Intelligent valve control and monitoring - Val · PDF fileIntelligent valve control and...

Intelligent valve control and monitoring

DVC-PL-001-03 - Intelligent Valve Controller

Intelligent Valve Controller

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Val Controls® A/S Intelligent valve control based on the latest know-how concerning digital technology for advanced valve control, monitoring and testing suited for pneumatic and hydraulic actuators. Our key task is to assist valve and actuator manufactures in finding the optimal solution for control, monitoring or testing of their products. We discover the best solutions for hazardous areas and harsh environments combined with cost reduction potentials. Index Introduction .................................................................................................................................... 2

Models ............................................................................................................................................ 3

Application...................................................................................................................................... 4

SIL .................................................................................................................................................. 5

Configuration .................................................................................................................................. 6

Diagnostic ...................................................................................................................................... 7

Power unit controller ...................................................................................................................... 8

Hardware features ......................................................................................................................... 9

Software features ......................................................................................................................... 10

Model selector .............................................................................................................................. 11


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Introduction The Intelligent Valve Controller (IVC) from Val Controls is a versatile controller for on/off valve systems. With this compact unit you can have on/off control, partial stroke test (PST) and hydraulic power unit controller (PUC) in the same unit. This controller can be offered as DIN rail or in a compact SS316, EX d enclosure. Configuration is done from a PC and is very easy to do with the user friendly software included. It can be done locally or remote via one of the built in communication types. Based on many years of experience with PST we have built this function in the product as standard. Now you have the opportunity to have a diagnostic of the valve, while it is in use. By performing a PST on a valve in operation and compare the performance data with the data from the reference stroke the current state of the valve system can be determined and the maintenance can be adjusted. With the included software, it is very easy to know the exact state of the valve system. Reports can be generated based on the measured data as documentation. Features:

Easy to install and configure

Automatic intelligent calibration

Different enclosures

Partial stroke test

Full stroke test

Solenoid test

Build in power unit controller

Local control panel

Third party SIL 1-4 approved

Multiple communication protocols

All software for control and diagnostics included

Price competitive

Ultra low power design

http://www.modbus.org/


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Models The Val Controls Intelligent Valve Controller comes in different models. Each model can be configured after customer requirements.

Flameproof This Flameproof is an IVC with a build in non-contact transmitter. It can be used for controlling and diagnosing on/off valve systems. The switchbox model is designed around a SS316 flameproof enclosure with Direct mounting. As an option limit switches can be mounted in the enclosure.

IVC24-F

Advanced and advanced flameproof This model is for customers with very high demands for performance and connection possibilities. This unit is very flexible and can be configured to almost any customers needs and can be easily expanded, e.g. with a backup battery or other advanced features. The Advanced Flameproof model is designed around a SS316 flameproof enclosure. It offers the same features as the Advanced model, but is very compact in the stainless steel enclosure.

IVC24-A

IVC24-AF


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Application

The IVC can be connected to a valve system as shown on the figure to the right. This setup allows the IVC to de-energize the solenoid valve, but can never interrupt an ESD. The “Operational” and “Fail position” buttons on the local control panel is for controlling the valve. The “Start test” button is for starting a PST and then the “Test in progress” lamp will turn on. After the test the result is shown to the user by the “Pass” and “Fail” lamp. Further analysis of the measured data is then carried out on a PC.

24 VDC ESD

Position sensor

Solenoid valve

Communication

T

Actuator

Valve

PASS

FAIL

TEST IN PROGRESS

ESD SOV

Local control panel

OPERATIONAL

FAIL POSITION

START TEST


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SIL

The IVC is designed to be used in safety instrument systems for partial stroke testing of emergency shut-down valves with no negative impact on the safety function. The IVC does not adversely affect the execution of the safety function. There exist two types of SIL circuits, which both are optional.

IVC with SIL expansion card This solution makes it easy to retrofit the IVC as no extra wiring is required. The unit is powered through the ESD line, which means that the IVC will lose power during an ESD.

Emergency shutdown controller

Emergencyshutdown

solenoid operated valve


ESD SOV (+)

ESD SOV (-)

ESD 24 VDC (+)

ESD 24 VDC (-)

24 VDC (+)

24 VDC (-)

IVC with SIL expansion card + extra 24 VDC When using an external power supply then the IVC can measure performance data in case of an ESD. This is beneficial as data from ESDs can be used to verify the status of the valve system.

Emergency shutdown controller

Emergencyshutdown

solenoid operated valve

Power supply


ESD SOV (+)

ESD SOV (-)

ESD 24 VDC (+)

ESD 24 VDC (-)

24 VDC (+)

24 VDC (-)


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Configuration

Setup of the unit is done from a PC by Val Controls – Configurator software. The digital in- and outputs connected to the local control panel can be set and easily adapted to the current system. All settings and limits for the tests can be set, such as valve travel for the PST.


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Diagnostic

A partial stroke test can be initiated from the local control panel or through a communication protocol. The unit stores the measurements from the last 10 tests of each type along with the data from the references. These data can be retrieved through a communication protocol to the control room for analysis and report generation. The reference partial stroke test is used to auto generate limits for errors and warning. These can be changed in the configuration.


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Power unit controller

The power unit controller can control a hydraulic pump to keep the pressure in the system within a specified range by monitoring the pressure in the system. Furthermore is the temperature of the oil, the level in the tank, and a safety relay monitored as safety functions to avoid damaging the system. The signals are used to determine when to turn the pump off, no matter what the pressure is. All inputs are optional.

Power output

Digital output (24VDC)

Safety timer Pressure input

High limit

Low limit

4-20 mA input

Switches (NO/NC) Level input

Low limit alarm

4-20 mA input

Switches (NO/NC)

Safety relay

Digital input (NO/NC)

Alarm Temperature input

High limit alarm

Low limit alarm

4-20 mA input

Switches (NO/NC) Control modes

Auto

Always on

Always off

Manual

Power supply

Communication

Hydraulic system

Pump

Pressure

Level

Temperature

ReturnSupply


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Hardware features Model A – Advanced AF – Advanced Flameproof F – Flameproof Analogue input

4-20mA sensors ●/5 ●/1

Position feedback

- Position sensor - 3-wire potentiometer ●

- Position loop - 4-20mA ● ●

Analogue output

Advanced 4-20mA transmitter loop ● ●

Transmitter (Non-contact) ●

Digital inputs

Digital inputs internal powered ●/4 ●/3

Power supply to unit 24VDC 24VDC

Digital outputs

Digital outputs ●/6 ●/3

Max power consumption per output 48W @24VDC 48W @24VDC

Limit switches ○

Digital outputs – Emergency Shutdown Controller (SIL)

Digital outputs ●/2 ●/1

Monitoring of power consumption ● ●

ESD detection ● ●

Max power consumption per output 48W @24VDC 48W @24VDC

Watch

Internal watch with battery backup ○ ●

Communication

HART v.7 ○ ○ Modbus RTU – RS-485 ○ ○ Foundation Fieldbus H1 ○ ○ Profibus DP/DPV1 Other communication protocols on request ○ ○

Wireless communication Bluetooth V2.0 ○ ○ Wireless HART ○ ○

Design

Temperature -40 to 85˚C -40 to 85˚C -20 to 55˚C

IP IP20 IP66/68 IP66/67

DIN-rail mounting EN 50022 ●

Flameproof - Ex-d IIC T6 – ATEX and IECEx ●

Flameproof - Ex-d IIC T6 – ATEX and IECEx with direct mounting ●

Limit switch

SPDT V3 Mechanical - 10 A @ 125 / 250 VAC, 0.5 A @ 125 VDC ○

SPDT Reed Type Proximity - Volts 500 VAC/ DC (Max.), Current 3 A (Max.), ○

V3 Namur Type Inductive Proximity - On I <1mA, Off I >3mA, 8 VDC Nominal ○

Standard = ● Extra option = ○


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Software features

The IVC range comes with the following software functions. Model A – Advanced AF – Advanced Flameproof F – Flameproof Functions

Automatic intelligent calibration ● ●

Manual calibration ● ●

Valve action – Direct/reverse ● ●

Spring Return or Double Acting actuator ● ●

Performance data, partial stoke test, full stroke test and solenoid test ● ● Installation, control, monitoring and diagnostic using IVC PC suite ● ● Manual control of valves and actuator ● ●

Error handling ● ●

Local control panel functions ● ●

- Manuel open/close – Operational/fail position ● ●

- Initiate test ● ●

- Test in progress indicator ● ●

- Open/Close indicator ● ●

- Pass/fail indicator ● ●

Advanced logging of performance and events ● ●

Power unit control

Output for starting pump unit ●

Motor safety relay ●

Max running time ●

Pressure monitoring

- 4-20mA pressure transmitter ●

- 2 x pressure switches – for on/off function ●

Level monitoring - low

- 4-20mA level transmitter ●

- Level switch ●

Temperature monitoring – high/low

- 4-20mA temperature transmitter ●

- Temperature switch ●



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Model selector The selector can be used for selecting the correct part number needed. Product name Type Communication 1 Communication 2 Expansion card 1 Expansion card 2 Expansion card 3 - Software features - Limit switch

IVC24 - A - B1 B2 C1 C2 C3 D E

A Type

F Flameproof ○ ○ ● ● ○

A Advanced ○ ○ ● ○

AF Advanced Flameproof ○ ○ ● ○

AFL Advanced Flameproof - Local Control Panel

○ ○ ● ○

B1 Communication 1

0 None

2 HART – Transmitter loop

3 Modbus RTU

4 Foundation Fieldbus H1

5 Wireless HART

7 Foundation Fieldbus H1 + 4-20mA transmitter loop

8 Profibus DP

9 Profibus DPV1

B2 Communication 2

0 None

1 Bluetooth

C1 Expansion card 1

1 Watch with battery

C2 Expansion card 2

0 None

3 Emergency Shutdown Controller (SIL)

4 Emergency Shutdown Controller (SIL) + extra 24VDC power supply

C3 Expansion card 3

0 None

D Software features

- None

E Limit switch

1 2 x SPDT V3 Mechanical

2 2 x SPDT Reed Type Proximity

3 2 x V3 Namur Type Inductive Proximity


Model example: Advanced version with Modbus and emergency shutdown controller – IVC24-A-30130


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Model selector – IVC24-F The selector can be used for selecting the correct part number needed. Product name Type Communication 1 Communication 2 Power supply - - Limit switch

IVC24 - A - B1 B2 C E

A Type

F Flameproof ○

B1 Communication 1

0 None

1 HART – Control loop

2 HART – Transmitter loop

3 Modbus RTU

4 Foundation Fieldbus

5 Wireless HART

7 Foundation Fieldbus H1 + 4-20mA transmitter loop

8 Profibus DP

9 Profibus DPV1

B2 Communication 2

0 None

1 Bluetooth

C Power supply

3 Emergency Shutdown Controller (SIL)

4 Emergency Shutdown Controller (SIL) + extra 24VDC power supply

D Limit switch

0 None

1 2 x SPDT V3 Mechanical

2 2 x SPDT Reed Type Proximity

3 2 x V3 Namur Type Inductive Proximity

4 2 x P&F NCN4-12GM35-NO

E Enclosure

S SS316

L SS316L

F Conduit entries

1 6 x M20x1,5

G Indicator

0 None

1 90° red closed/green open


Model example: Advanced version with Modbus and emergency shutdown controller – IVC24-A-30130

Val Controls A/S • Limfjordsvej 3 • DK-6715 Esbjerg N. • Tel. +45 7547 0600 • Fax +45 7547 0611 • [email protected] • www.valcontrols.com

CO

PSØ

A/S

, Oct

.200

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For further information: www.valcontrols.com

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