T 8389-3 ENEXPERTplus Valve Diagnostics
TROVIS 3730-3 Electropneumatic Positioner

Application
Positioner firmware to detect potential valve faults and to provide maintenance recommendations

The EXPERTplus valve diagnostics can detect faults and provide predictive, status-oriented maintenance recommendations
for valves with pneumatic actuators. The full scope of diagnostic functions is completely integrated into the positioner. The
numerous diagnostic functions allow faults to be pinpointed incontrol valves at an early stage.
The TROVIS-VIEW software, which allows the user to access,read and edit the diagnosis, is easy to learn. The integration
options including eDD, eEDD, FDT/DTM allow the diagnostic
functions to be also used in other engineering tools. Classified
status messages and the condensed state conforming to theNAMUR Recommendation NE 107 can also be read on site at
the positioner display.
TROVIS-VIEW: User interface used to configure various
SAMSON devices
FDT: Field device tool for the manufacturer-independent integration of field devices
DTM: Device type manager to describe the device and communication properties
DD/eDD: Device description/enhanced device description

Fig. 1: TROVIS 3730-3 Positioner with EXPERTplus valve
diagnostics

Special features•• Diagnosis data are constantly compiled, saved and analyzed in the positioner. Status messages are automaticallygenerated. Test data and their analysis are saved in thepositioner.
•• Cyclical polling of diagnosis data, multiplexer-capable•• Minimum and maximum temperature readings with analarm when the limits have been exceeded•• Statistical information (in-service monitoring) and tests(out-of-service diagnostics) pinpoint critical states before
malfunctions can affect the process, allowing the user toplan predictive maintenance and service work on controlvalves•• Display of classified status and error messages•• Status classification and condensed state based on
NAMUR Recommendation NE 107•• Status messages and condensed state can also be read off
at the positioner display•• Operating hours counter allows data and events to besorted by time•• Step response test to assess the valve's ability to move•• Diagnosis data, test results and analysis saved in the positionerOptions•• Binary input, e.g. to start tests, monitor external solenoidvalve etc.

SAMSON AKTIENGESELLSCHAFT · Weismüllerstraße 3 · 60314 Frankfurt am Main, Germany
Phone: +49 69 4009-0 · Fax: +49 69 4009-1507 · samson@samson.de · www.samson.de

Edition November 2018

Table 1: Overview of EXPERTplus functions
FunctionSee
sectionDescription

From user level 1)

Start-up diagnostics

1.1

Positioner self-test, mechanical attachment, valve working range, initialization
time, opening and closing times

On-site: readCurrent process variables

1.2.1

Process variables: set point, valve position, set point deviation, operating hourscounterOn-site: read

Operating parameters

1.2.2

Number of zero calibrations and initializations, temperature, total valve travel,self-monitoring of positioner

On-site: read

Status messages/
classification

1.2.3
3.1

Display and logging of classified status messages and condensed state

Diagnostics

Status classification change

Diagnostics

Statistical information

Data are compiled, saved and analyzed by the positioner while the process is running without disrupting the process. The data
are saved and analyzed in the positioner, i.e. the positioner follows the set point to position the valve. A classified status message
or error message is generated if the positioner detects an event.
Valve position histogram

2.1.1

Statistical distribution of the valve position

Diagnostics

Set point deviation
histogram

2.1.1

Statistical distribution of the set point deviation

Diagnostics

Load cycle histogram

2.1.1

Statistical distribution of the load cycle, dynamic stress factor acting on packing
and metal bellows

Diagnostics

Course of end position

2.1.2

Observing end position, detection of zero shift

Diagnostics

Tests

Similar to the statistical information, data are compiled, saved and analyzed by the positioner. However, in this case, the valve
position is not determined by the set point, but the active test. The tests can only be started when the conditions in the plant allow
it (e.g. plant shutdown or service work in the workshop).
Step response test (SRT)

2.2.1Time stamp, dead time, T86, overshooting, test status

On-site: write 2),
diagnostics

Step response test (SRT100 %)2.2.2

Time stamp, dead time (rising/falling), T86 (rising/falling), T98 (rising/falling),
test status

On-site: write 2),
diagnostics

Dead band

2.2.3Minimum dead band, maximum dead band, average dead band

Diagnostics

3

Collected data and analysis results can be displayed in graphs.

On-site: read4

Positioner with binary input option: logged actions of single functions and tests

Diagnostics

Status messages
Software for visualizationand parameterization
Options
Binary input
1)

2)

2

The positioner has three user levels with various read and write access privileges:–– On-site: read · Parameters, which can be displayed at the positioner, can be read using the software–– On-site: write · Parameters, which can be displayed at the positioner, can be read and written using the software–– Diagnosis · Parameters, which can be displayed at the positioner as well as the diagnostic parameters, can be read and written using thesoftware
Restricted function (including test start and test stop)

T 8389-3 EN

1EXPERTplus valve diagnostics

1.1 Start-up diagnostics
EXPERTplus monitors the valve during automatic initialization
to ensure trouble-free start-up. At the same time, the supply
and venting times are determined.
The diagnosis also highlights any faults concerning attachmentand the valve working range as well as any hardware, data
memory and initialization time errors.

1.2 Process variables and operating parameters1.2.3 Pinpointing faults and their sources
The alarm and status messages generated by EXPERTplus allow faults to be pinpointed quickly. The last 400 generated
messages are saved in a FIFO memory with a time-stamp(logged by the operating hours counter). Faults can be pinpointed quickly as a result.
The status messages are divided into the following categories:–– Start-up–– Configuration–– Process data–– Control valve diagnosis

1.2.1 Current process variables–– AMR signal outside range

EXPERTplus provides the key process variables collected by thepositioner (set point, controlled variable, set point deviationand temperature) and analyzes the diagnostic data.

–– Limit for total valve travel exceeded–– Lower/upper end position shifted

1.2.2 Key operating parameters/status messages–– Set point deviation

To evaluate the current condition of the valve and schedulemaintenance routines, EXPERTplus provides the user with asummary on the device state. The status messages for the operating parameters listed below are time-stamped:–– Brownout•• Operating hours counter, distinction between positioner
switched on since last initialization, positioner in closedloop operation and positioner in closed-loop operation
since last initialization•• Number of zero calibrations•• Number of initializations performed•• Setting a status message•• Resetting a status message•• Completion of a test–– Dynamic stress factor exceeded–– Current too low/too high–– IP shutdown–– Temperature inside device below min. limit/above
max. limit–– Angle limitation–– Logging suspended–– Operating range in CLOSED position/max. OPENposition–– Operating range shifts towards CLOSED position/max. OPEN position–– Limited working range: lower/upper range

Fig. 2: Event logging

T 8389-3 EN3

2Functions

2.1 Statistical information
By permanently recording raw diagnostic data in the positioner, the user can gather information about how the valve behaves under process conditions.
The continuous recording of signals enables an analysis of thecurrent measurement span as well as of the positioner’s entire
service life.
Recommendations for predictive maintenance can be given
based on the statistical information. In addition, immediately
required action is reported.
2.1.1 Histograms
Data are recorded in the background regardless of the operating mode selected. The data are plotted over the service life
or over a user-defined monitoring period in a histogram.
Valve position
The valve travel histogram is a statistical analysis of the plotted valve positions. It provides information about where thevalve mainly spends the majority of its time during its service
life and whether it shows a recent trend concerning changes
in its operating range.
Set point deviation
The set point deviation histogram contains a statistical analysisof any set point deviations recorded. This provides a summaryof how often and to which level a set point deviation has occurred during the valve service life and whether it shows a recent trend concerning the set point deviation. Ideally, the setpoint deviation should be as small as possible.
Load cycle
The cycle counter histogram provides a statistical analysis of
the cycles. As a result, the cycle counter also provides information on the dynamic stress of a bellows seal and/or packing. A valve cycle span starts at the point where the valve
stroke changes direction until the point where it changes direction again.

2.1.2 Course of end position
The positioner monitors the lower and upper end positions todetect wear and dirt in the trim at an early stage. The valve
position is recorded when the lower end position is reached
and any changes logged with a time stamp. The first measured value is used as a reference.
Shifts in the end position are registered according to the assigned status classification.

2.2 Tests
Before performing the tests, it is important to make surewhether the conditions (in the plant or process) allow the valve
to be moved.
The tests provide a trend showing the current valve state, any
possible existing malfunctions and help to pinpoint faults andto schedule predictive maintenance work.
2.2.1 Step response test (SRT)The step response test (SRT) is particularly suitable for the status-oriented detection of malfunctions in pneumatic shut-off
valves. As a result, the probability of failure on demand (PFD)
can be reduced and it may be possible to extend maintenanceintervals. A shut-off valve normally in its end position can beprevented from seizing up or getting jammed. The initial
breakaway torque must first be overcome after the valve starts
to move from its end position. The initial breakaway torquedepends on the plug/seat seal, deposits on the plug, the process medium and friction at the valve trim. After the initial
breakaway torque has been overcome, it can be assumed thatthe valve is able to close completely. The recording of the test
results additionally allows an analysis of the dynamic control
response. During the test, the valve is moved through a user-defined working range.
A report and diagram show the test results. The positioner cansave a maximum of 52 reports and 7 diagrams.

The positioner generates a corresponding message when thehistogram analysis indicates that the dynamic stress factor isoutside the permitted range.

Fig. 3: Valve position histogram

4T 8389-3 EN

Fig. 4: Set point deviation
histogram

Fig. 5: Load cycle histogram

Fig. 6: Course of lower end
positionFig. 7: Course of upper endposition

T 8389-3 EN5

2.2.2 Step response test (SRT-100 %)The dynamic valve performance can be evaluated by performing the test. During the step response test (SRT-100 %),the valve moves through its entire working range, contrary to
the step response test (SRT).
A report and diagram show the test results. The positioner cansave a maximum of 7 reports and 7 diagrams.
2.2.3 Dead band
The difference in set point w that causes a minimal change inthe valve position x is termed ‘dead band’.
The valve dead band is affected by the friction hysteresis andthe elastic processes in the valve stem packing.
A plotted diagram is generated after the test is successfullycompleted.

3Visualization and parameterization of
the integrated EXPERTplus diagnostics

The TROVIS-VIEW software or the DTM tool generate graphsfrom the data, test results and status messages collected by thediagnostic firmware in the positioner.
In addition, the diagnostic data can also be made accessible
to other engineering tools using the DD (device description).
The eDD (enhanced device description) enables the data to be
displayed in a graph, e.g. using Siemens PDM, AMS. Howthe data are displayed depends on the tool.

3.2 Graphs in TROVIS-VIEW, DTM, eDD(e.g. Siemens PDM)
The trend-viewer function in TROVIS-VIEW allows the compiled raw data and test results as well as variables recordedin the positioner to be displayed in a graph.
The raw data and test results include:–– Current process variables–– Course of end position–– Step response test (SRT)The histograms described in section 2.1.1 are displayed asbar graphs.
These graphs make any changes in positioning or control performance apparent to the user and support predictive maintenance.

4Binary input

The optional binary input allows various actions to be performed which also affect the diagnostic functions. The actions
are logged by the positioner.

3.1 Classification and marking of status
messages
Based on NAMUR recommendation NE 107, the messages(events) generated by EXPERTplus are assigned a status (classified).
The status messages can be classified as required. The classified status messages (event) are summarized in a condensed
state:Condensed state
Status message

TROVIS-VIEW/DTM

No message, OKgreen

Maintenance requiredblue

Out of specification

yellow

Function checkorangeFailurered

The condensed state is indicated on the positioner display andcan be read over the communication.

6T 8389-3 ENFig. 8: Step response test (SRT)

Fig. 9: Step response test
(SRT-100 %)Fig. 10: Dead bandT 8389-3 EN7

Data Sheet for TROVIS 3730-3 Positioner

u T 6661
u T 8484-3

Specifications subject to change without notice

T 8389-3 EN

2019-02-18 · English

Data Sheet for TROVIS-VIEW