Control Valves Selection

The Control Valves Selection Guide includes selection criteria, supplier profiles, and strategies to help process manufacturing organizations select the correct control valves and supplier for their unique operations and business requirements.

Consider Investing in Edge Computing to Maximize Process Performance and Uptime

Technical advances in edge computing are enabling centralized cloud-based dashboards designed to empower various stakeholders throughout the enterprise by providing real-time data essential to enabling proactive maintenance and ensuring maximum process performance while maximizing uptime. Some vendors are planning to enable data collection from digital positioners directly to the cloud using edge computing. Growing adoption of Ethernet APL with regards to process control and enabling direct access to field information relating to diagnostics and control valve performance anomalies into a centralize dashboard will allow maintenance and service teams to take immediate action to resolve anomalies as they occur, rather than waiting for these anomalies to result in an equipment failure.

Advances in data science, artificial intelligence, and computing power have converged in a “perfect storm” to enable the commercialization of algorithms that provide a human-like analysis of large data sets at machine speeds. These advances are allowing control valve suppliers to apply artificial intelligence capabilities in their digital valve positioners to provide more advanced warning of impending valve failure. With the increasing implementation of Industrial IoT across the process industries, holistic valve operation management is gaining more attention. Equipped with digital cloud solutions and cognitive analytical engines, the leading-edge control valve suppliers are developing holistic valve management services, including the remote monitoring of customers’ valves from a centralized location. Manufacturers trying to optimize their operations should consider investing in edge computing to facilitate greater process and equipment data analysis. 

Control Valves Selection Strategic Issues

Modular Plant Designs

End users should consider designing and building their plants in a modular fashion. Modularization breaks down systems, plants, processes, and unit operations into standard, modular components, much like those popular children’s building bricks that can be mixed and matched freely to make any number of different creations. While modularization is not a new concept for plants in the discrete and hybrid manufacturing industries, building plants in a modular fashion is even becoming practical for end users in the heavy process industries including petrochemical, refining, and power generation. For example, plants being built in the US are sourcing process modular components from countries such as Korea, Mexico, and the Philippines, which are then assembled on-site.

End users should consider modular approaches to automation because they offer significant cost savings both from a project standpoint and throughout the plant lifecycle. Modular approaches also offer a smaller footprint, easier regulatory compliance, and a path to open systems and standardization. It is no accident that end users are driving major industry initiatives—from ExxonMobil to Bayer—these companies heavily incorporate modular design concepts. Modularization concepts also fit quite well with existing standards activities such as NAMUR NE 148, ISA 106, and ISA 88.

Ensure Optimum System Performance

Control valves are prone to malfunction, often leading to losses due to leakages during continuous operations. Failure to actively monitor and avoid unaccounted leakages may lead to significant losses for companies in the heavy process industries. To avoid such losses, users should collaborate closely with suppliers during the installation, commissioning, and implementation phase to better understand any potential operational or maintenance nuances.

Remote Monitoring Services

As end users’ sites become increasingly remote and operations grow in scale, particularly within oil and gas midstream pipelines, the costs and risks associated with regularly dispatching valve maintenance personnel for routine servicing escalate significantly. In response, users are encouraged to consult with suppliers and system integrators to identify and implement advanced intelligent valve technologies that offer enhanced capabilities, such as remote monitoring and analytical functions.

Digital positioners with non-intrusive setting and commissioning, data logging, and data transfer functionalities are a viable solution for such a demanding remote application. The valve operating information can be recorded and transmitted to aid the user in evaluating valve performance, create an efficient asset management program, and schedule intrusive maintenance only when necessary.