 1.08 0.95 1.18 1.21 1.18 3 Maximum Dynamic Error(%) 1.75 1.75 1.90 1.93 1.87 4 Dynamic Linearity (Ind.) (%) 0.16 0.16 0.18 0.17 0.16 5 Zero Ranged Travel at (rnA) 20.20 20.27 20.18 20.21 20.31 6 Full Ranged Travel at (rnA) 3.64 3.62 3.62 3.64 3.65 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 Spring Rate NA NA NA NA NA 11 Bench Set (psi) 23.57-45.12 22.95-45.01 22.77- 45.05 23.78-44.99 23.21 -44.91 - - ------Parameter PST1 PST2 PST3 PST4 PSTS 1 AverageD "cError(%) 1.46 1.42 1.56 1.60 1.46 2 Minimum Dynamic Error (% 1.04 1.03 1.17 1.25 1.16 3 Maximum Dymuu.ic Error(%) 1.86 1.83 1.91 1.91 1.82 4 D ·c Linearity (Ind.)(%) 0.21 0.19 0.17 0.27 0.16 5 Zero Ranged Travel at (rnA) 20.21 20.27 20.25 20.24 20.34 6 FullRangedTravelat(mA) 3.54 3.68 3.65 3.68 3.62 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 Spring Rate NA NA NA NA NA 11 Bench Set (psi) 23.41 -45.01 23.65 -45.02 23.68- 44.96 23.88- 45.03 23.76-44.91 Day 18 Parameter PST 1 PST2 PST3 PST4 PSTS 1 Average Dynamic Error (%) 1.53 1.61 1.49 1.50 1.55 2 Minimum Dynamic Error(%) 1.16 1.35 1.06 1.11 1.12 3 Maximum Dyuwnic Error(%) 1.99 1.87 1.85 1.86 1.91 4 Dynamic Linearity (Ind.) (%) 0.14 0.23 0.17 0.16 0.21 5 Zero Ranged Travel at (rnA) 20.18 20.14 20.31 20.14 20.09 6 Full Ranged Travel at (rnA) 3.67 3.67 3.62 3.67 3.68 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 Spring Rate NA NA NA NA NA 11 Bench Set (psi) 24.27- 44.88 23.79-44.94 23.79-44.94 24.48-44.76 23.84-44.97 -II.IAJ .&-' Parameter PST 1 PST2 PST3 PST4 PSTS 1 Average Dynamic Error (%) 1.42 1.62 1.51 1.47 1.52 2 Minimum Dynamic Error (% 1.15 1.28 1.14 1.07 1.28 3 Maximum Dynamic Error (%) 1.97 1.93 1.80 1.86 1.76 4 Dynamic Linearity (Ind.)(%) 0.17 0.14 0.17 0.16 0.19 5 Zero Ranged Travel at (rnA) 20.12 20.23 20.12 20.06 20.21 6 Full Ranged Travel at (rnA) 3.67 3.67 3.68 3.67 3.67 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 Spring Rate NA NA NA NA NA 11 Bench Set (psi) 24.71-44.83 24.02-44.91 23.55-45.01 23.52-44.82 24.62- 44.74 Day20 Parameter PST 1 PST2 PST3 PST4 PSTS 1 Average Dynamic Error (%) 1.71 1.50 1.47 1.43 1.45 2 Minimum Dynamic Error(%) 1.31 1.10 1.11 1.12 1.17 3 Maximum Dynamic Error(%) 2.14 1.87 1.92 1.78 1.76 4 Dynamic Linearity (Ind.) (%) 0.28 0.20 0.20 0.20 0.18 5 Zero Ranged Travel at (rnA) 20.30 20.24 20.20 20.12 20.17 6 Full Ranged Travel at (rnA) 3.63 3.64 3.68 3.67 3.67 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 Spring Rate NA NA NA NA NA 11 __l!ench Set (psi) 23.01 - 45.08 23.50-45.10 23.40- 45.06 23.10-44.97 23.41-44.90 -- ----------Parameter PSTl PST2 PST3 PST4 PST5 1 Average Dynamic Error (%) 1.68 1.74 1.56 1.55 1.51 2 Minimum Dynamic Error (%) 1.33 1.43 1.30 1.12 1.08 3 Maximum Dynamic Error(%) 2.03 2.11 1.90 2.02 1.90 4 Dynamic Linearity (Ind.)(%) 0.25 0.18 0.18 0.17 0.16 5 Zero Ranged Travel at( rnA) 20.17 20.17 20.24 20.15 20.30 6 Full Ranged Travel at (rnA) 3.65 3.65 3.63 3.65 3.65 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 S_pring Rate NA NA NA NA NA 11 Bench Set (psi) __ ....... '23.23 - 44.98 24.30- 44.85 ,23. 75 - 45.04 23.52-44.90 22.79-45.12 ------Day22 Parameter PSTl PST2 PST3 PST4 PST5 1 Average Dynamic Error (%) 1.50 1.57 1.55 1.40 1.54 2 Minimum Dynamic Error ( % 1.17 1.10 1.14 0.90 1.20 3 Maximum Dynamic Error %) 1.83 1.92 1.92 1.82 1.89 4 Dynamic Linearity (Ind.) (%) 0.16 0.16 0.19 0.19 0.19 5 Zero Ranged Travel at (rnA) 20.12 20.20 20.18 20.26 20.11 6 Full Ranged Travel at (rnA) 3.65 3.66 3.65 3.65 3.68 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 Spring Rate NA NA NA NA NA II Bench Set (psi) 23.92- 44.98 23.76-44.92 23.31-44.99 23.94-44.85 24.62- 44.87 - -----------Parameter PST 1 PST2 PST3 PST4 PST5 1 Average Dynamic Error (%) 1.43 1.49 1.56 1.55 1.51 2 Minimum Dynamic Error(%) 1.12 1.17 1.30 1.12 1.08 3 Maximum Dynamic Error(%) 1.94 1.81 1.90 2.02 1.90 4 Dynamic Linearity (Ind.)(%) 0.15 0.21 0.18 0.17 0.16 5 Zero Ranged Travel at (rnA) 20.14 20.19 20.24 20.15 20.30 6 Full Ranged Travel at (rnA) 3.63 3.63 3.63 3.65 3.65 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 Spring Rate NA NA NA NA NA 11 Bench Set (psi) 24.63 -44.75 24.30-44.85 23.75 -45.04 23.52-44.90 22.79-45.12 Day24 Parameter PST I PST2 PST3 PST4 PST5 1 Average Dynamic Error(%) 1.71 1.66 1.53 1.46 1.45 2 Minimum Dynamic Error(%) 1.40 1.33 1.20 1.17 1.09 3 Maximum Dynamic Error(%) 2.03 2.13 1.85 1.78 1.84 4 Dynamic Linearity (Ind.) (%) 0.17 0.22 0.19 0.20 0.17 5 Zero Ranged Travel at (rnA) 20.24 20.16 20.16 20.18 20.22 6 Full Ranged Travel at (rnA) 3.66 3.69 3.66 3.65 3.63 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 Spring Rate NA NA NA NA NA 11 Bench Set (psi) 23.51 -44.97 23.45-45.18 23.79- 45.06 24.04-45.00 24.48- 45.04 Parameter PST 1 PST2 PST3 PST4 PSTS 1 AverageD ·c Error(%) 1.51 1.44 1.54 1.55 1.38 2 Minimum Dynamic Error(%) 1.12 1.06 1.17 1.21 0.94 3 Maximum Dynamic Error(%) 1.92 1.87 1.86 1.88 1.82 4 Dynamic Lineari_!y (Ind.)(%) 0.19 0.19 0.21 0.18 0.19 5 Zero Ranged Travel at( rnA) 20.22 20.15 20.21 20.38 20.22 6 Full Ranged Travel at (rnA) 3.60 3.67 3.66 3.65 3.67 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 S_pring Rate NA NA NA NA NA 11 Bench Set (psi) 23.75 - 44.91 23.40-45.01 23.61 - 44.97 23.05-45.15 23.22-45.09 Day26 Parameter PSTl PST2 PST3 PST4 PSTS 1 Average Dynamic Error (%) 1.58 1.54 1.59 1.52 1.50 2 Minimum Dynamic Error(%) 1.15 1.20 1.21 1.17 1.20 3 Maximum Dyuru~c Error(%) 1.93 1.95 1.94 1.95 1.84 4 Dynamic Linearity (Ind.) (%) 0.20 0.23 0.17 0.21 0.16 5 Zero Ranged Travel at (rnA) 20.23 20.28 20.22 20.22 20.23 6 FullRangedTravelat(mA) 3.63 3.64 3.66 3.65 3.63 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 Spring Rate NA NA NA NA NA 11 Bench Set (psi) 23.4-44.97 22.44- 45.17 22.86-45.09 23.62-45.03 23.02-45.00 - ~~., -Parameter PST 1 PST2 PST3 PST4 PSTS 1 Average Dynamic Error_{%} 1.50 1.51 1.48 1.47 1.42 2 Minimum Dynamic Error (%) 1.12 1.20 1.16 1.15 1.04 3 Maximum Dynamic Error(%) 1.92 1.87 1.77 1.81 1.75 4 Dynamic Linearity (Ind.) (%) 0.19 0.20 0.19 0.16 0.18 5 Zero Ranged Travel at (rnA) 20.22 20.23 20.16 20.17 20.19 6 Full Ranged Travel at (rnA) 3.65 3.66 3.67 3.67 3.66 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 Spring Rate NA NA NA NA NA 11 Bench Set (psi) 23.91 - 45.00 23.06-45.04 24.1-44.88 23.74-44.93 23.7-44.85 -·-···------ ----Day28 Parameter PSTl PST2 PST3 PST4 PSTS 1 Average D .r lli1l,..;c Error (%) 1.50 1.45 1.52 1.41 1.50 2 Minimum Dynamic Error(%) 1.10 1.12 1.25 1.14 1.18 3 Maximum Dynamic Error (%) 1.92 1.90 1.80 1.86 1.92 4 DynamicLmearicy(Ind.}(%) 0.17 0.15 0.15 0.16 0.15 5 Zero Ranged Travel at (rnA) 20.11 20.34 20.28 20.21 20.09 6 Full Ranged Travel at (rnA) 3.65 3.63 3.66 3.66 3.66 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 Spring Rate NA NA NA NA NA 11 Bench Set (psi) --24.08- 44.84 23.84-44.97 24.02-45.05 23.72-45.02 24.37- 44.94 --, --Parameter PST 1 PST2 PST3 PST4 PSTS 1 Average Dynamic Error (%) 1.50 1.45 1.52 1.41 1.50 2 Minimum Dynamic Error (%) 1.10 1.12 1.25 1.14 1.18 ' 3 Maximum Dynamic Error(%) 1.92 1.90 1.80 1.86 1.92 i 4 Dynamic Linearity (Ind.)(%) 0.17 0.15 0.15 0.16 0.15 5 Zero Ranged Travel at (mA) 20.11 20.34 20.28 20.21 20.09 6 Full Ranged Travel at (mA) 3.65 3.63 3.66 3.66 3.66 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA : ! 9 Minimum Torque NA NA NA NA NA I 10 Spring Rate NA NA NA NA NA I 11 Bench Set (psi) 24.08 - 44.84 23.84-44.97 24.02- 45.05 23.72-45.02 24.37-44.94 Day30 Parameter PSTl PST2 PST3 PST4 PSTS 1 AverageD 'c Error(%) 1.64 1.59 1.59 1.61 1.45 2 Minimum Dynamic Error(%) 1.26 1.26 1.26 1.29 1.12 3 Maximum Dynamic Error(%) 2.02 1.97 1.97 1.97 1.68 4 Dynamic Linearity (Ind.) (%) 0.19 0.21 0.21 0.20 0.17 5 Zero Ranged Travel at (mA) 20.13 20.08 20.08 20.14 20.16 6 Full Ranged Travel at (mA) 3.57 3.61 3.61 3.61 3.60 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 Spring Rate NA NA NA NA NA 11 Bench Set (psi) 24.15-44.87 23.89-45.01 23.89-45.01 23.98-44.94 24.12-44.97 Parameter PST 1 PST2 PST3 PST4 PSTS 1 Average Dynamic Error (%) 1.64 1.59 1.59 1.61 1.45 2 Minimum Dynamic Error(%) 1.26 1.26 1.26 1.29 1.12 3 Maximum Dynamic Error (%) 2.02 1.97 1.97 1.97 1.68 4 Dynamic Linearity (Ind.}_(%) 0.19 0.21 0.21 0.20 0.17 5 Zero Ranged Travel at (mA) 20.13 20.08 20.08 20.14 20.16 6 Full Ranged Travel at (mA) 3.57 3.61 3.61 3.61 3.60 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 Spring Rate NA NA NA NA NA 11 Bench Set (psi) . ----- ·-· 24.15 -44.87 23.89-45.01 23.89-45.01 23.98-44.94 24.12-44.97 Day32 Parameter PST 1 PST2 PST3 PST4 PSTS 1 Average Dynamic Error (%) 1.64 1.59 1.59 1.61 1.45 2 Minimum Dynamic Error(%) 1.26 1.26 1.26 1.29 1.12 3 Maximum Dynamic Error (%) 2.02 1.97 1.97 1.97 1.68 4 Dynamic Linearity (Ind.)(%) 0.19 0.21 0.21 0.20 0.17 5 Zero Ranged Travel at (mA) 20.13 20.08 20.08 20.14 20.16 6 Full Ranged Travel at (mA) 3.57 3.61 3.61 3.61 3.60 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 Spring Rate NA NA NA NA NA 11 Bench Set (psi) 24.15-44.87 23.89-45.01 23.89-45.01 23.98-44.94 24.12-44.97 L'A3 ~~ Parameter PSTl PST2 PST3 PST4 PSTS 1 Average Dynamic Error (%) 1.54 1.55 1.62 1.45 1.50 2 Minimum Dynamic Error (%) 1.09 1.22 1.26 1.12 1.20 3 Maximum Dynamic Error(%) 1.87 2.01 2.06 1.81 2.12 4 Dynamic Linearity (Ind.)(%) 0.24 0.20 0.18 0.17 0.19 5 Zero Ranged Travel at (mA) 20.11 20.05 20.04 20.21 20.21 6 Full Ranged Travel at (mA) 3.46 3.55 3.57 . 3.55 3.55 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 Spring Rate NA NA NA NA NA 11 Bench Set (psi) 24.07- 44.92 24.18- 44.87 23.42- 45.03 23.45-45.04 23.53-44.94 Day34 Parameter PSTl PST2 PST3 PST4 PSTS 1 AverageD "c Error(%) 1.58 1.65 1.58 1.65 1.65 2 Minimum Dynamic Error (%) 1.16 1.31 1.28 1.33 1.25 3 Maximum Dynamic Error(%) 1.97 2.04 1.92 1.92 1.92 4 Dynamic Linearity (Ind.)(%) 0.21 0.18 0.15 0.19 0.17 5 Zero Ranged Travel at (mA) 20.13 20.10 20.12 20.12 20.16 6 Full Ranged Travel at (mA) 3.56 3.58 3.58 3.58 3.59 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 Spring Rate NA NA NA NA NA 11 Bench Set (psi) 24.4-44.7 24.08-45.8 24.71-44.83 24.3-44.79 24.63 - 44.79 Parameter PST 1 PST2 PST3 PST4 PSTS 1 Average Dynamic Error(%) 1.64 1.59 1.59 1.61 1.45 2 Minimum Dynamic Error(%) 1.26 1.26 1.26 1.29 1.12 3 MaximumD ·c Error(%) 2.02 1.97 1.97 1.97 1.68 4 Dynamic Linearity (Ind.)(%) 0.19 0.21 0.21 0.20 0.17 5 Zero Ranged Travel at (rnA) 20.13 20.08 20.08 20.14 20.16 6 Full Ranged Travel at (rnA) 3.57 3.61 3.61 3.61 3.60 7 Average Torque NA NA NA NA NA 8 Maximum Torque NA NA NA NA NA 9 Minimum Torque NA NA NA NA NA 10 Spring Rate NA NA NA NA NA 11 Bench Set (psi) 24.15-44.87 23.89-45.01 23.89-45.01 23.98-44.94 24.12-44.97

Contributed Paper Measurement and Control

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Contributed Paper Measurement and Control

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