Revolutionizing Valve Maintenance

In industrial operations, ensuring reliability and reducing downtime are non-negotiable goals for maintenance teams. Emerson’s Fisher™ FIELDVUE™ Digital Valve Controllers, equipped with “The Big Three” diagnostics, offer a transformative approach to achieving operational excellence. These diagnostics—Supply Pressure Alert, Drive Signal Alert, and Travel Deviation Alert—are tailored to provide deep insights into process health, enabling teams to detect potential issues before they escalate and optimize overall plant performance.

“The Big Three” diagnostics empower maintenance teams to confidently transition from reactive to proactive maintenance, addressing key operational challenges while ensuring long-term equipment reliability.

What Are “The Big Three” Diagnostics?

“The Big Three” diagnostics work seamlessly together to provide a comprehensive picture of valve performance:

• Supply Pressure Alert monitors the air or gas pressure supplied to the valve actuator. By detecting fluctuations or drops in pressure, it ensures stable actuator operation, preventing performance disruptions.
• Drive Signal Alert ensures the valve moves as expected by monitoring the relationship between the drive signal and calibrated valve travel. If a mismatch between the commanded position and actual valve movement persists for more than 20 seconds, the alert is triggered, signaling potential mechanical issues, misalignment, or valve sticking.
• Travel Deviation Alert compares the commanded valve position to its actual position, identifying discrepancies caused by sticking, wear, or actuator issues. This insight allows for timely interventions, preventing costly process inefficiencies.

These diagnostics are a powerful combination that ensures maintenance teams have the tools they need to address problems early and safeguard critical processes.

Success Stories: Practical Benefits of “The Big Three”

Enhancing Stability in the Chemical Industry
During a major shutdown at a leading chemical production facility, “The Big Three” diagnostics proved instrumental. The Supply Pressure Alert identified fluctuating air pressure in valve actuators, allowing the maintenance team to quickly stabilize operations. Simultaneously, the Travel Deviation Alert highlighted minor misalignments in valve positions, enabling corrections that restored optimal performance.

Ramesh Tamilarasu, an Emerson Manager in Qatar, shared that this approach involved the diagnostic evaluation and optimization of 20 valves in a single cycle, delivering measurable results. By implementing “The Big Three” diagnostics, the facility reduced valve-related disruptions by approximately 30%, decreased maintenance costs by an estimated 20%, and improved overall system reliability, contributing to a significant increase in operational uptime. With operations back online faster than anticipated and running with enhanced reliability, the chemical production facility ensured consistent performance across critical systems, directly impacting the plant’s bottom line.

Preventing Downtime in the Energy Sector
In a prominent energy production plant, intermittent disruptions in control signals threatened operational efficiency. The Drive Signal Alert detected irregularities caused by faulty wiring, preventing what could have been a significant downtime event. Additionally, the Travel Deviation Alert identified sticking issues in several valves, allowing targeted maintenance during planned shutdowns.

These proactive measures not only resolved immediate issues but also ensured smoother, more consistent operations moving forward.

Creating Value in the Manufacturing Sector
In one notable case within the manufacturing sector, health checks powered by “The Big Three” diagnostics revealed inefficiencies that were subsequently addressed through lifecycle management solutions. This approach improved system reliability and showcased the measurable benefits of proactive diagnostics, reinforcing long-term customer trust and operational success.

Why “The Big Three” Is Essential for Plants Aiming To Improve Reliability

By adopting Fisher FIELDVUE DVC7K Digital Valve Controller or the legacy Fisher FIELDVUE DVC6200 Digital Valve Controllers with their strong diagnostic capabilities, maintenance teams can:

• Detect and resolve issues early, minimizing process disruptions.
• Optimize valve performance, ensuring consistent and reliable operation.
• Extend equipment life by addressing inefficiencies proactively.
• Enhance operational efficiency, reducing downtime and improving ROI.

The success stories from industries like chemicals, energy, and manufacturing demonstrate the immense potential of “The Big Three” diagnostics to revolutionize maintenance practices and deliver measurable outcomes.

A Pathway to Excellence

Emerson’s FIELDVUE Digital Valve Controller, equipped with “The Big Three” diagnostics, stands as a cornerstone for operational reliability in industrial plants. These diagnostics enable maintenance teams to uncover hidden issues, optimize performance, and achieve long-term plant success.

Whether your goal is to improve reliability, enhance operational certainty, or optimize maintenance practices, Emerson’s FIELDVUE Digital Valve Controller is the solution you need to stay ahead. Its innovative diagnostics, combined with real-world success, make it an indispensable tool for modern industrial maintenance teams.

Transform your maintenance practices today. Let Emerson’s FIELDVUE DVC 6200 and DVC7K “The Big Three” diagnostics elevate your plant’s reliability to the next level.