Fisher Guide: FIELDVUE Instruments - A Planning Guide for Effective use - HART Implemenations Manuals & Guides
FIELDVUE™ Instruments
A Planning Guide for Effective Use
HART® Implementations
February 2020
D103278X012
You've purchased a FIELDVUE instrument.....Now what???
How do you get the most value out of it?
Where do you start?
What's the best way to install it?
Where do you set your alerts?
Online/offline?
Diagnostics? When? How?
The answer is....... Start out with a good foundation and build on it!
X1182-1
X0379
W8858
www.Fisher.com
I. Introduction 1....................................................................
1. Scope 1..................................................................
™
2. Plantweb
Digital Ecosystem Discussion 1.....................................
3. FIELDVUE Instrument Background 2..........................................
4. ValveLink™ Software Background 3...........................................
5. ABC Asset Criticality Assessment 3...........................................
II.Startup and Commissioning 4.....................................................
1. Baseline Data Gathering 8..................................................
Using ValveLink Software or ValveLink SNAP-ON™ for AMS Device Manager 8....
Using AMS Trex or 475 Communicator with ValveLink Mobile App 9...........
Using AMS Trex or 475 Communicator with HART App 9.....................
III.Normal Operations 10..........................................................
1. Using ValveLink Software in Conjunction with
Multiplexers or ValveLink Integrated System
(ex. DeltaV™ or Ovation™ with AMS) 10........................................
2. Roving Laptop Using ValveLink Solo or
ValveLink SNAP‐ON for AMS Device Manager 11................................
3. Valves with AMS Trex or 475 Communicator Monitoring Only with
ValveLink Mobile App 12...................................................
4. Valves with AMS Trex or 475 Communicator Monitoring Only with HART App 13.....
IV.Turnarounds 14................................................................
Before Turnarounds
After Turnaround Begins
After Turnaround
V.Summary 15...................................................................
VI.Appendix A Alerts 16...........................................................
VII.Appendix B Diagnostics 20......................................................
1. FIELDVUE Diagnostics Overview 20...........................................
2. Performance Diagnostics Overview 21........................................
3. Performance Diagnostics - Test Details (In Service Testing) 21....................
4. Advanced Diagnostics - Test Details (Out of Service Testing) 28...................
5. Advanced Diagnostics - Look and Feel 31......................................
VIII.Appendix C Value‐Add Features 32..............................................
I. Introduction
1. Scope
The purpose of this guide is to help you develop a plan to use the FIELDVUE instrument more effectively.
We have made every effort to present meaningful and realistic information. The topic area is so broad that it is
difficult to cover all possibilities in a single comprehensive document. However, the contents of this document
should provoke thought process and work practice changes surrounding the full value of a digital technology coupled
with state‐of‐the‐art diagnostics.
This guide begins with a short discussion of the FIELDVUE instrument product line and the associated ValveLink
software tools, features and the functionalities they encompass. This is followed by methods to effectively implement
FIELDVUE instruments in the following situations:
Startup and commissioning
Normal operations
Turnarounds
These sections are intended to provide you with suggested initial settings. Also included are recommended changes
and/or additions to existing work practices that allow you to realize the full value of FIELDVUE instrument diagnostics.
A more detailed discussion of alerts and diagnostics, examples of specific value‐add features such as scheduler, alert
log, batch runner, etc., and troubleshooting can be found in the appendices.
If you have any questions regarding these subjects, please contact your Emerson sales office
.
2. Plantweb Digital Ecosystem Discussion
Plantweb digital ecosystem leverages the power of intelligence in field devices to securely improve the Industrial
Internet of Things (IoT) with measurable business performance improvement. The digital intelligence in the field
devices is used to provide the data for predictive diagnostics and to improve performance of final control elements
and measurement instruments.
The basis for the Fisher design philosophy, or what makes for a good control valve, is superior dynamic
responsiveness. The key characteristics of superior dynamic performance are:
Does the valve react to small changes in input signal (1/4%-1%)?
Does the valve move fast enough?
Does the movement provide the right installed gain for the PID process loop tuning to work over the operating
flow range?
The ability to “tune” FIELDVUE instruments to the valve/actuator assembly provides the required dynamic
responsiveness which:
allows operations to push setpoints closer to constraints,
allows for more aggressive PID tuning,
allows continuous use of Model Predictive or Advanced Control strategies,
drives more efficient plant operation, increased throughput, lower energy and utility costs, better quality, and
less rework.
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The diagnostics capability of the FIELDVUE instrument optimizes control valve assets and provides:
increased availability,
increased uptime,
decreased unscheduled outages for control valve problems,
faster problem identification and resolution,
increased maintenance effectiveness,
lower maintenance costs by pinpointing problems and eliminating unnecessary expenditures on parts, labor, or
downtime, and
Increased plant safety.
It is this combination of expertise in process control and control valve design, digital intelligence in the positioner,
and open communications protocols such as HART and FOUNDATION™ fieldbus, that deliver a positioner capable of
superior dynamic responsiveness as well as a “data server” capable of diagnostics.
3. FIELDVUE Instrument Background
FIELDVUE instruments are microprocessor based digital valve controllers. These digital valve controllers have the
ability to precisely position a control valve assembly using a setpoint received from a control system. More than just a
digital positioner, they also perform control valve diagnostics, alert you of critical information before it affects the
process, and communicate using HART, Fieldbus, or PROFIBUS protocol.
The first generation FIELDVUE instrument was the DVC5000 (HART) released in 1994. This was the first loop powered
digital valve controller available on the market. The next release was the DVC5000f (Fieldbus) in 1998. The third
generation instrument, the DVC6000 (HART) was released in 2000 and included many enhancements in control and
diagnostics functionality. The addition of multiple sensors and double-acting capability gave the instruments
industry‐leading functionalities. The DVC6000f (Fieldbus) was released in 2004 and added Fieldbus communications
as well as ground breaking control performance. Options for remote mount travel sensor and extreme temperature
construction are also available.
The DVC2000 was released in 2004. New functions included the use of a local user interface, multilingual display,
integrated limit switches, position transmitter, and non-contact feedback.
The fourth generation instruments, the DVC6200 and DVC6200f, were released in 2009, while the DVC6200p
(PROFIBUS) was released in 2012. These instruments incorporate the linkage-less non contact feedback design to
make a good product even better. New functions include the position transmitter or 1 switch, 316 SST model,
remote unit, and HART 7 communication option.
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4. ValveLink Software Background
ValveLink software is the companion tool used to get the most value out of FIELDVUE positioning instruments. While
there are a variety of packages available in the industry with the ability to configure, calibrate and view alerts, only
ValveLink software can perform valve assembly diagnostics.
ValveLink software has the ability to be installed and used in various forms:
ValveLink Solo working with a HART multiplexer, HART modem or F
ValveLink SNAP‐ON for AMS Device Manager
ValveLink DTM
ValveLink PLUG‐IN for PRM
ValveLink Mobile for AMS Trex or 475 Communicator
You will receive the most value from integrated HART or Fieldbus installations. The preferred method is to have a
maintenance station on an Emerson system, such as DeltaV, or Ovation, with AMS Device Manager, due to the
advanced integration, the ability to easily view needed information, and the ability to automate batch features.
®
OUNDATION fieldbus
5. ABC Asset Criticality Assessment
All assets in the plant are not equal. Final control assemblies, transmitters, sensors, pumps, and other process control
equipment have different degrees of criticality. The results of a criticality assessment can provide valuable
information that can be used to determine how each asset should be monitored and maintained. Typically A rated
assets are the most critical and have the most effect on plant operations. They require more monitoring and receive
the highest work order priority. If the final control assembly is an A asset, it should be tiered to a PD level. B assets are
of lesser criticality. The B critical final control element is typically tiered to an AD level. The ABC ranking should enable
you to define the critical valve assemblies in your plant, the alerts required, and the frequency for inspecting these
assets. Emerson’s Asset Management can help you get started with this assessment in your plant. For more
information, contact your Emerson sales office.
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II. Startup and Commissioning
The following steps are recommended guidelines for the setup, calibration, and configuration of a FIELDVUE
instrument. These steps can be performed using AMS Device Manager, ValveLink software, AMS Trex or 475
Communicator with ValveLink Mobile or DD, and most other HART host tools that use DD technology:
General recommendations to successfully set up FIELDVUE Instruments are:
- Always use the Setup Wizard (Do not use the Setup Wizard after the instrument is setup on a valve
assembly. You could accidentally reset the unit to factory defaults, erasing all of the custom configuration
that is in the instrument)
- Always try to use Auto Travel Calibration (Auto calibration of travel is always required if the instrument is
removed from the valve assembly for maintenance purposes)
- Always enable the Alert Record in the instrument (Clear the Alert Record after commissioning)
Create and follow a startup and commissioning plan. At a minimum, the plan should include the following:
- Review your application - gather valve data, serial cards, etc.
- Determine cutoffs/limits and travel alerts, if applicable.
- Mount instrument properly
- Run Setup Wizard
Run Performance Tuner if actuator was not listed in Setup Wizard
- Enable below Alerts for visibility to basic valve assembly health information:
Travel Deviation: 5% for 10 seconds
Supply Pressure: 3 psi above upper benchset for spring & diaphragm, 10 psi below nominal instrument
air supply for piston actuators
Drive Signal
- Reset Cycle Counter and Travel Accumulator to Zero (0)
- Ensure Valve Alerts are enabled, this will allow alerts to be written to the instrument alert record (on‐board
alert storage utility)
Set Instrument Date & Time
Clear Alert Event Record
Enable Triggered Profile on PD units
Use Travel Deviation as the Triggered Event for throttling control valves
Use Collection Variables of Travel Set Point, Travel, Drive Signal, and Supply
Use Trigger Record Length of 60 seconds. The DVC6200/DVC6000 can hold approximately 20 minutes
of triggered data sets.
Note
Triggered data in the device will show up on the alert record as Diagnostic Data Available.
When alert scanning using a DCS with HART cards or multiplexers, the following additional settings are
recommended:
- Device Alerts
- ValveLink SNAP‐ON, scan all valves as fast as possible, A critical valves more often than
B and C critical valves
- ValveLink Solo automatically scans at maximum speed possible for system
- PD One Button Sweep using Scheduler
A critical valves, one per week
B critical valves, one every two weeks
C critical valves, once a month
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- PD Friction using Scheduler (ensure upper and lower friction values are set up in PD Diagnostic Trends of
Friction
A critical valves, two per month
B critical valves, one per month
The following table provides a more detailed list of recommended initial settings. These are “best practices”, which
have been derived from the current installed base. They are general guidelines that may need to be modified based
upon the specific application. When starting with an alert strategy, keep the number of alerts enabled to a minimum.
Start with Travel Deviation, Supply Pressure Low, and Drive Signal Out of Range. These alerts are the most critical for
throttling control valves. If you set too many alerts to start with, they may be seen as nuisance alerts and have a
tendency to be ignored.
DVC6200 (HW2) Parameters
Setup Parameter Factory Default Alert Settings
Control Mode Analog (RSP) Analog (RSP)
Restart Control Mode Resume Last Resume Last
Burst Mode Enabled No No Set to Yes if a Tri‐Loop is used
Burst Mode Command Loop Current/PV/SV/TV/QV Loop Current/PV/SV/TV/QV
HART Tag As Specified on Order Fill in Plant Information Tag from DCS, P&ID, etc.
Message Blank Fill in Plant Information
Descriptor Blank Fill in Plant Information
Date Factory Calibration Date Set to Current Date
Valve Serial Number Blank Fill in Valve Serial Number
Polling Address 0 0
Max Supply Pressure 1.378 Bar 1.378 Bar
Feedback Connection Default Array Default Array Can be corrected to actual array
Zero Power Condition Valve Closed Valve Closed Determined by Setup Wizard
Travel Sensor Motion
Analog Input Units mA mA % for DeltaV
Analog In Range High 20 mA 20 mA 100% for DeltaV
Analog In Range Low 4.0 mA 4.0 mA 0% for DeltaV
Pressure Units Bar Bar End User to Determine
Temperature Units C C End User to Determine
Tuning Set H H Determined by Setup Wizard
Input Characteristics Linear Linear
Set Point Filter Lag Time 0 Sec 0 Sec
High Limit/Cutoff Select Hard Cutoff Hard Cutoff End User to Determine
Low Limit/Cutoff Select Hard Cutoff Hard Cutoff End User to Determine
High Limit/Cutoff Point 99.46% 99.46%
Clockwise/Away from Top of
Instrument
- Continued -
Recommended Initial
Alert Settings
Clockwise/Away from Top of
Instrument
Notes
Should be 5 psi above upper
benchset or actuator Maximum or
digital valve controller Maximum.
Determined by Setup Wizard
This parameter is dependent on
service and trim type eg. CAVIII or
standard. For example in BFP
Recirc with a Reverse Acting valve
you might want this set at 92%
whereas for standard trim 99.46%
might be acceptable
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DVC6200 (HW2) Parameters (continued)
Setup Parameter Factory Default Alert Settings
Low Limit/Cutoff Point 0.50% 0.50%
SP Rate Open 0 %/sec 0 %/sec
SP Rate Closed 0 %/sec 0 %/sec
Integral Enabled Enabled Enabled
Integral Gain 10 repeats/minute 10 repeats/minute
Integral Deadband* 0.26% 0.26% *See table below (page 7)
Travel Hi/Lo Alert Enabled Disabled Disabled End User to Determine
Travel Hi Hi/Lo Lo Alert Enabled Disabled Disabled End User to Determine
Travel Alert High Point 125% 125% End User to Determine
Travel Alert Low Point -25% -25% End User to Determine
Travel Alert High‐High Point 125% 125% End User to Determine
Travel Alert Low‐Low Point -25% -25% End User to Determine
Travel Alert Deadband 1% 3%
Travel Deviation Alert Enabled Yes Yes
Travel Deviation Alert Point 5% 5%
Travel Deviation Time** 10 sec 5 sec **See table below (page 7)
Pressure Deviation Alert Enable Yes Yes
Pressure Deviation Alert Point 0.345 bar 5 psi
Pressure Deviation Time 5 sec 10 sec
Cycle Counter Alert Enable No No
Cycle Counter Alert Point 500000 500000
Cycle Cnt/Tvl Accum Deadband 1% 3%
Cycle Counter 0 0 Verify 0 on initial setup
Travel Accumulator Alert Point 2147483647 500000
Travel Accumulator Deadband 1% 3%
Travel Accumulator 0 0 Verify 0 on initial setup.
Local Autocal Button Enabled Enabled
- Continued -
Recommended Initial
Alert Settings
Notes
This parameter is dependent on
service and trim type eg. CAVIII or
standard. For example in BFP
Recirc with a Direct Acting valve
you might want this set at 12%
whereas for standard trim 0.5%
might be acceptable.
This is a good tool to track
problems. The end user needs to
keep track of problems such as
packing leaks, travel sensor
failures, actuator diaphragm
failures, etc. Upon the first
problem showing up, this number
needs to be recorded in the
CMMS or AMS and reset. Repair
the problem and record the
number when the next problem
occurs. This will give a history of
good data that will allow us to
enable this alarm and then
generate a work order to address
the problem before it fails.
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DVC6200 (HW2) Parameters (continued)
2
2
2
2
Setup Parameter Factory Default Alert Settings
Supply Pressure Alert Enable Yes Yes
Supply Pressure Alert Point 0.345 bar 3 psi above upper benchset.
Drive Signal Alert Enable Yes Yes
Inst Time Invalid Enable No No
Cal in Progress Enable No No
Autocal in Progress Enable No No
Diag in Progress Enable No No
Diag Data Avail Enable No Yes
Integrator Sat High Enable No No
Integrator Sat Low Enable No No
Pressure Fallback Enable Yes Yes
Recommended Initial
Alert Settings
Notes
10 psi below nominal for piston
actuators.
*Integrator - Enabled and configured as follows:
Integrator Parameter PTFE Packing Graphite Packing
Integrator Dead Zone 0.26% 0.5% 0.7%
Enviro-Seal PTFE and
Graphite ULF Packing
**Travel Deviation Alert - Enabled and configured as follows:
Actuator Diaphragm Area PTFE Packing Graphite Packing
<= 100 in
> 100 in2 to <= 200 in
> 200 in2 to <= 300 in
> 300 in
Alert enabled
Alert Point = 2%
Alert Time = 2 sec
Alert enabled
Alert Point = 2%
Alert Time = 2 sec
Alert enabled
Alert Point = 3%
Alert Time = 5 sec
Alert enabled
Alert Point = 3%
Alert Time = 5 sec
Alert enabled
Alert Point = 3%
Alert Time = 2 sec
Alert enabled
Alert Point = 3%
Alert Time = 5 sec
Alert enabled
Alert Point = 5%
Alert Time = 8 sec
Alert enabled
Alert Point = 5%
Alert Time = 10 sec
Notes:
1. Travel Deviation Alert Point % and Travel Deviation Time set to around twice to three times what the valve's response when its new and
healthy.
2. Alternatives are to use the step response test to determine the time it normally takes for a 5% step and then set the Travel Deviation Time
to 2 times that value. Another option would be to use twice the T63 time
Enviro-Seal PTFE and
Graphite ULF Packing
Alert enabled
Alert Point = 5% Alert
Alert Time = 3 sec
Alert enabled
Alert Point = 5% Alert
Alert Time = 5 sec
Alert enabled
Alert Point = 5 % Alert
Alert Time = 10 sec
Alert enabled
Alert Point = 5 % Alert
Alert Time = 10 sec
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1. Baseline Data Gathering Procedures
It is important to get a good set of baseline data. This accomplishes two critical tasks: it ensures that the current
operating state of the control valve assembly is correct; and when a control valve has a problem the current data can
be compared to the baseline data to quickly pinpoint the issue. Valve outages can then be planned with the correct
parts, tools, and manpower. Most importantly, impact on the cost of operations will be minimized.
Using ValveLink Software or ValveLink SNAP-ON for AMS
Take baseline data:
1. Import valve “birth certificate” if purchased from factory
2. Fill out valve and actuator spec sheets under Detailed Setup of ValveLink software. (Factory assemblies have
been shipping with the spec sheet stored in the instrument since 2008).
3. After spec sheet is verified, read instrument and upload information into Database Dataset, save Dataset.
4. If HC, AD, or PD, run Status Monitor at 4, 12, and 20 mA (or 0%, 50%, and 100% input signal) with digital valve
controller In Service and save each dataset.
5. If AD/PD
5.1. Valve Step Response (0-100-0 Step Test)
5.2. Valve Step Response (Performance Test)
5.3. Total Dynamic Scan (DVC6200, DVC6000 or DVC2000)
5.4. Valve Signature, Drive Signal, Dynamic Error Band (DVC5000)
5.5. One Button Sweep (PD only)
5.6. Run Valve Friction diagnostic (PD only)
6. Make sure the Alert Record is enabled and clear.
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Using AMS Trex or 475 Communicator with ValveLink Mobile App
Take baseline data:
1. Fill out or verify valve and actuator spec sheets under Setup Icon of ValveLink Mobile software.
2. Save Detailed Setup under Setup Icon.
3. Under Status Icon, if HC, AD or PD run Status Monitor at 4, 12, and 20 mA (or 0%, 50%, and 100% input signal)
with digital valve controller In Service and save each dataset.
4. If AD/PD
4.1. Valve Step Response (Stroking Time Test)
4.2. Valve Step Response (Performance Test)
4.3. Total Scan (DVC6200, DVC6000, or DVC2000 instrument)
4.4. One Button Sweep (PD Only)
Note
ValveLink Mobile data can be imported to ValveLink Solo for more detailed analysis.
Using AMS Trex or 475 Communicator with HART Application App
Take baseline data:
Using the AMS Trex or 475 Communicator (HART Application overview screen) at 12 mA (or 50% input signal), copy
the below data into the computerized maintenance management system (CMMS):
1. Analog In
2. Valve Setpoint
3. Travel
4. Drive Signal
5. Pressures
5.1. Output A
5.2. Output B (double-acting piston)
5.3. A-B
5.4. Supply (AD or PD only)
6. Make sure the Alert Record is enabled and clear.
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III. Normal Operations
The goal is to move away from preventative maintenance tasks (PMs) into a predictive maintenance (PdM) mode
where we rely fully on the instrument to inform you of a pending issue. If there are no active alerts, there should be no
maintenance. If an alert is active, maintenance activities should be planned based upon the criticality of the control
valve application and the alert.
1. Using ValveLink Software in Conjunction with Multiplexers or
ValveLink Integrated System (ex. DeltaV or Ovation with AMS)
Configure the Alert Monitor to monitor all valves based on the criticality ranking of the valve. On PD units, setup
the ValveLink Scheduler to run a PD One Button Sweep and Valve Friction test on a periodic basis based on
criticality ranking.
HART Alert Troubleshooting and Correction
Alerts such as Travel Sensor Fail require a specific course of action like changing the feedback potentiometer on
a DVC6000 or checking the wiring on the DVC6205. Refer to Appendix A for a list of these alerts.
1. Other alerts such as the Travel Deviation Alert can be caused by many things and require a systematic
approach to determining what the exact problem is. A recommended approach is:
1.1. Run Status Monitor at the current operating position. Check Supply Pressure, Drive Signal, and Travel
Pressure State.
1.2. Compare current to baseline values to try to identify the problem. Check the ValveLink Alerts page to
see how the current Active Alert values compare with the Alert Point.
1.3. If unit is PD, check for triggered profile.
1.4. Correct any problems discovered.
1.5. If problems cannot be solved continue on with step 2. Use of PD and step 3. Use of AD.
2. Use of PD
2.1 Run One Button Sweep before performing any other diagnostic analysis.
2.2 Correct the problems identified by One Button Sweep.
2.3 If One Button Sweep does not clearly determine the problem, run a Valve Friction Test. Identify any
problems and correct.
2.4 If problems cannot be determined continue on with step 3. Use of AD.
3. Use of AD
3.1 Contact operations to have the valve taken out of service if possible.
3.2 DVC6200/ DVC6000 / DVC2000 - Perform a Total Scan and compare results with baseline results.
3.3 DVC5000 - Perform a Valve Signature, Drive Signal and Dynamic Error Band test and compare -
results with baseline data.
3.4 Determine the problem and correct it.
4. When the problem is corrected, reset the instrument Date & Time if required and Clear the Instrument Alert
Record.
5. If the problem still cannot be determined, contact your nearest Emerson sales office or Life Cycles Services
Center for support.
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