FlowScanner Valve Diagnostic User Guide by RMC Process Controls & Filtration, LLC.

FlowScanner Valve Diagnostic System User Guide

FlowScanner, FlowStor, RatRace, Fisher, Fisher-Rosemount, and Managing The Process Better are marks owned by Fisher Controls International, Inc. or Fisher-Rosemount Systems, Inc. All other marks are the property of their respective owners.

D101939x012

Preliminary Manual

FlowScanner User Guide

While this information is presented in good faith and believed to be accurate, Fisher Controls does not guarantee satisfactory results from reliance upon such information. Nothing contained herein is to be construed as a warranty or guarantee, e pressed or implied, regarding the performance, merchantability, fitness or any other matter with respect to the products, nor as a recommendation to use any product or process in conflict with any patent. Fisher Controls reserves the right, without notice, to alter or improve the designs or specifications of the products described herein.

FlowScanner User Guide Contents Section

Title

Introduction

1.1 1.2

2 2.1 2.1.1 2.1.2 2.2 2.2.1

3 3.1

4 4.1 4.2 4.3 4.4

5 5.1 5.2 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.4.1 5.3.4.2 5.3.4.3 5.3.5 5.4 5.4.1 5.4.1.1 5.4.1.1.1 5.4.1.1.2

Page

Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

FlowScanner Description Hardware Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 FlowScanner, Transducers, Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 FlowAux Software Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 The Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Theory of Operation Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

FlowScanner Startup and Shutdown Background Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Startup Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Shutdown Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Wonder Plus (1 DIR +) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Setting Up for a Test Quick Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Setting Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Defining Nametags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Filling in a New Nametag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Saving and Printing Nametags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Retrieving a Nametag File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Using Drive G for Nametag Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Storing Nametags on Drive G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Recalling Nametags from Drive G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Erasing Valve Nametag from the Screen . . . . . . . . . . . . . . . . . . . . . . . 28 Exiting the Nametag Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Making Physical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Measuring Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Transducer Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Transducers for Sliding-Stem Valves . . . . . . . . . . . . . . . . . . . . . . . . . 29 Transducers for Rotary Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

FlowScanner User Guide 5.4.1.2 5.4.1.3 5.4.2 5.4.2.1 5.4.2.1.1 5.4.2.1.2 5.4.3 5.4.3.1 5.4.3.2 5.4.4 5.5 5.5.1 5.5.2 5.5.3 5.5.4 5.5.5 5.5.6 5.5.7 5.5.8

6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 6.15 6.16

7 7.1 7.2 7.3 7.4

Transducer Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Travel Feedback Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Measuring Pneumatic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Installing Test Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Temporary Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Permanent Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Supplying and Measuring the Control Signal . . . . . . . . . . . . . . . . . . . . . 41 Command Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Monitor Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Auxiliary Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Setting Test Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Dynamic Scan Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Static Point Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Step Change Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Stepped Ramp Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Step Study Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Pressure Channel Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Auxiliary Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Storing a RUNTEST File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Running a Test in Control Mode Quick Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Changing the Travel Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Setting Transducer Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Disabling Automatic Zero of Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Graphing Measured or Commanded Current . . . . . . . . . . . . . . . . . . . . . . 48 Specifying Test Line Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Selecting to Hold or Zero the Output at the End of the Test . . . . . . . . . 49 Controling the Valve Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Recording the Static End Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Zeroing Travel and Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Scaling auxiliary Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Starting and Stopping the Test Sequence . . . . . . . . . . . . . . . . . . . . . . . . . 53 Recording Test Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Saving Test Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Exiting the Test Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Disconnecting from a Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Running a Test in Monitor Mode Quick Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Changing the Travel Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Setting Transducer Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Disabling Automatic Zero of Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

FlowScanner User Guide 7.5 7.6

8 8.1 8.1.1 8.1.2 8.1.3 8.1.4 8.1.5 8.1.6 8.1.7 8.1.8 8.1.9 8.1.9.1 8.1.9.2 8.1.10 8.1.11 8.1.11.1 8.1.12 8.1.13 8.1.14 8.1.15 8.2 8.3 8.3.1 8.3.2 8.3.3

9 9.1 9.2 9.2.1 9.2.2 9.2.3

Zeroing Travel and Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Scaling auxiliary Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Displaying and Analyzing Test Results Display Program Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Starting the Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Choosing Test Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Returning to the MENU Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Printing Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Capturing Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Graph Cursor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Zooming a Graph View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Marking Data Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Graph Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Possible Data Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Limiting Analysis Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Dynamic Scan Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Measurement vs. Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Miscellaneous Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Static Point Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Step Change Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Stepped Ramp Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Step Study Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Transferring Data to the Report Module . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Copying and Displaying from the Display Program . . . . . . . . . . . . . . . . . 74 Saving Data to a New Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Saving Data as an ASCII File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Compressing Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Quick Reports Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Procedures Retrieving Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Saving Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Printing Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Parts List

Appendices

11.1 11.2 11.3

Appendix A: Data Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Appendix B: Software Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Appendix C: Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

FlowScanner User Guide 11.4 11.5 11.6 11.7

Appendix D: Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Appendix E: Connectors for Diagnostic Tesing . . . . . . . . . . . . . . . . . . . . 97 Appendix F: Tech Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Appendix G: Related Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Glossary

Index

FlowScanner User Guide 1

Introduction

1.1

Scope of Manual This manual describes: how to setup the FlowScanner, run tests in control and monitor modes, analyze the test results, run reports, and includes a complete parts list.

1.2

Description The FlowScanner Valve Diagnostic System is a portable test device used to evaluate a control valveâ&#x20AC;&#x2122;s current operating condition without disassembly and to recommend any necessary corrective action. It can also be used during setup and calibration before a valve is placed in service to ensure that the valve will function as intended.

FlowScanner Valve Diagnostic System Description

2.1

Hardware Description The FlowScanner Valve Diagnostic System from Fisher Controls is a portable, microprocessorâ&#x20AC;&#x201C;based diagnostic and calibration system specifically designed for use with process control valves. The FlowScanner System analyzes each pneumatic valve assembly as a complete process control package. This system also analyzes individual components such as the I/P transducer, positioner, actuator, volume booster, and other accessories. The FlowScanner System then determines critical valve parameters such as bench set, seat load, valve stroke, packing and bearing friction, and other relevant aspects of valve performance. For more information about the FlowScanner System, contact the Fisher Controls sales representative or sales office.

FlowScanner User Guide 2.1.1

Specifications

FlowScanner System Hardware Processor: 486DX2 50 MHz, or better Random Access Memory: 16 MB Hard Drive: 500 MB, or greater 3.5-inch Diskette Drive: high density 1.44 MB Display: Monochrome LCD fold-up screen (standard), or Color, LCD (optional(1)) Keyboard: 82 keys with membrane cover Operating System Software MS-DOS operating system with DOS shell, Windows for Workgroups 3.11 and pointing device, FlowScanner software installed and configured for testing sliding stem and rotary valves Power Supply AC Power: 90 to 250 volts ac, 50–60 Hz Internal Battery: 7 amp-hour 12 volt Gel-cel provides 3 to 4 hours operation per charge(1). Charges internally from AC source in approximately 4 hours. Inputs 15 inputs: –6 pneumatic channels accept up to 100 psi signals, –2 pneumatic channels accept up to 30 psi signals, system records data on any 6 channels–5 auxiliary channels accept –10 to +10 volt dc signals, common ground –Monitor control signal accepts 0 to 55 mA or 0 to 10 volts dc, use to monitor FlowScanner system control signal or an external control signal –Travel, linear up to 30 inches (sliding-stem) or 360 degrees (rotary) Control Signal Output FlowScanner system provides a control signal of 0 to 25mA, 0 to 55mA, or 0 to 10 volts dc Computer Outputs External VGA color monitor port Parallel printer port Two RS-232 serial ports

FlowScanner User Guide Specifications Continued Accuracy Control Signal Output Accuracy Range

Loop Command Accuracy

Measurement Accuracy

0 to 25 mA 0 to 55 mA 0 to 10 Vdc

0.02 mA 0.03 mA 0.01 volts

0.03 mA 0.03 mA 0.01 V

Travel Input Accuracy Range

Resolution

Overall Accuracy

0 to 2 inch (0 to 50.8 mm)

0.0001 inch (0.0025 mm)

0.0001 inch ( 0.0025 mm)

0 to 4 inch (0 to 101.6 mm)

0.0001 inch (0.0025 mm)

0.0001 inch ( 0.0025 mm)

0 to 25 inch (0 to 635 mm)

0.0001 inch (0.0025 mm)

0.0001 inch 0.012% full scale ( 0.0025 mm) 0.012% full scale)

0 to 32 inch (0 to 812.8 mm)

0.001 inch (0.025 mm)

0.001 inch 0.05% full scale ( 0.025 mm) 0.05% full scale)

Rotary

0.0075 degree

Pneumatic Input Channel Accuracy Pressure Range

Resolution

Accuracy w/10 Min. Warm-Up & Within 20 Min. of Re-Zero

Accuracy w/2 Min. Warm-Up

0 to 100 psi 0 to 689.65 kPa)

0.04 psig (0.27 kPa)

0.1 psig + 0.2% of reading 0.68 kPa + 0.2% of reading

0.1 psig + 0.7% of reading 0.68 kPa + 0.7% of reading

0 to 30 psi (0 to 206.90 kPa)

0.01 psig 0.07 kPa)

0.03 psig + 0.2% of reading 0.2 kPa + 0.2% of reading

0.03 psig + 0.7% of reading 0.20 kPa + 0.7% of reading

Note: Also configurable to kg/cm2, Bar

Housing Haliburton metal case with O-ring seal Hazardous Area Classification None

FlowScanner User Guide Specifications Continued Pressure Connections Tubing: 1/8-inch OD, 1/16-inch ID (Parker p/n NB2-031, no substitutes) Removable Fittings: Parker ”Prestolok” Permanent Fittings from Factory: Swagelok quick connect (p/n B-QC4-B-2PM) (1/4-inch chrome-plated brass) Swagelok plug, body protector (p/n B-QC4-BP) (1/8-inch mating fitting) Note: for Stainless steel, change first alpha character, ”B” to ”SST” Approximate Weight 35 pounds (15.9 kg) Options spare battery and external charger package; remote pressure scanner adapter with 25 feet (7.6 m) of cable; removable keyboard with LCD display and 5 feet of cable; input conditioning card with 5 isolated input channels, configurable 0 to 55 mA or 0 to 10 Vdc; ValveLink Type VL2020 software(includes HART modem) 1. The optional color LCD display shortens average battery life to two hours due to increased power consumption

FlowScanner User Guide 2.1.2

FlowScanner, Transducers, Tool Kit The accessory kit contains the necessary hardware required to facilitate setup and data collection. The kit allows for the ease of transducer attachment to any operated valve (sliding stem or rotary) regardless of manufacture. The following items are included in the kit: Rugged polyethylene case 25-inch Celesco travel transducer (sliding stem valves) C25 DRC travel transducer (rotary valves) Travel transducer mounting brackets (4) Adjustable jaw vice-grip (Bessi Clamp) Std. 10-inch vice-grip (travel feedback arm) SPI Fisso Support Arm Flex Coupling Double stick tape 1/8-inch pressure tubing Pressure fittings Attachment screws Assortment of wrenches Assorted screwdrivers

2.2

FlowAux Software Description FlowAux software for the Fisher FlowScanner Valve Diagnostic system is designed to allow all normal valve testing plus additional data acquisition on the 3 to 5 auxiliary input data channels. FlowAux can be installed on a FlowScanner without replacing the original (2.3) system software. FlowAux creates new subdirectories on the hard disk and is run from new commands, so the original FlowScanner programs can still be used.

FlowScanner User Guide The distribution disk contains installation programs for the FlowScanner. It can only legally be installed on systems for which a license was purchased.

Note The software package contains two programs: a sliding stem application and a rotary valve application. Although these programs vary in appearance, they are similar in function, and the differences merely reflect the operational differences between the two valve styles. Because the two programs function so similarily, this manual will try to cover both versions and only mention one or the other programs when specific differences are applicable to the discussion.

A main menu starts when either the SLIDAUX.BAT or ROTAUX.BAT files are run. These files are placed in the 1APP directory of the FlowScanner. The other portions of the FlowScanner programs are selected from the main menu by moving a highlight bar with the keypad arrow keys.

2.2.1

The Main Menu

FlowAux Main menu

The main menu screen selects the various FlowScanner programs:

FlowScanner User Guide Start—Look at—or Change a Valve Nametag Identify the valve, actuator, accessories and plant site Select—View—or Change a Test Setup Select the test type and enter testing parameters Display and Analyze Test Data Review test results and manipulate the data as necessary Prepare a Test Report Display test data in report format Format a Data Disk Format a floppy diskette for data storage Record Data Drive and Operating Defaults Set default preferences for operation and data storage The up and down arrow (cursor) keys will move the highlight bar to the different choices, and pressing Enter will select the highlighted choice. Alt–V will toggle video between color and monochrome, and Alt–S will check space on a data disk. You will notice that every menu item and selection choice has one letter that is highlighted, you can type that letter either by itself, or incombination with the Alt key, to make that selection.

Theory of Operation

3.1

Description The FlowScanner is a data acquisition system used as an integral part of a condition-based maintenance program or as a valve troubleshooting device. The FlowScanner system allows multiple data acquisition inputs that a FlowScanner system operator can use to determine the overall efficiency of the control valve asset.

Note Best results are obtained if the system is operated by a Fisher factory-based engineer/technician or a Fisher factory-trained person.

FlowScanner User Guide The first step in determining a control valve assetâ&#x20AC;&#x2122;s efficiency always starts with a review of the application. Based on the operation history of the valve in question, a determination of the type of test to be run is made. This is typically a dynamic error band test. For a description of test types, see section 9. Serial cards and customer records are collected and reviewed to determine the valve construction and operating parameters. Any potential application problems are identified at this time (e.g., is the right valve being used for the right application). The next step involves a FlowScanner survey of the valve in question. This is normally a two-minute stroking test (test times vary depending on type of test and size of actuator). See section 6, for test setup guidelines. The test can be performed with the valve in control mode or monitor mode. The system normally measures the pressures at the positioner guage block via quick connect fittings. If no quick connection are installed on the valve, you can use tee connections into the instrumentation line. Valve travel is measured off the valve stem with a digital encoder. A control signal connected to the valve input (mA, volt, psi) strokes the valve through one cycle. The system then generates â&#x20AC;?signatureâ&#x20AC;? data curves and a summary report covering parameters like: benchset, seat load, valve stroke, packing friction, bearing friction, stroking time, dynamic response, actuator spring rate, air supply (pressure & volume) positioner dynamic response and I/P dynamic response. This data can then be interpreted by a factory-trained engineer/technician to determine the overalloperating efficiency of the valve assembly and can be used to determine the necessary corrective action. For additional information concerning data interpretation, ask your local Fisher Representative or Sales Office about Fisher Education Center Courses, #1425 and #1426.

FlowScanner User Guide

A6204-1/IL

FlowScanner Diagnostic System Test Connection Schematics

FlowScanner User Guide 4

FlowScanner Startup and Shutdown

4.1

Background Information The hard drive for a FlowScanner is partitioned into a C: partition and a D: partition. The C: partition contains the operating system, the FlowAux program directory, and the other application programs that are needed for the computer. The D: partition is used for data storage for the FlowScanner. With the D: partition, there are three directories that are created during the software installation. One is the \TEST subdirectory, the second is the \RAMRAUX directory, and the third is the \RAMSAUX directory. On the C: drive, the software creates the \FLOWAUX top level directory, beneath that is created a subdirectory called \SLIDSTEM and a subdirectory called \ROTARY. The software also creates a top level directory called \1APP. Within the \1APP directory, there are two startup files, ROTAUX.BAT and SLIDAUX.BAT. When a FlowScanner starts up, the CONFIG.SYS file and the AUTOEXEC.BAT files are run. The CONFIG.SYS file initializes two RAM disks. (A RAM disk is a portion of the computerâ&#x20AC;&#x2122;s RAM that operates like an additional hard drive). There are two advantages of using RAM disks instead of the hard drive: 1) much faster program access and 2) less power consumption. When the RAM disks are initialized, they are recognized as drive E: and drive F:. There is also a command in the FlowScannerâ&#x20AC;&#x2122;s AUTOEXEC.BAT file that substitutes the D:\TEST directory as drive G:. The FlowScanner program can only access data at the root directory of any drive. By making the substitution, you can store data within a subdirectory on the D: drive by selecting the G: drive as the data directory.

4.2

Startup Procedures There are two versions of the FlowAux program, for sliding stem valves and rotary valves. The following discussion refers to the sliding stem valve program, but these procedures are applicable for the rotary valve program also.

FlowScanner User Guide From the FlowScanner’s main menu, choose the letter O or go down to ”Record Data Drive and Operating Defaults” to get to the ”Operating Defaults” display. The upper left hand choice is Program Drive and for a FlowScanner this should be drive E:. The Data Drive should be drive A:, if using the floppy disk or drive G:, if you are storing data to the hard drive. The third line down says Temporary Storage (RAM disk). This should be drive F: for a FlowScanner. To start the sliding stem version of the FlowAux program, you need to run the file, SLIDAUX.BAT, found in the C:\1APP directory. First, the sliding stem executable programs and support files are copied from the C:\FLOWAUX\SLIDSTEM directory to the E: RAM disk. You will see the command lines scroll across the screen as these files are copied. Next, any data stored in D:\RAMSAUX from the last test is copied to the F: RAM disk. After all the files are copied to the RAM disks, the FlowAux MAINFS.EXE program is executed. While you are running the FlowAux program, updated versions of the various files are being created (e.g., test setups and calibration files for the current session). These new files reside in the RAM disk and will be lost, along with their settings and configurations, if the FlowScanner is powered off without following the proper shutdown procedures. (At this point, test data has already been stored to the A: or G: data drive, so this data would not be lost.) To preserve these files when testing is done, you need to copy the contents of the RAM disks back to the hard drive.

4.3

Shutdown Procedures As mentioned above, you must copy the data in the RAM disks back to the hard drive before powering off the FlowScanner, to avoid losing data from the current session. This is done by selecting ”Prepare for System Shutdown” from the Main Menu (or by pressing Alt-X). This initiates the system shutdown, which copies the files from the RAM disks back to the hard drive directories.

FlowScanner User Guide The rotary version of the software uses the same procedures described above. The difference is that the program files are executed from the C:\FLOWAUX\ROTARY directory instead of the C:\FLOWAUX\SLIDSTEM directory. The contents of the RAM disks are stored in the D:\RAMRAUX directory instead of the D:\RAMSAUX directory. The same A: or G: data drive is sued for both sliding stem and rotary valve files. The rotary program executes MAINROT.EXE after the files are copied to the RAM disks instead of MAINFS.EXE. Besides these minor differences, the startup and shutdown procedures are the same.

4.4

Wonder Plus (1 Dir +) The FlowScanner uses Microsoft DOS v6.22 as an operating system. To facilitate the use of the computer by non-computer literate users, there is a DOS menu program called ”Wonder Plus” or ”1 Dir +” that simplifies the startup procedures. When a FlowScanner is first booted up, it performs a memory test and then starts MS-DOS. After the CONFIG.SYS and AUTOEXEC.BAT files execute, the Wonder Plus program starts. The Wonder Plus interface appears as a series of boxes filled with various types of information about the computer, such as: memory usage, file listings, etc. Function keys are across the bottom of the screen. The names of the files in the current directory are listed in the left-hand box. The path to the current directory is displayed across the top of the Wonder Plus screen. When the program first starts, the path says C:\1APP. By using the up and down arrow keys, you move the word to the left-hand column that says ”Compose.” You move ”Compose” down to select either the SLIDAUX.BAT or ROTAUX.BAT depending on the version of the program you want to run. Press the <Enter> key to start the selected .BAT file. When the session is finished and the the shutdown procedure is completed (the RAM disk files have been copied back to the hard drive), the screen displays the contents of the C:\1APP directory. At this point the FlowScanner can be safely powered off.

FlowScanner User Guide 5 5.1

Setting Up for a Test Quick Reference More detailed instructions follow this section, but here is a quick overview of the operating sequence to test and report on a valve: 1. Check to see that all switches are off. Start the system according to the instructions in section 4.0 of this manual. 2. Check that Operating Defaults are set properly. 3. If necessary check or re–calibrate the pressure scanner or control current with the Calibrate program from the main menu. This is normally necessary only once or twice per year. 4. Verify that operating defaults are set properly. 5. Insert a data disk, and format it if it is unformatted. The ”Format” menu choice will let you choose between 720 KB and 1.44 MB formats. You can purchase pre–formatted diskettes and save time. 6. Select the Valve Nametag program and fill in all data for the nametag. Items marked on screen with an asterisk (*) are used in analysis, and must be filled in for the program to calculate results. If preferred, the nametag can be saved ”blank” with only a TAG number assigned for file name, and the rest of the data filled in after testing. However, before the data can be analyzed the nametag data must be completed and the revised data read into the analysis program. Save the Nametag to the data disk and print it if desired. It is often faster to complete this ahead of time from the serial card. 7. Return to the main menu and select Test Setup. Pick a pre–defined setup (stored on the system hard disk) for a standard test, or complete all entries for a new setup. Be sure to specify the travel transducer used, and assign the pressure channels to use for each parameter. If auxiliary input channels are used fill in descriptive names for the channels to be used. 8. Save the setup / valve combination to the RUNTEST file as prompted when exiting the Setup screen to the Main Menu. 9. Select the Test program from the main menu. Before applying pressure Zero the pressure readings with Alt–Z. 10. Connect the pressure tubing from the system to the valve test points (as defined in step 4). For repeated testing you may install test connections behind the positioner gauges.

FlowScanner User Guide 11. Mount the travel transducer to the valve assembly so it measures the stem travel. Typically the transducer is mounted to the actuator casing. 12. Connect the control cable to the I/P. 13. Connect the control cable to the FlowScanner system. 14. Using the keypad arrow keys stroke the valve to assure all is connected properly. Check that the pressure readings agree with the labels, and that the travel reading returns closely to zero. (Sometimes you may not want to stroke the valve first, if testing for sticking or a condition which could be affected by repeated stroking.) 15. Run the test. (F9 starts the test.) 16. Save the data to disk. (It is also possible to view the data from the RAM disk before deciding to save to the data disk.) At this point you can either view the results and make adjustments while connected to the valve, or disconnect from the valve. The data can be analyzed later if you want to test other valves first. The analysis and printing can be done on a suitable desktop PC, using RatRace Desktop Analysis Software, if desired. We recommend at least a cursory review of the graphs while still connected to the valve to insure that the data was properly collected and stored. 17. Return to the main menu and run the Display and Analyze program to view the data. Connect the printer and print any graphs (F5 or F6 to print) and analyses desired. 18. Save the analysis data to a report file. 19. Return to the main menu and run the report program. Read in the test report file and add comments to the results as indicated. Print the quick report if desired. 20. Save the report with comments to the data disk. 21. Return to the Main Menu and select â&#x20AC;?Prepare for System Shut Downâ&#x20AC;? before shutting off the power. This saves the information stored temporarily in memory to the hard drive for retrieval when you reâ&#x20AC;&#x201C;start the program. 22. Shut off the System as described in section 5.0 for that model.

5.2

Setting Defaults When first using FlowScanner, the Operating Defaults must be set. The Operating Defaults choice from the Main Menu lets you set the

FlowScanner User Guide default data drive, nametag file type (by Serial number or Tag number), whether or not to use a data RAM disk, whether or not to automatically save the test data upon test completion, whether or not to automatically analyze and print the graphs, and what type of graphics printer to expect, and what engineering units to display. The Operating Defaults screen looks like this:

Operating Defaults Screen

The program drive is set automatically when the program is started. The program drive can no longer be changed in the defaults screen. Set the data drive to the letter for the 3 1/2” Floppy drive. (Typically ”A” on FlowScanners) Data is normally saved by TAG number instead of a Serial number, but either can be used. If saved as a serial number only numeric digits can be entered. (The actual disk file will be named by an encoded number, but the pop–up menus will show the serial number as entered.) The F2 key will pop–up the menu to select either TAG or SERIAL defaults. This determines where all programs will look for the nametag files. The Temporary Storage drive on a FlowScanner should be set to “F” but on a desktop it is used only if you have created a RAM disk for that purpose. This allows the programs to run slightly faster. To disable temporary storage set the RAM disk to X. The Auto Save Data and Auto Print Graphs are normally set to ”N”o. If set to ”Y”es, the data will be automatically saved after it is taken and graphs will automatically be printed on analysis. Press the F2 key and pick the type of printer you will normally use to print graphs. (This setting has no effect on text printing for reports.)

FlowScanner User Guide You can over–ride this setting from the Printer menu in the Display and Analyze program. Select the units to use for pressures, linear travel, and force from the three pop–up menus. (F2 recalls all menus when the cursor is on the field location.) For pressures the possible choices are: psi, kPa, kg/cm2 and bar Displayed Travel Units can be set to inches or mm , and Displayed Force Units can be set to pounds (LBS), Newtons (N), or DecaNewtons (DN). The video mode can be toggled between Color and Monochrome by pressing Alt–V. The mode set when exiting the defaults screen will be used by all programs. After setting the defaults, Alt–X will save the default file and return to the main menu.

5.3

Defining Nametags The software needs to know details about the valve in order to analyze results. This information is entered as a valve nametag. The information from the nametag file is read each time the test data is selected, so corrections may be made to the nametag after testing, and they will be used in subsequent analysis. However, a nametag file must be saved for reference before a test can be run on a valve.

Sliding Stem Valve Nametag Screen

The nametag screen appearance and fields will differ slightly between the Rotary and Sliding Stem programs to reflect the operational differences between the two valve styles

FlowScanner User Guide

Rotary Valve Nametag Screen

The units shown on the various fields will match the units selected in the operating defaults screen. The file is always saved in US units, but the display and printouts will match the default units. The cursor should be flashing on the first character of the â&#x20AC;?Plant Siteâ&#x20AC;? field. Items marked on screen with an asterisk (*) are used in analysis, and must be filled in for the program to calculate results.

5.3.1

Filling in a New Nametag The nametag is filled in three sections: The valve data, the actuator data, and the accessory data. First fill in the Valve data. Move between sections by pressing the PgDn and PgUp keys. If you question what is required for a field, pressing the F1 key will bring up a help screen describing what is needed.

F1 Help Screen for Body Style Field

FlowScanner User Guide The Plant site is a reference field (not required) for your later identification of the data. Pressing Enter after an entry will move to the next field, or you can move between fields with the up and down cursor keys. An identifying description can be entered in the Description field. The TAG number is also used as the filename to store the nametag data on the disk. The first 8 characters only are used for the filename, and illegal characters (spaces, periods, etc.) are replaced by underscores in the file name. If possible, be consistent by using only letters and numbers in the TAG # field. This is the only field required to take test data Enter the Serial Number in its field (the serial number field will only accept numerical characters, no alphabetic characters allowed) If the accessories also have serial numbers they can be reference in the Comments fields (accessed by pressing Alt–C). The Body Type field will pop up a menu list of Fisher body types.

Sliding Stem Body Type Pop-Up Menu

Move through the list with the Up & Down arrow keys. Press Enter when the desired choice is highlighted to enter it into the field. For non–Fisher types press the Esc key to exit the menu and allow you to type in an entry. Once an entry has been made the menu will not pop up automatically when you move back to the field. It can be recalled by pressing the F2 key when the cursor is on the field. (This is true for all fields which have pop–up menus.) Next fill in the body size and class from the pop–up menus in the next fields.

FlowScanner User Guide The trim fields can be filled with any text string, as this field is not used for later calculations. They are typically used to describe the the materials of construction, characteristics or special designs. Select the flow direction, and indicate if flow tends to open or close the valve. On the Sliding Stem program, the field for BALANCED or UNBALANCED construction may be selected automatically if the body type and size so indicate. If the software canâ&#x20AC;&#x2122;t decide the construction a menu will be offered, otherwise the field is filled in and skipped. Select the port diameter, stem diameter, and packing type from the next menus. The Friction fields will normally be filled in by the software. (For the EHD, the added friction for the piston rings is filled in after the line pressure entries.) Select the leak class and seat type from the menus. If the valve is on Boiler Feedwater service, select the Feedwater leak class. This will use the Feedwater tables from Fisher Catalog 14 to specify the seat load. Pressing F1 with the leak class menu visible will bring up a table of standard leak classes for Fisher valves: Enter the specified inlet pressure and outlet pressure in the units selected.

Sliding Stem Leak Class Help Screen

The required seat load will then be calculated and filled in, based on the previously entered data. See Section 3.1. Enter the specified travel. Fractions entered will be converted to decimal.

FlowScanner User Guide The stoking time fields are for reference if there is a customer requirement. When the Valve section is complete, press PgDn to move to the Actuator section, and select the actuator type and size from the menus. Also select whether actuator air pressure opens or closes the valve. These entries are used in determining seat load and friction. Enter the specified bench–set from the nameplate. This will be compared to the measured bench set later. The software will fill in the effective area for Fisher actuators on the menu, if the Type and Size were selected from the pop-up menus. For other types the effective area must be manually entered before the valve is tested, as it is used in calculations. Press PgDn again to move to the accessories fields and select the I/P type and fill in the output range. Select the I/P input type (use psig if no I/P is used). Fill in the I/P resistance if the control current will be monitored through the I/P voltage. Select the positioner model (reference only). Specify whether the valve is in the Open or Closed position when zero control signal is applied. This field overrides all other choices to label the graphs. Note any other accessories in the Other fields. Enter longer comments (i.e., 2 lines or >50 characters) by pressing Alt–C for a comment window.

5.3.2

Saving and Printing Nametags Pressing F10 will save the completed nametag to the data disk under the TAG # as a filename (unless the operating default is set to Serial Number). The tag can also be saved by accessing the File menu (Alt–F); where existing nametag information can also be read off the disk and displayed or changed. From here it can be saved as either a nametag or serial number. The nametag can be printed by pressing F6 or Alt–P. You will then choose to print to the screen (for preview) or to the printer. Be sure the printer is properly connected and turned on before trying to print.

5.3.3

Retrieving a Nametag File Nametag file already stored on the data disk can be read back in from the File menu, selected by (Alt–F). Select either Tag Number

FlowScanner User Guide or Serial Number from the menu (Field data is normally saved as a Tag Number), and a list of nametags found on the disk under that file type will appear. The Sliding Stem program will not show Rotary nametags and viceâ&#x20AC;&#x201C;versa, and if you selected Tag Number files any saved as Serial Numbers will not show on the list. Use the cursor keys to select the file you want and press Enter to read the file and display it on screen. You can make changes and save the file again, and the changes will be reflected when you analyze data or print reports. If you want to set up another test for a valve already tested you must read in the nametag before setting up the test.

5.3.4

Using the Drive G for Nametag Storage If you have defined a data area of a hard drive or network drive as Drive G, it can be used to store a large group of Nametag files so they can be retrieved for any valve whenever they are needed. The software can currently access up to 500 sliding stem plus 500 rotary valve nametags. There are some special procedures to make this storage easier.

5.3.4.1

Storing Nametags on Drive G To store the tags only on drive G first set the Operating Defaults (off the Main Menu screen) to use drive G as the data drive while you fill in and save the nametags. Once all the nametags are stored, set the operating defaults back to the floppy drive as the data drive. To fillâ&#x20AC;&#x201C;in and store nametags on both a floppy disk and the hard drive, leave the Data Drive set to the floppy drive and fill in the nametag. Pressing F10 saves it to the Floppy disk (as either a Tag Number file or Serial Number file as set in the Defaults), and pressing F8 saves to G. If you have a group of nametags on a floppy disk you can use DOS to copy files with the extension T@G, SER, RRG and SRR from the floppy to drive G.

5.3.4.2

Recalling Nametags from Drive G You can recall nametags from Drive G even if you are using the floppy drive to store data. Start with a blank nametag and type either in the tag number or serial number under which the tag is stored, leave the cursor on that field and press F9 and the tag will be read in. (Pressing F9 causes the program to look for either the tag number or serial number depending on which field has the cursor.) The File menu also has a choice which will list the tags on the hard

FlowScanner User Guide drive by either Tag number or Serial number. If you are saving data to floppy disks, save the nametag to the floppy after calling it up from drive G. 5.3.4.3

Erasing Valve Nametag from Screen If you have made a mistake in entering the nametag data, you can erase the data from the screen and start again from scratch by pressing Alt-F

5.3.5

Exiting the Nametag Screen Exit the nametag program by pressing Altâ&#x20AC;&#x201C;X. From the exit menu you can go directly to the Setup Test screen, go back to the main menu or .

5.4

Making Physical Connections

5.4.1

Measuring Travel

5.4.1.1

Transducer Selection A variety of transducers and mounting techniques are available for the different types of valves that may be encountered. Because travel is a key diagnostic parameter, it is essential that a solid connection be established when mounting the transducer.

W6671

Complete Family of Transducers for the FlowScanner

FlowScanner User Guide 5.4.1.1.1

Transducers for Sliding-Stem Valve

Celesco Cable Transducer

W6670

W6673

Celesco Cable Transducers

The long stroke transducer comes in two varietites and can measure up to 25 inches. The 25-inch Celesco is the standard transducer provided in the accessory tool kit. The resolution of this transducer is0.0001 inches. The 50-inch Celesco is also available, with a resolution of 0.001inches. The transducer should be mounted so that stem movement will extend the cable and so that the cable is parallel to the stem. The cable must be securely attached to the feedback arm. The transducer is typically mounted to the actuator casing so the stretching of the yoke legs is detected at shutoff Linear Transducer

W6675

2-inch DRC

The DRC transducer (also available) will measure stem travel less than 2 inches. The resolution of this transducer is .0001. The trans-

FlowScanner User Guide ducer must be mounted so that stem travel will deflect the probe. The transducer must be securely mounted with the probe parallel to the valve stem and so that it can move freely with the movement of the valve stem. Nonâ&#x20AC;&#x201C;parallel mounting will cause the probe tip to move slightly on the position feedback extension. If this surface is not flat, some error will be introduced as the tip moves across the surface. This can be detected if the travel reading does not return to zero (within .0001) after the valve is stroked. A small error will not affect the evaluation but will show up in the graphs. The transducer mounting position should provide some preâ&#x20AC;&#x201C;compression of the probe beyond its free position and provide adequate coverage of the stroke range. The travel reading can be zeroed from the keyboard. 5.4.1.1.2

Transducer for Rotary Valve

W6672

Rotary Transducer

The rotary transducer measures 360 of rotation and has 0.0075 resolution. The transducer must be mounted perpendicular to the valve shaft. A slight offset can be compensated for by the flexible coupling. A probe with a plate for mechanical connection or a suction cup is used to connect to the shaft. Error may be introduced if the suction cup slips. This can be eliminated by the use of double sided tape to secure the cup to the shaft.

FlowScanner User Guide 5.4.1.2

Transducer Mounting 25-inch Celesco Transducers The 25-inch Celesco cable transducer is the standard linear transducer provided in the accessory kit. It can be used to measure up to 25 inches of travel at a resolution of 0.0001 inches. For optimum accuracy, the transducer must be mounted such that the cable motion is parallel to the valve stem motion. To facilitate this alignment, special slotted mounting brackets are included in the accessory kit. Also for extremely fast ”Stroking Speed Tests” (Step Change Test), it is important that the transducer is mounted such that the tranducer’s cable is being extended, not retracting. Attach Travel Transducer Bracket (TA0101-A) to the Celesco transducer via the 1/4-20 x 3/4 flat head stove bolts. Attach the drilled hole end of the slotted angle bracket (TA0103-A) to the hex adapter on the expandable-jawed vice-grip (Bessi Clamp) with a 3/8-16 x 1 cap screw. Clamp the Bessi Clamp onto the the actuator (diaphragm case, barrel, or yoke legs). Attach the travel transducer to the slotted portion of the angle bracket using 5/16-18 x 1 carrige bolt and wing nut. Clamp the 10-inch vice-grip to the stem connector or positioner feedback arm. DO NOT clamp directly to the valve stem, for this will cause damage to the stem finish and, consequently, damage the stem’s packing. Attach the transducer cable to the vice-grip using the S-hook provided. It is sometimes necessary to attach a 1-inch Cantilever C-clamp to the vice-grip to facilitate this hook-up. Utilizing the slots of the mounting bracket, align the transducer’s cable parallel with the valve stem. Verify that all connections are tight. Attach the transducer cable.

Multi–purpose Clamp (Preferred Method) Use adjustable cantilevered C–clamps to clamp the transducer mounting assembly to the diaphragm casing, yoke, bonnet, or other available mounting surfaces. Clamp the 4 1/2-inch cantilevered C–clamp to the appropriate clamping surface. Firmly tighten the T–handle. Extension studs may be oriented at any angle through the use of swivel joints to facilitate transducer mounting. Assemble additional studs and swivel joints, as needed, to obtain proper orientation and position. Tighten all jam nuts and swivel joints to eliminate slipping. Clamp the 2-inch multi–purpose clamp on the base of the transducer. Thread an extension stud into the adapter on the clamp.

FlowScanner User Guide Connect the extension stud from the transducer to the extension stud from the large clamp using a swivel joint. Position the completed assembly to the required transducer orientation and firmly tighten all connections. Verify alignment and re–adjust position as necessary until the transducer cable is properly aligned with the feedback platform. Connect the transducer cable to the feedback platform. 2-inch DRC Transducer Multi–purpose Clamp (Preferred Method) Use adjustable cantilevered C–clamps to clamp the transducer mounting assembly to the diaphragm casing, yoke, bonnet, or other available mounting surfaces. Select the appropriate cantilevered C–clamp for the required clamping surface. Mount and firmly tighten the T–handle. Extension studs may be oriented at any angle through the use of swivel joints to facilitate transducer mounting. Assemble additional studs and swivel joints, as needed, to obtain proper orientation and position. Tighten all jam nuts and swivel joints to eliminate slipping. Attach an extension stud to the transducer bracket and firmly tighten. Connect the extension stud from the transducer to the extension stud from the clamp using a swivel joint. Position the completed assembly to the required transducer orientation and firmly tighten all connections. Verify alignment and re–adjust position as necessary until the transducer probe tip is properly aligned with the feedback platform. Rotary Transducer The C25 DRC is the standard rotary transducer supplied in the accessory kit. It can measure 360 degree rotation with a resolution of 0.0075 degrees. The travel is to be measured at the end of the valve shaft, if possible. Normally, the most convenient place to connect is to the travel indicator plate. Some positioner are mounted directly in line with the shaft and, thus, the connection must be made on the positioner’s indicator plate. The transducer should be mounted perpendicular to the valve shaft. Two flex couplings are used to compensate for any offset. The connection is made using double stick tape.

FlowScanner User Guide Attach the rotary travel transducer bracket (TA0102 to the C25 DRC Transducer. Attach the drilled hole end of the slotted angle bracket (TA0103-A) to the hex adapter on the expandable jawed vice-grip (Bessi Clamp) with a 3/8–16 x 1 cap screw. Attach the Bessi Clamp to the valve’s bonnet or actuator. Install travel transducer mounting post (TA0104) to the flex coupling on the tranducer. Install flex coupling (17A8307 X012) to the mounting post. Tighten connections. Attach the rotary transducer to the slotted angle bracket using the SPC Fisso Support Arm. Attach the double-stick tape to the flex coupling and stick the transducer perpendicularly and centered to the valve shaft end utilizing the three pivot points of the Fisso Support Arm. Lock the arm in position usng the locking knob. Verify that all connections are tight. Attach transducer cable. Multi–purpose Clamp Adjustable cantilevered C–clamps are provided in the accessory kit to clamp the transducer mounting assembly to the diaphragm casing, yoke, bonnet, or other available mounting surfaces. Clamp the 4 1/2-inch cantilevered C–clamp to the appropriate clamping surface. Firmly tighten the T–handle. Extension studs may be oriented at any angle through the use of swivel joints to facilitate transducer mounting. Assemble additional studs and swivel joints, as needed, to obtain proper orientation and position. Tighten all jam nuts and swivel joints to eliminate slipping. The most convenient place to connect to the shaft is on the actuator indicator plate. Some positioners (PMV, 3710, etc.) are mounted in–line with the shaft and the only available travel feedback connection is the positioner indicator plate. When using the positioner indicator plate for feedback, inspect the positioner–valve connection to insure there is no problem. Mechanical stop between the valve and positioner may not be detected using this system for feedback, however, in some instances it is the only available feedback source. Clamp the 2-inch multi–purpose clamp on the base of the transducer. Thread an extension stud into the adapter on the clamp. Connect the extension stud from the transducer to the extension stud from the large clamp using a swivel joint. Position the completed assembly to the required transducer orientation and firmly tighten all connections. Verify alignment and re–adjust position as necessary until the transducer is properly aligned and the probe is firmly connected to the indicator plate.

FlowScanner User Guide Actuator Cover Plate Bolt Hole Remove one bolt from the actuator side cover plate. Select the appropriate extension stud and screw directly into the actuator side cover plate bolt hole from which the bolt was removed. Firmly tighten the jam lock nut against the actuator housing. Extension studs may be oriented at any angle through the use of swivel joints to facilitate transducer mounting. Assemble additional studs and swivel joints, as needed, to obtain proper orientation and position. Tighten all jam nuts and swivel joints to eliminate slipping. Clamp the 2-inch multiâ&#x20AC;&#x201C;purpose clamp on the base of the transducer. Thread an extension stud into the adapter on the clamp. Connect the extension stud from the transducer to the extension stud from the actuator cover plate bolt hole using a swivel joint. Attach the assembled rotary probe (See Section 5.4.1.3 under Mounting the Travel Feedback Platform). Position the completed assembly to the required transducer orientation and firmly tighten all connections. Verify alignment and reâ&#x20AC;&#x201C;adjust position as necessary until the transducer is properly aligned and the probe is firmly connected to the indicator plate.

5.4.1.3

Travel Feedback Connection Existing positioner connector arms provide the most convenient method for transducer feedback connections. A temporary connector arm or adapter can be installed to facilitate testing. Permanent test connections are based on the actuator type and the accessories encountered. Celesco Long Stroke Transducer The feedback platform provides the means to displace the spring loaded cable as the valve is stroked. This connection should be firmly established to minimize the effects of vibration or looseness in the assembly. Several techniques for mounting are presented as general guidelines for mounting with selection based on the accessories encountered. Since there are an infinite number of valve/accessory combinations, it is not possible to describe all the means required to mount the transducer. These guidelines should provide some ideas; the individual technician may have to devise alternate methods based on these suggestions.

FlowScanner User Guide Using existing positioner connector arm: Verify that no obstructions exist in the positioner linkage and that the transducer can be mounted parallel to the valve/actuator stem. Clamp a pair of vise grips to the connector arm. Clamp the crocodile clip with S–Hook (included in the kit) to the vise grips. Be sure it is a firm connection so the cable from the transducer does not snap loose. Connect the cable eyelet to the S–Hook.

Adding a temporary positioner connector arm: Verify that the transducer can be mounted parallel to the valve/actuator stem. Select the appropriate connector arm based on stem diameter. Loosen the valve/actuator stem jam nut and slide the connector arm between the lock nut and jam nut. Firmly tighten the jam nut. Clamp a pair of vise grips to the connector arm. Clamp the crocodile clip with S–Hook (included in the kit) to the vise grips. Be sure it is a firm connection so the cable from the transducer does not snap loose. Connect the cable eyelet to the S–Hook.

Adding a permanent positioner connector arm: Selection is based on the actuator type and size and the accessories involved. Refer to Fisher Instruction Manual for 3582 Series Valve Positioners, Form 5054 (Key 48) for the actuator type and size. Follow the steps in C above. 2-inch DRC Transducer The feedback platform provides the means to displace the spring loaded probe of the DRC transducer as the valve is stroked. This connection should be firmly established to minimize the effects of vibration or looseness in the assembly. Several techniques for mounting are presented as general guidelines for mounting with selection based on the accessories encountered. Since there are an infinite number of valve/accessory combinations, it is not possible to describe all the means required to mount the transducer. These guidelines should provide some ideas; the individual technician may have to devise alternate methods based on these suggestions.

FlowScanner User Guide Using existing positioner connector arm: Select the appropriate transducer based on required stroking range and mounting space. Verify that no obstructions exist in the positioner linkage and that the transducer can be mounted parallel to the valve/actuator stem. Position the transducer tip against the travel pin locking nut and ensure that an adequate perpendicular landing surface is provided by the locking nut. In some instances, it may be necessary to attach a beam clamp to the connector arm to obtain proper transducer orientation or adequate landing surface. Attach the fixture as far away from the valve as possible without impeding the travel pin or rotary shaft arm mechanism of the positioner.

Adding a temporary positioner connector arm: Verify that the transducer can be mounted parallel to the valve/actuator stem. Select the appropriate connector arm based on stem diameter. Attach a beam clamp to the end of the connector arm to provide a landing surface for the transducer probe. Loosen the valve/actuator stem jam nut and slide the connector arm between the lock nut and jam nut. Firmly tighten the jam nut. Adding a permanent positioner connector arm: Selection is based on the actuator type and size and the accessories involved. Refer to Fisher Instruction Manual for 3582 Series Valve Positioners, Form 5054 (Key 48) for the actuator type and size. Follow the steps in C above. Rotary Transducer The travel indicator scale provides a means for position feedback for the rotary transducer. This connection should be firmly established to minimize the effects of vibration or looseness in the assembly. The use of pliable suction cups, double sided tape, and/or flexible couplings is recommended.

Flexible couplings If the screws in the indicator plate are not corroded to the point that removal is impossible, remove the indicator plate and reâ&#x20AC;&#x201C;attach it.

FlowScanner User Guide Use the flexible coupling provided in the accessory kit to connect to the knob on the indicator plate. There are two couplings in the kit. One has a 3/8-inch opening on both ends; the other has a 1/4-inch opening on one end. Select the proper coupling to fit the knob on the indicator plate.

5.4.2

Measuring Pneumatic Pressure

Note These transducers are for pneumatic use only. DO NOT USE THESE TRANSDUCERS TO MEASURE LIQUID PRESSURE

The pneumatic pressure transducers are located in the Flowscanner case and connect to the valve through 1/8-inch nylon tubing and connector fittings. The Parker Prestolok fittings used with the tubing connect simply by pushing the tubing into the fitting. The tubing is released by pressing the gray collar around the tubing inlet and simultaneously pulling the tubing out. These fittings do not have internal check valves so the pressure must be shut off before disconnecting. The Prestolok fittings can be mated to existing connections on the valve and accessories. Most valves can be fully tested by measuring the Supply, Instrument (I/P), and Output pressures available at the positioner gauge block. Top and bottom actuator pressures must be measured for piston actuators. Volume boosters should be measured separately from the output pressure.

5.4.2.1

Installing Test Connectors

5.4.2.1.1

Temporary Installations

Positioners with Gauges Remove the gauges for supply, instrument, and positioner output. Select the appropriate Parker Prestolok fitting:

FlowScanner User Guide A. 1/8 x 1/8 MNPT (68 PL 2–2) B. 1/8 x 1/4 MNPT (68 PL 2–4) C. 1/8 x 1/8 FNPT (66 PL 2–2) Install the fittings in the gauge ports on the gauge block. Fisher Type 3570 Positioners require the use of a combination of the 68 PL 2–2 and the 66 C 2–2 Parker fittings on the bottom cylinder and instrument connections. Tighten fittings and connect 1/8-inch nylon tubing to Flowscanner transducer channels. Verify the installation matches the assigned channels on the test set–up parameters.

Positioners with Schrader valves (tire valves) Connect the 1/4 MNPT Parker Prestolok fitting to the Type SS–52 clip–on chuck for the required number of installations. Tighten fittings and connect 1/8-inch nylon tubing to Flowscanner transducer channels. Verify the installation matches the assigned channels on the test set–up parameters.

Tubing Tee Connections In cases where there is no gauge block available for taking pressure readings, temporary tees must be installed in the tubing to access the required pressures. Install the Parker Prestolok fitting in the tees and connect the Flowscanner tubing to the Parker fitting. Permanent Tee fittings are recommended if repeat tests are going to be performed on the valve. See section 5.4.2.1.2, Permanent Installations, for appropriate fittings. 5.4.2.1.2

Permanent Installations Permanent connections are used to provide a way to quickly connect the Flowscanner to obtain test pressures for a valve that will be subjected to repeat tests over an extended period of time. See section 11.5 (Appendix E) for a complete description of connectors for diagnostic testing. Listed below are a brief description of several recommended permanent connections.

FlowScanner User Guide Note Contact your local Fisher Representative to obtain required parts or assistance in making permanent connections

New valves purchased from Fisher can have permanent connections installed at the factory. Contact your local Fisher Representative for this option on new purchases. Type SS–52 Clip–On Chuck Automotive Tire Valve. Refer to 3570 Series Pneumatic Valve Positioners Instruction Manual, Form 1837 for general guidance. Automotive Tire Valve Test Connection – 1N908899012 Service Tee – 1P312321992 Pipe Nipple – 1B218826232 Pipe Tee – 1C597547362 Adaptor – 1H447099022 Swagelock Quick Disconnect Body – QC4–B–2PM For a complete ordering number use SS for 316 stainless steel or B for brass as a prefix to the number shown above. This number represents a quick connect body with 1/8-inch male NPT threads. Install this part in the gauge block or in a tee inserted in the gauge block. The tee is required if the gauges are to be installed. The tee may be omitted and the body installed alone. gauges can be connected by using the fitting described below. For more detailed information concerning this option, contact your local Fisher representative. Stem – QC4–S–2PF For a complete ordering number use SS for 316 stainless steel or B for brass as a prefix to the number shown above.

FlowScanner User Guide This number represents a quick connect stem with 1/8-inch female NPT. Insert a Parker Prestolok fitting (68PL2â&#x20AC;&#x201C;2; see I.A.2.a above) in the stem. Connect the Flowscanner tubing to the Parker fitting. Snap the stem into the body installed in the block.

Caution In order to install the temporary fittings, the supply air and instrument signal to the valve must be removed for a short period. This could cause the valve to move. Be sure all personnel are clear of the valve and operations is aware that the valve may move.

Note Contact your local Fisher Representative before ordering fittings for permanent installation. He can assist you in assuring the proper part numbers for your installation.

FlowScanner User Guide 5.4.3

Supplying and Measuring the Control Signal Control (I/P) Signal

Connecting to the I/P Transducer The control cable is a 20-foot long, 2 wire cable with spade lugs or alligator clips on one end and a Lemo connector on the other end. The spade lugs or alligator clips are used for connecting to the standard barrier strip on an I/P. Connect the Lemo connector to the port labeled I/P on the Flowscanner. When connecting the Flowscanner to the I/P, disconnect the control leads in order to isolate the I/P from the control circuit.

Adding an I/P Transducer In the event that a test is required on a valve that does not have an I/P, use an I/P with the appropriate ranged bellows and a 67AF regulator. Determine the tubing size for connecting to the positioner. For valves without positioners, connect directly to the actuator. Make the appropriate temporary tubing connections from the supply air to the I/P Regulator assembly. Make the appropriate temporary tubing connections from the I/P to the positioner (or actuator). Use the FlowScanner and I/P to provide the test instrument input signal.

5.4.3.1

Command Mode The command mode is the typical means of operation with the FlowScanner. It allows the FlowScanner to command the current signal to the valve and control the test that is being conducted. The power for the instrument is provided by the FlowScanner.

5.4.3.2

Monitor Mode Monitor mode allows the FlowScanner to sense the signal being sent to the valve, but the movement of the valve is being done by the control system. When the monitor mode is used, the resistance of the I/P must be known in order for the current to be properly calculated. The system monitors the current signal and the valve is moved by the operator of the control system. See section 8 for complete details.

FlowScanner User Guide 5.4.4

Auxiliary Inputs Signals can be monitored from transmitters or other devices in the process to gain added information on how the valve is controlling. These sensors can be monitored by paralleling the wires off of the sensor and the current or voltage back into the system.

5.5

Setting Up Test Parameters The FlowScanner has been made flexible enough to run a variety of tests, but normally only a few standard tests will be used. However, before running a test the nameplate must be loaded into memory and the Setup screen completed, which passes the data to the Test program. The Setup Test screen looks much like the Nametag Screen:

Setup Test Screen for Sliding Stem

The current valve ID (TAG or SERIAL #) will be shown at the top left window if a valve is in memory. The Setup Number is used to save and recall standard setups. Use a descriptive name like SCAN50 or SCAN100 for 50 and 100 second dynamic scan setups. You can recall a standard setup from the program drive from the file menu (Altâ&#x20AC;&#x201C;F). Setups are stored on the hard drive so they will be available for other data disks. If there are setup files on the disk the names will be displayed across the top of the screen. Use the cursor (arrow) keys to highlight the desired setup and press Enter. That setup will then be loaded into the setup screen.

FlowScanner User Guide Use the Description field to explain what the setup is for. The Test Type field has a menu with 5 choices. It defaults to Dynamic scan. To select another press the F2 key while the cursor is on the field. However, first we will cover how to set up a dynamic scan test.

5.5.1

The Dynamic Scan The Dynamic Scan test ramps the current at a controlled rate between two defined output levels. Data is recorded during both upstroke and down stroke, and may be analyzed for a good indication of valve condition. It is the normal FlowScanner test for valves. The Output type field defaults to milliamps. The Volts choice is for 0–10 volt E/P loops. The software also supports –10 to +10 E/P for control only. If 10–50 mA loops are used select milliamps. Switching to the 50 mA range is automatic if output levels above 25 mA are selected. The output function defaults to Control I/P instead of Monitor I/P. (For controlling the valve from the control room while the system monitors the I/P voltage. – See the section 8 on Monitor Mode Testing for more on this topic.) Select the proper travel Transducer from the menu (press F2). (This can be changed in the Test program if required.) The normal first test is to linearly ramp current from 4 to 20 mA to be sure you test for seat load and travel under control room range. If the control range is other than 4–20 use the actual controller limits. Limits may now be set in 0.1 mA increments. The appropriate scan time should be selected based on the actuator size. Pressing F1 (Help) accesses a table giving you the recommended scan times for your actuator size. The pause time is equal to approximately 50% of the selected scan rate. Thus, a ”50 sec” test requires approximately 150 seconds to complete.

FlowScanner User Guide

The calibrated times may vary somewhat; but the analysis software will display the actual elapsed time on the graphs.

5.5.2

Static Point Test A Static Point test duplicates a traditional lab deviation cycle test for hysteresis plus dead band, pausing at several levels on the up and down stroke to allow the valve to reach static conditions. Per the SAMA requirements the test limits should be selected to avoid hitting travel stops on the ends of travel. For example, a well–calibrated 4–20 range valve would normally be tested at 4.5, 8, 12, 16 and 19.5 mA steps, with a ramp rate of 1 mA/sec and a pause time of from 20 to 60 seconds. Large valves with graphite packing may require longer pause times because a static condition must be repeated after each step change. If the pause time is too short, the results will continue to improve as the pause time is increased.

5.5.3

Step Change Test The Step Change test is used to check stroking speed and valve dynamic response. This test makes an ”instantaneous” change in out put between two levels while recording data on valve response. Minimum pause time is about 20 seconds.

5.5.4

Stepped Ramp Test The Stepped Ramp test performs a ramp up and down test as a series of small steps. This may be used with steps down to 0.01 mA to test for valve response and resolution. You would normally select a starting output level within the valves normal operating range (eg. 12

FlowScanner User Guide mA), a number of steps to make up (eg 20), a step size (e.g., 0.08), a pause time at each step (e.g., 5 seconds), and the number of times to perform the ramp (e.g., 2). No automatic analysis is done on the data—simply view the elapsed time graphs and compare input steps to output step response. This test is often used with the process variable recorded on an auxiliary channel.

5.5.5

Step Study Test The step study test is used to check valve resolution and response quickly. A series of increasing small step sizes is defined (eg. .08, .16, .32, and .8 define 0.5%, 1%, 2%, and 5% steps for a 4–20 mA loop) to be run at different nominal loop output levels (eg. 12 mA or 50%). A pause time is specified for each step (eg. 10 seconds), and the normal procedure is to mirror the steps; that is to step up, back, and then down and back from the nominal output level. This type of test can quickly show an approximate deadband for valves, especially with the process variable recorded on an auxiliary channel.

5.5.6

Pressure Channel Assignments Press PgDn to access the pressure channel assignment window. For each pressure you need to measure on the test assign a pressure channel. Normally the Supply Pressure, Instrument (I/P), and Positioner Output pressures are assigned. (The Positioner Output pressure is used in analysis for the Actuator Pressure if another channel isn’t assigned to it.) Up to 6 channels can be assigned. Adding channels slows the tests and increases the size of the data files, so don’t assign unneeded channels. For pressure return piston actuators assign the return pressure as well. The sixth pressure has a blank name – if you need to measure some other pressure describe it in this field and assign a channel.

FlowScanner User Guide 5.5.7

Auxiliary Inputs The Auxiliary inputs can be used to collect data simultaneously with the control signal, valve travel, and valve pressure channels. Filling in a description for one or more auxiliary inputs causes the Test program to display and record information on the channels with a description. These can be displayed by the FlowAux display program. This might be used for recording line pressure, flow rate, or other variables. If more than one auxiliary channel is measured the control signal and travel data can be displayed simultaneously with either the valve pressures or the auxiliary channel data. You select which to display when reading the data for display; so you can alternately look at both data sets. If only one auxiliary channel is measured, and the 6th (user defined) pressure channel is not used by the pressure scanner, the auxiliary channel data is store in its place and can be displayed with all the rest of the valve data. You can enter other comments with Alt–C, print the setup information (Alt–P), and save the setup file (F10 or Alt–F) as in the Nametag Menu. Normally you only need to save the Setup file if you want to use it for other tests – the RUNTEST file will pass the setup screen data to the Test program.

5.5.8

Storing a RUNTEST File Exit the Setup Screen by pressing Alt–X. The exit menu will allow you to exit to the Nametag program or go to the main menu. If you haven’t saved the setup file for later use, but have made changes a pop–up window will ask if you want to save it.

Note If you exit to the main menu a pop–up window will ask if you want to use this setup and nametag data for the next test. If you answer ”Yes” the information will be ADDED to the RUNTEST file.

FlowScanner User Guide All saved Setup and Nametag combinations will still be available from the TEST program, so you can save several different setups for later testing.If you don’t see this window it probably means there is no Nametag in memory, and the test will not be setup to run. Pressing Alt-F gives you four menu options: 1) Retrieve Test Setup from File, 2) Save Test Setup to File, 3) Erase Test Setup from Disk or 4) Erase Test Setup from Screen.

Running a Test in Control Mode

6.1

Quick Reference Refer to section 6.1 for test procedures

6.2

Changing the Travel Transducer If the travel transducer shown is not the one you wish to use, press Alt–T to toggle the choice to the other models. Stop when the one shown is the one you want to use, and stroke it through a known distance to verify the calibration.

6.3

Setting Individual Transducer Resolution Celesco “cable” transducers have an individual calibration marked on the nameplate that can give slightly better accuracy than the default setting. To set this for the specific transducer used select the “Other” menu choice:

6.4

FlowScanner User Guide To run a test this way you should first disable the AutoZero of the travel transducer. To do so pick the ”Other” menu from the top of the screen (Alt–O). This menu appears: Select Disable AutoZero Travel and the automatic zero function is shut off. When the AutoZero function is shut off, the ”az” disappears from next to the travel transducer line on the screen. Changes made in the ”Other” menu to AutoZero Travel are saved as default, even if the system is shut off

6.5

Graphing Measured or Commanded Current The FlowScanner measures the actual current on the control loop through a resistor and an instrument amplifier. There are cases where it would be better to record the Commanded Current and graph it than to use the Measured Current. This might be true in these situations: Examining Very Small signal steps We have sometimes used signal steps of 0.1 mA to find a valve’s resolution. When looking at very small signal changes the accuracy of the commanded signal is actually slightly better than the measured signal, as the measured signal is a 12–bit conversion of a 55 mA span (55 mA divided by 4095 or 0.0134 mA resolution), while the commanded current (25 mA range) is a 12–bit conversion of a 25 mA span (25 mA divided by 4095 or 0.0061 mA resolution). There is also always a small amount of flutter or noise on the measured signal which doesn’t appear on the commanded signal. Thus in this case the graphs are cleaner and more accurate if the Commanded signal is used. Using a High Impedance I/P transducer At least one I/P transducer (Moore) is being marketed which has a much higher impedance than those we normally find. An impedance of 600 Ohms means that as the signal approaches 20 mA the driving voltage reaches 10 to 12 volts. (Most I/Ps are in the <200 Ohm impedance, so the driving voltage is under 5 volts at full current.) The way the FlowScanner measurement circuit was designed a drive voltage this high can cause the Measured Signal to drop suddenly even though the true loop current continues to increase. This is due to the input to the instrument amplifier getting too close to its supply

FlowScanner User Guide voltage. There is a circuit fix to cure this problem which requires returning the FlowScanner for modification. To work around the problem you can instead record and graph the Commanded current. The (*) next to the Measured Current line shows that it will be recorded and graphed normally. To change and record the Commanded Current pick the ”Other” menu from the top of the screen: Pick the Graph Commanded Current choice to record and graph the commanded signal instead of the measured signal. After selecting the Commanded current the (*) changes to that line of the screen to show which will be recorded: To change back again pick the ”Other” menu and select Graph Measured Current to change back.

6.6

Specifying Test Line Pressures If the valve is tested in line, and the line pressures are not zero psig, you should enter the inlet and outlet pressures so the valve unbalance can be allowed for in analysis. If the test line pressures are different from the nametag service pressures the ”service seat load” will still be corrected for the unbalance. Select the ”Other” menu from the top of the screen (Alt–O), and select ”Enter Line Pressures.” Type in the Inlet pressure as an integer (whole number only). Press Enter and the cursor will move to the Outlet pressure field. Type in the outlet pressure and press Enter. These pressures will be used to compensate for the valve’s unbalanced area in force calculations.

6.7

Selecting to Hold or Zero the Output at Test End By default the output control signal (in Control Mode) will instantly be dropped to zero at the end of the test, or if the test is aborted in mid– test. However there may be times when it is better to hold the signal at its last level when stopping a test, allowing you to manually ramp the signal back down. This might be true if you were testing a valve in a liquid process line and didn’t want the valve to suddenly slam shut if the test were aborted.

FlowScanner User Guide Warning This practice applies to in-process testing

To have the control signal held at its last output at the test end, select the Other menu and select â&#x20AC;?Hold Signal at Test Endâ&#x20AC;? from the menu. This setting is saved each time you leave the test program, and will be set the same next time you use the Test program. An indicator then appears at the end of the Commanded Current line to show it will be held:

Warning Whenever you leave the Test Program, the I/O card is powered down, so the control signal will still drop to zero at that time, even if youâ&#x20AC;&#x2122;ve selected to hold the signal at the time the test ends.

6.8

Manual Control of the Valve At this time you can control the output signal and stroke the valve through the keyboard. The left and right arrow keys on the keypad will step the output current up and down. Pressing the arrow key alone changes it in small steps; while holding the Ctrl key and pressing the arrow key will change it in larger steps. Thus you can quickly move near a value, and then fine adjust to the value you want. The manual control is useful for stroking the valve to check the tracking of the travel transducer, and also for setting the zero and span of the I/P and positioner (if needed).

FlowScanner User Guide Note It is recommended to manually stroke the valve before testing to ensure proper setup.

With FlowAux the F3 and F4 keys can also be used to jump the current to the end limits set for the active Dynamic Scan test. F4 pressed by itself will jump the output to 95% of the specified signal range. Alt–F4 will jump to 100% of the range. F3 will jump to 5% of the range, and Alt–F3 will jump to 0%. If an E/P (voltage loop) is used and the setup specifies a negative voltage, the software then sets its lower manual limit to –10V output.

6.9

Recording the Static End Points In a Dynamic Scan test the software will analyze the test data to find the end points of the control signal and I/P output pressure when the valve reaches zero and maximum travel. However, because the data is recorded ”on–the–fly” without waiting for the travel to equalize to the control signal, the end points found are dynamic end points which are different from the actual static calibration. The test program allows you to manually find the static end points and record these values in a file, which is later read automatically into the Quick Report. This data is stored along with the test files under the same test name, so the data must be saved after the end points are manually marked. It is important to understand that the zero signal (normally 4 mA) end point is not the point at which the valve begins to move as the signal is increased. It is instead the point at which the valve stops moving as the signal is decreased. Many times valves are incorrectly calibrated so they begin opening as the signal reaches 4 mA. Due to the hysteretic error in all instruments and valves the valve will then never close as the signal is reduced to 4 mA. Likewise the correct full signal (normally 20 mA) end point is also the point at which the valve stops moving at the signal is increased.

FlowScanner User Guide While you are connected to a valve in Control mode for a Dynamic Scan test, you can call up the Mark Static End Points routine from the ”Other” menu (Alt–O) or directly by pressing Alt–E (for End Points). You will then see the following screen: At this point use the Ctrl–left arrow key to increase the output signal (or press F4 for 95%) until close to the signal where the travel stops. Then use the left arrow key alone to increase the signal just until the actual pressure reaches full supply pressure. Be sure to wait long enough for the travel to equalize to the signal. Then press the Enter key to record those values for the control signal and I/P output pressure. After the enter key is pressed the screen will change to allow recording the zero signal end point: Here use Ctrl–Right Arrow to drop the signal (or press F3 for 5%) close to the point where the valve stops moving at low signal. Then use the Right arrow key alone to reach the point where actual pressure reaches zero, and press Enter again to record the signal and I/P output pressure at this end point. At this point the values are saved in memory. When the test files are saved, these values will be saved under the same test name.

6.10

Zeroing the Travel and Pressures Set the travel at zero by pressing the End key on the Keypad. (It will normally zero automatically when the test is started, unless ”Autozero” has been disabled from the ”Other” menu.) If the pressure zero points have drifted, open all lines to atmosphere and press Alt–Z to adjust zero.

6.11

Scaling Auxiliary Channels The Auxiliary channels are voltage inputs, and are normally calibrated 0–10 Volts. It is possible to calibrate any channel in other units, but this then becomes a permanent system calibration until it is re calibrated. Since the scaling of a channel may change with each test, we have revised FlowAux to allow scaling auxiliary channels to other units and ranges at the time a test is run. The data is recorded with the new units and scaled calibration so it will show up on graphs, but the system calibration remains unchanged, and it reverts to its ”official” calibration when the test program is exited. To scale a channel in engineering units using this method you need to know the desired units; the scaling slope in units/volt, and the intercept value of scaled units at zero volt input.

FlowScanner User Guide For example it you are recording a flow meter output you might want to scale the readings to GPM. Normally the test screen would show readings in Volts: To scale the units select the ”Scale Units” choice on the ”Other” menu: The system then asks which input you wish to scale: Select the channel and then input the units and scaling factors: If this were a 4–20 mA flowmeter being measured across a 250 ohm termination, with a range of 0 to 500 GPM, the voltage range would be 1 volt at 4 mA at 0 GPM and 5 volts at 20 mA at 500 GPM so slope would be 500 GPM/(5–1)V or 125 GPM/V, and the intercept at zero volts would be –125 GPM: The screen then shows the real–time values in the units and scale requested: If the scaling is not correct the channel may be reset or rescaled by repeating the procedure. If you leave the ”Engineering Units” description at ”V” the scaling is reset to nominal volts. Any or all of the auxiliary input channels may be rescaled in this manner for any test. The data is recorded with the scaled inputs and may be displayed with the FlowAux software.

6.12

Starting and Stopping the Test Sequence When all is set to start the test sequence, press the F9 key. The test sequence will start and the output current will ramp up to the starting value. The specified stroking time determines how quickly the current ramps up. The output (control) current is always displayed during a test; and the status boxes at the bottom of the screen will flash ”TESTING” and indicate if the current is changing up or down. The Stroking time selected also determines how much time is available between data readings to display information on the live screen. If the 10 second scan is selected there is only enough time to display the changing output current. The travel and pressures will not be shown until the test is over. During the 20 second scan the changing travel will also be shown; and as the stroking time increases the pressures are added to the display. During the test 8000 readings are recorded for each pressure, current, and travel channel. As the scan time increases multiple reads

FlowScanner User Guide of the pressure scanner are made for each point to average out possible electrical ”noise.” At the conclusion of a test the data will be temporarily stored in the RAM disk and the screen status block will show ”COMPLETED” and will prompt ”Press F10 to Save Test Data”. If readings are being taken on the auxiliary channels the saving is done automatically. Because of the data space available in memory, the system will also pause at mid–test to save the first half of the data. Then testing on the second half will resume. Whenever a test is in process, pressing any key on the keyboard will abort the test sequence, zero the output current, and discard any data in memory. Pressing F9 will restart the test from the beginning.

6.13

Recording Test Commands The ”Other” menu at the top of the screen has an ”Enter Test Comment” choice that will let you enter a 40 character comment about the test either before or after a test (but before the data is saved) to help identify the test later. This comment will show up when selecting the test data for display. The Enter Test Comment screen will now also automatically appear at the end of a test, after data reading is complete. You should enter a comment and save the data.

Note The test comment is a valuable tool to help you identify the test later

6.14

Saving Test Data Pressing F10 will save the test files to the designated data drive (data disk or ”G” drive). This will take about 20 seconds, as the files are arranged to save disk space. If the data is saved in the RAM disk it is possible to exit without saving to the data disk and review the graphs. You can then save the data from the Display program File menu under “save data to new disk.”

FlowScanner User Guide 6.15

Exiting the Test Program After saving the test data you can either select another test from the File menu, or exit to the main menu. Viewing the data is done from the Display program after you Exit the Test program. Press Alt–X to get the Exit menu, and exit to the main menu.

Warning When exiting the test program, the data card is reset and powered down. This means all output will also drop to zero, and relay switching may occur on the output cables. If this will cause any problem, disconnect the cables before exiting the test.

6.16

Disconnecting From a Valve First disconnect the output cable and travel transducer from the front panel. Then detach the pressure tubing (cut the pressure if check– valve fittings aren’t used). Carefully remove the travel transducer and disconnect the output cable from the I/P.

Running a Test in Monitor Mode

7.1

Quick Reference Refer to section 5.1.

7.2

FlowScanner User Guide 7.3

Setting Transducer Resolution Celesco “cable” transducers have an individual calibration marked on the nameplate that can give slightly better accuracy than the default setting. To set this for the specific transducer used select the “Other” menu choice:

7.4

Disabling Automatic Zero of Travel The system is normally set to zero the travel transducer automatically when the F9 key is pressed to start a test. This is fine as long as you are starting with zero signal and the valve is at one end of the travel. However, sometimes tests are run over a partial stroke, and the signal is manually increased to some partly open level before the F9 key is pressed. When the travel automatically zeros, the ”true” zero point is lost, and you don’t know how far the valve moved before the test was started. To run a test this way you should first disable the AutoZero of the travel transducer. To do so pick the ”Other” menu from the top of the screen (Alt–O). This menu appears: Select Disable AutoZero Travel and the automatic zero function is shut off. When the AutoZero function is shut off, the ”az” disappears from next to the travel transducer line on the screen. Changes made in the ”Other” menu to AutoZero Travel are saved as defaults even if the system is shut off.

7.5

7.6

FlowScanner User Guide test, we have revised FlowAux to allow scaling auxiliary channels to other units and ranges at the time a test is run. The data is recorded with the new units and scaled calibration so it will show up on graphs, but the system calibration remains unchanged, and it reverts to its ”official” calibration when the test program is exited. To scale a channel in engineering units using this method you need to know the desired units; the scaling slope in units/volt, and the intercept value of scaled units at zero volt input. For example it you are recording a flow meter output you might want to scale the readings to GPM. Normally the test screen would show readings in Volts: To scale the units select the ”Scale Units” choice on the ”Other” menu: The system then asks which input you wish to scale: Select the channel and then input the units and scaling factors: If this were a 4–20 mA flowmeter being measured across a 250 ohm termination, with a range of 0 to 500 GPM, the voltage range would be 1 volt at 4 mA at 0 GPM and 5 volts at 20 mA at 500 GPM so slope would be 500 GPM/(5–1)V or 125 GPM/V, and the intercept at zero volts would be –125 GPM: The screen then shows the real–time values in the units and scale requested: If the scaling is not correct the channel may be reset or rescaled by repeating the procedure. If you leave the ”Engineering Units” description at ”V” the scaling is reset to nominal volts. Any or all of the auxiliary input channels may be rescaled in this manner for any test. The data is recorded with the scaled inputs and may be displayed with the FlowAux software.

8 8.1

Displaying and Analyzing Test Results Quick Reference NOTE FOR STEVE COLWELL: if this section is needed, the following sections need to be renumbered

FlowScanner User Guide 8.1

Display Program Overview The Display program reads the test data files and gives you graphic displays of the test results. These graphs can be analyzed and printed directly to the printer. The program will analyze the graphs to numerically summarize the performance of the overall valve assembly, the I/P transducer, the positioner, and the Actuator and Valve combination. These calculated results can be printed as part of the printed graphs or can be saved to a Report file on the disk where the report program can print a summary report with your comments about the results included.

8.1.1

Starting the Program Select Display and Analyze Test Data from the main menu. Then Press Alt-F and select the appropriate menu item to retrieve your test results. When FlowAux finds test data it will present a list of test names for selection, and the following screen will be seen:

Test Data Screen

The most current data will be highlighted. Older versions of the FlowScanner software looked for the list of tests in a file named ”FSTEST.DAT” (or ”RSTEST.DAT” for Rotary) where all test files were listed. With this release the list comes from looking for a ”DTA” file for each test. If you have older data which did not create ”DTA” files those tests may not appear. The FileRetrieve menu in the Display program has a choice for ”Select Test from FSTEST file” which will allow you to read the older data.

FlowScanner User Guide 8.1.2

Choosing Test Data Select the data you want to display with the Up and Down arrow keys. If the data disk has more than 10 tests saved you can page through the test list in groups of 10 tests before selecting data. The most recent page of tests is shown first. The Test comment for the highlighted test is shown at the bottom of the test list window. Press Enter when the test you want is highlighted. If the test recorded data on the auxiliary inputs (A â&#x20AC;&#x201C; E) as additional data files the screen will then prompt for whether you wish to view the pressure scanner data or the auxiliary channel data with the control signal and travel: At this time you select which to view on graphs. You can always reâ&#x20AC;&#x201C;load the test data and view the other channels in a few seconds. The status blocks at the bottom of the screen will show that it is reading data. When looking at standard valve test (not the auxiliary channels) when the data is in memory the screen will change to look like this:

The Setup summary on the left can be replaced with the keystroke help screen by repeatedly pressing the PageUp key. If the test data is for a Dynamic Scan, page one of the graphs menu will be automatically shown. This page contains the graphs normally analyzed for this test. If the test data is for a Static Point, Step Change, Step Ramp, or Step Study test the second page of available graphs will be presented with the overall valve plot selected.

FlowScanner User Guide If the auxiliary channel data was selected, the names given to the auxiliary channels on the test setup will instead be shown on the graph menu.

8.1.3

Returning to the MENU Screen While in the graphics screen pressing the ESC key, the F2 (MENU) key, or Alt–X will return you to the graph menu and reset the graph parameters.

8.1.4

Printing Graphs Graph printing to Epson, IBM, HP, or Diconix printers is provided. If you are using a different printer than selected in the Main Menu Defaults you can change it from the Printer menu off DISPLAY MENU screen. Then display the graph. Pressing F5 will print a 1/3 to 1/2 page graph on most of the printers; and pressing F6 will print a full page graph on most of the printers. When printing, pressing ESC will abort the printout, and other keys will be ignored.

8.1.5

Capturing Graphs If the FlowScanner programs were started from Windows, simply pressing the Print Screen key will copy the graph to the Windows clipboard. However it would normally have a black background and would not print well. So before capturing the graph inverse the screen by pressing Alt–I. The graph will then capture with a white background. After the graph is captured, switch to Windows by pressing Alt–TAB, and run your Windows Word Processing or Paint program. Insert the graph by pressing Shift–Ins. You can then switch back to the FlowScanner graph just as you left it and keep both application running to add multiple graphs to a report if you want.

FlowScanner User Guide 8.1.6

Graph Cursors The graph cursors are moved with the keypad arrow keys. Pressing an arrow key will grab the cursor which will move into the graph in the direction pressed. So pressing the left arrow key will move the right–side cursor into the frame. The value showing the location of the cursor will appear at the bottom right of the screen. (Bottom left for the left border cursor.) The left and right keys will both be attached to the first cursor moved so it can be positioned back and forth. Pressing the ”Insert” key will ”freeze” that cursor in position and allow the opposite cursor to be selected. The Top and Bottom cursors are likewise moved by the up and down arrow keys, and display

their value just above the left and right cursor values. The ”Insert” key freezes all cursors in their positions, and will allow the display to zoom into the frame enclosed by all four cursors. Pressing Ctrl-rt. arrow or Ctrl-lft. arrow moves the cursors quickly to the right and left. PageUp and PageDn move the cursors quickly from the top and bottom.

8.1.7

Zooming a Graph View Zooming and resetting the display is done by pressing Enter or F9 to re–plot the graph to the frozen cursor positions; so first locate all four cursors, pressing Ins for each one; and then press Enter. The graph borders will re–scale to the zoomed limits; and all data points will be reviewed, plotting only the portion that is within the border limits.

FlowScanner User Guide

Alt–F9 will reset the view to the original scale, as will returning to the menu screen.

8.1.8

Marking Data Points When zoomed in to a high magnification it is useful to check the data point density, to see how many readings are being represented. Pressing Alt–P will cause the data points to be circled when the graph is re–plotted by pressing F9 or <Enter>. Alt–P again will toggle the marks off the next time the view is re–plotted.

8.1.9

Graph Analysis

Note Always start the analysis from the Full Graph View

Press Alt–F9 if you have zoomed in. If the cursors have been moved, many of the

FlowScanner User Guide

graphs will attempt to analyze the area between the cursors, which will give incorrect results if not used carefully (see below). The “Total Valve”; “I/P”; “Positioner”; and “Valve” graphs have analysis routines defined. Between 10% and 90% of Travel for Deg. Friction, Spring Rate and Bench Set and 2% of Travel for Seat Load. Start the analysis by pressing F3 or F4. The program will try to set the cursor limits appropriately, and will analyze between the cursors. The numerical results of the analysis are shown on the top– right section of the graphics screen. This is the Total valve analysis: The Total Travel number shows the distance the valve stroked during the test. The Zero Travel and Full Travel numbers show the points where the valve reached the limits of movement under the stroking speed conditions. Because the valve may not have ”caught up” with the changing control signal, these limits may not match actual static calibration results. The Dynamic Error Band numbers indicate the combined Hysteresis, Dead Band, and Slewing (Dynamic) Error for the valve under the stroking speed conditions. Because the Slewing Error increases as stroking speed increases the numbers will be higher than a static deviation cycle test, and will increase as stroking speed increases. Always use the same stroking speed when comparing like valves. The Average value is given as most representative of the performance, and the Minimum and Maximum show the consistency over the stroke. The Linearity number is Independent Dynamic Linearity based on best fit to the data. Sometimes the graph covers numerical results. To avoid this, the

FlowScanner User Guide shift, Alt, and Ctrl keys pressed with the F4 key will locate the numerical printout in the other corners of the graph. 8.1.9.1

Possible Data Problems

Analysis Errors The analysis can give misleading results in some cases. The actuator is normally checked between 10% and 90% of the travel, to avoid discrepancies often encountered in the pressure as the stem motion starts. These effects show up as a bulge in the curve near the ends of travel. If this bulge extends into the analyzed area the bench set and friction calculations may be off. Judgment must be used to decide if the â&#x20AC;?bulgeâ&#x20AC;? is really due to friction (possibly from galling) or to a restricted line between the positioner and actuator, causing a high pressure reading that doesnâ&#x20AC;&#x2122;t reflect the actuator pressure. The analysis limits can be changed to avoid such effects by first toggling the analysis off (press F4 again), and then moving the cursor at that end of the graph in past the curve discrepancy area. Then analyze again. The bench set is determined by extending the nominal curve to the travel limits based on the least squares data fit of the analysis area. If one end point is offset due to a data problem the slope of the line will be slightly wrong. 8.1.9.2

Limiting the Analysis Range The software attempts to locate the correct range of the graph to analyze, but strange data may be better analyzed by limiting the analysis to a different range. If the left and right cursors are moved in to the limits desired before analyzing, the results will be based on the range between those limits: The next three graphs listed on the first page of the graph menu show additional information about the performance of the components of a valve assembly,

FlowScanner User Guide 8.1.10

Dynamic Scan Tests I/P Plot

A6886*A/IL

The I/P plot of a dynamic scan shows the calibration and performance of the I/P and may help isolate performance problems related to the I/P or the Positioner. Since I/P performance depends on the volume of air it must deliver, the performance generally looks worse if no positioner is used (typically show a wider separation between the I/O and Down stroke). This is because the I/P must supply the total volume needed by the actuator. This graph plots the output pressure of the I/P as a function of the control signal. This plot is typical of an I/P when used with a positioner: Positioner Plot

FlowScanner User Guide This plot is labeled â&#x20AC;?Positionerâ&#x20AC;? to agree with a complete valve assembly, but actually shows the response of the valve to its pressure signal whether or not a positioner is used. It plots valve travel as a function of the pressure out of the I/P transducer. Because I/P performance is usually quite good, this plot looks very similar to the Total Valve plot, with slightly better numbers in the analysis: Net Pressure Plot

One very useful plot from the Dynamic Scan test is the plot of Net Actuator Pressure as a function of Travel. It may seem like the axes are backwards on this graph, but we are using it to solve for forces on the valve, which are determined from the actuator pressures, so they are plotted on the Y axis. For a spring and diaphragm valve, the plot analyzes like this: From this graph we determine the average, minimum, and maximum friction over the analyzed stroke. The range indicates how consistent the friction is and wide variations usually indicate valve problems. The spring rate is calculated and can be compared to that specified for the actuator. The total travel is repeated for reference. The bench set for the actuator does not include valve friction, so the analysis removes the friction to determine the true bench set. As friction changes the bench set does not change, although the friction does change the stroking range of the valve. The seat load is found under the test conditions, and if the service conditions are entered in the nametag the seat load under service conditions is also calculated. This can be compared to the required seat load from the nametag.

FlowScanner User Guide Seat Load Calculation : Automatic and Manual The net pressure vs. travel graph will automatically calculate the seat load based on the pressure change between the end of the closing stroke (which could be either end of the graph depending on whether zero signal is open or closed) and the pressure at a point near where the plug contacts the seat. It draws a small circle around the two pressure points it uses. This works well for most valves and tests, but sometimes test data is such that you may feel the points it automatically picks could be improved. You can over–ride the automatic selection of pressures by moving the top and bottom cursors to the pressures you think it should have selected before you analyze the graph. If either the top or bottom cursor is moved in from the edge of the graph before analyzing, the seat load calculation will be based on the pressure difference between the two cursors. Sometimes the ending pressure is directly at the bottom of the screen, and you can leave the bottom cursor in place, but it must be moved to the lowest actual pressure if that is not the bottom screen position. The top cursor will always have to be moved down. Seat Condition Although the Dynamic Scan test doesn’t perform an actual leak test, zooming in on the seating action shows how the plug wedges into the seat ring and gives an indication of the trim condition: The “stair–step” appearance of the plug moving into the seat is actually caused by the digital resolution of the travel sensor. If it had infinite resolution a smooth trace would be shown. New seats tend to have a sharper “break” in the curve as the plug contacts the seat. This profile degrades into a more gradual curve with wear. Different types and sizes of valves will have different profiles. You should always compare any results to a similar type and size for reference.

FlowScanner User Guide 8.1.11

Measurement vs. Time If you cursor down past the graph selections on the first page of the graph menu, the following page of graph choices will appear:This page of graphs displays the recorded variables on the Y axis vs. elapsed time on the X axis. Any combination of variables can be plotted, from 1 to all measured variables. By default all recorded channels will be selected for the Y axis when this page of graphs is selected. When multiple variables are plotted the traces are identified by letter symbols such as ”i” for current or ”an” for Actuator Net pressure.

Measurement vs Time Graph Showing Multiple Variables

On Dynamic Scan tests this screen is most often used to check the crossover pressures of piston actuators. Plot the Actuator Stroke, Actuator Return, and Net Pressure data at the same time: Check the manufacturer’s specs for the positioner used. If the crossover pressures are too low the valve may have control problems that are not otherwise obvious. Toggling Y–Axis Selections The variables selected to display on the Y axis can be changed by toggling the Y selection on or off. Move the highlight bar to the variable you want to change and press the SPACE bar (or the letter Y). This will toggle the ”Y” selection on or off. You may want to toggle off the pressures and display only the signal and the travel on the Y axis, to examine overall response and stroking time.

FlowScanner User Guide Displayed Y-Axis Scale If a combination of pressures and either signal or travel is selected to plot, the Y axis legend will call out the combination, and the scale will show the pressure values. If only pressures, or only non–pressure variables are plotted, the Y axis legend and scale will match the location of the Highlight bar on the graph menu. Stroking Time or Elapsed Time display If the F3 or F4 key is pressed with an elapsed time graph on the screen, the elapsed time between the cursor positions (left and right) will be displayed on the screen. For stroking time evaluation run a step change test, and plot the signal and travel vs. time. Zoom in on the closing step as needed, and set the left cursor on the start of the signal change, and the right cursor on the end of the travel change. Then press the F4 key and the graph will show the stroking time. Press F6 to print the graph. Recording Stroking Time in a Text File It is possible to record the analyzed stroking times in a text file for use by other programs. After analyzing a signal & travel vs. time graph for stroking time on both directions, return to the Graph menu screen and press F10 to save. The time difference on the left portion of the graph is recorded as “First Time = X.XXX Sec.” and the time difference on the right side of the plot is “Second Time = X.XXX Sec.” 8.1.11.1

Miscellaneous Graphs Moving the selection cursor past the bottom of the elapsed time graph choices brings up the third page of graph choices – the miscellaneous graphs. On this page of graphs any variable can be selected as the X axis variable, and any combination of 1 or more variables can be selected as the Y axis variables. Select the X axis variable by moving the highlight bar to your choice and pressing the letter X. Select the Y axis variables by moving the highlight bar and pressing Y (or SPACE).

FlowScanner User Guide As with the elapsed time graphs the highlight bar position determines the Y axis legend and scale for plots, so leave the highlight bar on the variable desired for the label. With multiple plots only the horizontal axis can be zoomed. Unless the graph plotted matches one defined on the first graph page, no analysis is defined for these graphs.

8.1.12

Static Point Test

A6886*B/IL

When Static Point Test details are first read into memory, the Control Signal and Travel choices on the elapsed time menu will be selected automatically. Just press Enter to display the overall valve graph, and analyze it by pressing F4: This gives the static test results that compare to published specifications for valves. By toggling off the â&#x20AC;?Travelâ&#x20AC;? selection and picking the I/P output pressure the I/P performance can similarly be analyzed. Then the positioner/valve performance can be analyzed by toggling off the Control Signal plot, and toggling on the Travel plot to go with the I/P output pressure .

FlowScanner User Guide 8.1.13

Step Change Test

A6886*C/IL

The Step Change test is performed to determine the ”Stroking Speed” or ”Response Time” of the valve assembly. The Display Program defaults to page 2 (Elapsed Time Display) in which both signal and travel will be plotted for the analysis of this test. For precise results, it is recommended that the area of interest (increasing or decreasing signal) be zoomed-in on by moving the left and right cursors near this region and then pressing the Enter key. The next step is to move and lock the left cursor at the exact location in which you can detect a signal change and the right cursor at the point of completed travel. By pressing the analysis key (F3 or F4), the time between the cursors is displayed. This is the elapsed time (stroking speed) it takes the valve to respond to an abrupt signal change. Pressing F5 or F6 will provide a printed copy of the results.

FlowScanner User Guide 8.1.14

Stepped Ramp Test

A6886*D/IL

The Stepped Ramp test is performed to measure the response or controllability of the process variable (i.e., pressure, flow, level, temperature, etc.) to the valveâ&#x20AC;&#x2122;s signal change and is expressed in percentage. The Display Program defaults to page 2 (Elapsed Time Display) on which you plot the control signal and the process variable (normally measured on an auxiliary channel). Because the input signal is stepped systematically in steps of equal value and that the stepping direction is changed a minimum of three times, the valveâ&#x20AC;&#x2122;s hysteresis and deadband can be captured. To manually analyze this data (there is no auto analysis) simply count the number of signal changes required to obtain an output (process variable) change. Multiplying this number times the percent of change per step equals the percent of response of the valve assembly. For example, if the test was performed at 0.5% step increments (0.08 mA for a 4-20 mA signal range) and it took four of these steps to achieve a change in process, you would call this 2% control. Hence the process tolerance, in this example, could not be held any closer than 2%.

FlowScanner User Guide 8.1.15

Step Study Test

need data for this test to include graph

The Step Study test is performed to measure the response or controllability of the process variable (i.e., pressure flow, level temperature, etc.) to the valveâ&#x20AC;&#x2122;s signal change and is expressed in percentage. The Display Program defaults to page 2 (Elapsed Time Display) on which you would plot the control signal and the process variable (normally measured on an auxiliary channel). Because this test systematically steps an input signal up and down at changing increments, the total hysteresis and deadband of the assembly can be captured. In this display, you look for what degree of signal change is required for the output (process) to follow. For example, if you see that there is minimal to non change in output with a 1% signal change, but the output mirrors the input with a 2% signal step, you would classify this assembly as being between a 1% and 2% device. There is no auto analysis of this test.

8.2

Transferring Data to the Report Module The Quick Report is only defined for Dynamic Scan tests. For Static Point, Step Change, Stepped Ramp and Step Study tests, the printed graph is the report. As each Dynamic Scan graph is analyzed the calculated results are saved in memory from the most recent analysis of that graph. This data can be written to a file for transfer to the report program for summary printout with your added comments. Pressing F10 once from the graph menu will display a screen showing which graphs have been analyzed and which have not. Check to

FlowScanner User Guide see that the appropriate graphs have all been analyzed for the construction of the test valve. Pressing F10 again will store the results on the data disk where the report program can read them later. The results are stored under a TESTNAME.QRP file. Exit the Display program back to the main menu.

8.3

Copying and Displaying from the Display Program The Display program is also used as the way to copy test data from one disk to another, to save data in ASCII format for use by other analysis methods, and to store data files in compressed ”ZIP” files for archiving and uploading to the BBS system. The Display program FileSave menu lists these options to save data:

8.3.1

Saving Data to New Disk This choice simply saves the test data in memory (ready to display) to the data drive. It is used if you didn’t save the data in the Test program and want to save it to a data disk, or to copy data from one disk to another. To copy data, first read in the test you want to copy from the original disk. Then insert the disk on which you want to put the test data and select this choice. Read the help screen to verify this is what you want and press F10 to save the data to the new disk.

8.3.2

Saving Data as an ASCII File The FlowScanner does not use ASCII format for test data because it is inefficient and takes up too much space. However data can be exported in ASCII format for use in spreadsheets and other analysis programs. To export data in ASCII first read in the data from the original data disk. Then insert a new disk with enough free space (each ASCII data file may be 500 kb) and select this choice from the FileSave menu.

8.3.3

Compressing Files FlowScanner data is normally saved in multiple files in typed binary format. Each test will take at least 5 data files, plus the nametag data. As a result the files may take up to 100 kb disk space and several files must be transferred if you want to copy tests or send them by modem. The FlowScanner can make use of the PKWare utilities

FlowScanner User Guide to compress a set of test files into a single file for transfer. To do this the temporary storage drive (RAM DISK or TRAM directory) is used to hold the test data while PKZIP does its work. Normally you should store data in the FlowScanner format, but when you need to transfer files, or archive groups of tests on a hard disk, you can use these utilities to compress them. To use these utilities you must have PKZIP.EXE and PKUNZIP.EXE stored on you disk in the DOS search path. (The DOS directory works well.) PKZIP is installed on all FlowScanners and is also available on the FlowScanner BBS. Like the other file saving formats, the test data you want to ZIP must first be loaded into memory. There are three ZIP saving options: Save as ZIP File by Test This is the only option which can be read directly back into the display program. A single ZIP file with the extension ”.ZPD” (Zipped Data) is created on the data drive holding all the test data in memory (and the Nametag) under the filename TESTNAME.ZPD – where TESTNAME is the same date–time name created when the test was done. Save as ZIP file by TAG This option first creates a ZPD file by TESTNAME, and then adds it to a file named by the valve nametag as TAGNAME.ZPT – where TAGNAME is the first 8 digits of the TAG number from the nametag. If you choose this option for several tests on the same valve, they will all be added to the single TAGNAME.ZPT file. If you have tests from more than one Nametag with the same first 8 digits, they will be grouped in the same file. Once you save tests in this format, you must extract the TESTNAME.ZPD files manually with PKZIP before the Display program can read them back in. Save as ZIP file by Serial This option first creates a ZPD file by TESTNAME, and then adds it to a file named by the valve nametag as SERIAL#.ZPS – where SERIAL# is the HEX value of the Serial number from the nametag. If you choose this option for several tests on the same valve, they will all be added to the single ZPS file. Once you save tests in this format, you must extract the TESTNAME.ZPD files manually with PKZIP.

FlowScanner User Guide 9

Quick Reports

9.1

Overview The Quick Report should include both the summary printout of the analyzed data with your added comments, and any appropriate prints of graphs that you printed from the display program. You should also attach a printout of the Nametag information, printed from that program. The summary report reads in the analyzed data and the nametag data and formats it in a table. You then can put comments next to any line of the table explaining the significance of the numbers.

9.2

Procedures

9.2.1

Retrieving Data Select the Report program from the main menu, being sure the data disk is in the drive. From the initial screen select the File menu (Alt–F) and select Retrieve Test results. Then select the test name desired from the list at the top of the screen, and press Enter to read in the data. The calculated data from the Display program will appear in the Specified and Measured Columns, with Comments section ready for your input: If the Static End Points were manually recorded when the test was run, those values will appear in the Comments lines next to the Dynamic End Points: You can add to these static calibration notes, or add additional comments in the report Comment fields. The screen isn’t long enough to show the entire report, so it is displayed in sections. The first part shown is the overall valve control. The cursor will be on the first comment field. You can enter a comment and move the next field. You can move between comments with the Up and Down arrow keys. After filling in the comments on this first screen, press the PgDn key to move to the second section ”Valve and Actuator Data”. Fill in the Comments on the Valve and Actuator combination as on the previous screen, and PgDn will show the last section, ”Positioner Data” and ”I/P Transducer Data”. After filling in this screen of comments the first screen will re–appear. The PgUp and PgDn keys will let you look through the completed report for review.

FlowScanner User Guide Pressing Alt–C will open a comment window where you can enter a couple of concluding comments to print at the bottom of the report.

9.1.2

Saving Reports The completed report, with comments, should now be saved to the data disk by pressing F10 (or from the file menu). This will save it as a FlowScanner report, formatted for use with either this Quick Report or the formal report package. If you do not save the report before exiting the report program your comments will be lost. Because the report is saved to a FlowScanner report file, retrieving the test results will again bring up the data without the comments. If you want to retrieve a report with comments, select the ”Get Saved FlowScanner Report” from the File Menu.

9.2.3

Printing Reports F6 or Alt–P will print the report; either to the screen for preview, or to a printer, if attached. While the report is printed as TEXT and not in graphics mode, the lines on the report are printed in the IBM extended character set. If the printer is not set up to use this character set it will instead print whatever extended characters it has, which may produce very strange looking characters in the report. Most printers can be set to use the IBM or PC–US, or ”graphics” (instead of italics) character set, which will produce the lines as shown on the screen.

FlowScanner User Guide 10

Parts List

FlowScanner parts and toolkit parts can be ordered through your local Fisher Representative or Fisher Sales Office. ITEM

PART NUMBER

Accessory Kit, Complete Adapter, Hex Adapter, Rotary *Battery Cable Kit, 50-inch transducer *Cable, Current Output Cable, Current Output, 25-foot Extension Cable, Pressure Scanner 25-foot Extension *Cable, Travel Transducer Cable, Travel Transducer, 25-foot Extension Case, Shipping Case, Tool Charger, Battery, External Clamp, 2.5-inch w/adapter Clamp, 1-inch Clamp, 4.5-inch w/adapter Clamp, Bessey Fitting, Parker 1/8 tube x 1/4 MNPT Fitting, Parker 1/8 tube x 1/8 FNPT Fitting, Parker 1/8 tube x 1/8 MNPT Fitting, Parker 62–PL–2 Fitting, Parker 66–C–2–2 Fitting, Parker 68–C–2–2 Guide, Cable, 50-inch transducer I/P, 0–60 PSI Output Rod, 1/2 x 10 Rod, 3/8 x 8 Swivel Joint, 1/4 x 3/8 Swivel Joint, 3/8 x 1/2 Swivel Joint, 3/8 x 3/8 Transducer, Travel, 2-inch Transducer, Travel, 25-inch *Transducer, Travel, 25-inch (BEI Style) Transducer, Travel, 50-inch *Transducer, Travel, Rotary *Tubing, Parker

T13845T0012 T13886T0012 T13885T0012 T13846T0012 T13924T0012 T13847T0012 T13848T0012 T13849T0012 T13850T0012 T13851T0012 T13904T0012 T13888T0012 T13852T0012 T13899T0012 T13902T0012 T13898T0012 T13923T0012 T13891T0012 T13890T0012 T13889T0012 T13892T0012 T13893T0012 T13894T0012 T13925T0012 T13853T0012 T13900T0012 T13895T0012 T13896T0012 T13901T0012 T13897T0012 T13858T0012 T13859T0012 T13862T0012 T13860T0012 T13861T0012 T13887T0012

*Recommended spare parts

FlowScanner User Guide 11

Appendices

11.1

Appendix A: Data Management

11.1.1

Transferring Data Normally with the FlowScanner, the data disk is either the A: floppy or the G: hard disk. When data for a FlowScanner test is stored, there are basically two types of data files. One is the name tag which is created from the ” Start, Look at, or Change of Valve Name Tag” choice from the Main Menu. If ”Tag Name” in the Operating Defaults is listed as ”TagName”, the name tag will be saved on the data drive as ”XXXXXXXX.T@G” (or ”XXXXXXXX.RRG” for rotary) where ”XXXXXXXX” is the first eight characters in the tag name field. If ”Serial Number” is selected, the file name will be in the format ”YYYYYYYY.SER” (or ”YYYYYYYY.SRR” for rotary) where ”YYYYYYYY” is a hexadecimal conversion of the serial number field. The other data file type is the data files gathered during a FlowScanner test. The file names for the data files all have the format ”MMDDHHMM.ZZZ” where the eight character filename is the month, day, hour, and minute the test was started and the ”ZZZ” suffix is ”DTA”, ”DNT”, ”DN1”, ”UPT”, and ”UP1” for sliding stem valve tests (or ”DTR”, ”DNT”, ”DN2”, ”UPT”, and ”UP2” for rotary valve tests). If the graphs have been analyzed, a ”MMDDHHMM.QRP” quick report file is also present. Also saved are the RUNTEST.DAT file that was created when you did the name tag and test setup. There is also a DEFAULT.DAT or SETTINGS.DAT. You may run out of space in the middle of a test or want to take files from several data disks and put them on one composite data floppy. This discussion of data management is concerned with moving files from one data disk to another. Transferring the Name Tag to a New Floppy Disk To transfer a name tag, insert the floppy disk that contains the source name tag. Open the Name Tag program, then select ”Retrieve Valve Name Tag” from the File menu. When you press <Enter>, the program reads the source data disk and displays the list of available valve name tags. Select the desired name tag by moving the selection field up or down with the arrow keys, then press <Emter>. This copies the valve name tag information to he Valve Name Tag program. At this point, remove the source disk and insert the

FlowScanner User Guide destination disk. Select ”Save the Valve Name Tag to File” from the File menu to copy the contents of memory to the destination data disk. Transferring the Test Data to a New Floppy Disk To tranfer the test data from one floppy data disk to another, insert the source data disk. Open the Display program, then select ”File Retrieve” from the File menu. Select ”Test to Display” and press <Enter>. This activates the program to read the source disk and display the available tests on the disk. Select the desired test by moving the selection field up or down with the arrow keys, then press <Emter>. Ths loads the selected test data into the Display program. At this point, remove the source disk and insert the destination disk. Select ”Save Data to New Disk” from the File Save menu, then press <Enter>. This copies the contents from the program memory to the destination data disk. Tranferring the Name Tag to a New Data Drive To transfer the name tag to a new data drive, open the Name Tag program, then select ”Retrieve Valve Name Tag” from the File menu. When you press <Enter>, the program reads the source data disk and displays the list of available valve name tags. Select the desired name tag by moving the selection field up or down with the arrow keys, then press <Emter>. This copies the valve name tag information to he Valve Name Tag program. Exit the Name Tag program, then open the ”Operatig Defaults” screen to change from the source data drive to the destination drive. Exit the ”Operating Defaults” screen and reopen the Name Tag program. Since the name tag data is still listed in this screen, you can save it to the new data drive by selecting ”Save Data to New Disk” from the File Save menu and pressing <Enter>.

FlowScanner User Guide Tranferring the Test Data to a New Data Drive To transfer test data from one data drive to another, begin by ensuring that the ”Operating Defaults” screen is referencing the source data drive. Open the ”Display Program” and select ”Tests to Display” from the File Retrieve menu.. Select the desired test and press <Enter> to load the data into the ”Display Program.” Exit the ”Display Program” and open the ”Operating Defaults” screen to change the data drive to the destination drive letter. Exit the ”Operating Defaults” screen and reopen the ”Display Program.” Since the test data is still in memory, you can save it to the new data drive by selecting ”Save Data to New Disk” from the File Save menu and pressing <Enter>.

11.1.2

Data Storage Tips Typically, field tests are stored on a floppy diskette. In practice, this has been the most effective way to store and transfer FlowScanner test information. One 3.5-inch, 1.44 Mb floppy will store approximately 16 tests. The number of tests that can be stored per disk depends on the test types and the number of parameters being monitored. Proper labeling should be used in order to identify the tests stored on each disk. A common practice should be developed so labeling is uniform throughout a particular site. After testing is completed, the floppy disks are typically stored for later comparisons or the information is transferred to a permanentarchive such as a desktop personal computer or local area network (LAN). Even though there is a hard disk on the FlowScanner, saving data to it should only be temporary. If used for permanent storage of test data, you are putting ”all your eggs” in a portable basket, which is used in various environments in the field and usually by more than one person. Data should be transferred, if the FlowScanner is used for storage. After testing is complete, the data should be stored in a more secure format such as, floppy disk, desktop PC hard drive or LAN. FlowStor Data Archive software was developed to address this need. Refer to Section 11.7, ”Appendix G: Related Products” for more information on FlowStor.

FlowScanner User Guide 11.2

Appendix B: Software Installation The distribution disk contains the programs in selfâ&#x20AC;&#x201C;extracting compressed format with an installation program to install them on your hard disk. This creates a FLOWAUX directory with SLIDSTEM and ROTARY subâ&#x20AC;&#x201C;directories for the programs, TRAMS and TRAMR directories for temporary storage of base data, and TEMPS and TEMPR directories for temporary storage of other data. It will also place SLIDAUX.BAT and ROTAUX.BAT files in either the 1APP directory (on FlowScanners) or the root directory (on Desktop PCs) to start the programs. FlowScanners copy the programs to a RAM disk to shut down the hard disk to save battery power. To install, place the distribution disk in the floppy drive, and run the INSTALL.EXE program on the floppy disk. The install program will check the hardware to see if it is a FlowScanner, and will ask where you want to install the programs.

11.2.1

Starting the Programs from DOS and Windows Starting from DOS The ROTAUX.BAT and SLIDAUX.BAT files created on the hard drive will start either the Rotary or Sliding Stem programs. Starting from Windows You can use the Windows DOS prompt or use the Program Manager (or other Windows shell, like Norton Desktop) to add a Rotary and Slidstem icon to a program group. For the Rotary program select the \FLOWAUX\ROTARY sub directory as the starting directory and MAINROT.EXE as the program. For the Sliding Stem programs (SLIDSTEM) select the \FLOWAUX\SLIDSTEM directory and the MAINFS.EXE as the program. The details of creating the program group vary with the Windows shell used, so follow normal procedures for your shell. Then just click on the icon to start the programs. (Icon files are installed for the programs.)

FlowScanner User Guide 11.3

Appendix C: Trouble Shooting Troubleshooting Overview The FlowScanner is a complex assembly of computer hardware, data acquisition and sensor hardware, computer operating software, data acquisition software and analysis software. If a problem occurs, it is first necessary to determine whether it is a hardware or software problem, and which part of the hardware or software is involved. This section will help you isolate the problem to a specific area.

Available Technical Support Technical Support is available through the MRO Field Support Group at the Fisher-Rosemount Technical Center, Marshalltown, IA 50158. If your FlowScanner does not respond to the field troubleshooting guide, please call one of the numbers below, for instructions on returning the unit. MRO Group secretary: (515) 754-2227 MRO Group Administrator: (214) 548-3145 Fisher Main Office:(515) 754-3011 A Return of Material Authorization (RMA) number will be issued to track the system. The return address is: Fisher Controls Inc. 310 E. University Dr. McKinney, TX 75069â&#x20AC;&#x201C;80004 Mark: Attn RMA # The FlowScanner must be shipped in the original shipping case provided with the unit.

Major Component Groups For troubleshooting letâ&#x20AC;&#x2122;s define the FlowScanner into the following groups of components (or files): 1. Battery and Power Supply 2. Computer Platform 3. Keyboard 4. Disk Drives 5. Data Acquisition and Sensors 6. LCD and Video Displays

FlowScanner User Guide 7. Printer and RS232 outputs. 8. Computer Operating Software 9. FlowScanner Data Acquisition Software 10. FlowScanner Analysis Software As we discuss various potential symptom’s, we’ll try to isolate the problem to one of these groups.

Suggested Tools We would suggest the following tools for assisting with locating and repairing problems: 1. Phillips and Slotted screwdrivers 2. Digital volt meter – several vendors have small, shirt–pocket sized units at negligible costs. 3. Access to a VGA monitor if LCS is blank 4. Battery Charger for Gel Cell Batteries

Avoiding Trouble If the system has been shipped or dropped, check it over BEFORE turning it on. Open the cover, fold up the screen, and look for any signs of damage or bent parts. Pick the unit up (flat) and tip it in all directions, listening for sounds of anything loose. If you hear suspect noises, DON’T TURN IT ON! Contact Marshalltown Technical Support for Instructions. You may be instructed to take out the 10 top panel screws and lift the system out of the case. Look for loose screws, cable connectors, circuit boards that have popped out of sockets. If it looks OK, turn it on and check it out.

Note Taking the unit apart without approval of the MRO Technical Support Group will void the warranty.

Problem History Overall, the FlowScanner has proven to be a rugged and reliable system. However, there have been a few problems reported.

FlowScanner User Guide Where problems have been traced to hardware design we have made changes to eliminate items of hardware that were not as reliable as required. The Power Supply, Computer Section, data acquisition section, and LCD screen power supply have all been redesigned or re–sourced for the greatest reliability. The majority of problems have been due to shipping damage. The FlowScanner components are rugged, but must be protected from excessive shock. Several units have been shipped with the outside protected from damage, but without effective shock cushioning, resulting in sometimes severe internal damage with no sign of external problems.

Note Never ship a FlowScanner without the plastic, foam–lined shipping case.

Shipping on pallets or padded with “peanuts” or paper has proven inadequate, and damage is likely. Fortunately, shipping damage has usually been connectors or fasteners coming loose, and reassemble has normally restored the system to operation. In the most severe case, a unit was shipped strapped to a pallet, covered by a box. The exterior was undamaged, inside, the LCD screen was smashed, most keys had popped off the keyboards, several wire connectors were detached, circuit boards had popped loose, and even “chips” had popped out of the main computer boards. As the unit was needed for a customer demonstration (outside the USA), we talked through the identification of loose parts and how to fit it back together, and with an external monitor replacing the LCD screen the unit worked properly. Other “repeat” problems have involved mysterious erasing of computer system files from the hard disk, and “virus–like” damage to the hard disk partition table. These problems almost always stemmed from someone trying to use the FlowScanner for some other “computer” use. While it is a very capable computer, it is setup specifical-

FlowScanner User Guide ly for FlowScanner operation, and changing that setup can cause problems.

Symptoms and Possible Areas to Check 1. DEAD – No signs of life – No power LED, no meter indication Battery Connections – Remove cover and check. Battery – Check with DVM, or try spare 2. Battery Drains and doesn’t charge AC Power Indicator – Should be ON with AC connected AC cord – If no power indicator AC Power Supply Remove DC power assy. and check for 15VDC at connector. DC Power Supply – If it has + 15V in and battery contacts are dead, replace the DC assembly. 3. Unit has power, but LCD stays blank LCD Assembly – Check contrast adjustment, LCD switch. LCD Assembly – Turn System Off, plug in VGA Monitor and check for output. If VGA image, check LCD cable to top panel and ribbon cable to video module. 4. “Drive C not ready” message, or seizes with “Loading...” on screen SETUP info. changed – enter computer setup program & check drive type for Hard Disk 1. Should be type 17 for 40 megabyte drive, or refer to cmos configuration document for larger drive. Hard Drive Damage of virus damage – Replace hard drive and return to us for evaluation. 5. FlowScanner software doesn’t run, “Heads Parked” message appears instead RAM disks missing – check CONFIG.SYS file on hard disk. Copy CONFIG.BAK or CONFIG.OLD to CONFIG.SYS and reboot. 6. Will Not Access any files on Floppy Disk Disk Defective or Not Formatted – try disk in another PC. Drive Type set wrong in “SETUP” – should be 1.44 MB drive. Defective Drive – Replace with 1.44MB drive. 7. FlowScanner locks up when trying to run a TEST.

FlowScanner User Guide Data Disk not formatted RUNTEST.DAT file not created on data disk – see software manual. Operating Defaults set incorrectly – check that data drive letter is assigned to “A”. 8. Measured Current doesn’t track Commanded Current Cable not connected or broken lead – with an open loop the measured current reading is unpredictable. Unit not calibrated for output range – separate calibration is done for 0–25 and 0–55 ranges. 9. Travel Transducer dead – no reading when moved Bad cable connection – check continuity No power to transducer – check for + 5 V at cable connector red lead to black lead. Bad transducer or connector – As transducer is stroked there should be +5V to 0V ”toggle” between the white and black cable leads and the green and black cable leads. If not, try new cable, new transducer. 10. Text Printouts have strange characters instead of lines and boxes Printer not set for IBM extended character set or IBM emulation. 11. Graphs don’t print or print ”garbage” Printer Type set incorrectly on operating defaults. Bad printer cable. Printer set for wrong emulation. Did not wait for image to process – On LaserJets (and Deskjets) the image is pre–processed for about 30 seconds before printing starts. Esc can abort before the printout starts. 12. Quick Report is missing data Test Type not Dynamic Scan – the Quick Report is only used for Dynamic Scan tests; other test types print graphs with analysis. Graphs Not Analyzed First – the QRP file is written using information from the analysis of the basic 4 graphs. 13. Comments Missing from Quick Report File FlowScanner Report not saved after entering comments (select off file menu).

FlowScanner User Guide Retried QRP file instead of Old FlowScanner Report. No room on disk for FlowScanner Report File. 14. Analysis incorrect, ”fit–line” not drawn to data spread Auto Analysis not finding range property, set analysis range manually with cursors. Some data conditions can cause the software to analyze the curve beyond the linear region. Set the left and right cursors to just inside the linear region before analyzing. Non–Linear cam in the positioner – A non–linear cam will not analyze to a linear fit, so the zero and span numbers may be off, and of course, linearity numbers will be high. Note the end points manually on the print–out. 15. Bench–set calculation appears incorrect Actual Travel different from nominal travel – The Bench–Set is based on the nominal travel entered on the Nametag. The analysis first fits the mid–line curve to the data and then located the end of the curve at the upper travel stop. An ”X” is drawn on the FIT line at the point. Then a ”X’ is drawn at the nominal travel point, and pressures at these points are used for the bench set. Fit line extends into non–linear area – If a high friction area or pilot spring area is included in the auto–analysis region the fit line can be skewed. Move cursors to the ends of the linear region before analyzing. Nametag mis–labeled for OPEN position – The bench set is calculated from the upper travel stop. If the wrong position is identified the bench set will be off. 16. Seat Load calculation incorrect Curve shape not ”typical” and points taken not representative of the pressure build–up. Circles are drawn around the points used for the seat–load calculation. If they are not in the right place, use the top and bottom cursors to identify the correct pressures before analyzing. Unbalance area or ”Pressure Tends To” entry wrong on nametag, this will make the service seat load incorrect. Wrong Service Pressures entered on Nametag – Enter the service pressures at shutoff as closely as possible. If they aren’t known at all, don’t enter any pressures, as the calculation could be misleading.

FlowScanner User Guide 11.4

Appendix D: Calibration When installed on a FlowScanner the FlowAux programs offer to copy the standard software (2.3) calibration for use with FlowAux. When recalibration is done after installing FlowAux, the FlowAux programs are calibrated separately from the 2.3 programs, and results are kept in different directories. The file formats are identical, and you can copy the calibration files (TSCAL.DAT) from C:\FLOWSCAN\SLIDSTEM to C:\FLOWAUX\SLIDSTEM if you want to avoid separate calibration. If the FlowScanner has –10 V to +10 V output it is still only necessary to calibrate the output from 0 to +10 V; since the negative voltages are done simply by reversing polarity of the output. Calibration is all done in the software and should be necessary only once or twice per year, or as often as the site requires. The pressure calibration does shift as the system warms up, so the system should be left at the CALIBRATE screen for 20 minutes before calibrating. The warmup affects primarily the ”zero” calibration, which is easily reset at test time.

Note Zero shift is the most common pressure calibration drift. The zero point can be recalibrated without affecting the slope and linearity by pressing Alt–Z when all pressure ports are open to atmosphere. In the calibration program, the new zero reference can be saved by pressing F10 after adjusting the zero point. (The zero can also be set during the TEST program, but the new zero is not saved from the TEST program.)

When you enter the calibration program the system accesses the data card and displays live readings of all channels. As in the other programs the menus at the top of the screen are accessed by holding the Alt key and pressing the highlighted letter of the menu name. (Alt–F opens the File menu.)

FlowScanner User Guide Print/View Data on the calibration including the master meter description and serial number, person calibrating, and all master meter readings and FlowScanner readings is kept on the hard disk and may be viewed or printed on demand. Alt–P opens the menuto look at old calibrations. The last choice, ”View/Print All Calibrations” will show on-screen a complete summary of the calibration records stored on the system hard disk. This will be split into several screens of information. At the bottom of the last screen it will say ”Press P to Print the calibration record or any other key to continue.” This will print to a printer attached to the printer port (LPT1). Any other choice from this menu will simply show the part of the calibration requested, and give a chance to print that record.

Calibrate/Check.. The Calibrate/Check menu is selected to compare system readings to a master gauge or instrument, calculate new calibration constants, and compare results using both the old and new calibrations. Then you can decide whether to record the new calibration constants or keep the old ones. (Sometimes you may want to check the calibration when a master instrument meeting your accuracy standards is not available. In such a case you would go through the procedure and verify that the calibration agrees, but would not record the less– accurate new calibration.) If the calibration password is not set, Alt–C opensthe Calibrate/Ceck menu. From this menu you can calibrate the complete pressure scanner, the 25 mA, 55mA, and 10V control loops, the auxiliary inputs, single channels of the pressure scanner, and check the travel encoders. Details of these procedures are given later in this section.

Reset.. The Reset menu allows you to delete the calculated calibration of any channel and substitute generic values. The Travel encoders are most accurate if you use the reset values rather than calculating new values. The other channels are not very accurate using the RESET values, and should be re calibrated if reset. The main use of this menu is to recover from an accidental bad calibration that may make re calibrating otherwise difficult.

FlowScanner User Guide Options.. A calibration password may be set from the ”Options” menu. If a password is set the system may not be calibrated unless the password is verified. If you re–enter the password from the Options menu it clears the password again.

Calibration Methods Calibration of all I/O functions is done using a 5–point calibration to an external master gauge or meter. Pressure inputs are calibrated to a second–order fit, and all other functions are done to a linear, least– squares fit to the 5 points. To calibrate the pressure measurement system the following is required: 1. An adjustable pressure source or 5 pre–set pressures. 2. An accurate master gauge connected in line with the FlowScanner system so the pressure can be read simultaneously. 3. A pressure source of 100 psig to operate the calibration valve in the FlowScanner. 4. The necessary 1/16” x 1/8” plastic tubing and fittings to connect to the pressures and gauges. To calibrate the Current Loop (4–20 mA) output you will also need an accurate current meter and an I/P (or 150 Ohm load resistor). The auxiliary channels are 0–10 volt inputs and are calibrated to a master meter. The travel transducers are digital encoders which do not require calibration, but the calibration procedures can be used to check accuracy and operation. Control Signal Output Accuracy Range

Loop Command Accuracy

Measurement Accuracy

0 to 25 mA 0 to 55 mA 0 to 10 Vdc

0.02 mA 0.03 mA 0.01 volts

0.03 mA 0.03 mA 0.01 V

FlowScanner User Guide Travel Input Accuracy Range

Resolution

Overall Accuracy

0 to 2 inch (0 to 50.8 mm)

0.0001 inch (0.0025 mm)

0.0001 inch ( 0.0025 mm)

0 to 4 inch (0 to 101.6 mm)

0.0001 inch (0.0025 mm)

0.0001 inch ( 0.0025 mm)

0 to 25 inch (0 to 635 mm)

0.0001 inch (0.0025 mm)

0.0001 inch 0.012% full scale ( 0.0025 mm) 0.012% full scale)

0 to 32 inch (0 to 812.8 mm)

0.001 inch (0.025 mm)

0.001 inch 0.05% full scale ( 0.025 mm) 0.05% full scale)

Rotary

0.0075 degree

Pneumatic Input Channel Accuracy Pressure Range

Resolution

Accuracy w/10 Min. Warm-Up & Within 20 Min. of Re-Zero

Accuracy w/2 Min. Warm-Up

0 to 100 psi 0 to 689.65 kPa)

0.04 psig (0.27 kPa)

0.1 psig + 0.2% of reading 0.68 kPa + 0.2% of reading

0.1 psig + 0.7% of reading 0.68 kPa + 0.7% of reading

0 to 30 psi (0 to 206.90 kPa)

0.01 psig 0.07 kPa)

0.03 psig + 0.2% of reading 0.2 kPa + 0.2% of reading

0.03 psig + 0.7% of reading 0.20 kPa + 0.7% of reading

Note: Also configurable to kg/cm2, Bar

The FlowScanner accuracy is expected to be as follows, if properly warmed–up and calibrated to a master gauge or instrument at least 3 times as accurate as the FlowScanner. (Some company standards require even higher accuracy of the master instruments in order to claim the stated accuracy of the FlowScanner.) Calibrating to less accurate masters can result in mis–calibrating the FlowScanner. (You obviously can’t calibrate to 0.01 mA with an instrument that only reads to 0.1 mA.) Digital pressure gauges should resolve at least 0.01 psig. The system should be warmed–up at least 20 minutes before calibrating, and should be calibrated at near the ambient temperature for which it will be used. The pressure scanner exhibits noticeable drift during power–on warm–up in the Test or Calibration mode. The drift decreases with time, and is most noticeable in the first 5 minutes of reading pressures. To reach stated accuracy allow the unit to warm up in the Test or Calibrate program for at least 10 minutes, re–zero immediately before each test or other measurement, and take readings within 25 minutes of each re–zero.

FlowScanner User Guide Overview: Calibrating Pressures Normally all pressure channels are 0–100 psig range and all pressure channels are calibrated at once. The internal calibration valve is switched to connect the port marked ”CAL” to all 8 transducers internally. Five pressures are applied to the CAL port covering the needed range. For each pressure the actual applied pressure is read from the test master gauge, and this correct value is manually entered into the system. Pressing the Enter key causes the system to record the entered value and the current readings for each of the 8 channels. After all pressures are entered, the actual readings from the 8 channels can be reviewed (PgDn) and compared to readings using the new calibration constants. If the new calibration is better, pressing F9 saves the new constants to the calibration file for default use. Then the calibration valve is switched back to the RUN mode for test. If the high–accuracy transducer option is installed channels 7 & 8 are 0–30 psig range and are isolated from the other channels to avoid over pressure during calibration. From the Options selection on the Calibration menu the software is told whether 7 and 8 are 0–30 or 0–100 psig range. If 0–30 is selected the scanner calibration only calibrates channels 1–6, and channels 7 & 8 are individually calibrated later.

Calibrating Current The current loop is calibrated by connecting the system in series with an I/P (or approximately 150 Ohm resistor) and a current meter. Connecting directly to a current meter without a load in the loop is not recommended. This procedure calibrates both the current controller and the measured loop current. Separate calibrations are done for the 0–25 and 0–55 output sections.

Calibrating Voltage The voltage output and auxiliary inputs are calibrated by controlling the voltage with the cursors and recording the readings of a master meter.

Full Calibration Procedure: 1. Select the Calibration program from the main menu. The old pressure calibration (if any) will be used for the pressure displays. If

FlowScanner User Guide any channel numbers are flashing it means there is no valid calibration on file for that channel and the displayed values are known to be inaccurate. 2. First calibrate the pressure scanner. From the ”Calibrate...” menu (Alt–C) select the pressure scanner. Instructions will be shown on the left side of the screen. Page through them with the PgDn key, or skip them by pressing Enter. 3. Connect the 100 psig air source to the port marked ”C1”. Apply pressure for a few seconds. A ”click” should be heard as the shuttle valve shifts to the calibrate position. The pressure can now be shut off and disconnected. 4. After paging through the instructions (PgDn) a screen of information about the master gauge and the person doing the calibration is presented. Fill in this screen and press PgDn. 5. Leaving CAL port disconnected (to atmosphere) type in a ”0” and press Enter. This records a zero reading on all channels. 6. Connect the master gauge and pressure source to the CAL port, and adjust the pressure source to 4 more pressures spanning the range to be calibrated. 7. As each pressure becomes stable type in the reading of the master gauge and press Enter to read all the channels and record the master reading. 8. Press PgDn to see a summary of the proposed calibration. If you wish to use the results for the system calibration press ”F9” to record the calibration. 9. Shut off and disconnect the test pressures. Connect the 100 psig air source to the port marked C2 to switch the transducers back to the individual ports on the front panel. Then disconnect this line. 10. If the high accuracy transducers are installed on channels 7 & 8, or if you want to re–calibrate a single channel, from the ”Calibrate...” (Alt–C) menu select ”Calibrate a Single Pressure Channel,” and repeat the process except leave the scanner in normal operation so each channel is connected to its own input. 11. Then calibrate the current loop. From the ”Calibrate...” menu (Alt–C) select either the 0–25 mA loop or the 0–55 mA loop. Instructions will be shown on the left side of the screen showing how to connect a current meter in series with a load to the output cable.

FlowScanner User Guide 12. After paging through the instructions (PgDn) a screen of information about the master meter and the person doing the calibration is presented. Fill in this screen and press PgDn. 13. Using the left and right cursor keys (or Ctrl–left and Ctrl–right for fast changes) adjust the current so the external meter reads approximately 4 mA. Then enter the actual reading from the master current meter and press Enter. The internal reading is recorded as the Enter key is pressed, and the system assumes it should equal the master instrument reading. 14. Repeat this for the other 4 readings, spanning the range to the maximum current for the loop (20 or 50 mA). Be sure to press Enter to record each reading. 15. Press PgDn to see a summary of the proposed calibration. If you wish to use the results press ”F9” to record the calibration. 16. Repeat for the other current range (each must be calibrated to use). 17. Likewise calibrate the Voltage output, and then calibrate each of the auxiliary inputs. 18. After calibration is complete DO NOT JUST SHUT THE SYSTEM OFF or the new calibration will be lost. Exit the calibration program and select ”Prepare for Shutdown” from the FlowScanner Main Menu. This saves the calibration from temporary storage to the hard disk.

FlowScanner User Guide Additional Notes: In this program the left and right arrow keys on the keypad control the current loop output. Thus it is possible to use an I/P unit to control the calibration pressures. Either arrow key by itself adjusts the output slowly. Holding the Ctrl key and pressing the arrow key adjust the output in larger steps. The travel transducer reading is also displayed during this test, so its calibration can also be checked. If the wrong transducer is displayed, pressing Altâ&#x20AC;&#x201C;T will toggle to the other possible models with each press. While the calibration can be adjusted to match a known displacement, the most accurate calibration is the default value for each transducer. Since you have live control over the output; and can read all pressures and the travel, this routine can be used to calibrate a valve and accessories. The same control exists in the Test program before starting a test sequence.The calibration records can be recalled from the View/Print menu and shown on screen or printed to a printer.

FlowScanner User Guide 11.5

Appendix E: Connectors for Diagnostic Testing This section describes ‘‘quick’’ connectors which are now available from Fisher Controls to support diagnostic testing of process control valve packages. Process control valve packages include a control valve, actuator, positioner, and accessories. D The connectors are for use with any actuator, positioner, volume booster, or other product available from Fisher Controls. The new connectors allow a quick, positive connection between installed control devices and the FlowScanner Valve Diagnostic System from Fisher Controls. To support the use of the FlowScanner System, connectors are recommended for all actuators and positioners available from Fisher Controls especially as retrofit items for installed units. D Only personnel qualified through training or experience should install the connectors and operate and maintain process control equipment. If there are any questions concerning these instructions, contact your Fisher Controls sales representative or sales office before proceeding. The connector assembly consists of pipe nipple, pipe tee, and pipe bushing as necessary to tap pneumatic lines and a connector body and body protector. With connectors installed, the FlowScanner can be rapidly configured for testing of a control valve package.

Specifications Specifications for diagnostic connectors are listed below. Available Configurations Pipe nipple, pipe tee, pipe bushing, and connector body. Install for ease of connection with the FlowScanner System Recommended Applications Fisher Controls (instruction manuals):J 377 Series Trip Valves,J Types 546 and 546S Electro–Pneumatic Transducers,J Type 646 Electro–Pneumatic Transducer,J Type 2625 Volume Booster,J 3570 Series Pneumatic Valve Positioners,J 3582 Series Valve Positioners, Type 3582i Valve Positioner, and Type 3583 Valve Stem Position Transmitter,J Types 3590, –S, and –ST Electro–Pneumatic Valve Positioners,J 3610J and 3620J Series Positioners,J Types 3660 and 3661 Positioners,J Type 3710 Pneumatic Positioner,J 471 Series Actuators,J Type 481 Actuator,J 490 Series Actuators,J Type 513 and 513R Diaphragm

FlowScanner User Guide Actuators,J Types 585 and 585R Actuators,J Type 657 Diaphragm Actuator,J Type 667 Diaphragm Actuator,J Type 1031 Piston Rotary Actuators,J Type 1032 Rack–and–Pinion Rotary Actuators,J Types 1051 and 1052 Diaphragm Rotary Actuators,J Type 1061 Piston Rotary Actuators,J Types 1066 and 1066SR Piston Rotary Actuators,J Types 1250 and 1250R Actuators Other Manufacturers:J PMV Positioners,J Moore 61H Booster Relay,J Bailey P88–21 Positioner when these products are installed on valve/actuator packages by Fisher Controls Connector J stainless steel orJ brass Connector Body: 1/8 inch NPT male with female ”quick-connect” receptacle. 1.83 inches (46.5 mm) overall length. Internal poppet valve Body Protector: Male component (solid plug). 1.75 inches (44.5 mm) overall length. Inserted into connector body to protect internal body components against damage or plugging caused by foreign contamination Stem: 1/8 inch NPT female, for gauge, with male component (open connection). 2.02 inches (51.3 mm) overall length. Stem does not contain internal valve The FlowScanner System comes equipped with flexible tubing and stems to mate with installed connector bodies for diagnostic testing Maximum Temperature Limit 250_F (70_C) Maximum Safe Working Pressure When coupling/uncoupling body/stem: 250 psi When body/stem are coupled SST: 3000 psi Brass: 2000 psi

Installation Connector Mounting Orientation Assemble the pipe nipple, pipe tee, pipe bushing, and connector according to the orientations shown. Refer to the appropriate assembly drawing for the installation points for diagnostic testing. Rotate the connector body for ease of connection with the FlowScanner System.

FlowScanner User Guide Piping

Warning To avoid personal injury or property damage resulting from the sudden release of pressure, do not install any system component, including piping, where service conditions could exceed the limits given in this manual, in product manuals, or on product nameplates. Use pressureâ&#x20AC;&#x201C;relieving devices as required by government or accepted industry codes and good engineering practices.

Warning If a flammable, toxic, corrosive, or reactive gas is to be used as the supply pressure medium, personal injury or property damage could result from fire or explosion of accumulated gas or from contact with toxic, corrosive, or reactive gas. Follow appropriate safety practices and instructions given in product instruction manuals when installing connectors in piping carrying flammable, toxic, corrosive, or reactive gas.

Refer to the appropriate assembly drawing in this manual and figures in the product instruction manual for the location of all input and output connections where connectors will be installed. Use the correct size and type of tubing or piping for all connections. Always follow accepted engineering, installation, and safety practices to insure the safe and accurate transmission of pneumatic signals and process pressures. Install shutoff valves, vents, drains, or seal systems as required by accepted practices.

FlowScanner User Guide Supply Pressure

Warning Personal injury or property damage may occur from an uncontrolled process if the supply medium is not clean, dry, oilâ&#x20AC;&#x201C;free, or noncorrosive gas. Industry instrument air quality standards describe acceptable dirt, oil, and moisture content. Due to the variability in nature of the problems these influences can have on pneumatic equipment, Fisher Controls has no technical basis to recommend the level of filtration equipment required to prevent performance degradation of pneumatic equipment. A filter or filter regulator capable of removing particles 40 microns in diameter will suffice for most applications. Use of suitable filtration equipment and the establishment of a maintenance cycle to monitor its operation is recommended.

Supply pressure must be clean, dry air or noncorrosive gas. Follow instructions given for specific products when installing process control valve packages with connectors.

Principle of Operation The connector body contains an internal poppet valve. The poppet valve provides positive shutoff to minimize pressure loss when removing the stem or body protector. Inserting the stem or body protector into the body does not open the poppet valve until the stem or body protector is seated in the body. When removing the stem, the poppet valve seals before the stem or body protector leaves the body. To Couple: Align stem with body. Push stem into body until stem and body lock together.

100

FlowScanner User Guide To Uncouple: Pull knurled sleeve on body toward stem until stem and body unlock. Remove the stem from the body.

Maintenance

Warning If maintenance procedures require taking process control devices out of service, avoid personal injury and property damage caused by uncontrolled process pressure. Provide some temporary means of control for the process before taking any control device out of service. Before performing any maintenance operations: Disconnect any operating lines providing supply air pressure, a process input signal, or other pressure source to an actuator, positioner, or controller. Shut off the supply pressure to the positioner or controller. Follow all procedures given the product instruction manuals.

Connectors are subject to normal wear. Inspect and replace parts as necessary. Inspection and maintenance frequency depends on the severity of service conditions. Because of the care Fisher Controls takes in meeting all manufacturing requirements (heat treating, dimensional tolerances, materials of construction, and other product characteristics specified by Fisher Controls), use only replacement parts manufactured or furnished by Fisher Controls. Select the appropriate maintenance procedure and perform the numbered steps. Shut off the supply pressure and process pressure before beginning maintenance.

101

FlowScanner User Guide Parts Part Ordering Parts Ordering Whenever corresponding with your Fisher Controls sales office or representative about process control equipment, always mention the serial number of each component. When ordering replacement parts, refer to the 11–character part number of each required part as found in the following parts list

Connector/Hardware, for diagnostic testing (FlowScanner System hook-up) Part numbers listed here are for complete FlowScanner System hook–up assemblies. Each assembly includes the connector body, body protector, gauge stem, and hardware such as pipe tees, bushings, and nipples. Contact your Fisher Controls sales office or representative for assistance in ordering individual parts.

Positioners For Type 546 Transducers If The Type 546 Transducer Is Used In A Valve Assembly With A Positioner, No Hook–up For Diagnostic Testing Is Required For The Type 546. The Hook–up For Diagnostic Testing Should Be Installed At The Positioner. Key

Description

Part Number Qty

FOR UNITS W/GAUGES SST FITTINGS 12B8041X012 BRASS FITTINGS 12B8041X022 FOR UNITS W/OUT GAUGES SST FITTINGS 12B8041X032 BRASS FITTINGS 12B8041X042 FOR TYPE 646 TRANSDUCERS IF THE TYPE 646 TRANSDUCER IS USED IN A VALVE ASSEMBLY WITH A POSITIONER, NO HOOK–UP FOR DIAGNOSTIC TESTING IS REQUIRED FOR THE TYPE 646. THE HOOK–UP FOR DIAGNOSTIC TESTING SHOULD BE INSTALLED AT THE POSITIONER. FRONT OUTPUT FOR UNITS W/GAUGES SST FITTINGS 12B804X0X012 BRASS FITTINGS 12B8040X022 FOR UNITS W/OUT GAUGES SST FITTINGS 12B8040X032 BRASS FITTINGS 12B8040X042

102

1 1 1 1

FlowScanner User Guide Key

Description

Part Number

Qty

SIDE OUTPUT FOR UNITS W/GAUGES SST FITTINGS 12B8040X052 BRASS FITTINGS 12B8040X062 FOR UNITS W/OUT GAUGES SST FITTINGS 12B8040X072 BRASS FITTINGS 12B8040X082 FOR TYPE 2625 VOLUME BOOSTER FOR UNIT USED W/DIAPHRAGM ACTUATOR SST FITTINGS 12B8042X012 BRASS FITTINGS 12B8042X022 FOR UNIT USED W/PISTON ACTUATOR SST FITTINGS 12B8043X012 BRASS FITTINGS 12B8043X022 FOR 3570 SERIES POSITIONERS W/TYPE 377 VALVE FOR UNITS W/GAUGES SST FITTINGS BRASS FITTINGS FOR UNITS W/OUT GAUGES SST FITTINGS BRASS FITTINGS FOR 3582 SERIES VALVE POSITIONERS

1 1 1 1

12B8044X012 1 12B8044X022 1 12B8044X032 1 12B8044X042 1

FOR UNITS W/GAUGES SST FITTINGS BRASS FITTINGS FOR UNITS W/OUT GAUGES SST FITTINGS BRASS FITTINGS FOR TYPE 3582i VALVE POSITIONER

12B8045X012 1 12B8045X022 1 12B8045X032 1 12B8045X042 1

FOR UNITS W/GAUGES SST FITTINGS BRASS FITTINGS FOR UNITS W/OUT GAUGES SST FITTINGS BRASS FITTINGS FOR TYPE 3590 POSITIONERS

12B8046X012 1 12B8046X022 1 12B8046X032 1 12B8046X042 1

FOR UNITS W/GAUGES SST FITTINGS BRASS FITTINGS FOR UNITS W/OUT GAUGES SST FITTINGS BRASS FITTINGS

12B8047X012 1 12B8047X022 1 12B8047X032 1 12B8047X042 1

103

FlowScanner User Guide Key

Description

Part Number

Qty

FOR TYPE 3610J POSITIONERS FOR UNITS W/GAUGES SST FITTINGS BRASS FITTINGS FOR UNITS W/OUT GAUGES SST FITTINGS BRASS FITTINGS FOR TYPE 3610JP POSITIONERS

12B8048X012 1 12B8048X022 1 12B8048X032 1 12B8048X042 1

FOR UNITS W/GAUGES SST FITTINGS BRASS FITTINGS FOR UNITS W/OUT GAUGES SST FITTINGS BRASS FITTINGS FOR TYPE 3620J POSITIONERS

12B8050X012 1 12B8050X022 1 12B8050X032 1 12B8050X042 1

FOR UNITS W/GAUGES SST FITTINGS BRASS FITTINGS FOR UNITS W/OUT GAUGES SST FITTINGS BRASS FITTINGS FOR TYPE 3620JP POSITIONERS

12B8049X012 1 12B8049X022 1 12B8049X032 1 12B8049X042 1

FOR UNITS W/GAUGES SST FITTINGS BRASS FITTINGS FOR UNITS W/OUT GAUGES SST FITTINGS BRASS FITTINGS FOR TYPE 3660 POSITIONER

12B8051X012 1 12B8051X022 1 12B8051X032 1 12B8051X042 1

FOR UNITS W/SUPPLY GAUGE SST FITTINGS BRASS FITTINGS FOR UNITS W/OUT SUPPLY GAUGE SST FITTINGS BRASS FITTINGS FOR TYPE 3661 POSITIONER

12B8052X012 1 12B8052X022 1 12B8052X032 1 12B8052X042 1

FOR UNITS W/SUPPLY GAUGE SST FITTINGS BRASS FITTINGS FOR UNITS W/OUT SUPPLY GAUGE SST FITTINGS BRASS FITTINGS

12B8053X012 1 12B8053X022 1 12B8053X032 1 12B8053X042 1

104

FlowScanner User Guide Key

Description

Part Number

Qty

FOR TYPE 3710 PNEUMATIC POSITIONER SINGLE–ACTION UNITS FOR UNITS W/GAUGES SST FITTINGS BRASS FITTINGS FOR UNITS W/OUT GAUGES SST FITTINGS BRASS FITTINGS DOUBLE–ACTION UNITS FOR UNITS W/GAUGES SST FITTINGS BRASS FITTINGS FOR UNITS W/OUT GAUGES SST FITTINGS BRASS FITTINGS FOR BAILEY P88–21 POSITIONER

12B8054X012 1 12B8054X022 1 12B8054X032 1 12B8054X042 1

12B8055X012 1 12B8055X022 1 12B8055X032 1 12B8055X042 1

SINGLE–ACTION FOR UNITS W/GAUGES SST FITTINGS BRASS FITTINGS FOR UNITS W/OUT GAUGES SST FITTINGS BRASS FITTINGS DOUBLE–ACTION FOR UNITS W/GAUGES SST FITTINGS BRASS FITTINGS FOR UNITS W/OUT GAUGES SST FITTINGS BRASS FITTINGS FOR MOORE 61H BOOSTER RELAY

12B8062X012 1 12B8062X022 1 12B8062X032 1 12B8062X042 1

12B8056X012 1 12B8056X022 1 12B8056X032 1 12B8056X042 1

USED W/SPRING/DIAPHRAGM ACTUATOR SST FITTINGS BRASS FITTINGS USED W/PISTON ACTUATOR SST FITTINGS BRASS FITTINGS FOR PMV P–1200 SERIES POSITIONER

12B8058X012 1 12B8058X022 1 12B8057X012 1 12B8057X022 1

FOR UNITS W/GAUGES SST FITTINGS BRASS FITTINGS FOR UNITS W/OUT GAUGES SST FITTINGS BRASS FITTINGS

12B8059X012 1 12B8059X022 1 12B8059X032 1 12B8059X042 1

105

FlowScanner User Guide Key

Description

Part Number

Qty

FOR PMV P–1500 SERIES POSITIONER FOR UNITS W/GAUGES SST FITTINGS BRASS FITTINGS FOR UNITS W/OUT GAUGES SST FITTINGS BRASS FITTINGS FOR PMV P–2000 SERIES POSITIONER

12B8060X012 1 12B8060X022 1 12B8060X032 1 12B8060X042 1

FOR UNITS W/GAUGES SST FITTINGS BRASS FITTINGS FOR UNITS W/OUT GAUGES SST FITTINGS BRASS FITTINGS

12B8061X012 1 12B8061X022 1 12B8061X032 1 12B8061X042 1

Actuators Key

Description

Part Number

Qty

FOR TYPE 471 ACTUATOR, SIZES 30 – 130 SST FITTINGS BRASS FITTINGS FOR TYPE 481 ACTUATOR, SIZES 30 – 130

13B8717X012 1 13B8717X022 1

SST FITTINGS BRASS FITTINGS FOR TYPE 490 ACTUATOR, ALL SIZES

13B8718X012 1 13B8718X022 1

SST FITTINGS BRASS FITTINGS FOR TYPE 513 ACTUATOR, SIZES 20, 32

13B8721X012 1 13B8721X022 1

SST FITTINGS 13B8720X012 BRASS FITTINGS 13B8720X022 FOR TYPE 513R ACTUATOR, SIZES 20, 32 SST FITTINGS 13B8720X032 BRASS FITTINGS 13B8720X042 FOR TYPES 585, 585R ACTUATOR, SIZES 25, 50, 100

1 1 1 1

SST FITTINGS 13B8715X012 1 BRASS FITTINGS 13B8715X022 1 FOR TYPE 657 ACTUATOR, SIZES 30 – 87, W/ or W/O TOP–MTD HANDJACK SST FITTINGS BRASS FITTINGS

12B8097X012 1 12B8097X022 1

106

FlowScanner User Guide Key

Description

Part Number

Qty

FOR TYPE 667 ACTUATOR, SIZES 30 – 34, 40 SST FITTINGS BRASS FITTINGS FOR TYPE 667 ACTUATOR, SIZES 46, 60, 70, 87

12B8098X012 1 12B8098X022 1

SST FITTINGS BRASS FITTINGS FOR TYPE 667 ACTUATOR, SIZES 80, 100

12B8098X052 1 12B8098X062 1

SST FITTINGS BRASS FITTINGS FOR TYPE 667 ACTUATOR, SIZES 45, 50

12B8099X012 1 12B8099X022 1

SST FITTINGS 12B8098X032 1 BRASS FITTINGS 12B8098X042 1 FOR TYPE 1031 FAILCLOSE ACTUATOR, MODELS 33082, 33102, 33122, 45102, 45122, 45171, 45211 SST FITTINGS 13B8724X012 1 BRASS FITTINGS 13B8724X022 1 FOR TYPE 1031 FAILCLOSE ACTUATOR, MODEL 33072 SST FITTINGS 13B8725X012 1 BRASS FITTINGS 13B8725X022 1 FOR TYPE 1031 DOUBLE–ACTING ACTUATOR, MODELS 45102, 45121, 45171, 45211 SST FITTINGS 13B8726X012 1 BRASS FITTINGS 13B8726X022 1 FOR TYPE 1031 FAILOPEN ACTUATOR, MODELS 33082, 33102, 33122 SST FITTINGS 13B8727X012 1 BRASS FITTINGS 13B8727X022 1 FOR TYPE 1031 FAILOPEN ACTUATOR, MODEL 33072 SST FITTINGS 13B8728X012 1 BRASS FITTINGS 13B8728X022 1 FOR TYPE 1032 DOUBLE–ACTING ACTUATOR, ALL SIZES SST FITTINGS 13B8722X012 1 BRASS FITTINGS 13B8722X022 1 FOR TYPE 1032 SPRING RETURN ACTUATOR, ALL SIZES SST FITTINGS BRASS FITTINGS

13B8723X012 1 13B8723X022 1

107

FlowScanner User Guide Key

Description

Part Number

Qty

FOR TYPES 1051, 1052 ACTUATOR, SIZES 30 – 70, W/ or W/O TOP–MTD HANDJACK SST FITTINGS BRASS FITTINGS FOR TYPE 1061 ACTUATOR, SIZES 30 – 68

12B8097X012 1 12B8097X022 1

SST FITTINGS 13B8716X012 1 BRASS FITTINGS 13B8716X022 1 FOR TYPES 1066, 1066SR ACTUATOR, SIZES 20 – 75 SST FITTINGS BRASS FITTINGS FOR TYPE 1250 ACTUATOR, SIZES 225, 450, 675

13B8714X012 1 13B8714X022 1

SST FITTINGS 13B8719X012 1 BRASS FITTINGS 13B8719X022 1 FOR TYPE 1250R ACTUATOR, SIZES 225, 450, 675 SST FITTINGS BRASS FITTINGS

13B8719X032 1 13B8719X042 1

A6071

Standard Application Arrangements

108

Figure XX.

FlowScanner User Guide

12B8042-B A6074

Type 2625 Volume Booster with Diaphragm Actuator

12B8042-B A6075

Type 2625 Volume Booster with Piston Actuator

109

FlowScanner User Guide

12B8047-A A6079

Type 3590 Positioner

12B8052-A A6084

Type 3660 Positioner

110

FlowScanner User Guide

12B8053-A A6085

Type 3661 Positioner

12B8054-A A6086

Type 3710 Pneumatic Positioner, Single-Action

111

FlowScanner User Guide

12B8055-A A6087

Type 3710 Pneumatic Positioner, Double-Action

12B8062-A A6119

Bailey P88-21 Positioner, Single-Action need A6119

112

FlowScanner User Guide

12B8056-A A6120

Bailey P88-21 Positioner, Double-Action

12B8058-B A6121

Moore 61H Booster Relay, Used w/Spring/Diaphragm Actuator

113

FlowScanner User Guide

12B8057-8 A6122

Moore 61H Booster Relay, Used w/Piston Actuator

12B8059-A A6116

PMV P-1200 Series Positioner

12B8060-A A6117

PMV P-1500 Series Positioner

12B8061-A A6118

PMV P-2000 Series Positioner

114

FlowScanner User Guide

13B8718-A A6089 13B8717-A A6088

Type 481 Actuator

Type 471 Actuator

13B8721-A A6090

Type 490 Actuator

13B8720-A A6091

Types 513, 513R Diaphragm Actuators

115

FlowScanner User Guide

13B8721-A A6090

Types 585, 585R Actuators

12B8097-A A6093

Types 657, 1051, 1052 Diaphragm Actuators

12B8098-A A6094

Type 667 Diaphragm Actuator (Sizes 30â&#x20AC;&#x201C;87)

116

FlowScanner User Guide

12B8099-A A6095

Type 667 Diaphragm Actuator (Sizes 80, 100)

13B8728-A A6096

Type 1031 Piston Rotary Actuator (Fail Open, Model 33072

117

FlowScanner User Guide

13B8727-A A6097

Type 1031 Piston Rotary Actuator (Fail Open, Models 33082, 33102, 33122)

13B8725-A A6098

Type 1031 Piston Rotary Actuator (Fail Closed, Model 33072)

118

FlowScanner User Guide

13B8724-A A6099

Type 1031 Piston Rotary Actuator (Fail Closed, Models 33082, 33102, 33122, 45102, 45122, 45171, 45211)

13B8726 A6100

Type 1031 Piston Rotary Actuator (Double-Action, Models 45102, 45121, 45171, 45211)

119

FlowScanner User Guide 11.6

Appendix F: Tech Support Technical support is available through all of the following: Local Fisher Representative or the Fisher Direct Sales Office Local Fisher Service Companies MRO Field Support Group: Marshalltown, Iowa, (515) 754-2227 MRO Headquarters: McKinney, Texas, (214) 548-3145

120

FlowScanner User Guide 11.7

Appendix G: Related Products FlowScanner Diagnostic System Support Package With the FlowScanner diagnostic systemsupport package, available to all FlowScanner system owners, you can extend your diagnostic capability by taking advantage of a vast array of control valve diagnostic services, including technical support from the factory support group; Flowscanner system factory test repair and recalibration; access to an online bulletin board that provides technical assistance and diagnostic data interpretation; FlowScanner system software and instruction manual updates. The support package also extends the warranty on your FlowScanner system.

RatRace Desktop Analysis Software RatRace desktop analysis software is used with a desktop personal computer for fast and detailed display and analysis of FlowScanner diagnostic system test data. The RatRace software adds the ability to overlay graphs from up to ten tests. The overlayed data sets plot in different colors and all the displayed tests are listed on the menu page helpsection in the same order and color in which they are plotted to aid in review. The software includes tools that allow drawing lines and circles and adding text notes to annotate graphs. All graphs may be zoomed multiple times in both directions. Because of the extensive use of colors and hard disk, this package is sold for use on desktop computers for FlowScanner diagnostic system analysis support. However, the same installation disk allows installation on FlowScanner systems, if desired.

FlowStor Data Archive Software This Windows compatible software program permits copying and compressing data collected with the FlowScanner Diagnostic System for long-term storage. The program also combines functions that let you access and manage the stored data. You can review summary information for the archived data, or use the built-in link to RatRace desktop analysis software to view and analyze the data. You can easily determine valve performance degradation by comparing recently collected data to data that was collected and archived when the valve was new. The FlowStor software allows you to search and sort data and convert the data for use with popular database programs.

121

FlowScanner User Guide Control Valve Diagnostics: Course 1425 This three-day course uses class lectures and hands-on workshops to teach the student to make a detailed diagnosis of a control valve assembly using the FlowScanner Diagnostic System. Students who complete this course will be able to: properly setup and operate the FlowScanner Diagnostic System perform diagnostic testing on sliding stem and rotary valve, both single and double-acting understand basic diagnostic data interpretation and analysis concepts as related to valve setup and performance

Control Valve Diagnosticsâ&#x20AC;&#x201D;Data Interpretation Seminar: Course 1426 This three-day seminar is designed to teach the advanced diagnostic enginner/technician how to interpret and analyze diagnostic data. Students are encouraged to bring three to five signatures for class review. Students who complete this course will be able to: understand advanced diagnostic data interpretation and analysis concepts as applied to real world problems understand advanced testing techniques needed to diagnose non-standard valve applications use the various elements of the Fisher valve diagnostics program, including the bulletin board system, FlowScanner Users Network and data archive system

122

FlowScanner User Guide 12

Glossary

Actuator

Control Valve Assembly

Bonnet

Valve Body A1550

Relationship of Major Components Accessory Kit Kit supplied with the FlowScanner containing travel transducers, pneumatic tubing, various brackets and miscellaneous hand tools. Actuator A piston or spring and diaphragm assembly for positioning the actuator stem in relation to the operating pressure(s). Actuator Return In a piston actuator, the pressure opposing the stroke pressure. Actuator Stroke In a piston actuator, the pressure opposing the return pressure. In a spring and diaphragm actuator, the pressure opposing the spring.

123

FlowScanner User Guide AutoZero Function (az) A function on the test screen that automatically zeroes the travel reading at test start. Automatic Zero of Travel See autozero function. Auxiliary Input Data Channels Input ports on the FlowScanner for recording auxiliary input such as transmitters or strain gages. Loading Pressure Connection

Diaphragm Casings Diaphragm Plate

Diaphragm Actuator Spring

Actuator Stem Spring Seat

Spring Adjuster Stem Connector

Travel Indicator

Indicator Scale

Valve Plug Stem Yoke W0363

Direct-Acting Actuator

124

FlowScanner User Guide BBS System Electronic Bulletin Board System. Bench Set The pressure range required to move the actuator from its upper stop to its rated travel without any body frictional forces present. Commanded Current The output current signal commanded by the test and displayed on the test screen. Control Signal The voltage or current signal provided by the FlowScanner to control the valve during testing. Dead Band The range through which an input can be varied without initiating observable response. Displayed Travel Units The unit of measure for travel display, selected from the Options screen. Displayed Force Units The unit of force measure for display, selected from the Options screen. DOS Disk Operating System. Dynamic Error Band (DEB) For any given signal level, the difference between upstroke and downstroke position, expressed as a percentage of total travel. Dynamic Scan Test A test in which the control signal is ramped from a preset starting to a preset ending point at a specific rate. FlowAux The FlowScanner operating software. FlowScanner A portable, self窶田ontained test device for analyzing valve condition and performance. Hold Signal at Test End An option (Other) on the test screen that will hold the current at the minimum preset value at the test end or at its current value if the test is aborted rather than dropping to zero.

125

FlowScanner User Guide Hysteresis That property of an element evidenced by the dependence of the value of the output, for a given excursion of the input, upon the history of prior excursions and the direction of the current traverse. Valve Plug Stem

Packing Flange Actuator Yoke Locknut Packing Packing Box

Bonnet

Valve Plug

Cage Seat Ring

W0989

Push-Down-To-Close Valve Body Assembly Hysteretic Error Hysteretic error is usually determined by subtracting the value of the dead band from the maximum measured separation between upscale going and downscale going indications of the measured variable I/P Plot A graph that plots input current versus I/P output and provides performance and calibration data for the I/P.

126

FlowScanner User Guide I/P Resistance The input resistance value of the I/P necessary for current calculation when using the monitor function. Leak Class The classification of the valve performance based on the quantity of fluid passing through an assembled valve when the valve is in the closed position under stated closure forces, with pressure differential and pressure as specified. Linearity An inherent flow characteristic which can be represented ideally by a straight line on a rectangular plot of flow versus percent travel. Main Menu The menu of FlowAux programs used to run the FlowScanner Diagnostic tests. MAINFS.EXE The executable file of the FlowAux sliding-stem valve application. MAINROT.EXE The executable file of the FlowAux rotary valve application. Measured Current The output signal from the Flowscanner as measured by a measurement loop and displayed on the test screen. Monitor Mode A function of the FlowScanner in which it records data while the valve is controlled by the control room. Net Actuator Pressure In a piston actuator, the difference between the pressures in the upper and lower piston cylinders. Net Pressure Plot A graph that plots actuator net pressure versus travel and provides analysis of travel, friction, spring rate, bench set and seat load. Operating Defaults The default settings for the FlowAux application Password A character string that identifies the access privileges of the user. PKUNZIP.EXE A decompression utility used to inflate files compressed using PKZIP.EXE.

127

FlowScanner User Guide PKZIP.EXE A data compression utility that allows large amounts of data to be stored using minimal disk space. Positioner Plot A graph that plots I/P output (positioner input) versus travel and provides analysis of position calibration and performance. Prepare for System Shut Down A menu option from the Main Menu that takes the FlowScanner through a programmed shut down process. Quick Report A report providing comparison of specified values from the nametag and measured values from the test and analysis. RAM Disk A temporary storage device that uses a portion of random access memory to store currently active data files. Required Seat Load The required contact force between the seat and the valve plug. Resolution The least interval between two adjacent discrete details which can be distinguished one from the other. Response Time A test format used to measure the time required for a valve to repond to a given signal change. ROTAUX.BAT The batch file used to start the FlowAux rotary valve application. Seat Load The contact force between the seat and the valve plug. SLIDAUX.BAT The batch file used to start the FlowAux sliding-stem valve application. Spring Rate Force change per unit change in rate Stroking Time The rate of travel of the actuator Static End Points Total Valve Plot

128

FlowScanner User Guide Valve Friction Valve Stroke

129

FlowScanner User Guide 13

Index

1APP directory, 12, 82, 123

AC power, 8, 123 accessory kit, 8, 11, 31, 32, 33, 37, 86, 123 actuator, 7, 13, 14, 20, 23, 26, 29, 31, 33, 34, 35, 36, 37, 41, 43, 45, 58, 64, 65, 66, 68, 76, 97, 98, 101, 106, 123 approximate weight, 10 ASCII format, 74, 124 auto print graphs, 21, 125 auto save data, 21, 125 AUTOEXEC.BAT file, 16, 18, 125 automatic zero of travel, 47, 56, 125 AutoZero function, 48, 56, 126 auxiliary channels, 8 auxiliary input data channel, 11, 126

balanced construction, 25, 126 battery charging time, 8 BBS system, 74, 126 bearing friction, 7, 14, 126 bench set, 7, 26, 63, 64, 66, 88, 126

C25 DRC travel transducer, 11, 32, 33, 93, 126

130

FlowScanner User Guide calibrating current, 126 calibrating pressure, 93, 126 calibrating voltage, 93, 126 calibration, 7, 17, 47, 51, 52, 55, 56, 57, 63, 65, 76, 87, 89-96, 126, 128 Celesco transducer, 11, 29, 31, 34, 47, 48, 49, 50, 56, 87, 126 color monitor, 8 command mode, 41, 127 commanded current, 127 comments field, 24, 127 computer outputs, 8 CONFIG.SYS file, 16, 18, 86, 127 connector arm, 8, 9, 14, 26, 34, 35, 36, 41, 46, 49, 50, 51, 52, 59, 63, 65, 70, 72, 73, 91, 127 control mode, 4, 7, 14, 47, 49, 52 control signal, 127 control signal output, 8 control signal output accuracy, 9 critical valve parameters bearing friction, 7 bench set, 7 packing, 7 seat load, 7 valve stroke, 7 crossover pressure, 68, 127

data acquisition, 11, 13, 83, 84, 85 DC power, 8, 10, 86, 127 dead band, 44, 63, 127, 128 diagnostic, 7, 97, 102, 121

131

FlowScanner User Guide displayed force units, 22, 127 displayed travel units, 22, 127 DOS, 8, 18, 27, 75, 82, 127 DRC transducer, 29, 32, 35, 127 Drive G, 16, 17, 27, 28, 127 dynamic error band, 14, 63, 127 dynamic scan test, 43, 51, 52, 65, 66, 67, 68, 73, 87, 128

E elapsed time display, 69, 71, 72, 73, 128

F Fisher Controls, 7, 83, 97, 98, 100, 101, 102 floppy disk, 13, 17, 27, 28, 79, 80, 81, 82, 86, 93, 128 floppy drive capacity, 8 FlowAux, 11, 16, 17, 46, 52, 53, 57, 58, 89, 128, 129 full calibration procedure, 128

H Haliburton metal case, 9 hard disk, 11, 19, 75, 79, 81, 82, 85, 86, 90, 95, 121, 128 hard disk capacity, 8 hard drive. See hard disk hardware, 8 hazardous area classification, 9 housing construction, 9 hysteresis, 44, 63, 72, 73, 128

132

FlowScanner User Guide hysteretic error, 51, 128

I I/P, 7 I/P plot, 65, 128 I/P resistance, 26, 128 I/P transducer, 41, 48, 58, 66, 76, 129 Impedance, 48, 128 input channels, 8 INSTALL.EXE, 82, 128 internal battery, 8

K keyboard, 8

L LCD assembly, 86, 129 leak class, 25, 129 linear transducer, 29, 31, 129 linearity, 63, 88, 89, 129

M main menu, 12-14, 17, 19, 20, 22, 27, 28, 46, 55, 58, 60, 74, 76, 79, 93, 95, 129 MAINFS.EXE, 17, 18, 82, 129 MAINROT.EXE, 18, 82, 129 measured column, 76, 129 measured current, 48, 49, 87, 129

133

FlowScanner User Guide measuring travel, 28-37 microprocessor, 7 monitor control signal, 8 monitor mode, 7, 14, 41, 43, 55, 129

N nametag program, 13, 19, 21, 22-28 net actuator pressure, 66, 130 net pressure plot, 66, 130

O operating defaults, 13, 17, 19, 20, 21, 23, 27, 79, 80, 81, 87, 130 options, 10 output pressure, 37, 45, 51, 52, 65, 70, 130

P packing, 7 packing friction, 14, 130 Parker Prestolok fittings, 10, 37, 38, 40, 130 password, 90, 91, 130 permanent fittings, 10 PKUNZIP.EXE, 75, 130 PKZIP.EXE, 75, 130 pneumatic, 7, 8 pneumatic input channel accuracy, 9 pneumatic valve assembly, 7, 130 pointing device, 8

134

FlowScanner User Guide positioner, 7, 14, 19, 26, 31, 32, 33, 34, 35, 36, 37, 38, 39, 41, 45, 50, 58, 63, 64, 65, 66, 68, 70, 76, 88, 97-134 power supply, 8 pressure connections, 10 process variable, 45, 72, 73, 130

Q quick report, 20, 51, 73, 76, 77, 79, 87, 131

R RAM, 8 RAM disk, 16, 17, 18, 20, 21, 54, 75, 82, 86, 131 random access memory, 8 RatRace desktop analysis software, 20, 121, 131 removable fittings, 10 required seat load. See seat load resolution, 9, 29, 30, 31, 32, 44, 45, 47, 48, 56, 67, 92, 131 response time, 71, 131 rotary valve, 8 ROTAUX.BAT, 12, 16, 18, 82, 131 RSâ&#x20AC;&#x201C;232 serial port, 8 RUNTEST file, 19, 46, 79, 87, 131

S seat condition, 67, 131 seat load, 7, 14, 25, 26, 43, 49, 63, 66, 67, 88, 131 seat load calculation, 67, 131 serial number, 21, 24, 26, 27, 28, 75, 79, 90, 102, 131

135

FlowScanner User Guide service conditions, 66, 99, 101, 131 setup, 7, 11, 13, 14, 17, 19, 28, 42, 46 slewing (dynamic) error, 63, 131 SLIDAUX.BAT, 12, 16, 17, 18, 82, 132 sliding stem valve, 8 software description, 11 specifications, 8-11 operating system, 8 spring rate, 14, 63, 66, 132 static end points, 51, 52, 76, 132 static point test, 44, 70, 132 step change test, 44, 69, 71, 132 step study test, 45, 59, 73, 132 stepped ramp test, 44, 72, 132 stroking speed. See response time stroking time, 14, 53, 68, 69, 132 system hardware, 8

tag number, 19, 21, 24, 26, 27, 28, 75, 132 TEMPR directory, 82, 132 theory of operation, 13 tool kit, 11, 29, 132 total valve plot, 66, 132 TRAMR directory, 82, 133 TRAMS directory, 82, 133 transducer, 7, 11, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 47, 48, 50, 55, 56, 93, 94, 96, 102, 133 transducers, 28-37

136

FlowScanner User Guide travel, 8, 28, 29, 30, 31, 32, 33, 34, 36, 43, 44, 46, 47, 48, 50, 51, 52, 53 travel indicator scale, 66 travel input accuracy, 9 travel transducer, 11, 19, 20, 31, 33, 47, 48, 55, 56, 87, 91, 96, 126 tubing, 10

U unbalanced construction, 25, 126

V valve friction, 133 valve stroke, 7, 14, 63, 133 VGA, 8 video mode, 22, 133 volume booster, 7, 37, 97, 133

W Windows for Workgroups, 8

Y Yâ&#x20AC;&#x201C;axis scale, 68, 133

137