1. Optimizing valve maintenance using condition analysis IPPTA seminar 17-18th July, 2014

2. Optimizing valve maintenance using condition analysis IPPTA seminar 17th July, 2014 Speaker: Jarkko Räty Director, Services, Business Solutions

3. Typical Maintenance Issues 3 Unexpected failures −Production breaks cause loss of revenue −Safety and environmental issue Lack of targeted maintenance −Unnecessary maintenance costs −Unnecessary risk of damage −Are the right issues tackled ? Typical Performance Statistics −30 % of controls increases process variability −10-30 % of controls in Manual −30 % of valves with problems

4. Traditional ways of selecting Valves for shutdown maintenance 4 Certain Critical always Operator indications Grouping for each shutdown No actions if by-pass available Run to failure (=no actions) Typically one rule is not directly followed, reality is more like combinations of the rules

5. Operational History Making a maintenance recommendation Device history and present condition defines the action 5 Condition Analysis Condition Analysis Service History

6. Maintenance decision making Defining the actions is a continuous process 6 Prioritize Analyse Plan Repair Report Filter

7. Maintenance based on known condition May reduce valve shutdown cost by up to 50 % 7 Field Work Removal, reinsertion Lifting, scaffolding Transportation Traditional Shutdown Maintenance Refurbishment Spare parts Testing Condition Analysis Visual Inspection Diagnostic Analysis Devices Testing Adjustments Calibrations Preventive Actions Tightening Shutdown with Condition Analysis 70 % reduction in Field Work cost 30+ % reduction in Maintenance costs 70 % reduction in Field Work cost 30+ % reduction in Maintenance costs Typically 30% valves require no action 40% valves can be maintained in place 30% valves require removal for maintenance Typically 30% valves require no action 40% valves can be maintained in place 30% valves require removal for maintenance Up to 50 % reduction in Shutdown

8. Condition Analysis Known device conditions – makes maintenance intelligent 8 Various intelligent analysis tools and methods are available to reveal field device conditions. The suitable tools are sellected according to the existing installed device base and control system infrastructure. Various intelligent analysis tools and methods are available to reveal field device conditions. The suitable tools are sellected according to the existing installed device base and control system infrastructure. Intelligent Maintenance Device analyses are scheduled according the criticality. The known device conditions and criticality are used to prioritize daily maintenance actions. Intelligent Maintenance Device analyses are scheduled according the criticality. The known device conditions and criticality are used to prioritize daily maintenance actions. Intelligent Shutdown Devices are sellected for maintenance based on known device conditions and unnecessary maintenance can be avoided. Intelligent Shutdown Devices are sellected for maintenance based on known device conditions and unnecessary maintenance can be avoided.

9. Condition Analysis Tools Remote performance and diagnostics analysis Smart Device Check One-shot diagnostic analysis of large amount of devices for Shutdown planning purposes Smart Device Check One-shot diagnostic analysis of large amount of devices for Shutdown planning purposes 9 Control Device Monitoring Use the loop monitoring system to identify underperforming valves and identify probable root causes Control Device Monitoring Use the loop monitoring system to identify underperforming valves and identify probable root causes

10. Control Device Monitoring An example: Detecting oscillations caused by a sticky valve 1.Graphical view to illustrate Valve Health 2.Deeper analysis reveals valve stiction 3.Process trend confirms typical sticky valve behavior -Process Value remains steady despite of changes in Control actions until it moves 10 1 2 3 ENGHIS PCS OPC Contol Loop Monitoring

11. Smart device diagnostics utilization An example: Detecting air leakage in valve actuator 1.Condition Monitoring alarms malfunction 2.Remote analysis reveals excessive air consumption -Gradual chance in Spool Valve Position 3.Actuator membrane failure (a hole) was discovered in devices maintenance 11 1 2 3 Utilizing diagnostic information: Trouble Shooting (one device at the time) Analysis of 10’s or 100’s of devices 24/7 monitoring Utilizing diagnostic information: Trouble Shooting (one device at the time) Analysis of 10’s or 100’s of devices 24/7 monitoring

12. Condition Analysis Tools Portable testing devices 12 Control Valve Testing Testing of valve condition with portable testing system for Shutdown and Maintenance planning Control Valve Testing Testing of valve condition with portable testing system for Shutdown and Maintenance planning Safety Valve Testing Testing of safety relief pressure valves in process to determine if they are operating correctly at correct pressure setting Safety Valve Testing Testing of safety relief pressure valves in process to determine if they are operating correctly at correct pressure setting Valve Leak Testing Testing of valves in process to determine if they are leaking when shut Valve Leak Testing Testing of valves in process to determine if they are leaking when shut

13. 13 Control Valve Testing Detecting sticky valve by ramp movement PC Measurement system 1.Testing system connection to valve 2.Attachment options for external potentiometer 3.Testing results revealed valve sticking -while leaving the seat -in the upper half of the stroke 12 3

14. 3 Valve Leak Testing Leakage detection and leak rate estimation 1.Acoustic measurement on predefined spots of valve assembly 2.A leak detected by acoustic signal 3.Estimation of leakage rate 4.Reporting devices conditions and recommended actions 14 1 3 4 2

15. Safety Valve Testing Testing verifies pressure setting of safety valves 1.Setting up of testing system 2.Automatic testing run 3.Test report and pressure setting certificate with Maintenance recommendations 15 12 3

16. Condition Analysis 16 Analysis for different field device types

17. Suzano BA Shutdown 2012, Brazil Company profile Suzano - 2nd largest eucalyptus pulp producer in the world (8th in market pulp) - Pulp production costs is one of the lowest in the world - Six industrial units in Brazil Suzano BA (Mucuri) - Pulp production 1.540 ktons yearly - Uncoated paper 250 ktons yearly 17

18. Suzano BA Shutdown 2012 Results through Condition Analysis 18 232 pcs Preliminary list for valve maintenance 153 pcs Condition analyses by Smart Device Check 79 pcs Visual inspection and Operational tests 22 pcs Maintenance 131 pcs OK 44 pcs Maintenance 35 pcs OK 66 pcs Maintenanc at workshop 93 pcs Adjusment and preventive action on pipeline 73 pcs No action Customer RequestTesting PlanTest ResultsShutdown Actions

19. Shutdown timeShutdown 11 days Start-up 3 days Shutdown timeShutdown 11 days Start-up 3 days Manning33 Metso Professionals 2 Partner Professionals for electrical actuators Manning33 Metso Professionals 2 Partner Professionals for electrical actuators Shutdown activities 66 pcs maintenance of automatic valves 7 pcs maintenance electric actuators 93 pcs positioners adjustments and preventive tasks 5 pcs extra activities requested by Suzano. Shutdown activities 66 pcs maintenance of automatic valves 7 pcs maintenance electric actuators 93 pcs positioners adjustments and preventive tasks 5 pcs extra activities requested by Suzano. Suzano BA Shutdown 2012 Maintenance Execution Planning & Execution Activities included in the master schedule Monitoring the progress of activities Implementation of maintenance actions according to company procedures Planning & Execution Activities included in the master schedule Monitoring the progress of activities Implementation of maintenance actions according to company procedures Smart Device Check Maintenance PlanningShutdown Start- up Visual & Operational Checking Operational & Maintenance History 19

20. Suzano BA Shutdown 2012 Direct reduction in maintenance costs 44 % 100 % Preliminary Estimation Condition Analysis Visual Inspection Diagnostic Analysis Devices Testing Adjustments Calibrations Preventive actions Tightening 56 % Actual 44 % reduction in Maintenance costs Results 31% valves required no action 40% valves adjusted in place 29% valves required removal for maintenance Results 31% valves required no action 40% valves adjusted in place 29% valves required removal for maintenance 50 + % reduction in Shutdown costs when Field Work taken into account Field Work Removal, reinsertion Lifting, scaffolding Transportation Maintenance Refurbishment Spare parts Testing 20

21. Condition Analysis The way to optimize valve maintenance 21 “Don’t fix if its not broken” “Tackle the right issues”