Streamlined pre-start preparation helps to shorten periodic repair periods
Since the preparation before starting up a plant is critical, it used to require several days of work by specialists. But with InnovativeField Organizer (IFO) and the control valve maintenance support system PLUG-IN Valstaff, our customers have been able to dramatically streamline inspections and testing in order to shorten the periodic maintenance period.
Streamlining loop checks Streamlining step response tests Streamlining interlock and sequence checking
Streamlining loop checks
Maximizing instrumentation maintenance efficiency, IFO carries out tasks that used to be dependant on multiple field technicians.
1. Analog input loop checks(e.g., 3 loops, 100 pressure gauges)
Conventional method
3days
Field technicians feed simulated input using a communicator, and an operator checks the result.
IFO-based method
2hours
Instead of field technicians, IFO obtains and monitors a variety of measurements.
2. Analog output loop checks(e.g., 5 points, round trip, 85 control valves)
Conventional method
2days
Field technicians check the actual opening of control valves against DCS output, and an operator changes DCS output manually.
IFO-based method
3hours
Instead of field technicians, IFO checks the actual opening of control valves against the DCS output. If OPC communication can be used with the DCS, instead of the operator, IFO automatically changes the DCS output.
3. Streamlining AO loop checks using Yokogawa PRM + Valstaff
Conventional method
An operator changes the MV from the DCS manually, and field technicians check the actual opening of the control valves in response to the MV from the DCS.
New method
Reduce man-hours by 90% or more
Instead of the operator, Valstaff automatically changes the output MV from the adjustment control block through Exaopc. Instead of field technicians, Valstaff checks the actual opening of the control valves against the MV output from the DCS through PRM using HART communication.
This function is available in Valstaff R51 and later
For details, please refer to our document “Users of Yokogawa Electric’s PRM can experience dramatically more efficient loop checking by Valstaff before restarting the plant after regular maintenance, or when expanding or modifying equipment!”
Streamlining step response tests
Valstaff performs step response tests to check whether valves open accurately and smoothly in response to commands. By plotting test results on graphs, Valstaff makes it easier to assess performance and to identify deteriorating control valves and incompatibilities. Since tests can be run automatically on multiple control valves simultaneously, you can significantly reduce the work-hours needed for periodic repair and inspection.
Stroke test of 42 control valves
using a conventional method
1day
2–3 workers needed, 1 in the control room and 1 or more in the field.
Testing by Valstaff
45min
Sequentially testing the listed valves, as many as 16 at a time, can save a lot of time.
Streamlining interlock and sequence checking
By using the IFO simulated input tool for sequence testing or interlock testing, you can command simulated input in a batch from IFO instead of sending simulated input at the production site or at the terminal board.
This tool eliminates the need for labor-intensive simulated input work, and helps make testing more efficient. In addition, there is a safety benefit. By eliminating wire disconnection work, it eliminates wiring errors that might occur when the instruments are reconnected.
Conventional method
Many workers are required for simulated input.
IFO-based method
Batch sending of simulated signals frees you from highly labor-intensive work.
Significant reduction in manpower
A must-see for those tasked with site improvement
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