GE Baker Hughes Masoneilan SVI FF Installation And Operation Manual

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Masoneilan

SVI* FF Digital Positioner

Advanced Performance

Installation and Operation Manual (Rev F)

BHGE Data Classification: Public

About this Guide

This instruction manual applies to the following instruments and approved software:

 SVI FF

The information contained in this manual, in whole or part, shall not be transcribed or copied without BHGE’s written permission.

In no case does this manual guarantee the merchantability of the positioner or the software or its adaptability to a specific client needs.

Please report any errors or questions about the information in this manual to your local supplier or visit valves.bhge.com.

DISCLAIMER

THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PROJECT-SPECIFIC REFERENCE INFORMATION IN ADDITION TO THE CUSTOMER/OPERATOR’S NORMAL OPERATION AND MAINTENANCE PROCEDURES. SINCE OPERATION AND MAINTENANCE PHILOSOPHIES VARY, BHGE (BAKER HUGHES, A GE COMPANY AND ITS SUBSIDIARIES AND AFFILIATES) DOES NOT ATTEMPT TO DICTATE SPECIFIC PROCEDURES, BUT TO PROVIDE BASIC LIMITATIONS AND REQUIREMENTS CREATED BY THE TYPE OF EQUIPMENT PROVIDED.

THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL UNDERSTANDING OF THE REQUIREMENTS FOR SAFE OPERATION OF MECHANICAL AND ELECTRICAL EQUIPMENT IN POTENTIALLY HAZARDOUS ENVIRONMENTS. THEREFORE, THESE INSTRUCTIONS SHOULD BE INTERPRETED AND APPLIED IN CONJUNCTION WITH THE SAFETY RULES AND REGULATIONS APPLICABLE AT THE SITE AND THE PARTICULAR REQUIREMENTS FOR OPERATION OF OTHER EQUIPMENT AT THE SITE.

 with firmware version 1.0.0.1 or higher

 with ValVue* version 3.0

 with handheld communicator with DD published for SVI FF

Copyright

THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT NOR TO PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH INSTALLATION, OPERATION OR MAINTENANCE. SHOULD FURTHER INFORMATION BE DESIRED OR SHOULD PARTICULAR PROBLEMS ARISE WHICH ARE NOT COVERED SUFFICIENTLY FOR THE CUSTOMER/OPERATOR'S PURPOSES THE MATTER SHOULD BE REFERRED TO BHGE.

THE RIGHTS, OBLIGATIONS AND LIABILITIES OF BHGE AND THE CUSTOMER/OPERATOR ARE STRICTLY LIMITED TO THOSE EXPRESSLY PROVIDED IN THE CONTRACT RELATING TO THE SUPPLY OF THE EQUIPMENT. NO ADDITIONAL REPRESENTATIONS OR WARRANTIES BY BHGE REGARDING THE EQUIPMENT OR ITS USE ARE GIVEN OR IMPLIED BY THE ISSUE OF THESE INSTRUCTIONS.

THESE INSTRUCTIONS ARE FURNISHED TO THE CUSTOMER/OPERATOR SOLELY TO ASSIST IN THE INSTALLATION, TESTING, OPERATION, AND/OR MAINTENANCE OF THE EQUIPMENT DESCRIBED. THIS DOCUMENT SHALL NOT BE REPRODUCED IN WHOLE OR IN PART TO ANY THIRD PARTY WITHOUT THE WRITTEN APPROVAL OF BHGE.

All information contained herein is believed to be accurate at the time of publication and is subject to change without notice.

Document Changes

Version/Date Changes

A/03-2014 Original release

B/05-2014 Made changes to specification for Conformity, Linearity and Repeatability.

Made changes to the Remote Positioner installation section,

C/05-2014 Made formatting changes.

D/06-2014 Omitted Link Master chapter.

Made modifications to the Transducer Blocks Parameters table.

Made modifications to the Foundation Fieldbus: Process Example appendix.

Made modifications to the Fault State Processing appendix.

Removed Remote Position Sensor section from install. Now a standalone manual.

E/08-2017 Added Appendix for Continuous Valve Diagnostics Concept.

Made modifications to Transducer Block Parameters table.

Added Diagnostics Comparison table to Introduction.

Modified the Adv Setup pushbutton menu.

Added LO mode appendix.

F/07-2019 Added Configuring the SVI FF and a Yokogawa Centum DCS.

Updated Troubleshooting.

Changed graphics for DCS switches installation.

Updated download site url.

Masoneilan SVI FF Instruction Manual =| 3

Contents

1. Safety Information ........................................................................................................................................................................... 9

Safety Symbols ............................................................................................................................................................................... 9

SVI FF Product Safety.................................................................................................................................................................10

2. Introduction ......................................................................................................................................................................................13

ValVue Software...........................................................................................................................................................................14

ValVue Standard Edition ..................................................................................................................................................14

Operational Overview................................................................................................................................................................14

SVI FF Features .............................................................................................................................................................................15

Available Options.................................................................................................................................................................16

Characterization ..................................................................................................................................................................16

Control Sets............................................................................................................................................................................16

Continuous Diagnostics ...................................................................................................................................................17

Diagnostic Versions............................................................................................................................................................19

Block Modes ...................................................................................................................................................................................20

Resource Block Modes......................................................................................................................................................20

Transducer Block Modes..................................................................................................................................................20

Overview of Available Tools....................................................................................................................................................22

Principle of Operation................................................................................................................................................................23

Physical and Operational Description................................................................................................................................24

Electronics Module..............................................................................................................................................................24

Output Switch........................................................................................................................................................................25

Pneumatic Module..............................................................................................................................................................26

Optional Display and Pushbuttons..............................................................................................................................29

Link Active Scheduler.................................................................................................................................................................29

About This Manual.......................................................................................................................................................................30

Conventions Used in This Manual................................................................................................................................30

3. Quick Start .........................................................................................................................................................................................31

Step 1: Install the Positioner on the Valve........................................................................................................................31

Step 2: Connect Pressure Supply..........................................................................................................................................31

Step 3: Wire the SVI FF...............................................................................................................................................................32

Step 4: Set Tag and Address...................................................................................................................................................32

Step 5: Basic Configuration.....................................................................................................................................................33

Step 6: Run Find Stops METHOD...........................................................................................................................................34

Step 7: Run Auto Tune METHOD ...........................................................................................................................................34

Downloads......................................................................................................................................................................................34

4. Mechanical Installation ...............................................................................................................................................................35

Overview ..........................................................................................................................................................................................35

SVI FF Positioner Types .............................................................................................................................................................35

Single Acting Positioner Description...........................................................................................................................35

Double Acting Positioner Description ........................................................................................................................41

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Installation......................................................................................................................................................................................44

Pre-Installation Issues.......................................................................................................................................................44

Installation Steps.................................................................................................................................................................46

Installation Notes ................................................................................................................................................................47

Control Sets Configuration..............................................................................................................................................48

Mounting the SVI FF on Rotary Valves ......................................................................................................................50

Mounting the SVI FF on Reciprocating Valves.......................................................................................................55

Dismantling the SVI FF from Reciprocating Valves.............................................................................................58

Installing the SVI FF for Double- Acting Operation..............................................................................................59

Connecting the Tubing and Air Supply......................................................................................................................62

Wiring the SVI FF..................................................................................................................................................................65

5. Check Out and Power Up ...........................................................................................................................................................73

Overview..........................................................................................................................................................................................73

Check Out Procedures ..............................................................................................................................................................73

Physical Inspection.............................................................................................................................................................73

Check the Electronic Module Connections..............................................................................................................77

Operational Checkout ...............................................................................................................................................................77

Connect to the H1 Network............................................................................................................................................77

Power Up the SVI FF...........................................................................................................................................................78

6. Failsafe/OOS Considerations ....................................................................................................................................................79

Failsafe Mode vs. OOS Mode..................................................................................................................................................79

Exiting Failsafe Using AMS..............................................................................................................................................81

7. Maintenance ....................................................................................................................................................................................83

SVI FF Maintenance and Repair............................................................................................................................................83

Repair........................................................................................................................................................................................83

Tools Needed.........................................................................................................................................................................83

Display Cover Removal and Installation...................................................................................................................83

I⁄P Module Removal and Installation ..........................................................................................................................85

Relay Removal and Installation....................................................................................................................................88

Adjusting I/P Zero................................................................................................................................................................88

Connecting Components to the Electronics Module ..........................................................................................88

Repair by Replacement ............................................................................................................................................................89

Internal Diagnostics ...................................................................................................................................................................89

FAILSAFE Mode.....................................................................................................................................................................89

Viewing Firmware Versions ....................................................................................................................................................90

Spare Parts .....................................................................................................................................................................................91

Appendix A. Specifications and References ...........................................................................................................................95

Physical and Operational Specifications..........................................................................................................................95

Appendix B. About Fieldbus ........................................................................................................................................................103

Outline............................................................................................................................................................................................103

Internal Structure of SVI FF.................................................................................................................................................. 103

Logical Structure of Each Block......................................................................................................................................... 105

System Configuration............................................................................................................................................................. 106

Connection of Devices ................................................................................................................................................... 107

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Integration of DD ......................................................................................................................................................................107

Appendix C. Foundation Fieldbus: Process Example .......................................................................................................109

Overview .......................................................................................................................................................................................109

Reference Model Process......................................................................................................................................................109

P & I D.............................................................................................................................................................................................110

Function Block Links................................................................................................................................................................ 111

Device Operational States and Block Modes...............................................................................................................113

Block Modes........................................................................................................................................................................ 113

Multiple Modes and States..........................................................................................................................................115

Examples of Operational States................................................................................................................................115

Transferring Modes ......................................................................................................................................................... 116

RCas Mode...........................................................................................................................................................................116

Appendix D. Troubleshooting .....................................................................................................................................................117

What to Do First ........................................................................................................................................................................117

Troubleshooting Communications...................................................................................................................................118

Troubleshooting Function Block Parameters ..............................................................................................................119

Troubleshooting Valve Control........................................................................................................................................... 120

Troubleshooting Auto Tuning..............................................................................................................................................123

Troubleshooting Tuning.........................................................................................................................................................125

Troubleshooting Position, Pressure, and Temperature Sensors.........................................................................126

Appendix E. Using the Pushbuttons and Digital Interfaces .......................................................................................... 127

Overview .......................................................................................................................................................................................127

Local Display and Pushbuttons .................................................................................................................................127

Handheld Communicator.............................................................................................................................................128

ValVue....................................................................................................................................................................................128

Pushbuttons and Local Display..........................................................................................................................................128

Pushbuttons........................................................................................................................................................................ 129

Pushbutton Locks and Configuration-Lock Jumper ........................................................................................130

Hardware Configuration Lock .................................................................................................................................... 130

Hand Held Communicator ...................................................................................................................................................131

Check-out with a Handheld Communicator........................................................................................................132

ValVue ............................................................................................................................................................................................133

Installation of ValVue Software, and Registration ............................................................................................133

Installation of Cover ................................................................................................................................................................ 133

Display Menus ............................................................................................................................................................................133

NORMAL Operating Mode Menus .............................................................................................................................133

BAS SETUP Menu............................................................................................................................................................... 134

ADV SETUP Menu..............................................................................................................................................................137

VIEW DATA Menu.............................................................................................................................................................. 139

VIEW ERROR Menu...........................................................................................................................................................142

MAN POS Menu..................................................................................................................................................................148

METHOD Menu...................................................................................................................................................................148

Appendix F. Transducer Block Parameters ..........................................................................................................................149

Appendix G. Static Parameters During Restore to Defaults ........................................................................................197

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Appendix H. Notes on Characterization ................................................................................................................................ 199

Valve Over/Under Reaction Near Endpoints ............................................................................................................... 199

Configuration of Position Limits, Position Rate Limits and FINAL_VALUE_CUTOFF and Characterization 200

Relationship Between Alerts, Alert Response Type and Block Error......................................................... 202

Appendix I. Fault State Processing .......................................................................................................................................... 203

Initiate Fault State from the Host ............................................................................................................................. 203

Fault State Conditions Detected by AO Block..................................................................................................... 204

Fault State Conditions Detected by Transducer Block ................................................................................... 204

Fault State Condition is Detected and Processed by the Position Control Hardware and Software 205

Appendix J. Configuring the SVI FF and a Yokogawa Centum DCS ......................................................................... 207

Purpose and Scope.................................................................................................................................................................. 207

Status of SVI FF interoperability with Yokogawa DCS............................................................................................. 208

Special Notes When Working with Yokogawa DCS ......................................................................................... 208

Procedure..................................................................................................................................................................................... 209

1. Preparation for Device Connection .................................................................................................................... 209

2. Connecting the SVI FF ............................................................................................................................................... 215

3. Edit Block Parameters............................................................................................................................................... 217

4. Set Device Information ............................................................................................................................................. 220

Appendix K. Views ........................................................................................................................................................................... 225

Views ..............................................................................................................................................................................................225

Appendix L. References ................................................................................................................................................................ 229

Appendix M. Continuous Valve Diagnostics Concept .....................................................................................................231

Introduction................................................................................................................................................................................. 231

Off Line Diagnostics ........................................................................................................................................................ 232

On Line Diagnostics ........................................................................................................................................................ 232

Continuous Diagnostics......................................................................................................................................................... 233

Positioner Diagnostics ................................................................................................................................................... 233

Valve/Actuator Diagnostics......................................................................................................................................... 234

Supporting Information for Diagnostic Configuration.................................................................................... 237

Application Specific Categorization......................................................................................................................... 241

Reporting Diagnostic Condition to the Host ................................................................................................................242

Diagnostic Events Reported by Block Error ......................................................................................................... 242

Diagnostic Events Reported by Alarms.................................................................................................................. 244

Diagnostic Events Reported According to FF-912 Field Diagnostic Profile Specification.............. 246

Discrete Switch Configuration ................................................................................................................................... 249

Processing to DI Block.................................................................................................................................................... 249

Conclusion ................................................................................................................................................................................... 249

Appendix N. Changing Out of LO Mode ................................................................................................................................ 251

Local Display............................................................................................................................................................................... 251

Device DTM.................................................................................................................................................................................. 252

Handheld...................................................................................................................................................................................... 253

DD Method...................................................................................................................................................................................256

Masoneilan SVI FF Instruction Manual =| 7

DD Host .........................................................................................................................................................................................258

Appendix O. Air to Open/Air to Close Configuration ........................................................................................................259

Standard DD-based Configuration Tool: Transducer Block - Fail Action Parameter................................260

SVI FF DTM....................................................................................................................................................................................261

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1. Safety Information

CAUTION

WARNING

CAUTION

NOTE

This section provides safety information including safety symbols that are used on the SVI FF and the safety symbol definition.

Read this entire section before installation and operation.

Safety Symbols

SVI FF instructions contain WARNINGS, CAUTIONS labels and Notes, where necessary, to alert

you to safety related or other important information. Total compliance with all WARNING, and CAUTION notices is required for safe operation.

Indicates a potentially hazardous situation, which if not avoided could result in serious injury.

Indicates a potentially hazardous situation, which if not avoided could result in property or data damage.

Indicates important facts and conditions.

Masoneilan SVI FF Instruction Manual =

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SVI FF Product Safety

NOTE

The SVI FF digital valve positioner is intended for use with industrial compressed air or, natural gas systems only.

Ensure that an adequate pressure relief provision is installed when the application of system supply pressure could cause peripheral equipment to malfunction. Installation must be in accordance with local and national compressed air and instrumentation codes.

General installation, maintenance or replacement

 Products must be installed in compliance with all local and national codes and

standards by qualified personnel using safe site work practices. Personal Protective Equipment (PPE) must be used per safe site work practices.

 Ensure proper use of fall protection when working at heights, per safe site work

practices. Use appropriate safety equipment and practices to prevent the dropping of tools or equipment during installation.

Installations using natural gas are Zone 0 or Div 1 installations.

 Under normal operation, compressed supply gas is vented from the SVI FF to the

surrounding area, and may require additional precautions or specialized installations.

Intrinsically Safe Installation

Products certified as explosion proof or flame proof equipment or for use in intrinsically safe installations MUST BE:

 Installed, put into service, used and maintained in compliance with national and local

regulations and in accordance with the recommendations contained in the relevant standards concerning potentially explosive atmospheres.

 Used only in situations that comply with the certification conditions shown in this

document and after verification of their compatibility with the zone of intended use and the permitted maximum ambient temperature.

 Installed, put into service and maintained by qualified and competent professionals

who have undergone suitable training for instrumentation used in areas with potentially explosive atmospheres.

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Before using these products with fluids/compressed gases other

WARNING

than air or for non-industrial applications, consult the factory. This product is not intended for use in life support systems.

Under certain operating conditions, the use of damaged instruments could cause a degradation of the performance of the system, which can lead to personal injury or death.

Under certain operating conditions the SVI FF High Flow unit can produce noise levels greater than 85 dBA. Perform proper site monitoring and testing to verify the need for engineering or administrative controls to eliminate or reduce hazardous noise levels.

Installation in poorly ventilated confined areas, with any potential of gases other than oxygen being present, can lead to a risk of personnel asphyxiation.

Use only genuine replacement parts which are provided by the manufacturer, to guarantee that the products comply with the essential safety requirements of the European Directives.

Changes to specifications, structure, and components used may not lead to the revision of this manual unless such changes affect the function and performance of the product.

Masoneilan SVI FF Instruction Manual =| 11

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2. Introduction

The SVI FF (Smart Valve Interface) is the next generation of Masoneilan’s intelligent digital valve positioners with the FOUNDATION Fieldbus interface. The SVI FF is a high performance, digital valve positioner that combines a local display with remote communication and diagnostic capabilities. The SVI FF offers a multitude of options that fulfill the broadest range of applications, using the FF protocol. The High Flow version is capable of 2.2 C

An optional pushbutton and LCD display enables local operations of calibration and configuration functions. Remote operations can be performed with ValVue (Version 3) software, with any FDT-based frame application or any FF Registered host interface that has been pre-loaded with the Device Description files (DD) for SVI FF.

The SVI FF is provided with Masoneilan’s ValVue software. The user-friendly interface facilitates the setup and diagnostics of a control valve.

air throughput.

Figure 1 SVI FF

Masoneilan SVI FF Instruction Manual =

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ValVue Software

Not only does ValVue provide the ability to quickly and easily set up the SVI FF you can also monitor operation and diagnose problems with ValVue’s advanced diagnostic capabilities.

ValVue Standard Edition

ValVue Standard Edition software is downloadable and is used with each SVI FF for positioner calibration and configuration. ValVue Standard Edition software is freeware. It provides functions to properly set up and start up an SVI FF digital valve positioner on any type of control valve, along with diagnostics, Sequence, Audit Trial, and Monitoring Device. After a 30 day trail period the Sequence, Audit Trial, and Monitoring Device functionality will become inoperable.

Contact

For the most recent software visit our SVI FF web site at:

https://valves.bhge.com/resource-center

Operational Overview

The SVI FF is a smart electro-pneumatic positioner that:

1. Receives a digital setpoint from the controller and compares the setpoint input to the valve position reported by the position sensor.

2. Uses the position control algorithm to analyze the difference between the position setpoint and position feedback and sets a servo signal for the I/P converter.

3. Uses the output pressure of the I/P, which is amplified by a pneumatic relay that drives the actuator. Once the error between the setpoint and the valve position feedback is eliminated, no other correction is applied to the servo signal in order to maintain valve position.

The local explosion proof LCD/Buttons (if equipped) display provides information about the device. The LCD can display data from blocks on other devices, if the system is so configured. The switch board provides a user-configurable discrete output, which is optionally used to indicate different controller states.

14 | BHGE

SVI FF Features

The SVI FF Digital Valve Positioner is suitable for installation indoors or outdoors, and in a corrosive industrial or marine environment and is equipped with the following features:

 Extreme Accuracy, Reliability and Digital Precision

 Automated Valve Commissioning

 Precise, Quick, Responsive Control of Valve Position

 Valve Position Auto Tuning

 One Model for Rotary or Reciprocating Valves

 Local Operation⁄calibration⁄configuration with Optional Flameproof Push Buttons and

LCD Digital Display

 Compatible with Air-to-Close or Air-to-Open Actuators

 Non-contact Magnet Coupled (Hall Effect) Position Sensing for Rotary and

Reciprocating Control Valves

 Sealed Housing with No Moving Shafts, No Shaft Penetration, and Fully Potted

Electronics

 Uniform Hazardous Area Approvals for ATEX, FMc, and FM with Other Approvals

Available Upon Request

 Local, On-line Diagnostic Condition Monitor: Total Stem Travel, Number of Valve Cycles,

Predictive Maintenance Data

 Advanced Valve Diagnostics with ValVue Software and the Pressure Sensor Option

 User-adjustable Response Times

 Split-range Capability

 Configurable High and Low Position Limits

 Characterize Stroke:

Linear  Equal Percentage 50:1



 Equal Percentage 30:1  Quick Opening

 2 up to 21 Point Custom Characterization  Camflex Percentage

 Optimized Performance Regardless of Actuator Size

 Linearity Compensation for Actuator Linkages with ValVue Software

 User Configurable Tight Shutoff/Tight Open at Adjustable Input Threshold

 Remote Operation Calibration Configuration Diagnostics Using ValVue software or a

handheld communicator

 Single or Double Acting (not available for the High Flow version)

Masoneilan SVI FF Instruction Manual =| 15

Available Options

NOTE

Some of the options available for the SVI FF include:

 Remote Position Sensor

 A Contact Output User Linked to Various Status and Alarm Flags

 Offshore Construction - Stainless Steel Housing and Components

 Pushbutton Display

Characterization

A characterization defines the relationship between the input signal and the output position of the valve. The SVI FF has a five built-in characterization curves. The additional Custom characterization requires manually entering values and is only for experts and under special circumstances.

The characterization may contain up to 21 configurable XY pairs and the position is linearly interpolated between the pairs. The first position is always 0, 0 and the last position is always 100,100. You can specify how many points to define between the start point (0, 0) and the endpoint (0, 100). The points are added as xy pairs.

The algorithm posts a failure if the curve slope violates the slope limitations: x/y or y/x < 20.

When you change characterization type, the Transducer block and AO block must be in OOS and the system is de-energized.

Control Sets

The position controller is a type of non-linear PID control algorithm with eight parameters listed below, as well as Auto Tune and Custom.

The preferred method is Auto Tune, which automatically tunes the valve. Custom requires manually entering values and is only for experts and under special circumstances. A Custom control set with out of range PID parameters is rejected by the system.

Configure the parameters using the parameter name or using FF parameter. Also see the “Control Sets Configuration” on page 48.

When the characteristic is linear, the displays of position setpoint and target valve position all match. For all other (non-linear) characteristics the valve target position differs from the setpoint.

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Continuous Diagnostics

Alerts

Most systems monitor block errors and these can be linked for alert reporting in the DCS. See Table 31 on page 149 for a full list of Transducer blocks parameters used for configuration. Also see “Continuous Valve Diagnostics Concept” on page 231 for an in depth discussions of this topic.

Alert configuration is available for the following areas:

 Deviation alerts: You can configure a Deviation Value, a Position Error (Alert Point), a

Deadband around the Position Error and a Time before the alert is set. Active and historical alerts are indicated.

 HI, HI HI, LO and LO LO Alerts (): You can configure a desired Position, an Alert Point,

and a Deadband around the Alert Point. Active and historical alerts are indicated.

 Near Closed Alert: You can configure a desired Position Closed value and an Alert Point

in hours after which the alert is set. Active and historical alerts are indicated.

 Setpoint Timeout Alert: You can configure a desired Alert Point and Maximal Detect

Time. Active and historical alerts are indicated.

 Pressure Alarms for HI, LO and LO LO: You can configure a desired Position, an Alert

Point, and a Deadband around the Alert Point. Active and historical alerts are indicated.

 Temperature Alarms for HI and LO: You can configure a desired Position, an Alert Point,

and a Deadband around the Alert Point. Active and historical alerts are indicated.

 IP Output Alarms for HI and LO: You can configure a desired Position, an Alert Point,

and a Deadband around the Alert Point. Active and historical alerts are indicated.

 Travel Alerts: You can configure two sets of travel accumulation alarms based on an

Alert Point and a Deadband. Active and historical alerts are indicated.

 Counter Alerts: You can configure two sets of cycle counter accumulation alarms

based on an Alert Point and a Deadband. Active and historical alerts are indicated.

 Operating Time Alerts: You can configure an operating time alarms based on an Alert

Time. Active and historical alerts are indicated.

Masoneilan SVI FF Instruction Manual =| 17

Alarm/Alert Causes

Some causes of alarms/alerts include:

Low Supply Pressure  High friction



 Obstacle  Bad Tuning

 Valve Sticking  Position Alerts

 Position HI HI: Position Feedback Slip  Position HI: Process out of range or Control

 Position LO: Process out of range  Position LO LO: Position Feedback Slip

Trends

There are three trends available in the ValVue FF DTM or using a handheld device:

Travel Accumulation Trend Displays travel accumulation for the following areas:

Loop is not tuned

 Yearly Travel Accumulation Trend (%)

 Monthly Travel Accumulation Trend (%)

 Weekly Travel Accumulation Trend (%)

Cycle Counter Trend Displays cycle counter accumulation for the following areas:

Position Error Trend Displays a trend of average error over time. for the following areas:

Histograms

Position Histogram Displays how many cycles are spent in each 10% position increment

 Daily Travel Accumulation Trend (%)

 Yearly Cycle Counter (Counts)

 Monthly Cycle Counter (Counts)

 Weekly Cycle Counter (Counts)

 Daily Cycle Counter (Counts)

 Yearly Average Error Over Time

 Monthly Average Error Over Time

 Weekly Average Error Over Time

 Daily Average Error Over Time

There are two histograms available in the ValVue FF DTM or using a handheld device:

and to you can reset the total operating time for the histogram.

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Position Error Histogram Displays the position error as function of position and you can reset

the histogram.

Diagnostic Versions

There are two versions – Standard and Advanced. Table 1 illustrates the capabilities of each version.

Table 1 Advanced versus Standard SVI FF Diagnostic Versions

Feature Sub-feature Advanced Standard

Device States Positioner State XX

Configuration Control Configuration XX

Positioner Alert Log XX

Trend and Position Setup X-

Device State XX

Extended RB Configuration X -

Extended TB Configuration X -

Alerts XX

LCD Display XX

Calibration Find Stops XX

Auto Tune XX

Quick Wizard X-

Full Wizard X-

Diagnostics Step Test X-

Ramp Test X-

Signature Test X-

Histograms X-

Trends X-

Identification XX

Security X-

Print XX

Write Notes XX

Masoneilan SVI FF Instruction Manual =| 19

Block Modes

WARNING

Resource Block Modes

Resource block has two major modes:

 OOS – The block configuration parameters can be changed.

 AUTO – This is normal operational mode.

BLOCK_ERROR_DESCR_1 provides additional details if the target mode is AUTO and the actual mode cannot be switched to AUTO (stays in OOS).

Transducer Block Modes

You can request the block to switch to one of the following block modes by writing MODE_BLK.TARGET parameter:

ALL blocks are switched to OOS mode when the Resource block is switched to OOS mode.

When the TB is in OOS mode, the valve moves to its de-energized position.

 OOS – The device de-energizes the valve. This mode also may be necessary for setting

SETPOINT SOURCE, ACTUATOR_3.ACT_FAIL_ACTION and CHAR_SELECTION.TYPE, that can trigger a large movement of the valve if the valve is not de-energized.

 MAN – You are in control of the valve position. You can use this mode for most of the

configuration, maintenance and diagnostic procedures. If the SETPOINT_SOURCE=AO-Final Value, you can move the valve by writing a value to FINAL_VALUE parameter.

 AUTO – The valve is under FF blocks control. Depending on the configuration of the

SETPOINT_SOURCE, the SETPOINT is set from FINAL_VALUE, FINAL_VALUE_D or FINAL_VALUE_DINT.

Depending on the Transducer block configuration, valve position control and valve condition, the transducer block (MODE_BLK.ACTUAL) may be in one of the following states:

 OOS – This is an indication that the valve is in de-energized position. The valve cannot

be moved until the block is in this mode. The TB goes to OOS mode if one of the following condition exists:

 The Transducer block MODE_BLOCK.TARGET = OOS mode. You must change the

Transducer block target mode to make the device operational.

 The Resource block MODE_BLOCK.TARGET = OOS mode

20 | BHGE

 The device has detected an abnormal condition, that does not allow it to operate.

You must review the value of parameter 87.COMPLETE_STATUS for more

information about the reason for failure. You must correct the condition (e.g.

WARNING

connect the air supply if Air Supply Low error is reported or remove obstacle, stopping the valve if Actuator or Position Error is reported). When the condition is corrected, clear faults by writing the appropriate value to parameter

88.CLEAR_STATUS. In some cases you may need to restart the device.

 A failure condition exists in the valve position control algorithm that won’t allow the

valve to operate. Verify that state by reading parameter 74.FAILED_STATE. For more information see the previous point.

 You have set the device to Fault State from the local LCD display. Review this by

reading the value of parameter 86. APP_MODE. Correct the condition by switching the Application mode to Normal from the local display or by setting the parameter

86.APP_MODE to Normal.

Changing the Application to Normal mode may switch the TB to MAN or AUTO mode and move the valve. It may be dangerous if someone is still working with the valve.

 LO – This is an indication that the valve is controlled from the local display. Verify this

by reading parameter 86.APP_MODE – it has a value of Setup. Transfer the control back to the FF interface by switching the local LCD display to Normal mode. The mode can be switched remotely through FF, by writing to parameter

86.APP_MODE the value Normal.

Changing the Application to Normal mode may switch the TB to MAN or AUTO mode and move the valve. It may be dangerous if someone is still working with the valve.

 MAN – You are in control of the valve positioner. You can execute configuration,

maintenance and diagnostic procedures. If the SETPOINT_SOURCE=AO-Final Value, you can move the valve by writing a value to FINAL_VALUE parameter.

 AUTO – The valve position is being set from the function block, configured for that

purpose. The following cases are possible:

 SETPOINT_SOURCE=AO-Final Value, the Analog Output block is in control and

SETPOINT is set from FINAL_VALUE

 SETPOINT_SOURCE= DO-Final Value D in Open/Close mode, one of the Discrete

Output blocks is in control and SETPOINT is set from FINAL_VALUE_D.

 SETPOINT_SOURCE= DO-Final Value D in 1% steps mode, one of the Discrete

Output blocks is in control and SETPOINT is set from FINAL_VALUE_DINT.

Masoneilan SVI FF Instruction Manual =| 21

Overview of Available Tools

There are several different tools for use in configuring and operating the SVI FF including:

 Local pushbuttons and display: Uses the optional pushbutton and LCD display to

monitor, configure and operate the unit (see“Using the Pushbuttons and Digital Interfaces” on page 127).

 Handheld Communicator: Use any FF-capable handheld communicator, along with the

Masoneilan FF DD to control operations.

 SVI FF DTM: Use the Masoneilan DTM to operate the unit inside a DTM program such as

PACTWare or ValVue’s SVI FF DTM.

 Full ValVue software: Use the ValVue Suite software (see“ValVue Software” on page 14).

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Principle of Operation

The SVI FF Electro- Pneumatic Digital Valve Positioner receives an electrical position setpoint signal as depicted in Figure 2. The output pressure is amplified by a pneumatic relay that drives the actuator. When the valve position agrees with the value called for by the position setpoint input signal, the system stabilizes with no further movement of the actuator.

Figure 2 Block Diagram with I/P Converter and Pressure Sensor

Masoneilan SVI FF Instruction Manual =| 23

Physical and Operational Description

The SVI FF is housed in an industrial, tough, weatherproof, corrosion resistant aluminum housing that has been designed for operation in hazardous areas as listed in Appendix B. Electrical connections are made through two 1/2" NPT conduit entries. Pneumatic connections are made through two or three ¼" NPT ports.

Electronics Module

The Electronics module consists of an electronic circuit encapsulated in a housing. The electronics include a multiplexer, A/D, D/A, temperature sensor, Hall-Effect magnetic position sensor, pressure sensors, a micro controller, and a power management/distribution circuit. The programs controlling the SVI FF digital valve positioner are stored in a flash memory that allows for the downloading of upgraded firmware.

A separate non-volatile memory stores configuration information, and continuous diagnostic results. Expansion capabilities include connectors for the addition of the optional local display with pushbuttons. Using the internal programmed positioner algorithm, the CPU computes the required output based on information received from the measurement sensors. The base module has no user repairable components.

Magnetic Position Sensor

A non-contact sensor uses a magnetic field to transfer the position through the wall of the housing, without penetration, to sense the valve position. A Hall effect device, sealed within the electronics housing, senses the rotation of a magnetic assembly mounted on the end of a rotary valve shaft or on a driven linkage mounted on a reciprocating valve.

The output of the Hall sensor provides the position feedback signal to the position control algorithm. The magnetic assembly is environmentally sealed and is entirely external to the electronics housing (See Figure 26 on page 57). The Hall effect sensor has a maximum travel range of up to 140° rotation.

Position Display

The position sensor also provides, through the electronics module, a readout of valve position on the optional display and communication of valve position via FF protocol.

Pressure Sensor

The pressure sensor located in the Electronics Module measures the output of the single acting relay. The pressure measurement is displayed on the local display or read by an FF communication device.

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Temperature Sensor

A temperature sensor is located in the electronics module and measures ambient temperature. This measurement is used to provide temperature compensation for the position and pressure sensors and other internal electronic components. The temperature is read via the FF communication link to provide a warning of excessive ambient temperature at the positioner.

Output Switch

The SVI FF supports a contact output, SW #1 (Discrete Output switch), that can be logically linked to status bits. The Discrete Output switch terminal is a solid state contact. The switch requires its own power source and must be connected to the appropriate connector on the Electronics Module Terminal Board. See “Output Switches” on page 67.

Masoneilan SVI FF Instruction Manual =| 25

Pneumatic Module

Vent

Relay (Pneumatic Amplifier)

I/P Current to Pneumatic Converter

The pneumatic module consists of an I/P and Relay assembly.

Current-to-Pressure Converter, I/P

The I/P converts a current signal to a pressure signal in the following manner. A fixed coil creates a magnetic field proportional to the applied current. The field magnetically pulls a flexure towards a nozzle to increase pressure on the flexure. The pressure on the flexure increases in response to an increase in the coil current. Encapsulation of the coil provides protection from the environment.

Single Acting Pneumatic Relay

The single acting pneumatic relay amplifies the pressure from the I/P and increases airflow as required for stable, responsive, actuator performance. The single acting relay operates on any supply pressure that is at least 5 psi (.345 bar, 34.5 kPa) above the required actuator pressure, up to 150 psi (10.3 bar, 1034 kPa).

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Figure 3 SVI FF Pneumatic Module with Single Acting Relay

SVI FF High Flow

IP Current to Pneumatic Converter

Vent

Relay (Pneumatic Amplifier)

Figure 4 SVI FF High Flow Pneumatic Module with Single Acting Relay

Masoneilan SVI FF Instruction Manual =| 27

Double Acting Pneumatic Relay

I/P Current to Pneumatic Converter

Double Acting

Vent

Output 2 Gauge

Output 1 Gauge

Output 1 Act 1

Output 2 Act 2

Supply Inlet

Supply Gauge

Relay

The double acting pneumatic relay amplifies the pressure from the I/P and provides a pair of high flow output signals for operating a double acting cylinder actuator. The double acting relay operates on any supply pressure that is at least 5 psi (.345 bar, 34.5 kPa) above the required actuator pressure, up to 150 psi (10.3 bar, 1034 kPa). The two output pressures may be balanced by means of an adjustable seat assembly. The average of the two pressures is adjusted to equal 70% of the supply pressure. The double acting relay is rated for supply pressure to 150 psi (10.3 bar, 1034 kPa).

Figure 5 Double Acting Pneumatic Relay

Double Acting Supply Pressure Balance

After installation on the actuator, set supply pressure in accordance with actuator specifications. Do not exceed the maximum pressure rating of the actuator. The double acting relay is adjusted at the factory and set to 70% of supply pressure. If adjustment is required consult the factory.

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Optional Display and Pushbuttons

The optional display and buttons (Figure 6) are mounted on the SVI FF cover plate. The three pushbutton switches operating in conjunction with the display permit reading and modification of the instrument operating parameters without a PC or hand-held communicator. These switches perform generic functions - Increase, Decrease, and Accept by movement through a conventional menu structure, see“Using the Pushbuttons and Digital Interfaces” on page 127. The switches are operated in a hazardous environment without compromising the flameproof enclosure.

Link Active Scheduler

To use the SVI FF in a link active scheduler configuration refer to the documentation for the specific DCS.

Figure 6 Optional Display

Masoneilan SVI FF Instruction Manual =| 29

About This Manual

The SVI FF Instruction Manual is intended to help a field engineer install, setup, and calibrate an SVI FF in an efficient manner. This manual also provides in-depth information on SVI FF software, digital interfaces, operation, intrinsic safety configurations, and specifications. If you experience problems that are not documented in this guide contact the factory or your local representative. Sales offices are listed on the back cover of this manual.

Conventions Used in This Manual

Conventions used in this manual are as follows:

 Uppercase, italicized letters are used when referencing a term used in the SVI FF

display window. For example, when indicating the term mode, as in setup mode, and referring to the display/software operation the convention is to spell mode is all uppercase letters: MODE.

 Italics is used for emphasis on important items.

 Fields where data is entered or user-entered data is italicized.

 Actions performed on buttons, checkboxes, etc. appear bolded. For example: Click

Done.

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+ 234 hidden pages

GE Baker Hughes Masoneilan SVI FF Installation And Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

About this Guide

DISCLAIMER

Copyright

1. Safety Information

Safety Symbols

SVI FF Product Safety

2. Introduction

ValVue Software

ValVue Standard Edition

Operational Overview

SVI FF Features

Available Options

Characterization

Control Sets

Continuous Diagnostics

Diagnostic Versions

Block Modes

Resource Block Modes

Transducer Block Modes

Overview of Available Tools

Principle of Operation

Physical and Operational Description

Electronics Module

Output Switch

Pneumatic Module

Optional Display and Pushbuttons

Link Active Scheduler

About This Manual

Conventions Used in This Manual