Optimizing valve maintenance using condition analysis

1. Optimizing valve maintenance using condition analysis IPPTA seminar 17-18th July, 2014

2. Optimizing valve maintenance using condition analysis IPPTA seminar 17th July, 2014 Speaker: Jarkko Räty Director, Services, Business Solutions

3. Typical Maintenance Issues • Unexpected failures • Production breaks cause loss of revenue • Safety and environmental issue • Lack of targeted maintenance • Unnecessary maintenance costs • Unnecessary risk of damage • Are the right issues tackled ? • Typical Performance Statistics • 30 % of controls increases process variability • 10-30 % of controls in Manual • 30 % of valves with problems

4. Traditional ways of selecting Valves for shutdown maintenance • Certain Critical always • Operator indications • Grouping for each shutdown • No actions if by-pass available • Run to failure (=no actions) Typically one rule is not directly followed, reality is more like combinations of the rules

5. Making a maintenance recommendation Device history and present condition defines the action OK Condition Analysis Maintain in Place Operational History Remove & Maintain Service History

6. Maintenance decision making Defining the actions is a continuous process Prioritize Filter Analyse Report Plan Repair

7. Maintenance based on known condition May reduce valve shutdown cost by up to 50 % Typically 30% valves require no action 40% valves can be maintained in place 30% valves require removal for maintenance • Condition Analysis • Visual Inspection • Diagnostic Analysis • Devices Testing • Adjustments • Calibrations • Preventive Actions • Tightening • 70 % reduction in Field Work cost • 30+ % reduction in Maintenance costs • Maintenance • Refurbishment • Spare parts • Testing • Up to 50 % reduction in Shutdown • Field Work • Removal, reinsertion • Lifting, scaffolding • Transportation Traditional Shutdown Shutdown with Condition Analysis

8. Condition AnalysisKnown device conditions – makes maintenance intelligent Intelligent Shutdown Devices are sellected for maintenance based on known device conditions and unnecessary maintenance can be avoided. Intelligent Maintenance Device analyses are scheduled according the criticality. The known device conditions and criticality are used to prioritize daily maintenance actions. Various intelligent analysis tools and methods are available to reveal field device conditions. The suitable tools are sellected according to the existing installed device base and control system infrastructure.

9. Condition Analysis ToolsRemote performance and diagnostics analysis Control Device Monitoring Use the loop monitoring system to identify underperforming valves and identify probable root causes Smart Device Check One-shot diagnostic analysis of large amount of devices for Shutdown planning purposes Smart Device Monitoring Continuous diagnostic analysis architecture for Maintenance and Shutdown planning

10. Control Device Monitoring An example: Detecting oscillations caused by a sticky valve Graphical view to illustrate Valve Health Deeper analysis reveals valve stiction Process trend confirms typical sticky valve behavior Process Value remains steady despite of changes in Control actions until it moves 1 Contol Loop Monitoring OPC HIS ENG PCS 2 SP = SetPoint PV = ProcessValue (a flow meter) CO = Control (to valve) 3

11. Smart device diagnostics utilization An example: Detecting air leakage in valve actuator Condition Monitoring alarms malfunction Remote analysis reveals excessive air consumption Gradual chance in Spool Valve Position Actuator membrane failure (a hole) was discovered in devices maintenance 1 2 3 • Utilizing diagnostic information: • Trouble Shooting (one device at the time) • Analysis of 10’s or 100’s of devices • 24/7 monitoring

12. Condition Analysis ToolsPortable testing devices Valve Leak Testing Testing of valves in process to determine if they are leaking when shut Safety Valve Testing Testing of safety relief pressure valves in process to determine if they are operating correctly at correct pressure setting Control Valve Testing Testing of valve condition with portable testing system for Shutdown and Maintenance planning

13. Control Valve Testing Detecting sticky valve by ramp movement Testing system connection to valve Attachment options for external potentiometer Testing results revealed valve sticking while leaving the seat in the upper half of the stroke 1 2 PC Measurement system 3

14. Valve Leak Testing Leakage detection and leak rate estimation Acoustic measurement on predefined spots of valve assembly A leak detected by acoustic signal Estimation of leakage rate Reporting devices conditions and recommended actions 2 1 A leak detected 3 3 4

15. Safety Valve Testing Testing verifies pressure setting of safety valves Setting up of testing system Automatic testing run Test report and pressure setting certificate with Maintenance recommendations 1 2 3

16. Condition Analysis Analysis for different field device types

17. Suzano BA Shutdown 2012, Brazil Company profile Suzano -2nd largest eucalyptus pulp producer in the world (8th in market pulp) - Pulp production costs is one of the lowest in the world - Six industrial units in Brazil • Suzano BA (Mucuri) • Pulp production 1.540 ktons yearly • Uncoated paper 250 ktons yearly

18. Suzano BA Shutdown 2012 Results through Condition Analysis Customer Request Testing Plan Test Results Shutdown Actions 35 pcs OK 79 pcs Visual inspection and Operational tests 73 pcs No action 232 pcs Preliminary list for valve maintenance 44 pcs Maintenance 93 pcs Adjusment and preventive action on pipeline 153 pcs Condition analyses by Smart Device Check 131 pcs OK 66 pcs Maintenanc at workshop 22 pcs Maintenance

19. Suzano BA Shutdown 2012Maintenance Execution • Planning & Execution • Activities included in the master schedule • Monitoring the progress of activities • Implementation of maintenance actions according to company procedures Shutdown time Shutdown 11 days Start-up 3 days Manning33 Metso Professionals 2 Partner Professionals for electrical actuators • Shutdown activities • 66 pcs maintenance of automatic valves • 7 pcs maintenance electric actuators • 93 pcspositioners adjustments and preventive tasks • 5 pcs extra activities requested by Suzano. Operational & Maintenance History Visual & Operational Checking Smart Device Check Maintenance Planning Shutdown Start-up

20. Suzano BA Shutdown 2012 Direct reduction in maintenance costs 44 % Results 31% valves required no action 40% valves adjusted in place 29% valves required removal for maintenance • Condition Analysis • Visual Inspection • Diagnostic Analysis • Devices Testing • 44 % reduction in Maintenance costs • Adjustments • Calibrations • Preventive actions • Tightening • 50 + % reduction in Shutdown costs when Field Work taken into account • Maintenance • Refurbishment • Spare parts • Testing • Field Work • Removal, reinsertion • Lifting, scaffolding • Transportation 100 % Preliminary Estimation 56 % Actual

21. Condition Analysis The way to optimize valve maintenance “Don’t fix if its not broken” Gather and collect information Pinpoint the issues Prioritize actions “Tackle the right issues”